Bucher Hydraulics VF-iValve VF-i250 Series User manual

Lift Control Valve VF-iValve – VF-i250… and VF-i500…
Operating Instructions
1/33
Reference: 300-I-9010546-EN-00
Issue: 03.2015
Issue: 09.2015
1/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve
2/33 300-I-9010546-EN-00/03.2015
E2015 by Bucher Hydraulics AG, CH-6345 Neuheim
All rights reserved. This documentation, in whole and/or in part, is protected by copyright. It may no
t
be reproduced, nor may it be stored, processed, replicated or distributed by electronic means, withou
t
written permission from Bucher Hydraulics.
Data is provided for the purpose of product description only, and must not be construed as warrante
d
characteristics in the legal sense. No assertion regarding either a particular property or the fitnes
s
for a particular intended purpose can be derived or deduced from this information. The informatio
n
does not relieve users from the duty of conducting their own evaluations and tests.
Because the products are subject to continual improvement, we reserve the right to amend the pro

duct specifications contained in this catalogue. The original language and legal terminology of all Bu

cher Hydraulics documentation is exclusively German. Bucher Hydraulics cannot be held liable fo
r
any possible errors in translation.
Published by
Bucher Hydraulics AG
Industriestrasse 15
CH-6345 Neuheim
Phone [phone]
Fax [phone]
Email [email protected]
Internet www.bucherhydraulics.com
Classification: 430.310.501
Issue: 09.2015
2/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve
3/33
300-I-9010546-EN-00/03.2015
Contents Page
1 About this document 5
.................................................................
1.1 Scope 5
.......................................................................
1.2 Target group 5
..................................................................
1.3 Other applicable documents 5
....................................................
1.4 Specialist terms 5
...............................................................
2 Safety instructions 6
...................................................................
2.1 Description of the safety notices 6
.................................................
2.1.1 Meaning of the signal words 6
.............................................
2.1.2 Meaning of the pictograms 6
..............................................
2.1.3 Example of asafety notice 7
..............................................
2.2 Basic principles 7
...............................................................
2.3 General safety instructions 7
.....................................................
2.3.1 Intended use 7
..........................................................
2.3.2 Operator's obligations 8
...................................................
2.3.3 Duties of the operating staff 8
..............................................
3 Product description 9
..................................................................
3.1 Intended use 9
.................................................................
3.1.1 Conformity 9
............................................................
3.2 Product identification 9
..........................................................
4 Construction and function 10
............................................................
4.1 Factory settings 10
...............................................................
5 Operating controls and indicators 11
......................................................
5.1 VF-iValve lift control valve 11
......................................................
5.1.1 Components of the VF-iValve –VF-i250 11
...................................
5.1.2 Components of the VF-iValve –VF-i500 12
...................................
5.2 Hand pump /Emergency lowering 13
...............................................
5.3 Electronic card iCon with VF-board 15
..............................................
5.3.1 LED indications 16
........................................................
5.3.2 LED indications (options board –switching outputs) 18
.........................
5.3.3 LED indications (options board –VF) 18
.....................................
6 Installation and commissioning 19
........................................................
6.1 Safety information 19
.............................................................
Issue: 09.2015
3/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve
4/33 300-I-9010546-EN-00/03.2015
6.1.1 Surroundings 19
..........................................................
6.2 Assembly 19
....................................................................
6.2.1 Hose or pipe 19
...........................................................
6.2.2 Electrical installation 20
....................................................
6.2.3 Installation of the ParamCard 21
............................................
6.2.4 Hydraulic fluids and oil additives 23
.........................................
6.2.5 Positioning of the deceleration switches 24
...................................
6.2.6 Check/setting of the max. operating pressure (EN 81-2, art. 12.5.3) 24
...........
6.3 Safety checks 25
................................................................
6.3.1 Test of the monitoring of the UCM/A3-valve 25
................................
6.3.2 Pipe rupture valve test 27
..................................................
7 Maintenance 29
.......................................................................
7.1 Maintenance schedule 29
.........................................................
7.2 Maintenance work 30
.............................................................
7.2.1 Pilot filter 30
..............................................................
7.2.2 Cleaning/replacing the VF-i250 pilot filter 30
..................................
7.2.3 Cleaning/replacing the VF-i500 pilot filter 30
..................................
8 Repair 33
.............................................................................
8.1 Troubleshooting and clearing faults 33
..............................................
Issue: 09.2015
4/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve 1 About this document
5/33
300-I-9010546-EN-00/03.2015
1 About this document
This commissioning and maintenance manual provides the basis for us
ing the lift control valve VF-iValve – VF-i250 / VF-i500 and iCon elec
tronic card for its intended purpose in a proper, effective, and safe
manner. This manual must be accessible to the commissioning and ser
vice personnel.
1.1 Scope
This manual is:
Sa part of the lift-control VF-iValve / iCon for commissioning and main
tenance
Sapplicable to the valve and all components referred to, such as the
iCon, Handterminal, iWIN, power supply unit and their connectors
and cables.
1.2 Target group
This commissioning and maintenance manual provides commissioning
and service personnel with all the information required for installation
and commissioning.
1.3 Other applicable documents
Reference No. Definition
300-P-9010073 Recommended hydraulic fluids
300-D-9010545 Planning information VF-iValve
300-P-9010553 Data sheet for handterminal
300-I-9010531 Parametrisation and Maintanance Manual
ESVH 018 Type examination certificate
300-S-9010554 Service manual for iBox
300-S-9010547 Spare parts VF-iValve i250
300-S-9010459 Spare parts VF-iValve i250
IMPORTANT!: These and other documents can be found in the
LOGintern section of our website
www.bucherhydraulics.com
1.4 Specialist terms
Term Definition
VF-iValve Intelligent lift control valve
iCon Electronic control card for VF-iValve valve
Handterminal Terminal (optional) for the parameterisation of the VF-iValve
iWIN PC-software (optional) for the parameterisation of the
VF-iValve
iBox Sensor unit in the VF-iValve
iTeach Program on the iCon
ParamCard Memory card
SMA Monitoring of the UCM/A3-valve
(“Self Monitoring Acknowledgement”)
Issue: 09.2015
5/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve2 Safety instructions
6/33 300-I-9010546-EN-00/03.2015
2 Safety instructions
This documentation (manual) advises the user of the dangers and re
maining risks that can arise even when the product is being used pro
perly and for its intended purpose. It is essential to take note of the sa
fety instructions in each section.
2.1 Description of the safety notices
This commissioning and maintenance manual contains safety informa
tion for the safe operation of the product. Dangers and residual risks are
signalled with the following elements:
2.1.1 Meaning of the signal words
The table below shows the meaning of the signal words that are used to
identify the different levels of danger.
Signal words Meaning
DANGER! This denotes a directly imminent danger. If it is not at
tended to, it will result in death or serious injuries to
people.
WARNING! Denotes a potentially dangerous situation. If it is not
prevented, it may result in death or serious injuries to
people.
CAUTION! Denotes a potentially dangerous situation. If it is not
prevented, it may result in slight or minor injuries to
people.
ATTENTION! Denotes a potentially harmful situation. If it is not pre
vented, the product or its surroundings may be dama
ged.
2.1.2 Meaning of the pictograms
The following pictograms are used as warning symbols. They are com
bined with the appropriate signal word, depending on the danger level.
Meaning
This warning symbol is used in conjunction with the
signal words "DANGER", "WARNING" or "CAU
TION".
Warning of dangerous electrical voltage.
This warning symbol is used exclusively in conjunc
tion with the signal word "WARNING".
This warning symbol indicates the risk of a large po
tential difference (ESD).
Issue: 09.2015
6/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve 2 Safety instructions
7/33
300-I-9010546-EN-00/03.2015
2.1.3 Example of a safety notice
SPictogram
SSignal word
SType and source of danger
SPossible consequences of the danger
SMeasures for preventing the danger
WARNING!
Dangerous electrical voltage
Touching electrical components may result in serious injury or
death. During installation or repair work, ensure that the power
supply is interrupted.
2.2 Basic principles
The intelligent lift control valve VF-iValve is an electronically controlled
hydraulic valve block for controlling hydraulic lifts. The VF-iValve is situ
ated on the hydraulic power unit and activated by the lift control system.
2.3 General safety instructions
ATTENTION!
Take note of the following instructions before carrying out any
work.
2.3.1 Intended use
The Lift Control Valve has been built in accordance with the state of the
art and recognised safety regulations. Nevertheless, risks to the life and
limb of users or third parties may arise during its use, or damage to the
car frame kit or other material assets may result.
SKeep this manual and all other applicable documents complete and
legible, and accessible to all personnel at all times
SDo not work in any manner that endangers personnel or uninvolved
third parties
SIf there is a safety-related fault, shut down the Lift Control Valve im
mediately and have the fault rectified by a competent person
SIn addition to the entire documentation for the product, always com
ply with statutory or other safety and accident-prevention rules as
well as with the applicable standards and guidelines in the country
where the valve is operated
Issue: 09.2015
7/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve2 Safety instructions
8/33 300-I-9010546-EN-00/03.2015
2.3.2 Operator's obligations
Working with safety in mind
SOnly operate the valve if it is in perfect technical condition; only use it
as intended, staying aware of safety and risks, and adhearing to the
instructions in this manual
SEnsure that the following are observed and monitored:
- adherence to intended use
- statutory or other safety and accident-prevention rules
- safety regulations governing the handling of hazardous sub
stances
- applicable standards and guidelines in the country where the valve
is operated
SMake protective equipment available
Staff qualifications
SEnsure that all personnel tasked with work on the valve have read
and understood this manual and all other applicable documents, es
pecially the safety, maintenance and repair instructions, before they
begin the job
SOrganize responsibilities, who is in charge of any specific duty and
how personnel are supervised
SEnsure that all work is carried out by specialist technicians only:
- fitting, repair and maintenance work
- work on the valve electrical system
Warranty
SObtain the manufacturer's approval prior to carrying out any modifica
tion, repair or alterations during the warranty period
2.3.3 Duties of the operating staff
SObserve and keep legible all instructions given on the Lift Control
Valve, e.g. the arrow indicating the direction of rotation and the
markings for fluid connections
SCarry out work on the Lift Control Valve only while the motor is not
running
SIsolate the motor from its supply voltage and keep it locked in that
state while carrying out any fitting or maintenance work
Issue: 09.2015
8/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve 3 Product description
9/33
300-I-9010546-EN-00/03.2015
3 Product description
3.1 Intended use
The VF-iValve intelligent lift control valve is an electronically controlled
hydraulic valve block for controlling hydraulic lifts. The VF-iValve is situ
ated on the hydraulic power unit and activated by the lift control system.
Electronic control is accomplished by an electronic unit – the iCon – that
is housed in the control cabinet. At standstill, the weight of the lift is sup
ported by a check valve integrated in the VF-iValve. In operation, the
electronic controller regulates the three states "Bypass", "Travel UP"
and "Travel DOWN", and the transitions between them. In the electronic
unit, this travel is represented in a form known as travel curves. During
operation, the travel curves for that particular lift are optimised by the
learning algorithm "iTeach". In addition, the valve block includes the fol
lowing functions and components: a hand pump with manual emergency
lowering (with piston-creep prevention), a ball valve, a pressure gauge,
a pressure sensor with up to two pressure switches, speed monitoring, a
temperature sensor, a UCM/A3 valve in accordance with EN 81-2 + A3.
3.1.1 Conformity
The product was designed and developed in conformity with the follow
ing directives and standards:
EC-directive 2006/42/EG
EC-directive 95/16/EG
Standards EN81-2:1998+A3:2009
Safety rules for hydraulic lifts
Standards EN12015:2014, EN 12016:2013
(Electromagnetic compatibility for lifts)
3.2 Product identification
The lift control valve has a stuck-on nameplate with the following infor
mation:
1. Valve type
2. Certificate no.
3. Month / year
4. Serial number
Issue: 09.2015
9/33
Reference: 300-I-9010546-EN-00

VF-iValve Lift Control Valve4 Construction and function
10/33 300-I-9010546-EN-00/03.2015
4 Construction and function
IMPORTANT!: Information on schematics and diagrams is avail
able in the VF-iValve Planning Information (300-D-9010545).
4.1 Factory settings
Installation specific settings are stored on the ParamCard:
SKit type
SCylinder type and diameter
SMax. speed UP and DOWN
SDeceleration distance acc. to diagram
STravel curve settings
SOther settings
Issue: 09.2015
10/33
Reference: 300-I-9010546-EN-00