Hydraulic Pumping Unit (HPU) W/Logo
Contents
1. 10 BD Introduction Se E EEPE EE S EEEE E 10 3 2 Monthly Inspections anmenn e aie ca E a T T EAE aE edad 10 3 3 Six Month Inspections oseiro ayo EAE a A O EOE NA REER A OKEERE 11 3 4 Annual Maintenance 11 3 5 Hydraulic Oil Changing Procedure 11 4 5 12 4 1 612x Series HPU Troubleshooting 12 WARRANT a E A vanes 14 6 APPENDIX oo eere Ee EEE Ree E EE E EEEE E EEE 15 6 1 Electrical Schematic mn E e a a Rede Gs evens esses eee des 15 6 2 Electrical Field Wiring sities saves n e a ei 17 6 3 Equipment Maintenance Log 18 B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU TABLE OF CONTENTS 5 1 ORIENTATION 11 Overview The model 612x hydraulic pumping unit is designed to operate hydraulic barriers that require medium pressure and low flow The electric motor is operated by a system pressure switch connected directly to a gear hydraulic pump which operates ind2. NOTE Do not turn or spin the motor in the reverse direction as this will damage the hydraulic pump 3 4 4 lower the barrier use the electric valve with the red knob that is located on the front of the pump below the motor and above the reservoir lower the barrier push in the red knob and turn it counterclockwise This action must be reversed to operate in normal condition 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 B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU MAINTENANCE 3 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 3 1 Introduction The 612x Series HPUs are designed to be largely maintenance free As with any complex electromechanical device however they must be regularly inspected to ensure 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
3. ORIENTATION 1 1 4 Cabinet The pump cabinet houses the pumping unit components The hydraulic pump enclosure is lockable Typical environmental operation is between 0 F and 110 F Typical enclosure is designed to provide a NEMA level 3R rating 1 1 5 Options The 612x 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 2 OPERATION 2 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 2 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 2 3 Manual Operation You can operate the HPU manually during a power outage as follows 3 31 Turn the power switch to the OFF position in case the power is suddenly restored 3 3 2 Place a speed wrench on the screw head located on the top of the electric motor and turn it in the direction of the arrow This drives the hydraulic pump and raises the barrier 3 3 3 speed up raising the barrier you can drive the screw head on the motor with a cordless drill and socket
4. 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 any 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 Check hoses for wear and report any abnormalities DOCO OOOOOD B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU MAINTENANCE 11 Check the operation of the control panel s Check the control panel s buttons and lights for proper operation and replace if necessaty Update the operation and maintenance log 3 3 Six Month Inspections We recommend you perform the following inspections every six months 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 Measure the resistance in any traffic loops and log the measurements and report anomalies if applicable When the inspection is comp
5. 1 Revision C6 Installation and Operations Manual 612x Series HPU ORIENTATION 7 Figure 1 1a Hydraulic Unit and Control System Electrical Box Neutral Loop Detector Socket Siemens Logo PLC Contactor Overload 24V DC Incoming Power Output Terminals 1 1 2 Hydraulic System The key components of the hydraulic unit are shown in Figures 1 1 through 1 1 The motor powers a hydraulic pump that delivers oil through a series of valves as directed by the control unit If the beam is in the up position for extended periods the control circuit monitors any drift in the beam s position and automatically corrects the position The unit includes a manual operation override so the beam can be raised and lowered during power outages 1 1 3 System relief Valve The system relief valve enables the system to be de pressurized during maintenance and service operations B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU ORIENTATION Fig ure 1 1b Hydraulic Unit Left Side View PUSH BUTTON CONTROLLER RESERVOIR FILL Figure 1 1c Hydraulic Uni MANUAL CRANK POINT REMOVABLE MANUAL HAND CRANK DOWN VALVE MANUAL RELIEF UP FLOW CONTROL VALVE DOWN FLOW CONTROL VALVE B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU
6. MODEL 6120 SERIES Hydraulic Pumping Unit HPU W Logo INSTALLATION AND OPERATIONS MANUAL B amp B ARMR Corporate Office amp Tech Support 2009 Chenault Drive Carrollton TX 75006 Suite 114 Phone 972 385 7899 Toll Free 800 367 0387 Fax 972 385 9887 E mail info bb armr com techsupport bb armr com www bb armr com MADE IN THE USA B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x 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 ARMR products Spare or replacement parts Cu
7. OQ WHY 21 dN Way LI SLANI T ao sz or VON QI VON d O39NVHD e CY as NOD RNY BS MM 190 297 009 90062 SVXAL eve 8 S Wid JSYHd 2DAgOZ dHZ 01911 5337 il ONNOOD 6120 9001 Revision C6 A Division of B amp B Roadway and Security Solutions B amp B ARMR 17 APPENDIX Installation and Operations Manual 612x Series HPU iagram D iring 6 2 Electrical Field W so tsa amena aos co A 193NNO9Y31NI 93 0009 aa aalaya JTOIHSA WVYOVIG LOANNOOYSLNI Tresa GOD CORE WA 902 UNE IOC 000 921 98 The following figure shows a typical field wiring schematic for 612 HPU 59935 ONIGWN1d ON Sd3IMS IVOINLOIIS 19215419313 LINGNOO s NIN p IVAOZL S3SOH Z OGAPZ SIJYIM Z OVAIOGA 9 0 v OWANZZ Z GALSIML SAYIM 2 IYAMA 92 01 SIYIM Z IVAOZL SAYIM p OVAOZL dINNd dWNS Yad SIYIM 2133 JO INY1 Yd SSYIM 6 OOAPZ 2133 40 Yad SIYIM 6 TVWNOLLdO 1 5 WHY 31 9 TYNOIS YAMOd WHY ALYS 1 919 ISOH HOLMS WYSE ALJAYS YALVSH SLSYONOO Y0L193130 LHON WY38 ALSSVS QIYYY4ANI LHON la VXL TANVd IO
8. YNLNOD 8NS TANVd IOYLNOO YJLSYW YAMOd 9319915 YIWOLSNO QN3931 LHON DIsddVeLs FOYNOS LHONM WV38 ALSSVS WHY ALVS 1VNOIS Y0193130 AILAYS LINN ONIGWAd SANVGYAH TANVd TOULNOO 8NS TANVd TOULNOD x lt mo0oaogwugor vxY4s DAD 6120 9001 Revision C6 A Division of B amp B Roadway and Security Solutions B amp B ARMR Installation and Operations Manual 612x Series HPU APPENDIX 18 6 3 Equipment Maintenance Log Form S Product Type B amp B ARMR 800 367 0387 fe M Location servicedept bb armr com B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6
9. ct 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 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU TROUBLESHOOTING Symptom Actions Barrier does not raise up when commanded on control panel 1 Check power 2 Check for binding 3 Check overload protector 4 Manually raise the barrier to see if problem is mechanical or electrical see section 3 3 5 Check PLC input on pumping unit 6 Check that safeties are clear 7 Check PLC output on pumping unit 8 Check push button operation 9 Check that speed valves are open Barrier does not close when commanded on control panel Check power Check for binding Check overload protector Manually lower the barrier to see if problem is mechanical or electrical see section 3 3 Check PLC input on pumping unit Check that safeties are clear Check PLC output on pumping unit Check push button operation Check that speed valves are open HPU pump will not turn on 1 Check power 2 Check motor overload press start Check motor starter Hydraulic unit excessively hot 1 Check that the fan is operating properly 2 Check for correct voltages Barrier moves too slowly Check for mechanical binds Check flow control valve 3 In extreme cold temperatures a higher grade hydraulic fluid may be required t
10. ependently from the signal command The oil from the pump is drawn through a filter and directed into a speed control valve through a directional control valve The flow control valve monitors the operational speed of the barrier The operating logic controls a series of manifolds and valves to ensure the correct position of the barriers based on input controls from any set of dry contacts 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 electrical control box contains the electrical components and a programmable logic controller that is pre programmed with the barrier s operating logic The unit has a minimum 1 5 horsepower 208 240 480 volt three phase motor A single phase motor is available on special order An overload circuit protects the motor in the event of power fluctuations The control unit is 120 volt single phase with 24 volt dc output The key components of the electrical control box are shown in Figures 1 1a through 1 1c B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 900
11. lete turn the power on and test cycle the barrier to verify operation and control 3 4 Annual Maintenance Inspections We recommend you perform the following inspections annually Perform all monthly and six month maintenance steps Replace the hydraulic fluid 3 5 Hydraulic Oil Changing Procedure Follow the steps below to drain and refill the oil tank We recommend using environmentally safe oil such as Mobil EAL 224 Refer to the drawing titled Assembly Drawing 120 2001 see the Engineering Drawings section at the end of this manual 4 4 1 Drain the reservoir using a pump and remove the fluid with the gate in the down position 4 4 2 Refill the reservoir with the same fluid used previously to about 5 6 from the top of the reservoir B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU MAINTENANCE 12 4 TROUBLESHOOTING The table below provides a general guidance on identifying and correcting any problems with your 612x 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 4 1 612x 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 conta
12. o keep viscosity constant Ne B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU APPENDIX 5 WARRANTY BBRSS warranties for a period of one 1 year FOB manufacturing facility unless otherwise specified by BBRSS in writing from defects due to faulty material or workmanship Damage due to handling during shipment and installation are not covered under warranty BBRSS assumes no responsibility for service at customer site BBRSS 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 others BBRSS shall not have any liability under these specifications other than for repair or replacement as described above for faulty product material or workmanship Equipment malfunction or equipment failure of any kind caused for any reason including but not limited to unauthorized repairs improper installation installation not performed by BBRSS authorized personnel incoming supply power is outside the tolerance for the product failure to perform manufacturer s suggested preventative maintenance modifications misuse accident catastrophe neglect natural disaster are not under warranty The exclusive remedy for breach of any warranty by BBRSS shall be the repair or replacement at BBRSS s opti
13. on of any defects in the equipment IN NO EVENT SHALL BBRSS BE LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES OR ANY KIND OF PERSONAL DAMAGES Except as provided herein BBRSS makes no warranties or representations to consumer or to anyone else and consumer hereby waives all liability against BBRSS as well as any other person for the design manufacture sale installation and or servicing of the Products 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 BBRSS will render the warranty herein as null and void B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU APPENDIX 6 APPENDIX 6 1 Electrical Schematic Diagram The following figure shows a typical electrical schematic for a 612x HPU The schematic shown is for a typical single lane barrier system B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 16 APPENDIX Installation and Operations Manual 612x Series HPU 80 Hd 0219 X90197 244 1 AHO Java YOLVIIONI HOLVOIONI 0J NMOG NAY SLNdLNO X907 91 Alasy S SI NMOO pi l NMO
14. on 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 o Traffic arms o Traffic lights B amp B ARMR A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU INTRODUCTION iv How to Contact Us If you have any questions or experience any problems with your vehicle barrier or if we can help y
15. ou with any other facility security issues please contact us directly at B amp B ARMR 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 A Division of B amp B Roadway and Security Solutions 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU TABLE OF CONTENTS Table of Contents INTRODUCTION E E E a exe ii SATE VAE E SE E EE T SE E TEN E ASE E EE ES ii Flow to Contact iv To ORIEN TATION 6 LEDS OVERVIOW eases Seuss 6 LI Electrical Control BOX 6 11 2 ry drauic System esses fee stars sie eevee fe Meech dace O ee I EA Eene RAEES CEE TEASE r E AENEAS 7 System felief Valve ysu eea e E Ea a PEE en E SE ETAPES i atis 7 I E S Ei DST aci ATE E E E EEE E E E EE E 9 115 OpPtOns ASAE OEE E EEEE E EE E E E ENTE 9 2 OPERATION 9 2L ANGPOMUCTION bea E E TRE 9 Ded GONETOL SIGNALS oss EEE SA Sve 9 2 3 Mantial Operation estes Mewes ented ats 9 32 MAINTENANCE
16. stom 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 Safety OOO OO 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 6120 9001 Revision C6 Installation and Operations Manual 612x Series HPU INTRODUCTION iii 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 are responsible for correct and safe installati
17. 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 3 2 Monthly Inspections We recommend 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 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 and condition in the HPU 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 OO OOOO 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
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