Bucher iValve i250 User manual

iValve Lift Control Valve – i250 / i500
Operating Instructions
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Reference: 300-I-9010544-EN-01
Issue: 10.2014
Issue: 09.2015
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve
2/31 300-I-9010544-EN-01/10.2014
E2014 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
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve
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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 iValve 10
.........................................................
5 Operating controls and indicators 11
......................................................
5.1 iValve lift control valve 11
.........................................................
5.1.1 Components of the iValve i250 11
...........................................
5.1.2 Components of the iValve i500 12
...........................................
5.2 Hand pump /Emergency lowering 13
...............................................
5.3 Elektronic card iCon 15
...........................................................
5.3.1 LED indications 16
........................................................
6 Installation and commissioning 18
........................................................
6.1 Safety information 18
.............................................................
6.1.1 Surroundings 18
..........................................................
6.2 Assembly 18
....................................................................
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iValve Lift Control Valve
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6.2.1 Hose or pipe 18
...........................................................
6.2.2 Electrical installation 19
....................................................
6.2.3 Installation of the ParamCard 19
............................................
6.2.4 Hydraulic fluids and oil additives 21
.........................................
6.2.5 Positioning of the deceleration switches 22
...................................
6.2.6 Check/setting of the max. operating pressure (EN 81-2, art. 12.5.3) 22
...........
6.3 Safety checks 23
................................................................
6.3.1 Test of the monitoring of the UCM/A3-valve 23
................................
6.3.2 Pipe rupture valve test 25
..................................................
7 Maintenance 27
.......................................................................
7.1 Maintenance schedule 27
.........................................................
7.2 Maintenance work 28
.............................................................
7.2.1 Pilot filter 28
..............................................................
7.2.2 Cleaning/replacing the i250 pilot filter 28
.....................................
7.2.3 Cleaning/replacing the i500 pilot filter 28
.....................................
8 Repair 31
.............................................................................
8.1 Troubleshooting and clearing faults 31
..............................................
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve 1 About this document
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300-I-9010544-EN-01/10.2014
1 About this document
This commissioning and maintenance manual provides the basis for us
ing the lift control valve iValve i250 / i500 and iCon electronic card for its
intended purpose in a proper, effective, and safe manner.This manual
must be accessible to the commissioning and service personnel.
1.1 Scope
This manual is:
Sa part of the iValve lift-control valve / iCon for commissioning and
maintenance
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
Term Definition
300-P-9010073 Recommended hydraulic fluids
300-P-9010528 Data sheet for lift control valve iValve i250/i500
300-D-9010542 Planning information iValve
300-P-9010553 Data sheet for handterminal
300-I-9010543 Parametrisation and maintanance manual
ESVH 001/1 Type examination certificate
300-S-9010554 Service manual for iBox
300-S-9010437 Spare parts iValve i250
300-S-9010548 Spare parts iValve i500
IMPORTANT!: These and other documents can be found in the
LOGintern section of our website
www.bucherhydraulics.com
1.4 Specialist terms
Term Definition
iValve Intelligent lift control valve
iCon Electronic control card for iValve valve
Handterminal Terminal (optional) for the parameterisation of the iValve
iWIN PC-software (optional) for the parameterisation of the iValve
iBox Sensor unit in the iValve
iTeach Program on the iCon
ParamCard Memory card
SMA Monitoring of theUCM/A3-valve
(“Self Monitoring Acknowledgement”)
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve2 Safety instructions
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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).
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve 2 Safety instructions
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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 lift control valve is an electronically controlled hydraulic valve block
for controlling hydraulic-powered passenger and goods lifts.
The lift control valve is situated on a hydraulic power unit and activated
by a 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 pump is operated
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve2 Safety instructions
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2.3.2 Operator's obligations
Working with safety in mind
SOnly operate the pump 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
pump is operated
SMake protective equipment available
Staff qualifications
SEnsure that all personnel tasked with work on the pump 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 pump 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
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve 3 Product description
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3 Product description
3.1 Intended use
The iValve intelligent lift control valve is an electronically controlled hy
draulic valve block for controlling hydraulic lifts. The iValve is situated on
the hydraulic power unit and activated by the lift control system. Elec
tronic 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 iValve. In operation, the elec
tronic 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 oper
ation, the travel curves for that particular lift are optimised by the learn
ing algorithm "iTeach". In addition, the valve block includes the following
functions and components: a hand pump with manual emergency lower
ing (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12016:2004+A1:2008
(Electromagnetic compatibility for lifts)
The lift control valve has a stuck-on nameplate with the following infor
mation:
3.2 Product identification
1. Valve type
2. Certificate no.
3. Month / year
4. Serialnumber
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve4 Construction and function
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4 Construction and function
IMPORTANT!: Information on schematics and diagrams is avail
able in the iValve Planning Information (300-D-9010542).
4.1 Factory settings iValve
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
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iValve Lift Control Valve 5 Operating controls and indicators
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5 Operating controls and indicators
5.1 iValve lift control valve
5.1.1 Components of the iValve i250
300-4-10022900-D
Z1
HP T
P
Z
65
27 6
1
8
5
3
11
10
7
9
12 2
4
C
Legend 1
2
3
4
5
6
7
8
9
Solenoid UP/DOWN
Pressure relief valve
Ball valve
Magnet UCM / A3
slack rope safety device
Hand pump/emerg. lowering
Pressure relief valve for the
hand pump
Handle for hand pump (sup
plied loose)
Pressure gauge
10
11
12
C
P
T
HP
Z
Z1
Connection, sensor cable iBox
LED
Nameplate
iBox
Pump port
Tank port
Tank port, hand pump,
emergency lowering
Cylinder port
Port for relevelling / test port
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iValve Lift Control Valve5 Operating controls and indicators
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5.1.2 Components of the iValve i500
Legend 1
2
3
4
5
6
7
8
Solenoid UP/DOWN
Pressure relief valve
Ball valve
Magnet UCM / A3
Hand pump
Pressure relief valve for the
hand pump
Pressure gauge
Connection, sensor cable iBox
9
10
11
C
P
T
HP
Z
Z1
LED
Nameplate
Emergency-lowering
valve
iBox
Pump port
Tank port
Tank port, hand pump
Cylinder port
Port for relevelling / test port
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iValve Lift Control Valve 5 Operating controls and indicators
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5.2 Hand pump / Emergency lowering
iValve i250
The iValve comes with a combination of hand pump and emergency
lowering valve as standard.The car can be moved upward with the hand
pump when needed, and downward by means of the emergency-lower
ing facility.
Operating the hand pump
Caution
1
1. Push the extension pipe onto the lever stub of the hand pump as
far as it will go, then retract by approx. 3cm
2. Swing the hand pump lever up and down
DANGER!
Car descent
Can lead to death or serious injuries.
Before operating the emergency-lowering valve, make sure that
there are no people or materials in the lift shaft.
Operating the emergency lowering
Caution
90°
1
2
3007019379
3
1. Push the extension pipe onto the lever stub of the hand pump as
far as it will go, then retract by approx. 3cm
2. Push the hand pump lever down
Temporary deactivation of piston slack rope safety device
(preload pressure)
In order to prevent slack-rope build up as per EN81-2 number 12.9.1.5
operation of the emergency lowering valve will leave a preload pressure
of 6bar.
In order to temporarily deactivate the preload pressure:
3. Turn the slack rope safety device (1) by 90°clockwise. See pictures
4. Push the hand pump lever down (with extension pipe) until the
pressure is completely relieved
5. Turn the slack rope safety device (1) by 90°anticlockwise to the
original position
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300−7−10024540
1
iValve Lift Control Valve5 Operating controls and indicators
14/31 300-I-9010544-EN-01/10.2014
iValve i500
In the iValve i500, the hand pump and emergency-lowering facility are
separated. The car can be moved upward with the hand pump when
needed, and downward by means of the emergency-lowering facility.
Hand pump
300−7−10024540
Emergency lowering
DANGER!
Car descent
Can lead to death or serious injuries.
Before operating the emergency-lowering valve, make sure that
there are no people or materials in the lift shaft.
The car is lowered by pressing the lever of the emergency-lowering
valve.
Note: The minimum preload pressure of 6bar remains
(prevents slack-rope build-up as per EN81-2, sect. 12.9.1.5).
Temporary deactivation of preload pressure
For the purpose of checks or maintenance the preload can be
temporarily deactivated.
If no other M3-screw is ready to hand:
1. Remove the fastening screw from a solenoid plug
2. Screw the M3-screw into the opening (1) of the lever of the
emergency-lowering valve
In order to deactivate the preload pressure:
3. Pull the M3-screw and simultaneously press the lever of the
emergency-lowering valve
4. Undo the M3-screw from the lever of the emergency lowering
If the M3-screw had been undone from the solenoid plug:
5. Screw the M3-screw back into the solenoid plug
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve 5 Operating controls and indicators
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5.3 Elektronic card iCon
ATTENTION!
Electrostatic discharge (ESD)
The iCon can be damaged by incorrect handling.
Always keep the iCon in its ESD protective bag and only hold it
by the frame.
errror
s1
s2
pwr
run
up
down
misc.
card
ok
select
12 45 678
GND GND
GND
+SMA
m0(9) m1(10)
-+ -+ com/meas
GND
PE
+24V DC
errror s1 s2
X9
RS232
C011
1
1
1
1
111
300-P-10024940-00
X8
X10
X3
X6X7 X5 X4
X1
X8
X2
X4X5
X6
X7
X10
X3
2
1
X2
X1
X9
3
4
5
5
5
Item Description Item Description
1 ParamCard X4 Connection, iBox
2Top-hat rail TS15, TS35 (EN50022) or
G-type rail G32 (EN50035)
X5 Connector block, solenoids
3Push putton ok X6 Connector block, command signals K6…K8
4Push button select X7 Connector block, command signals K1…K5
5 LED X8 Socket for options boards
X1 Connector block, power supply X9 Socket for options boards
X2 Connector block, switching outputs X10 Connector block, SMA
X3 Connection, Handterminal / PC
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iValve Lift Control Valve5 Operating controls and indicators
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5.3.1 LED indications
LED Description
Status
Function
com Communication with
valve
on communication with valve ok, data packages properly
transmitted/received
flashes ra
pidly
no (correct) communication with valve
meas Measurement of feed
back values
on feedback values from valve (flow, pressure, temperature)
plausible
off when LED “com” flashes rapidly simultaneously: no correct
communication with valve
flashes ra
pidly
feedback values from valve (flow, pressure, temperature)
not plausible, zero balance outside permissible range
flashes
slowly
versions of iCon and iBox not compatible with each other
or
error during function/EEPROM access on valve
m1(10) Solenoid UP/DOWN on solenoid actuated, current correct
off solenoid not actuated
flashes ra
pidly
solenoid actuated, resistance not correct
flashes
slowly
current not correct
m0(9) Solenoid
UCM/A3
on solenoid actuated, current correct
off solenoid not actuated
flashes ra
pidly
solenoid actuated, resistance not correct
flashes
slowly
current not correct
8Command input 8 on command signal K8 present
7Command input 7 on command signal K7 present
6Command input 6 on command signal K6 present
5Command input 5 on command signal K5 present
4Command input 4 on command signal K4 present
3Command input 3 on command signal K3 present
2Command input 2 on command signal K2 present
1Command input 1 on command signal K1 present
+SMA Monitoring of
UCM/A3-valve
on termimal +SMA (X10-2) supplies +24V
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iValve Lift Control Valve 5 Operating controls and indicators
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Function
Status
DescriptionLED
pwr Power supply on all monitored voltages within the permissible range
flashes ra
pidly
one of the internally generated voltages outside the permis
sible range
flashes
slowly
external supply voltage (+24V) outside the permissible
range
run Readiness for opera
tion
on program running, ready for travel
off not ready for travel
flashes
slowly
not ready for travel, error while starting the program (e.g.
EEPROM could not be read), incorrect parameters, param
eter synchronisation running (during start, can take up to
10s)
up Travel UP on travel UP
down Travel DOWN on travel DOWN
flashes pipe rupture test activated
misc iTeach on All iTeach functions on and operating in the permissible
range
off All iTeach functions off
flashes
slowly
At least one iTeach function has reached correction limit
on for
8…9s,
then inter
rupted for
an instant
Indication of deactivated iTeach-functions (number of inter
ruptions = number of
deactivated iTeach-functions)
card ParamCard on ParamCard plugged in, with plausible data
flashes ra
pidly
no ParamCard detected
flashes
slowly
data not plausible
error Error flashes
rapidly
Error present (error relay is energised; list of error mes
sages
s1 Switching output 1 flashes
rapidly
Switching point 1 under-run or exceeded (relay s1 is ener
gised)
s2 Switching output 2 flashes
rapidly
Switching point 2 under-run or exceeded (relay s2 is ener
gised)
IMPORTANT!:Further information on parametrisation is available
in the Parametrisation and Maintenance Manual 300-E 9010543.
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iValve Lift Control Valve6 Installation and commissioning
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6 Installation and commissioning
6.1 Safety information
Before beginning any installation and commissioning work, it is a re
quirement that all personnel have read and understood the chapter
"Safety information".
6.1.1 Surroundings
For reliable operation, the following conditions must be maintained in
the surroundings:
General characteristics
Surroundings
Description, value, unit
Requirement
Machine room temperature +2°C … +40°C
Relative air humidity max. 90% (non-condensing)
Packaging materials must be disposed of in accordance with the gener
ally recognised regulations of the respective countries
6.2 Assembly
6.2.1 Hose or pipe
CAUTION!
Contamination in the line
Contamination adversely affects the valve's function. This can
lead to a dangerous system condition.
Preventive measures:
SClean the hose or pipe before fitting it
SLeave sealing caps/plugs in place until assembly
SCheck that all fittings are assembled correctly
SDo not twist the hoses
SDo not mount hoses under tensile strain
SObserve minimum bending radia
SProtect hoses against mechanical damage (e.g. from sharp edges)
SSupport hoses with hose clamps (approx. 1.5m away from valve)
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Reference: 300-I-9010544-EN-01

iValve Lift Control Valve 6 Installation and commissioning
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300-I-9010544-EN-01/10.2014
6.2.2 Electrical installation
DANGER!
Dangerous voltage
Leads to death or serious injuries.
Before starting electrical installation works, disconnect all power
to the control cabinet.
1. Check whether the 24VDC output of the lift control meets the
requirements of the iCon (see Planning Information 9010542)
When the 24VDC output of the lift control meets the requirements of
the iCon:
2. Execute the cabling acc. to the diagram (see Planning Information
300-D-9010452)
IPlug the grey connector (B) onto the solenoid UP/DOWN,
plug the black connector (A) onto the solenoid UCM/A3
When the 24VDC output of the lift control does NOT meet the require
ments of the iCon:
3. Install the optionally available power supply unit and execute the
wiring acc. to the diagram (see Planning Information
300-D-9010452)
IPlug the grey connector (B) onto the solenoid UP/DOWN,
plug the black connector (A) onto the solenoid UCM/A3
ATTENTION!
Unexpected behaviour of the lift
Air in the iValve can cause unexpected behaviour of the lift such
as
- severe starting jolt UP
- no start DOWN
Make sure that the connections between the iValve and the tube
to the pump(P) as well as the hoses to the tank(T, HP) are tight
and that there will be no venting and hence draining of the tube
or of the hoses.
6.2.3 Installation of the ParamCard
The ParamCard is a memory card which stores installation specific para
meters and data. The ParamCard is plugged onto the iCon. There is no
travel without ParamCard.
If the iCon needs to be replaced the ParamCard will be pulled off the old
iCon and plugged onto the new iCon. Hence all installation specific pa
rameters and data will be available to the new iCon from the first travel
on.
B
A
Issue: 09.2015
19/31
Reference: 300-I-9010544-EN-01

iValve Lift Control Valve6 Installation and commissioning
20/31 300-I-9010544-EN-01/10.2014
As a rule the iValve and the pertinent ParamCard come with factory
settings for the lift to be installed.
2. 4.
3.
5.
CD
B
1. A
iValve i500
iValve i250
1.A
ATTENTION!
Note: Always quote the serial no. when making enquiries. This
makes it easier for the factory to help you!
Note: The serial numbers on the ParamCard and the iValve must
be the same to avoid the need for resetting.
1. Read the serial no. (A) from the housing of the iValve
2. Read the serial no. (B) from the Quality-Certificate and check that it
matches the serial no. (A) on the iValve
3. Detach the ParamCard (C) from the Quality-Certificate
4. Read the serial no. (C) from the backside of the ParamCard and
check that it matches the serial no. (A) on the iValve
Issue: 09.2015
20/31
Reference: 300-I-9010544-EN-01