HYDRAULIC DROP ARM BARRIER INSTALLATION GUIDE

HYDRAULIC DROP ARM BARRIERS
ISO 9001: 2008

EN ISO 14001: 2004
SECURITY SYSTEMS
Gate Barriers
INSTALLATION INSTRUCTIONS
www.optima-engineering.com

2
I NDEX
Page

1. GENERAL INFORMATION .......................................................................... .4

2. SYSTEM COMPONENTS ............................................................................. .6

2.1 Construction and Foundation .......................................................................................... .6

2.2 Control Cabinet .............................................................................................................. 9

2.3 Electrical and Electronics Components .............................................................................. 10

2.4 Hydraulic Components .................................................................................................... 18

3. OPERATION INSTRUCTIONS .................................................................... 20

3.1 Taking the Hydraulic Drop Arm Barrier into Operation ...................................................... 20

3.2 Operation of the Hydraulic Drop Arm Barrier .................................................................... 22

4. MAINTENANCE .......................................................................................... 23

5. PRACTI CAL TROUBLESHOOTING PROCEDURES ...................................... 24

6. HOW TO PUMP MANUALLY ....................................................................... 25

7. CE DECLERATION ...................................................................................... 26

8. ISO 14001:2004 CERIFICATE ................................................................... 27

9. ISO 9001:2000 CERIFICATE ..................................................................... 28


3

SYSTEM
SPECIFICATIONS
and
DATASHEET


4
1. GENERAL INFORMATION

Hydraulic Drop Arm Barriers are designed especially for entrances where there is a threat of
suicide vehicle attact, or for the entrances that have high security requirements. If there is a threat of
vehicle attack in addition to the control of vehicle access in high security applications, hydraulic drop
arm barriers are one of the best and most secure solution. Even though the attack is from high
tonnage vehicles with high speeds, it is not possible for the vehicle to keep on moving forward
anymore beyond the arm of the barrier. Optima Hydraulic Drop Arm Barriers are designed to
DOSK12/L3 and to stop vehicles with 80km/hr speed and 7500kg weight or more.

Drive unit is hydraulic, but in case of power failure barrier can be closed or opened manually
with the help of hand pumps and valves. Opening time is between 5-15 seconds depending on the
crash beam lenght.

With the help of PLC controlled electronics, open/close function can be achieved by every kind
of card readers, biometric readers like fingerprint or hand shape, radio control, on/off key switch etc.
Besides, safety accessories like photocells, inductive loop detectors, flashing lights or red/green lights
can be integrated to the system.

Picture 1. General View of Hydraulic Drop Arm Barrier

1- Control Cabinet
2- Support Column for Driving Group
3- Barrier Arm
4- Support Column for Arm


5
Environmental Conditions and Power Requirement

Between -20 C and +75 C, % 95 non-condensing humidity, 380 V 50~60 Hz
(or 220 V, 50~60 Hz, optional )
Electronical motor of 1 6 HP depending on the crash beam lenght.
Optional Accessories
1. Flashing or red/green lights
2. Radio control receiver, transmitter and antenna
3. Safety photocell, stand and casing
4. Inductive loop detector
5. Drainage Pump
6. Card Reader System
7. Manual Hand Pump (Standard)
8. Oil Cooler/Heater according to weather conditions (Standard)
9. Uninterrupted Power Supply(UPS) to raise/lower the drop arm barrier in case of no
electricity

HDAB Series Hydraulic Drop Arm Barriers
TYPE DESCRIPTION
Hdab 3000
Traffic lane width 3000 mm
Hdab 3500
Hdab 4000
Hdab 4500
Hdab 5000
Hdab 5500
Hdab 6000


6
2. SYSTEM COMPONENTS

2.1 Construction and Foundation

The arm of the barrier which is called the crash beam is supportet by two
support columns in both ends when closed.

Drive of the barrier is both adjustible counterweight and hydraulic. the crash beam
is manufactured by welding two NPU 260x90x10 beams and 80x10 mm steel plates,
constructing a 250x250x10 mm tubular steel structure. Similarly, support columns
and support mounting parts are manufactured by 200x90x8.5 mm NPI beams.
Required foundation depth is around 1000 mm.Similarly the length of the foundation
is 2500 mm and width 2000 mm.Height of the center line of the crash beam is 850
mm from ground level. All the elements are hot-dip galvanized or epoxy coated for
long service lives.

10MM RUBBER PLATE
200x90 mm NPI BEAM
200x75 NPU BEAM
12 MM HARDENED STEEL
200x90 mm NPI BEAM
FOR MORE SAFETY
MOUNTING

Figure 1. Support Columns

7
TOP VIEW
SIDE VIEW
A
A
200X90X8.5 NPI
200X90X8.5 NPI
IMPACT SIDE
200X90X8.5 NPI 200X90X8.5 NPI

Figure 2. Concrete Foundation of HDAB 4000

Height : 1000 mm (from the bottom of the foundation to the Top-plate of the Barrier )
Width : 2000 mm
Length : 2500 mm
Weight : 0.8 - 1.2 tons (depending on drop arm barrier type)


8
Sample Concrete Foundation Dimensions

Figure 3.Hydraulic Drop Arm Barrier Concrete Foundation View.

Depth : 1000 mm
100x100x3 MM
BOX BEAM
1000x250x10 MM
BASE PLATE
D VIEW
C

V
I
E
W
CROSSWISE POSITION
200x90 mm NPI BEAM
250x250x10 MM
BOX BEAM
CROSSWISE POSITION
200x90 mm NPI BEAM
100x100x3 MM
BOX BEAM
100x100x3 MM
BOX BEAM
HORIZANTAL POSITION 100x100x3 mm
2 Pcs. BOX BEAM
(250x250x10 mm)
CARRIERS
B-VIEW
A
-
V
I
E
W
C VIEW D VIEW
A VIEW B VIEW
LAND
CONCRETE
LAND
CONCRETE
12 / 200 mm
IN HORIZANTAL
12 / 200 mm
DETAIL OF GROUND IRON
IN VERTICAL

9
Width : 2000 mm
Length : 2500 mm
Wall thickness : 300 mm
Customer must request a layout drawing for each project from the manufacturer as dimension may
change in every application as installation site may force for different factors (underground piping
etc.)

2.2 Control Cabinet

Material:
2 mm thick sheet metal (electrogalvanized, RAL 7032/7035 electrostatically(epoxy) powder
coated and furnaced) for water-resistant outdoor plating
2.5 mm thick sheet metal (electrogalvanized, RAL 7032 electrostatically(epoxy) powder coated
and furnaced) for inside hydraulic and electric group carriages
Dimensions: 78 cm x 127 cm x 190 cm (cabinet may be manufactured in different dimensions
according to requirements)

Picture2. Control Cabinet (Closed View)

10

Picture2. Control Cabinet (Opened View)

1- Cabinet Side Cover 4- Open/Close Handle and Lock with Key
2- Air Circulation Opening 5- Gasket
3- Cabinet Front Cover 6- Plate

2.3 Electrical and Electronics Components

Control electronics utilized in hydraulic drop arm barrier is PLC controlled. Raise/lower function
can be achieved by every kind of card readers, biometric readers like fingerprint or hand shape, radio
control, on/off switches or key switches etc. Besides, safety accessories like inductive loop detectors,
photocells, flashing lights or red/green lights can be integrated to control electronics very easily.
Power requirement of the hydraulic drop arm barrier is 380 V 50~60 Hz

Pic.5. Cabinet Control Panel Pic.6. Desktop Control Panel

11
1 Emergency Stop Stops the operation of the drop arm barrier in case of
emergency. If pressed, the drop arm barrier is locked and no
comment could be given. In order to return to the normal mode
of operation, turn the button clockwise until the switch releases
itself.
2 Auto Down Lowers the drop arm barrier automatically. It is enough to
push the button ONCE in order to operate the drop arm barrier
from Cabinet Control Panel. No other comment could be given
until the process is accomplished.
3 Auto Up Raises the drop arm barrier automatically. It is enough to
from Cabinet Control Panel. No other comment could be given
until the process is accomplished.

4 Phase R Shows the operation of the first phase cable of the three phases
380 VAC. If it does not light, no voltage on the first cable of the
three phases 380 VAC on the terminal and maintenance is
needed.
5 Phase S Shows the operation of the second phase cable of the three
phases 380 VAC. If it does not light, no voltage on the second
cable of the three phases 380 VAC on the terminal and
maintenance is needed.
6 Phase T Shows the operation of the third phase cable of the three phases
380 VAC. If it does not light, no voltage on the third cable of the
three phases 380 VAC on the terminal and maintenance is
needed.
7 Auto Down Lowers the drop arm barrier automatically. It is enough to
from Desktop (Override/Guard House) Control Panel. No other
comment could be given until the process is accomplished.
8 Auto Up Raises the drop arm barrier automatically. It is enough to
from Desktop (Override/Guard House) Control Panel. No other
comment could be given until the process is accomplished.
9 Emergency Stop Stops the operation of the drop arm barrier in case of
emergency. If pressed, the drop arm barrier is locked and no
comment could be given. In order to return to the normal mode
of operation, turn the button clockwise until the switch releases
itself.
10 Local Enabled Shows that current Desktop (Override/Guard House) Control
Panel is in charge for the operation of the drop arm barrier if
this light in ON.
11 Keyboard: Off/On Depending on the priority of the Control Panel, this switch
changes the operating Control Panel. The priority is Override
Desktop Panel, Guard House Desktop Panel and Cabinet Control
Panel from the most prior to the least prior respectively

12

Picture 7. Electrical Components

1 Cabinet Control Panel Explained in the previous pages
2 Main Fuses For the whole system.
3 Fuses For the UPS.

4 Fuses +24VDC
220VAC input
5 Phase Control Relay If the connection of phase cables
is false, Lamp (As side picture)
will light on the Phase Control
Relay.
If the connection of phase cables
is true, Lamp wont light.
While the phase cables connect
, Please Be carefull.

6 Thermic Magnetic Switch Motor safety switch. If a problem occurs in the oil pump
inside the drop arm barrier, the switch becomes 0 (zero) and
cuts the energy of the oil pump motor to be available for the
maintenance.

13
7-8 Contactor Drives the Motor
9 Telemechanic Zelio PLC Card 24 VDC, Password protected, programmable software
operated PLC card user interface. 12 inputs and 8 outputs are
used. For the further additions and modifications of the
system, 4 inputs and 2 outputs is available. (Total 16 input/10
Output).
10-
11-
12-
13
Relay Group PLC output protection relays.
14 Power Supply AC/DC Converter. If the energy is supplied to the system from
three phases 220/380 VAC, this device changes the voltage to 24
VDC in order to supply power to some of the components in the
system.
15 Loop Dedector
16 (+-) 24V Distrubuter For all systems
17 Terminal Connects electric (energy) connection of the whole system.
A- 3 Phase 380 VAC input
B- Motor output
C- 220VAC Output.
D- UPS input/output
E- Cooler Fan Motor Output.
F- Solenoid Output
G- Main Keyboard Input
H- Keyboard Input
I- Proximity Sensor Input
J- Traffic Light Output
K- Loop Antenna
L- Cabinet Fan Output


14

Pic. A. Keyboard Terminal Group inside Cabinet Pic. B. Keyboard Term. Group Inside
Desktop Keyboard
YOU SHOULD CONNECT KEYBOARD CABLE ONE BY ONE WI TH TERMI NAL I NSIDE DESKTOP
KEYBOARD AND INSIDE CABINET.

15

LOOPANTENNAINPUT
O
p
t
i
m
a
E
n
g
i
n
e
e
r
i
n
g

C
o
.

L
t
d
.
MOTOROUTPUT
UPSINPUT-OUTPUT
PROXIMTYSENSOR+24VDC
PROXIMTYSENSORGND
PROXIMTYSENSORDATA
380VACINPUT
220VACOUTPUT
RED
NATURAL
GREEN
COOLERFAN
UPSOLENOIDOUTPUT
DOWNSOLENOIDOUTPUT
CABINETFANOUTPUT
(220V)
N
MP
R
S
T
U
V
W
N
L
U P S I N P U T
U P S O U T P U T
+ 2 4 V D C
G N D
AUTOUP
AUTODOWN
EMERGENCYSTOP
KEYBOARDOFF/ON
GREENLAMP(24VDC)
REDLAMP(24VDC)
+24VDC
GND
AUTOUP
AUTODOWN
EMERGENCYSTOP
GREENLAMP(24VDC)
REDLAMP(24VDC)
+24VDC
GND
TRAFFICLIGHT
OUTPUT
N
L
9
1
0
1
1
1
2
1
3
1
4
4
5
6
7
8
2
6
2
5
2
4
2
3
2
2
4
5
4
4
8
7
6
5
4
1
5
1
4
1
3
1
2
1
2
3
1
2
3
4
3
4
2
4
1
4
0
3
9
3
8
1
0
1
1
1
6
1
7
2
1
2
0
1
9
1
8
2
9
2
8
2
7
3
4
3
3
3
2
3
1
3
0
3
7
3
6
3
5
4
7
4
6
1
5
1
6
2
0
1
9
1
8
1
7
2
5
2
4
2
3
2
2
2
1
2
8
2
7
2
6
3
3
3
2
3
1
3
0
2
9
3
6
3
5
3
4
3
9
3
8
3
7
4
2
4
1
4
0
4
4
4
3
4
6
4
5

16
TERMINAL NAME TERMINAL NO TERMINAL CONNECTION
380 VAC INPUT
1 R PHASE
2 S PHASE
3 T PHASE
4 NEUTRAL
5 GROUND
MOTOR OUTPUT
6 U
7 V
8 W
220VAC OUTPUT
9 L
10 N
UPS INPUT & OUTPUT
11 220 V
12 NEUTRAL
13 NEUTRAL
14 220 V
COOLER FAN OUTPUT
15

(+) 24VDC
16

GND
UP SOLENOID OUTPUT
17 DATA
18 (-) 24V
DOWN SOLENOID OUTPUT
19 DATA
20 (-) 24V
MAIN KEYBOARD INPUT
21

AUTO UP
22 AUTO DOWN
23 EMERGENCY STOP
24 KEYBOARD OFF/ON
25 GREEN LAMP (24VDC)
26

RED LAMP (24VDC
27

(+) 24VDC
28

GND


17
KEYBOARD INPUT
29

AUTO UP
30 AUTO DOWN
31 EMERGENCY STOP
32
33 GREEN LAMP (24VDC)
34 RED LAMP (24VDC
35 (+) 24VDC
36 GND
PROXIMITY SENSOR INPUT
37 (+) 24VDC
38 GND
39 DATA
TARFFIC LIGHT OUTPUT
40 GREEN
41 NEUTRAL
42 RED
LOOP ANTENNA INPUT 43 LOOP ANTENNA (TWISTED)
LOOP ANTENNA INPUT 44 LOOP ANTENNA (TWISTED)
CABINET FAN OUTPUT
45 220V
46 NEUTRAL


18
2.4 Hydraulic Components
There are two pumps in the hydraulic system: Electric motor coupled gear pump (17 cc) and
manual operated hand pump. The first one is the default used pump in the system. The hand pump is
installed in case the gear pump does not work. When the direction control valves are in tandem
positions, the oil is pumped back to the reservoir through the pressure relief valve.
The oil level in the hydraulic system could be checked with the help of the Oil Level Gauge
and oil could be added through Oil Reservoir Plug.

Picture 8. Hydraulic Group
1 Electric Motor 4KW (approximately)
2 Oil Reservoir Plug (To fill the tank)
3 Direction Control Valve (Manually by handle)
4 Hose Connection Block
5 Manometer
6 Direction Control Valve (Solenoid Actuated)
7 Oil Cooler Fan
8 Hand Pump
9 Manual Hand Pump Valve (it will be tightened when using manually)
10 Oil Level Gauge
11
Tank

The handles of Direction control Valve Manually by handle, namely No:3 in Picture 8
must be unscrewed all the time of normal operation by motor.
They are to be screwed ONLY when there is no electric power and the system is to be
operated manually by hand pump.After the electricity is available, these handles (2 pieces of handles
numbered as 2) must be unscrewed before operating by motor. Otherwise, the system will be
damaged.

19

OPERATION
and
MAINTENANCE


20
3. OPERATION INSTRUCTIONS
3.1 Taking the Drop arm barrier Into Operation
1. Open the control cabinet. Meanwhile unscrew the 4 pcs of holding rings from the roadblocker s top plate.

Figure : 12/1 Figure :12/2

Figure : 12/3 Figure : 12/4

Figure : 12/5

21
2. Connect the hoses coming from the hydraulic cylinder with the hydraulic system in the
cabinet.
3. If there is a Drainage Pump in the Drop arm barrier System, connect the electric power
cable to the terminal.
4. If there is a Red/Green Traffic Light in the Drop arm barrier System, connect the electric
power cable of the Red/Green Traffic Light to the terminal.
5. If there is a Loop Detector in the Drop arm barrier System, connect the antenna cables of
the Loop dedector to the terminal.
6. If there are Radio control receiver, transmitter and antenna in the Drop arm barrier
System, connect the electric power cable of it to the terminal.
7. If there are Safety photocell, stand and casing in the Drop arm barrier System, connect
the electric power and data cables of Safety Photocell to the terminal.
8. If there is a Card Reader System in the Drop arm barrier System, connect the electric
power and data cables of Card Reader System to the terminal.
9. Make sure that fuses on the Cabinet Panel are ON (upward position).
10. Make sure the emergency stop buttons on the Cabinet Control Panel and Guard House
Desktop Panel are not pressed.
11. Initially, there will be no oil in the hydraulic system, therefore fill the oil reservoir with
Shell Thellus 46 or equivalent. Check oil level from the gauge (Picture 8, No: 10) on the
oil reservoir (Picture 8, No: 2). It must show full .
12. Make sure that Motor safety switch on the Cabinet Panel (Picture 7, No: 6) are ON.
13. Connect the three phase 380 VAC cables to the terminal.( Picture 7, Item 17-A)
14. Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the Cabinet
Control Panel (Picture 5, No: 3 ,4, 5) are ON.


22

3.2 Operation of the Drop arm barrier

Depending on the position of the Local/Remote Switch on the Override Desktop Panel and
Guard House Desktop Panel, either Override Desktop Panel or Guard House Desktop Panel or Cabinet
Control Panel could control the Drop arm barrier. For each Drop arm barrier, only ONE panel could be
in charge, i.e. two panels could not operate the drop arm barrier at the same time.

Case 1) The Guard House Desktop Control Panel is in Charge: If the Local/Remote Switch of
the.Desktop Control Panel is on the Enable position (switch is heading to the RIGHT) the
Local Enabled Light on the Guard House Desktop Control Panel becomes ON which
means that the Guard House Desktop Control Panel is in charge and Cabinet Control Panel
could not operate the Drop arm barrier.

Case 2) The Cabinet Control Panel is in Charge: If the Local/Remote Switch of the Desktop
Control Panel is on the Disable position (switch is heading to the LEFT), the Cabinet Control
Panel is in charge.

For each case, the operation of the drop arm barrier is as follows:
Raising of the Drop arm barrier is done automatically. In order to raise it automatically, push
Auto Up button (Picture 5 No: 2, Picture 6 No: 8) ONCE.
Lowering of the Drop arm barrier is done automatically. In order to raise it automatically,
push Auto Down button (Picture 5 No: 1, Picture 6 No: 7) ONCE.
Unless a successive command is sent, the motor will stop in 4 seconds.
Depending on the customer desire, DEAD-MAN BUTTON could be added to the system. In
that case, in order to raise and lower the drop arm barrier, either automatically or manually,
Guard House Desktop Control Panel and the dead-man button MUST be pushed at the same
time; otherwise the drop arm barrier could not be operated from the guard house. This
function is added to the system in order to prevent the drop arm barrier from being operated
by people other than the guard staff in case of emergency.
Depending on the customer desire, inductive loop detector(s) could be added to the system.
These devices work on the PULSE ON EXIT or SAFETY LATCH principle, i.e. when the
vehicle leaves the loop detectors magnetic area, it sends the PLC controller a pulse in order to
inform it about the vehicles position or it sends a signal as long as there is a vehicle on the

23
loop antenna. According to the design of the control logic, the drop arm barrier could be
raised and lowered automatically even without using the desktop panels.
Depending on the customer desire, card reader system could be added to the system.
According to the design of the control logic, the drop arm barrier could be raised and lowered
automatically even without using the desktop panels with the help of the pulse sent by the
card reader system.

4. MAINTENANCE

Oil Check
Oil Used: Shell Thellus 46 or equivalent
First oil change to be made after 500 working hours, next changes to be made after every
5000 working hours.

Filters Check
Filters to be changed at every oil change.

Oil Leakage Check
System to be eye-controlled for oil leakage once in every 3 months.
Piston to be eye-controlled if there is any leakage once a year.

Pressure Check
Manometer pressure values must be checked at every leakage control to see if there is
any deviation from the values stated by the manufacturer.

Maintenance Staff
All system controls to be made by qualified technical staff only.
Only original equipment manufactured or recommended by the manufacturer to be used
at repair and/or maintenance procedures.


24

5. PRACTI CAL TROUBLESHOOTING PROCEDURES

If there is no movement observed after pressing auto or manual raise/lower buttons;
Make sure the emergency stop buttons on the Cabinet Control Panel and Guard
House Desktop Panel are not pressed.
Make sure that fuses on the Cabinet Panel are ON (upward position).
Make sure that Motor safety switch on the Cabinet Panel are ON.
Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the
Cabinet Control Panel (Picture 5, No: 3, 4, 5) are ON.

If there are unexpected behaviors in system, quickly stop the system by pressing one of
the emergency stop buttons on the Cabinet Control Panel, Override Desktop Panel and
Guard House Desktop Panel.

In case of power failure, drop arm barrier could ONLY be controlled by the cabinet control
panel due to the battery in the cabinet supplies the needed power for the electronics and
in case of the battery power shortage, the hand pump is used to raise/lower the drop arm
barrier manually.


25

6. HOW TO PUMP MANUALLY
Insert manual pump arm into the slot and pump manually (Figure 13).
Push the pressure direction rod (Fig.10 No:4) to the right side of direction control
valve for raising and to the left side of direction control valve for lowering (Fig.10
No:3) as shown in the picture.
Pump the system manually by hand as shown in the pictures.

Figure 13-A.Raising Position

Figure 13-A.Lowering Position
**If the system is not still running after all these controls, please contact with the
manufacturer.


DECLARATION OF CONFORMITY FOR MACHINES
(DIRECTIVE 98 / 37 EEC, ATTACHMENT II , PART B)

Manufacturer:

Declares that the products,

V 100, V 200, V 300, V 400, V 500 Series Tripod Turnstiles
M 100 Series Motorized Turnstiles
F 100 Series Full-Height Turnstiles
HH100 Series Half-Height Turnstiles
SWG200 Series Swing Gate Turnstiles
are constructed to be incorporated in a machine or to be assembled with other
machinery to construct a machine considered modified by the directive 98 / 37 EEC
are in confirmity with the regulations of the following EEC directives.

Directive 98 / 37 EEC directive for machines
Directive 73 / 23 EEC and directive 93 / 68 EEC low voltage
Directive 89 / 336 EEC and directive 92 / 31 EEC and directive 93 / 68 EEC
electromagnetic compatibility.

And also are in confirmity with the following national standards.

- TS EN 292-1 / January 1996 Standard
- TS EN 292-2 / January 1996 Standard
- TS EN 563 / April 1997 Standard
- TS EN 418 / November 1995 Standard
- TS EN 60204-3-1 / December 1995 Standard
- TS EN 50082-1 / April 1995 Standard
- TS EN 50082-2 / February 1998 Standard
- TS EN 60000-4-2 / April 1997 Standard

4 April 2001

Ankara smail Tamer LGEN
TURKEY President
Mechanical Engineer, B. Sc.

26
OPTMA MHENDSLK LMTED RKET
KERESTECLER SANAY STES
3. CADDE NO:8 SARAY 06980
KAZAN / ANKARA/ TRKYE

2

2

HYDRAULIC DROP ARM BARRIER INSTALLATION GUIDE

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