Hydraulic Pumping Unit (HPU)
Contents
1. 611 Series HPU APPENDIX 28 7 4 Maintenance Log Form Equipment Maintenance Log oo BS FIRMR Tel 800 367 0387 703 335 6006 email servicedept bb armr com Location Checklist Perfomed By complete Anomolies Annual __ Annual YES B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B22. Installation and Operations Manual 611 Series HPU INSTALLATION 16 2 4 Electrical Connections DANGER High voltage electrical components are located in the Hydraulic Pumping Unit HPU cabinet Service by qualified technicians only The electrical connections required for proper operation include power and control The power is required to drive the motor and power the PLC while the control voltage is 24VDC and is used to power the inputs of the electrical wiring should be fed through conduits in the hydraulic pumping unit into the electrical control box mounted in the front of the hydraulic unit The power feed is connected to terminals L1 L2 L3 Neutral and Ground Specific control connections may be found by referencing the control circuit drawing supplied in the HPU The motor will run any time the fluid level is adequate and the system pressure is below its set point to charge the accumulator The motor drives the hydraulic pump directly through a coupling and transports the oil to the manifold and into the directional control valve Depending on the command the flow will either run the hydraulic motor to open or close the gate 2 5 Proximity Switch Connection If your barrier is equipped with a proximity switch route wires clear of cylinder travel and pinch points Once power is applied the proximity switch will show a red LED light on when switch is closed and no LED light when switch is open Proximity switch wi
3. Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611 Series HPU INSTALLATION 18 Pressure Adjustment Ring Figure 11 Pressure Adjustment 3 OPERATION 3 1 Introduction The HPU is controlled via a variety of dry contact closures into the Programmable Logic Controller PLC Most common systems use a B amp B ARMR supplied control panel Please reference control panel user manual for specific control options 3 2 Control Signals The dry contact control signals are field connected based on optional equipment ordered per installation For a detailed point to point connection please refer to the site submittal prepared for the specific installation site 3 3 Emergency Fast Operation EFO Optional emergency fast operation enables the pump to provide all pressure and flow possible in the shortest amount of time EFO operation normally requires the user to provide a reset signal to the HPU to enable normal operation to continue During EFO operation is it common for ALL safety signals to be bypassed to enable the barrier to close regardless of such safety devices EFO is recommended to be used in emergency situations only B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU OPERATION 19 3 4 Manual Operation The Model 611X series pumps are equipped with a manual hand pump to pressurize the a
4. are responsible for correct and safe installation operation and maintenance of this equipment Users must follow the specific instructions and safety precautions located in this manual In addition they must Follow the safety standards of the Occupational Safety and Health Administration OSHA as well as other applicable federal state and local safety regulations and industry standards and procedures For installation outside the United States users must also follow applicable international regional and local safety standards Engage only trained and experienced staff to install operate and maintain the equipment Ensure that all repairs are performed correctly using properly trained technicians and the correct tools and equipment This HPU comes with a power ON OFF switch Although this switch does cut the power to the motor and various other devices always use correct lock out and safety procedures when servicing the unit This unit is designed to be operated with the covers in place Extreme caution should be used when operating without covers Additional system safety devices may be included with this barrier system o Vehicle loop detector s Safety loop Traffic arms Traffic lights IR beams Safety edges O OO 0 B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611x Series HPU INTRODUCTION iv How to Contact Us If you have any
5. ARMR products Spare or replacement parts Custom designs or special installations Equipment upgrades modernize your old equipment with state of the art hydraulics and control systems Ancillary security equipment such as security guard enclosures card readers security lighting and many other security related products Technical support via telephone and possible on site support with advanced scheduling D O OOO OO Safety CAUTION RISK OF ELECTRIC SHOCK DO NOT OPEN CAUTION TO REDUCE THE RISK OF ELECTRIC SHOCK DO NOT REMOVE COVER OR BACK NO USER SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611 Series HPU INTRODUCTION lii SYMBOL MEANING The lightning flash with arrowhead symbol within an equilateral triangle is intended to alert the user to the presence of non insulated dangerous voltage within the product s enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance servicing instruction in the literature accompanying the product B amp B ARMR does not assume responsibility for injury to persons or property during installation operation or maintenance As the user you
6. B 9001 Revision B2 Installation and Operations Manual 611 Series HPU ORIENTATION 10 A traffic control gate arm to warn the vehicle operator This arm is positioned in front of the gate and does not rise until the gate is fully open and it closes before the gate starts to close Red amber traffic lights The light remains red if the gate is in any position except fully open Infrared safety beams to detect pedestrian traffic or as an additional vehicle sensing device 2 INSTALLATION 2 1 Introduction This section of the manual describes the procedure to set up and configure a 611X Series HPU for first time operation The product ships from the factory tested and ready for deployment following these steps DANGER High voltage electrical components are located in the Hydraulic Pumping Unit HPU cabinet Service by qualified technicians only CAUTION Heavy components and pinch points are present in this product Use extreme care and proper lifting techniques when servicing this unit NOTE The hydraulic hoses are constructed with JIC fittings to allow removal and installation without sealant Care should be used when disconnecting the pressure side of the hose to insure the pressure has been released prior to disconnecting the fitting The pressure can be relieved by activating the down control button and visually watching the cylinder close If the hydraulic cylinder does not fully close the hose is still under p
7. E 25 To APPENDIX rper cp EIER 25 7 1 Simplified Standard Hydraulic Diagram eee nennen 25 7 2 Typical Bollard Hydraulic Flow Diagram eese enne 26 7 3 Electrical Field Wiring Diagram esee eene nennen nennen rennen ene 27 7 4 Maintenance Log FOTM rei 28 1 ORIENTATION 1 1 Overview The model 611X hydraulic pumping unit is designed to operate hydraulic barriers that require medium pressure and high flow The electric motor comes on any time the system pressure drops below the set point and the level of fluid is adequate It is connected directly to a hydraulic pump which operates independently from the signal command The oil from the pump is drawn through a filter and directed into a directional control valve The flow control valve monitors the operational speed of the barrier B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU ORIENTATION XENC A24N20ACP ELECTRICAL SIDE PANELS DOORS HOSES AND SOME CONTROLLER FITTINGS REMOVED FOR CLARITY 2041 BOR CABINET XHYD FCV FLOW CONTROL o a RR XH YD VALVE DCV VAL DIRECTIONAL SYSTEM RELIEF 6 VALVES XHYD P551553 6119 200 TANK WEL msg BASE FILTER ASSY EFO VALVE amp COIL XHYD CSE C565 XIND G610 12AL at 1 MOTORS O
8. IL SITE GAUGE 3 PH 5 HP 1s ne RLD S XMTR G1310165HP teres tct es XMAN AD PO vs i amp 3 02 A ia XMTR 114615 00 XMAN AD03P03 M A v 1 PH 3 HP 003 04 T N XMTR 121060 00 MANIFOLD BLOCK ils Z i EN sg y P gt Aa auct AA pL xPUMP G1220t XSW PSW B 0 AA nen PRESSURE UL __ 7 N XHYD 6 7AL 20 ACCUMULATOR XPUMP HP121DANT 7 HAND PRESSURE GAUG Figure 1 Orients you to the basic components of the 6118 amp 6119 series HPU The HPU contains HIGH VOLTAGE components that can cause serious injury or death Only trained service technicians should attempt any repair Ensure at all times that proper safety lock outs barrier safety braces and all other safety systems are in place prior to any maintenance or service The HPU is a hydraulic system that can be under extreme pressure Caution should be used when working in and around unit without proper covers in place 1 1 1 Electrical Control Box The control box houses the electronic controls in the HPU The program installed in the PLC varies based on the barrier style and application B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU ORIENTATION The power switch should be turned off any time the unit is serviced Do not restore power to the unit until all traff
9. Installation and Operations Manual Model 611 HPU Series MODEL 611x SERIES Wedges amp Bollards FRMR Hydraulic Pumping Unit HPU INSTALLATION AND OPERATIONS MANUAL B amp B ARMR CORPORATE OFFICE amp TECHNICAL SUPPORT 2009 CHENAULT DRIVE SUITE 114 CARROLLTON TX 75006 PHONE 800 367 0387 FAX 972 385 9887 E mail info 2 bb armr com techsupport bb armr com MADE IN THE USA B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611x Series HPU INTRODUCTION 11 Your safety is extremely important to us If you have any questions or are in doubt about any aspect of the equipment please contact us INTRODUCTION Welcome Congratulations on your purchase of a B amp B ARMR Hydraulic Pumping Unit HPU In addition to providing detailed operating instructions this manual describes how to install maintain and troubleshoot your HPU If you require additional assistance with any aspect of your installation or operation please contact us We have years of experience in all aspects of perimeter security and related disciplines and our products are used throughout the world to control access and to protect people equipment and facilities We offer a broad range of vehicle barrier and related security services Turnkey installations Routine barrier preventative maintenance or emergency repairs including work on non B amp B
10. ccumulator and operate the barriers in case of power failure The following lists out the recommended sequence to operate the pump in a manual mode 1 Open door to HPU cabinet and identify the power switch pressure gauge manual hand pump and control valve s Your pumping unit may vary slightly from these illustrations Consult technical assistance if unsure of locations of these components HPU Power Switch aM Gauge mand Pump Figure 12 Model 6119 HPU without EFO Manifold 2 Turn the power switch off to the unit to ensure pump system does not inadvertently turn on without warning on power restore 3 Verify area surrounding the barrier is clear of pedestrian traffic or other obstacles Manual operation of the pump to raise and lower the barrier by pass all safety lockouts and switches Use extreme care when operating any barrier in the manual mode 4 Check pressure gauge on pump to determine if accumulator system has adequate pressure to raise the barrier 1500 1900 psi or greater B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU OPERATION 20 5 If pressure is less than barrier requirements operate the manual hand pump until pressure reaches the desired level 6 Manually shift desired control valve by placing a small screwdriver or other pointed instrument on the solenoid end and push The B side of t
11. cklist isse ee ertet eer terreri ine 16 2 6 1 Start up procedure of Hydraulic Pumping units esee 17 2 6 2 Line Purging Procedure after 5 rennen 17 2 0 3 Pressure Adjustment euet epe e Deniqne pe pte puede 17 3 TIN aa UNE Ue SEEN UNE dna tate Ie n opa eo ena 18 3 1 18 3 2 Control 916 ci ep e EF PEERS D rete 18 3 3 Emergency Fast Operation EFO ies tte ee foie tbe pde andes rever Roe 18 3 4 Manual Operation ep teg ege tee ie v etur ene e chives 19 B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU TABLE OF CONTENTS q MAINTENANCE p PAR EHTU 20 4 1 Introductions ee deg a ed edo leen A osten nope Be 20 4 2 Monthly Inspections 4 ei diee deett ee utei etes ee Ree ede deo de Rte ied dee aae 21 4 3 Six Month Inspections eter RH PHOT D HP ea 21 4 4 Annual Maintenance 22 5 TROUBLESHOOTING wccicccistatacceavetsenvsnahedsvanehseeversdedevareheosvarsbedevedekercsaredecedencss 22 5 1 611x Series Troubleshooting Guide eese nennen 22 Gs WARRANT N p PO ple RO eR teo RP A aie Reine lo FAV RS R
12. d you perform the following visual inspections monthly on the barrier system An equipment maintenance log is supplied in the appendix to assist in the logging Q Inspect the condition of the finish If rust is present wire brush and sand the area then paint with a primer and a matching color Vacuum and clean the pumping unit area Check paint and touch up if required Check oil for level pressure and condition in Recommended oil Mobil EAL 224 If oil is contaminated report and recommend replacement immediately Recommended oil Mobil EAL 224 Replacement requires authorization Check barrier for operation through normal cycles Adjust barrier speed to ensure proper operation Check original submittal documents for normal operating speed for up and down During the opening and closing cycles verify the barrier operates smoothly and does not bind Also verify that the barrier does not hit with excessive force when it contacts its full open or full closed positions If necessary adjust the barrier s speed Check the hydraulic pumping unit for leaks at all points Visually inspect the operation and electrical contacts Tighten electrical contacts if required Check adjust and tighten all sensors limit switches proximity switches If applicable check traffic lights and replace any burned bulbs or LEDs Check safety devices loop IR etc for proper operation and report an
13. e E Ue Y Ote atn ee UR eee wed ERIS 7 1 L2 Valve ise Rete ette tee E ber EN CEE ERN ORE E Ree EEN RE 8 LL3 System relef Valves eet etes lette e b Up saben 8 FIA eR ERREUR SERERE REB a EES ER UER ERE UR Ree TREE 8 1 15 Gauge oett eerte er Ire em te RS codons REEL ER e oreet eroe 8 L6 Manifold Block eese SERE ERE EIE 8 TI Pressure Sweer e 8 l1 H ndPu mpuc suoni nei eb ee re ene e e oH 8 12 9 PresSUFe gaUBE oc nonien ei Re e E e ne HE e 8 1 1 10 Accumnulatot eoe dee c e e e HR t pei e ple eus 9 1 1 11 P inp eene e ea En oie i es 9 1 1 12 ee eite pes 9 1 1 13 FFO Valvedand Coll iii ete et ee rero eee ede 9 1 1 14 Base Filter Assembly e eO RIA Be ires 9 1 1 15 Dir ctional Control Valve deer ertet recta eere eee eee ns 9 1 1 16 Cabinet ione Eon oor e e nhe e 9 1 1 17 T 9 2 INSIALEATIGOTN itera eoe eek vu Cine rA ye eo CERE YS Oa FR ree KATA TE NINS 10 2 1 Introduction ea o PEE RENE RM CER MG ER ERE eer e e 10 2 2 Site Preparation DP 10 2 3 Hydraulic Connections i iae ted tee i teda eee bete tea have betae 14 2 4 Electrical Connections s d at e pe be eate nep esee a ele aR eee 16 25 Proximity Switch Connection 16 2 6 Final Pre operation Che
14. en the barrier by depressing the directional control valve to see if problem is mechanical or electrical 6 Check PLC input on pumping unit 7 Check that safeties are clear 8 Check PLC output on pumping unit 9 Check push button operation Barrier does not close when commanded on control panel Check power Check for binding between moving plate and frame Check connection of linkage between frame and plate Check for foreign debris Check pressure gauge Check overload protector Manually close the barrier by depressing the directional p ES DUROS control valve to see if problem is mechanical or electrical Check PLC input on pumping unit Check that safeties are clear Check PLC output on pumping unit Check push button operation OQ por mI HPU pump will not build up pressure but is running Check power Check hydraulic fluid level Close pressure relief valve HPU pump will not turn on Check power Check motor overload press start Check motor starter Check low level switch Check pressure switch Hydraulic unit excessively hot kc eir 99 Ras Check that the pressure relief valve is closed fully clockwise Check that the pressure switch is adjusted to shut the motor off before 1900 PSI Check for correct voltages bs Barrier moves too slowly Check for mechanical binds Check flow control valve In extreme cold temperatures a higher grade hydraulic fl
15. es if applicable Open the hydraulic oil tank in the HPU and inspect the oil for dirt or water When the inspection is complete turn the power on and test cycle the barrier to verify operation and control DO O O OOO 4 4 Annual Maintenance Inspections We recommend you perform the following inspections annually Perform all quarterly maintenance steps Replace the hydraulic fluid 5 TROUBLESHOOTING The table below provides a general guidance on identifying and correcting any problems with your 611X Series HPU If you encounter problems that you cannot fix contact B amp B ARMR and we will gladly work with you to correct them 5 1 611x Series HPU Troubleshooting Guide The table below provides guidance on identifying and correcting any problems with your 611X series HPU Please refer to the barrier manual for more detailed troubleshooting guides If you encounter problems that you cannot fix contact B amp B ARMR and we will gladly work with you to correct them B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611x Series HPU TROUBLESHOOTING 23 Symptom Actions Barrier does not open when commanded on control panel 1 Check power 2 Check for binding between moving plate and frame Check connection of linkage between frame and plate Check for foreign debris 3 Check pressure gauge 4 Check overload protector 5 Manually op
16. he valve deploys raises the barrier The A side of the valve stows lowers the barrier Figure 13 Model 6119 HPU without EFO Manifold 7 Multiple operations may require additional hand pumping to increase accumulator pressure 8 After power is restored turn pumping unit power back to the on position No additional changes are required 4 MAINTENANCE Do not attempt repairs unless you are trained and qualified This vehicle barrier can cause equipment damage and severe injury if it is operated or maintained improperly 4 1 Introduction The 611X Series HPUs are designed to be largely maintenance free As with any complex electromechanical device however they must be regularly inspected to ensure B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU MAINTENANCE 21 they are operating correctly We recommend a simple monthly visual inspection and a more thorough biannual inspection as described below Please contact B amp B ARMR Technical Service Support for assistance with inspections maintenance or repairs if needed Component damage is likely if a vehicle strikes the barrier If this occurs contact B amp B ARMR We can help you assess the damage to make sure there is no hidden damage that will compromise safety or effectiveness and help you determine which components should be replaced 4 2 Monthly Inspections We recommen
17. ic and pedestrians have been cleared from harm s way 1 1 2 Flow Control Valve The flow control valve s are located on the manifold and are used to control the amount of flow of hydraulic fluid both to and from the barrier under control This in turn sets the speed of operation of the barrier The lower flow control valve controls how fast the gate travels while the upper control valve restricts how fast the barrier is opened 1 1 3 System relief Valve The system relief valve enables the system to be de pressurized during maintenance and service operations 1 1 4 Tank Weldment The tank reservoir holds the hydraulic fluid that is not under pressure The nominal capacity of the tank is 20 gallons 40 gallons on the 6117 B amp B ARMR recommends the use of environment friendly oil such as Mobil EAL 224 in all of our hydraulic systems 1 1 5 Oil Site Gauge The oil site gauge gives an easy indication of the fluid level in the reservoir tank without requiring the removal of the top cover 1 1 6 Manifold Block The main manifold block routes the pressurized hydraulic fluid to the various locations in the hydraulic system via control valves 1 1 7 Pressure Switch Adjustment of the pressure switch determines the system pressure This switch controls the motor to maintain the system pressure See pressure switch adjustment process to ensure proper system pressure 1 1 8 Hand Pump In case of electrical failure a manual hand pump is prov
18. ided to enable the system to be pressurized to operate the unit once the directional control valve is shifted The valve should be shifted and then manually stroke the hand pump until the barrier has closed the roadway NOTE the manual pump is used in case of power loss when the barrier must be moved 1 1 9 Pressure gauge The pressure gauge shows the actual HPU system pressure Standard operations should be less than 2000 PSI If higher pressure is required please verify operation with B amp B ARMR technical support B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU ORIENTATION 1 1 10 Accumulator The accumulator acts as a pressure reservoir to store pressurized fluid The electric pump pressurizes the accumulator and the accumulator provides a high volume of pressurized fluid in a short period of time 1 1 11 Pump The pump is mechanically connected to the electric motor and provides the required pumping pressure to charge the accumulator The pump typically provides fluid at a rate of 2 GPM 1 1 12 Electric Motor The electric motor drives the hydraulic pump The 611x series HPUs are provided with variety of motor voltages Ensure correct voltages prior to initial operation 1 1 13 EFO Valve and Coil The Emergency Fast Operation EFO valve bypasses the flow control circuit and allows the system to provide full flow at highest sy
19. ions may be made to either port A or port B on the main manifold Systems using a single barrier per lane should connect the hose going to the cylinder to raise the barrier to the manifold port labeled B This enables the flow controls on the EFO manifold to be positioned for easier access The second hose used with the 820 model is plumbed back from the cylinder to the reservoir through the NPT coupling at the top of the tank Installer is to provide the appropriate fitting for the connection to the tank The unused pressure ports will be plugged from the factory The figures below show a typical 2 lane manifold and locations of connection points and flow controls Use care in tightening hydraulic fittings Extreme torque is usually not required and will damage fitting if done improperly Figure 7 Hydraulic Connections B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU INSTALLATION B amp B ARMR A Division of B amp B Roadway and Security Solutions Port A p Flow rate p Flow rites Port A EFO gt Solenoid Connector PortA EFO Solenoid System Pressure Reliet Port B DOWN Flow rate control Port B 2 EFO Solenoid Connector Port B UP Flow rate control EFO Solenoid Figure 9 HPU with EFO Manifold Flow Control Port B 611XWB 9001 Revision B2 15
20. m me emm or ores e men A 193NN09Y31NI Y33 0009 Sa 319IH3A WVYSVI LOANNOOYILNI 80 018 EOL CORE eva ROI we Rd NEUEN 1008 dio saamas MINUV The following figure shows a typical field wiring schematic for a 611X HPU Sd33MS lt ON Sd33MS 1V2I310313 71VOI410313 NIN S3SIM OVAOZL SASOH OGAPZ S3UIM Z IYAMA v92 04 t OVAOZ S3HIM Z GALSIML S39IM Z OVA OQA 92 01 S3HIM Z OVAOZI p OVAOZL dWNS 43d SIYM Ol33VHL JO 3NYT1HS3d S3HIM 6 OQAvZ 2IJ4VNL JO S3SIM 6 TVNOILdO 1 5 WHY 31V9 1VN9IS N3MOd WHY 31V9 1VNSIS ISOH On VHOAH HOLIMS AL33VS Q3HVHJNI M31V3H 31389NOO Q030038MWl Y0193130 dOO1 LHOM WV38 AL34VS O3HVHJNI 1H9N Odd VL dWns TANVd 1OSNINOO 915 T3NVd 1ONLNOO H31S VW YAMOd Qariddns YAWOLSND QN39311 1H9N 2133 1 LH9N Wv38 AL33VS Q33 VHHNI WHY 31V9 1VNOSIS SauvTiiogandansva 193130 dOO1 WV38 A3143VS O3N VHJNI ONIdWAd Or1n vauAH dNNS TANVd 1OHLNOO 8hS TANVd TOULNOD N31S VW moouuuo0r 5 xcziaz e 611XWB 9001 Revision B2 A Division of B amp B Roadway and Security Solutions B amp B ARMR Installation and Operations Manual
21. nd manually pushing the motor starter in The motor needs to rotate clockwise looking down on motor Correct if necessary Turn the unit on by pushing the START button on the overload protector Stop the unit at 500 700PSI via START STOP button Look for leaks and correct if necessary Restart unit and allow it to build pressure One the pressure is achieved the unit will cut off automatically Check for leaks and correct if necessary Line Purging Procedure after Start up With all the Flow Control Valves closed give Lane 1 a close up Command At each device in Lane 1 attach a small piece of hose 2 3 to the close up hydraulic line and place open end in a 5 gallon bucket Slowly open the flow control valve for that device Oil will begin to flow Allow approximately 1 quart to flow into the bucket Close that flow control valve and reconnect the hose to the device Repeat for all the devices on that directional control valve Repeat for all Lanes of traffic Pressure Adjustment The system pressure is adjusted by turning the adjustment ring on the pressure switch assembly counterclockwise to increase pressure and clockwise to decrease pressure With power on and oil in the reservoir press the start button on the motor starter and monitor the system pressure on the gauge Standard operation is 1500psi Adjust using adjustment ring as necessary See photo below B amp B ARMR A Division of B amp B Roadway and
22. p B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU INSTALLATION 12 10 00 7 00 6 50 5 50 Hydraulic hoses Conduit space 8 50 SERE 18 00 18 50 12 00 5 00 Electrical Conduit space 8 00 46 00 Figure 3 Dimensions of concrete pad with conduit spaces for 6118 amp 6119 Figure 4 Top view of 6118 amp 6119 HPU showing mounting tabs B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611 Series HPU INSTALLATION 13 Electrical Conduit Space Hydraulic Conduit Space Figure 5 Dimensions of concrete pad with conduit spaces for 6117 draulic Fuid Accumulator s Figure 6 Angled overview of 6117 on foundation B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU INSTALLATION 14 2 3 Hydraulic Connections Connect hydraulic lines through conduit to cylinder connection using JIC fittings As a reference use environmentally safe oil Mobil EAL 224 or equivalent when adding hydraulic oil to the HPU CAUTION The hydraulic system when in operation is under N extreme pressure Verify pressure on the barrier is completely relieved prior to removal of any hydraulic fittings Cylinder operated type barriers Model 820 B30 Hydraulic field connect
23. proper installation installation not performed by Supplier personnel nor by Supplier authorized personnel failure to perform manufacturer s suggested routine maintenance modifications misuse accident catastrophe neglect natural disaster act of God or if at any time the power supplied to any part of the Security Barrier falls short or exceeds the rate of tolerance for the equipment The exclusive remedy for breach of any warranty by Supplier shall be the repair or replacement at supplier s option of any defects in the equipment IN NO EVENT SHALL THE SUPPLIER OF SECURITY BARRIER BE LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES OR ANY KIND OF DAMAGES TO ANYONE Except as provided herein Supplier makes no warranties or representations to consumer or to anyone else and consumer hereby waives all liability against Supplier as well as any other person for the design manufacture sale installation and or servicing of the Security Barrier THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE NO OTHER WARRANTIES EXIST Any modification or alteration by anyone other than B amp B ARMR will render the warranty herein as null and void 7 APPENDIX 7 1 Simplified Standard Hydraulic Diagram The following figure shows a typical hydraulic schematic for a 611 X The schematic shown is for a single lane barrier system using a c
24. questions or experience any problems with your vehicle barrier or if we can help you with any other facility security issues please contact us directly at Corporate Tech Support B amp B ARMR 2009 Chenault Drive Suite 114 Carrollton TX 75006 USA Telephone 972 385 7899 Toll Free 800 367 0387 Fax 972 385 9887 E mail info bb armr com techsupport bb armr com System Installation Record To assist in documenting the products installed in your system please take a minute to record the following reference information This information can be located on the blue B amp B ARMR model number plate located on the product Additional columns are added for your convenience in documenting other components in the system Site Job Date Serial Number Model Number Voltage Phase B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611 Series HPU TABLE OF CONTENTS Table of Contents INIRODUGCTION iiis eee eene e Nego ee ha e ER NERA SER eaa Sa ERE ERU R ES PR E Ya SATE oera Ta re rm ii How to Contact Us iere RR ee REX Re ae SREERR REESE SER ER ES iv System Installation iv 1 ORIENTATION 1 1 0172 4772 ELE 6 LAS Box eerte ettet E b
25. re connections are shown in figure 10 Connector face view Female plug end view 1 not used 2 not used 3 blue 4 black Figure 10 Proximity Switch Connections 2 6 Final Pre operation Checklist Before operating the HPU go through the checklist below and verify that each of these steps has been completed B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU INSTALLATION 17 CAUTION For your safety complete each of these steps before operating the barrier 2 6 1 SUS Oe SS 10 11 12 2 6 2 4 3 6 2 6 3 Verify unit has hydraulic fluid to recommended level Verify control unit is plugged in and cable is routed clear of barrier operation Verify area is clear of personnel and other obstructions Ensure supplied power to HPU matches product requirements Verify electrical hookups are completed per electrical wiring diagram matching particular product DOCCCOC Start up procedure of Hydraulic Pumping units Close all the flow control valves completely Shift all directional control valves manually to the left Confirm the reservoir is clean and clear of debris Install clean filtered oil into the reservoir Confirm that the draw line ball is open below motor Turn overload protection devices off by pushing the stop button red Check the motor rotation by turning the power on at the disconnect switch a
26. ressure and must not be serviced until the directional control valve has been manually released and the cylinder can be verified to be in a fully released position and the barrier is in the lowered no pressure position 2 2 Site Preparation The hydraulic pumping unit should be securely fastened prior to operation The feet are designed to accept a standard concrete anchor for mounting If the unit is put on a steel structure it should be mechanically connected to prevent unnecessary vibration The unit is designed with a large open area to allow the positioning of conduits Normal construction sequence would have the electrical control and hose conduit running together before turning up out of the concrete slab The pumping unit is then positioned over the conduits and anchored into place The power and control conduits terminate into the electrical box The hydraulic conduit should not extend beyond the height of cabinet base This conduit elevation will allow the hose freedom to move during the B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU INSTALLATION 11 application of pressure without scraping the sides of the hose against a sharp top edge of the conduit Electrical Cabir draulic Fluid Tank Electric Motor Accumulator s Figure 2 Angled overview of 6118 amp 6119 HPU on foundation B amp B ARMR A Division of B am
27. stem pressure This operation is intended to move the barrier in the deployed position in a short amount of time safety inputs are ignored during EFO operation 1 1 14 Base Filter Assembly The filter assembly is used to filter contaminants from the hydraulic oil during operation Routine maintenance is required to replace the filter and ensure system is kept free of contamination The strainer and spin on filter should be replaced as part of normal maintenance whenever the oil is serviced B amp B ARMR recommends the use of environment friendly oil such as Mobil EAL 224 in all of our hydraulic systems 1 1 15 Directional Control Valve The directional control valve operates the unit in the normal operation mode It changes to allow fluid to pass to the barrier for deployment 1 1 16 Cabinet The pump cabinet houses the pumping unit components The hydraulic pump enclosure is weather tight and lockable Typical environmental operation is between 0 F and 110 F Typical enclosure is designed to provide a NEMA level 3R rating 1 1 17 Options The 611X series HPU s are available with a broad array of options and field installed kits Consult your ordering documentation to determine whether your system has the optional equipment Multiple manifolds to drive multi lane solutions Multi loop detection components for a variety of programmable modes of operation B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XW
28. uid may be required to keep viscosity constant B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611x Series HPU TROUBLESHOOTING 24 Symptom Actions 1 Check proper limit switch operation 2 Check bulbs 3 Check PLC outputs Traffic indicator light does not change B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611x Series HPU WARRANTY 25 6 WARRANTY B amp B ARMR warranties for a period of one year after delivery F O B plant unless otherwise specified by Supplier from failure of operation in ordinary use and against defects due to faulty material or workmanship Any defective equipment in the Barrier shall be returned to the factory at Supplier s option for repair or replacement and Supplier assumes no responsibility for service at any consumer site Supplier is in no event responsible for any labor costs under the warranty Subject to the above limitation all service parts and replacements necessary to maintain the equipment as warranted shall be furnished by the end user Supplier shall not have any liability under these specifications other than for repair or replacement as described above for equipment malfunction or equipment failure of any kind caused for any reason including but not limited to unauthorized repairs im
29. y anomalies if applicable Check the PLC for normal operation of all logic and functions Lubricate all pivot points and the clevis pin Inspect the cylinder and report abnormalities if present Check hoses for wear and report any abnormalities Check the operation of the control panel s Check the control panel s buttons and lights for proper operation and replace if necessary Update the operation and maintenance log 4 3 Six Month Inspections We recommend you perform the following inspections every six months B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU MAINTENANCE 22 Repeat the visual inspections in the monthly inspection list Turn the master power switch on the control circuit box to the OFF position Inspect the hydraulic system for signs of oil leaks CAUTION The hydraulic system when in operation is under extreme pressure Verify pressure on the barrier is completely relieved prior to removal of any hydraulic fittings Check the hoses for wear or abrasion Check all fittings for tightness Inspect the oil level in the HPU by opening the tank the level should be 1 1 5 inches below the top of the tank Add oil as necessary We recommend using environmentally safe oil such as Mobil EAL 224 Measure the resistance in any traffic loops and log the measurements and report anomali
30. ylinder such as an 820 model B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 Installation and Operations Manual 611X Series HPU APPENDIX f N EE SIMPLIFIED STANDARD HYDRAULIC SCHEMATIC CYLINDER CONTROL PRESSURE EFO MANIFOLD FLOW SWITCH PRESSURE CONTROL AX GAUGE VALVE WA ut p a na N P B MH N J jf FLOW eM EN A Y CONTROL MOTOR pump T d VALVES 4 y X L INTERNAL SYSTEM x mE B MANUAL ACCUMUEATOR PUMP PRESSURE CYLINDER 5 cd RELIEF b DIRECTIONAL VALVE CONTROL i VALVE Sage er FIELD HOSES Y RESERVOIR Revision B Ne A 7 2 Typical Bollard Hydraulic Flow Diagram 1 PRESSURE 1 EFO MANIFOLD i SWITCH PRESSURE i XX GAUGE wa i X cylinder k capp I l lott 5 BA CONTROL Or aes Or f MOTOR 1 Y gy i DIRECTIONAL CONTROL VAWE B amp B ARMR A Division of B amp B Roadway and Security Solutions 611XWB 9001 Revision B2 27 APPENDIX Installation and Operations Manual 611X Series HPU 7 3 Electrical Field Wiring Diagra
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