Intelligent Lift Control Valve with Electronic Card
Qmax = 500l/min,pmax = 80bar
Leak-free, two-stage, electronically controlled, without frequency control
Series iValve – i250 and i500
1
Information – lift-control valve
S No modifications of the travel curve
or mechanical adjustments are necessary
S Constantly short travel times,
regardless of loading and temperature
S Constant levelling accuracy of ± 3 mm,
which prevents dangerous tripping accidents
S Self-monitoring function guarantees
fully integrated A3 conformity (TÜV approved)
S Pleasant acceleration and slowdown
thanks to an electronically controlled travel curve
S Soft-stop function for smooth approach and entry
1.1 Description
The iValve lift-control valve is an electronically controlled
hydraulic valve block for controlling hydraulic lifts. The
iValve is situated 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 supported by a
check valve integrated in the iValve. In operation, the elec­
tronic controller regulates the states “Travel UP” and “Travel
DOWN”, and the transitions between these states. In the
electronic unit, the 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 following
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, an emergency stop DOWN valve (UCM/A3) in ac­
cordance with EN 81-2 + A3.
1.2 Technical data – iValve
General characteristics
Description, value, unit
i250
Designation
Intelligent lift-control valve
Design
Leak-free, two-stage, electronically controlled
Mounting method
Size
G1
- Port P
- Port T
- Port HP
- Port Z
- Port Z1
Tightening torque
i500
- Port P
- Port T
- Port HP
- Port Z
- Port Z1
Pipe mounting or
low mounting
(see interface in
“Installation info.”)
G1½ Pipe mounting or
low mounting
(see interface in
“Installation info.”)
G1
G1
Hose, oil-resistant
(id = 8 mm, od = 12 mm)
28L EN ISO 8434-1
G¼
G1½
G1½
Hose, oil-resistant
(id = 8 mm, od = 10 mm)
42L EN ISO 8434-1
G¼
230 Nm ± 10%
230 Nm ± 10%
Hose 10 x 1
(pushed on)
230 Nm ± 10%
35Nm±10%
500 Nm ± 10%
500 Nm ± 10%
Hose 10 x 1
(pushed on)
500 Nm ± 10%
35Nm±10%
Reference: 300-P-9010528-EN-02
Issue: 09.2015
1/13
General characteristics
Weight
Description, value, unit
i250
10.4 kg
Mounting attitude
22.5 kg
As illustrated – see section “Dimensions”
Ambient temperature range
Hydraulic characteristics
i500
+2°C … +40°C
Description, value, unit
i250
i500
Nominal pressure
80bar
80bar
Maximum flow rate
250l/min
500l/min
Nominal flow rate Down (Z > T)
see section “Performance graphs”
Flow direction
P → T (bypass)
P → Z (UP)
Z → T (DOWN)
Hydraulic fluid
HL and HLP mineral oil to DIN 51 524;
for other fluids, please contact BUCHER
Hydraulic fluid temperature range
Viscosity range
Minimum fluid cleanliness
Cleanliness class to ISO 4406:1999
Electrical characteristics
+0°C … +60°C
20 ... 500mm2/s (cSt)
Class 21/19/16
Description, value, unit
i250
i500
Supply voltage
24VDC
Supply voltage tolerance
±10%
2/13
300-P-9010528-EN-02/09.2015
Series iValve
1.3 Schematic – iValve
Z
3
Z1
C
9
6
P
U
Q
U
T
U
8
A
D
7
4
5
1
300−P−10024709
2
HP
P
T
Item
Description
1
Main spool
2
Pressure relief valve
C
iBox
3
Ball valve
P
Pump
4
Pilot operated check valve
T
Tank
5
Emergency stop DOWN valve (UCM / A3)
6
Piston-creep prevention
Z
Cylinder
7
Hand pump
Z1
Test port
8
Pressure relief valve in the hand pump
9
Pressure gauge
300-P-9010528-EN-02/09.2015
Series iValve
Item
Description
iCon (included in the delivery)
HP
Hand pump
3/13
1.4 Performance graphs
–––
Legend
500 mm2/s (cSt) Motorex Corex HLP 46 at approx. 2°C
_____ 75 mm2/s (cSt) Motorex Corex HLP 46 at approx. 30°C
iValve 250
1.4.1
Δp = f (Q) Pressure drop - Flow rate characteristic [i250/160]
(min. dynamic pressure/flow rate)
Δp = f (Q) Pressure drop - Flow rate characteristic [i250/250]
(min. dynamic pressure/flow rate)
Δ p [bar]
Δ p [bar]
12.5 iValve-250_P01.ai
12.5 iValve-250_P02.ai
10.0
10
Down (Z-T)
Down (Z-T)
7.5
7.5
Up (P-Z)
5.0
5.0
Up (P-Z)
2.5
2.5
0
20
1.4.2
40
80
120
140
160 Q [l/min]
0
160
175
190
205
220
235
250 Q [l/min]
iValve 500
Δp = f (Q) Pressure drop - Flow rate characteristic
(min. dynamic pressure/flow rate)
Δ p [bar]
9
iValve-500_P01.ai
8
7
Down (Z-T)
6
5
4
Up (P-Z)
3
2
1
0
150
4/13
250
350
500 Q [l/min]
300-P-9010528-EN-02/09.2015
Series iValve
1.5 Dimensions, interface iValve – i250
159.3
313
512
312.25
(G1“)
(G1/4“)
72.4
T
HP
(G1“)
67.6
101.6
134.3
B-B
300-4-10022900
P
Z1
95
25
42
3
A-A
52
153.5
187.5
507
Low-mounting connection – see Figure A-A
60
A-A
Pipe-mounting connection – see Figure B-B
60
52
B-B
34
ø44
ø42
T
300-P-9010528-EN-02/09.2015
Series iValve
43
43
HP
34
(17)
109
7
P
71
52
16.5
5/13
1.6 Dimensions, interface iValve – i500
142
(490)
(466)
49
Z
HP
172
(M52x2)
4
A-A
T (G1½)
300-P-10024847-03-B1
75
(G1½) P
B-B
148.75
71
197
Low-mounting connection – see Figure A-A
Pipe-mounting connection – see Figure B-B
93.7
71
71
B-B
100
100
T
HP
HP
300-P-10024847-03-B2
P
74
37
70
A-A
44.5
6/13
300-P-9010528-EN-02/09.2015
Series iValve
1.7 Application examples
S The lift-control valve is an electronically controlled hy­
draulic valve block for controlling hydraulic-powered pas­
senger and goods lifts.
S The lift-control valve is situated on a hydraulic power unit
and activated by a lift control system.
1.8 Model code – iValve
IVALVE
-
250
/
160
Rx.x
IVALVE = Intelligent lift-control valve
500
250
500
250
160
=
=
=
=
=
R1.0
= Release / Design stage
2
Nominal size 500
Nominal size 250
Flow rate 500l/min (nominal size 500)
Flow rate 250l/min (nominal size 250)
Flow rate 160l/min (nominal size 250)
Electronic card for lift-control valve – iCon
S Potential-free switching output for faults
S Two configurable switching outputs
(pressure switch, train speed supervision)
S Functions can be expanded via options board
2.1 Description iCon
The iValve lift-control valve is an electronically controlled
hydraulic valve block for controlling hydraulic lifts. The elec­
tronic control is accomplished by an electronic unit – the
iCon – that is housed in the control cabinet. In operation, the
electronic controller regulates the states “Travel UP” and
“Travel DOWN”, and the transitions between these states.
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".
300-P-9010528-EN-02/09.2015
Series iValve
The ParamCard is a memory card on which the system-spe­
cific parameters and data are stored. The ParamCard plugs
into the iCon. Without the ParamCard being plugged in, no
lift travel can be carried out.
7/13
2.2 Technical data
General characteristics
Description, value, unit
Designation
iCon
Design
Printed circuit board with 4 layers
Electrical connection
- solenoids
- electronics
3-pin square plug to ISO 4400 / DIN 43650
PCB connector 3.5 / 5 mm (screw terminals)
Plug connector kit available - see the chapter Accessories
Mounting method iCon
15/35 mm cap rail
acc. to EN50035 (G32) or EN 50022 (TS15, TS35)
Mounting method
Option boards
4 spacer studs M4x16 (included in delivery)
Weight
0.20kg
Ambient temperature range
+2°C … +40°C
Relative air humidity
0…90% (without condensation)
Dimensions (overall sizes W x H x D)
112x122x63mm (without options board)
Supply voltage
24VDC
Supply voltage tolerance
±10%
Max. ripple
250 mV pp max. (ripple and noise)
Power consumption at max. control current
50W (i250) – 75 W (i500)
Command inputs
GNDactive/+24Vactive (configurable)
Switching outputs
Potential-free relay contacts
Relative duty cycle
100%
Max. Nominal power consumption at standstill
3W
Relay contact rating:
Min. control current
Max. voltage
Max. power
10 mA / max. 3A
250 VAC
750 VA (AC) / 90W (DC)
Electromagnetic compatibility: interference immunity
EN 12016
Electromagnetic compatibility: interference emission
EN 12015
Protection class to ISO20653 / EN60529
IP 00
8/13
300-P-9010528-EN-02/09.2015
Series iValve
2.3 Block diagram
iCon
Lift control system
(customer`s)
X1
+
24V
DC
1
+24V DC
2
GND
3
PE
ParamCard
X7
K1
6
1
K2
5
2
K3
4
3
K4
3
4
K5
2
5
1
GND
X6
K6
4
6
K7
3
7
K8
2
8
1
GND
+24V
*
**
X8
+24V
2k15
+24V DC
0,7A
17W
+24V
X10
Monitoring
SMA
2
1
i500
i250
+24V DC +24V DC
2.0 A
1.2 A
30W
+SMA (24V DC)
(0.2A)
GND
X5
NR
FR
4
m0-
3
m0+
2
m1-
1
m1+
X2
1
2
3
NR'
FR'
4
5
6
ge
gn
br
ws
7
8
iValve
9
nc
error
no
Switching output
Relay - fault /
SIU
nc
s1
no
Switching output
Relay s1
nc
s2
no
Switching output
Relay s2
iBox
X4
Solenoid
Solenoid
UCM / A3 UP-/DOWN travel
(black plug)
(grey plug)
X3
RS232
Handterminal / PC
*
Configurable via software, GND-active/ +24V-active
(applies to all inputs K1 ... K8)
300-P-9010528-EN-02/09.2015
Series iValve
*
300-P-10024761-02
com/meas
Configurable via software, GND-active/ +24V-active
(applies to all inputs K1 ... K8)
9/13
2.4 Dimensions
2.4.1
Electronic card iCon – basic board
112
min.60
100
~44
122
100
105
~47
11
6
G32 EN 50035
300−P−10024940−00
TS35 EN 50022
106
2.4.2
Electronic card iCon – with options board (2 additional switching outputs)
56.8
70
10
33.8
72
59
8
50
G32 EN 50035
300-P-10024940-00
TS35 EN 50022
10/13
300-P-9010528-EN-02/09.2015
Series iValve
2.5 Pin assignments
iCon electronic card – basic board
X7
X10
X5
X10
X7
X6
1
1
1
X4
X5
X4
1
X8
1
2
3
4
5
6
7
8
GND
GND
1
+SMA
pwr
run
up
down
misc.
X6
GND
X8
−
−
+
m0(9)
+
m1(10)
com/meas
X3
1
X9
X3
card
RS232
2
X9
X1
PE
GND
+24V DC
select
1
errror
error
s1
s2
X2
s1
s2
1
X1
300−P−10024940−00
C011
ok
X2
Item
Description
Item
1
ParamCard
X5
Connector block solenoids
2
Top-hat rail TS15, TS35 (EN50022) or
G-type rail G32 (EN50035)
X6
Connector block command signals K6…K8
X7
Connector block command signals K1…K5
X8
Socket for ParamCard
X9
Socket for options boards
X10
Connector block, SMA
X1
Connector block power supply
X2
Connector block switching outputs
X3
Connection Handterminal / PC
X4
Connection iBox
IMPORTANT!:
Two independent switching outputs are available
on the iCon. For each switching output, a relay (s1
and s2) is available, each with a break/make con­
tact.
300-P-9010528-EN-02/09.2015
Series iValve
Description
IMPORTANT!:
K coding and binary coding are possible.
For other information, please contact BUCHER!
11/13
2.5.1
Options board, switching output
Options board for version with pressure switch
X150
X150
X20
1
X20
S3
X21
300-P-10024940-01
S4
Item
Description
X-20
Connector block, switching outputs
X-21
Not used
12/13
Item
Description
X-150 Socket for options board
300-P-9010528-EN-02/09.2015
Series iValve
2.6 Dummy iCon – optional
2.6.1
Description
The "Dummy iCon" can be pre-installed in the control cabin­
et as a "placeholder" instead of the real iCon (control elec­
tronics for the iValve). It has all the plug connectors that the
iCon has, so that the wiring can also be done in advance
(cable lengths and cable positions).
2.6.2
How customers contact the test system
The central "X11" plug offers an additional benefit. All sig­
nals that are wired from outside to the iCon are available on
this plug. Consequently, the wiring can be checked with an
automatic test system.
2.7 Accessories
PartNo.
Description
3007019906
Dummy iCon
3007010231+
Handterminal including connecting cable
3007020027+
PC software "iWin", including connecting cable
3007020442+
Power supply module i250
3007020476+
Power supply module i500
3007020030+
Plug connector kit
3007010472+
3000008998+
3000009002+
Solenoid connection cable: 1.5 metre
, 6.0 metre
, 12 metre
(for Halogen-free versions, contact Bucher)
3007019644+
3007020460+
3007020461+
iBox connection cable:
3
1.5 metre
6.0 metre
12 metre
Related documents
Reference
Description
300-D-9010542
Planning information iValve
300-I-9010544
Commissioning and maintenance iValve
300-I-9010543
Parametrization and maintenance iValve
300-S-9010437
Spare parts iValve / iCon – i250
300-S-9010548
Spare parts iValve / iCon – i500
info.ch@bucherhydraulics.com
www.bucherhydraulics.com
E 2015 by Bucher Hydraulics AG, CH-6345 Neuheim
All rights reserved.
Data is provided for the purpose of product description only, and must not be construed as warranted characteristics in the legal sense. The
information 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 product specifications contained in this catalogue.
Classification: 430.330.500..
300-P-9010528-EN-02/09.2015
Series iValve
13/13