Bucher IValve i250 Bedienungsanleitung

iValve Lift Control Valve – i250 / i500

Operating Instructions

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Reference: 300-I-9010544-EN-01

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iValve Lift Control Valve

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E2014 by Bucher Hydraulics AG, CH-6345 Neuheim

be reproduced, nor may it be stored, processed, replicated or distributed by electronic means, withou

written permission from Bucher Hydraulics.

Data is provided for the purpose of product description only, and must not be construed as warrante

characteristics in the legal sense. No assertion regarding either a particular property or the fitnes

for a particular intended purpose can be derived or deduced from this information. The informatio

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

any possible errors in translation.

Published by

Bucher Hydraulics AG

Industriestrasse 15

CH-6345 Neuheim

Phone +41 41 757 03 33

Fax +41 41 757 05 00

Email [email protected]

Internet www.bucherhydraulics.com

Classification: 430.310.501

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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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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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iValve Lift Control Valve 1 About this document

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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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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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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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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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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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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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Reference: 300-I-9010544-EN-01

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