USER MANUAL
CRASH RATED HYDRAULIC ARM BARRIER
HAB‐500
TABLE OF CONTENTS
1. GENERAL INFORMATION ............................................................................................................. 3
1.1. FEATURES IN HAB SERIES BARRIER .................................................................................. 4
1.2. OPTIONAL FEATURES AND ACCESSORIES ........................................................................ 4
2. SYSTEM COMPONENTS ............................................................................................................... 5
2.1. CONSTRUCTION AND FOUNDATION ............................................................................... 5
2.2. CONTROL CABINET .......................................................................................................... 6
2.3. ELECTRICAL AND ELECTRONICS COMPONENTS .............................................................. 7
2.4. HYDRAULIC COMPONENTS ............................................................................................ 10
3. OPERATION INSTRUCTIONS ....................................................................................................... 12
3.1. TAKING THE BARRIER INTO OPERATION ....................................................................... 12
4. HOW TO PUMP MANUALLY ...................................................................................................... 13
5. MAINTENANCE .......................................................................................................................... 14
6. TROUBLESHOOTING .................................................................................................................. 16
7. CE DECLARATION OF CONFORMITY .......................................................................................... 18
8. ISO9001:2008 CERTIFICATE ...................................................................................................... 19
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SYSTEM SPECIFICATIONS
AND
DATASHEET
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1. GENERAL INFORMATION
OPTIMA high security hydraulic arm barriers are designed especially for entrance points
which have a threat of vehicle attack or for the ones that have high security requirements. The
barrier arm is square shape.
Drive unit is hydraulic, but in case of power failure barrier can be closed or opened manually
with the help of manual hand pumps.
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.
Pic.1. General View of Crash Rated HAB
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1.1. FEATURES IN HAB SERIES BARRIER
1.1.1 Length of Arm: 5000mm
1.1.2 Weight (approximately): 1,5‐2,5 tons (depending on barrier type).
1.1.3 Strength: Designed and manufactured for K4 crash rating..
1.1.4 Structure: Heavy duty.
1.1.5 Red/Green Traffic light: 200 mm diameter traffic lamps with 4" diameter 2 mm thick
steel pole.
1.1.6 Hinges of Cylinder: Hinges used on cylinder designed and manufactured as special
designed by CNC machines. Heavy duty hardened steel is used for hydraulic cylinder
connections and moving part of the barrier.
1.1.7 Power Failure: Manual hand pump.
1.1.8 Safety Loop Detector with Dual Antenna: Prevents vehicles from closing of barrier
during passage.
1.1.9 Safety Photocell with Mounting Leg: Prevents vehicles from closing of barrier during
passage.
1.1.10 Flashing Light: Flashes on barrier cabinet at regular time interval.
1.1.11 Desktop Keyboard: Auto Up, Auto Down, Emergency Stop, Key Operated (off/on
switch), "Keyboard in use" light indicator.
1.1.12 Proximity Switch: Available to sense the position of the barrier.
1.1.13 Cabinet: IP 55 with dust filter.
1.1.14 Times of Use: 1500 full‐cycle/day, heavy duty.
1.2. OPTIONAL FEATURES AND ACCESSORIES
1.2.1 Structure: Hot‐dipped galvanized.
1.2.2 Cabinet Cooler Fan: Used to dispel any hot air from cabinet
control panel to outside.
1.2.3 Different Color: Barrier can be painted with different color
upon request.
1.2.4 Radio control receiver, transmitter and antenna: To operate
barrier with a remote controller.
1.2.5 Scada or Any Control System: It is possible to change and
check the position of barrier with touch screen control
panel, mobile devices (ios‐android), computer, etc.
1.2.6 Transformer: Used to convert power.
1.2.7 Uninterruptible Power Supply (UPS): Used to keep system
components running in case of power failure.
ENVIRONMENTAL CONDITIONS AND POWER REQUIREMENT
Between ‐20 °C and +65 °C, % 95 non‐condensing humidity, 220‐240 VAC, Mono Phase, 50~60 Hz.
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2. SYSTEM COMPONENTS
2.1. CONSTRUCTION AND FOUNDATION
The arm of the barrier which is called the "crash beam" is supported by two "support
columns" in both ends when closed. Both support columns and the crash beam is manufactured by
welding NPU, box beams and sheet metals, constructing a robust steel structure. Steel construction is
sand blasted and primer coated to prevent corrosion.
The hinges are made of hardened steel. Parts forming the drive unit, namely, piston,
reservoir, solenoid and manual valves, pump, motor, etc. are very precisely manufactured so that
they can stand harsh environmental conditions.
Fig.1. Construction View of HAB Barrier
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2.2. CONTROL CABINET
Material:
• Sheet metal (electro galvanized, RAL 2004 electrostatically (epoxy) powder coated and furnaced)
for water‐resistant outdoor applications.
Fig.2. Control Cabinet Views
1‐ Arm Fixing Plates 4‐ Open/Close Handle and Lock with key
2‐ Safe Cover 5‐ Cover of Cabinet
3‐ Air Circulation Opening
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2.3. ELECTRICAL AND ELECTRONICS COMPONENTS
Control electronics utilized in hydraulic arm barrier is PLC controlled. Power requirement of
the hydraulic arm barrier is 220‐240 VAC, Mono Phase, 50‐60 Hz.
Pic.2. Electrical Components
5. Fuse Group 1. Relay Group
6. Thermic Magnetic Switch 2. Loop Detector
7. Motor Contactor 3. +24 VDC and 0VDC Terminals
8. Power Supply 4. Terminal Group
9. PLC
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Pic.3. Desktop Control Panel
Emergency Stop: Stops the operation of the barrier in case of
emergency. If pressed, the 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.
Auto Up: Raises the barrier arm automatically. It is enough to push the
button ONCE in order to operate barrier. Except "Emergency Stop" no
other comment could be given until the process is accomplished.
Auto Down: Lowers the barrier arm automatically. It is enough to push the
button ONCE in order to operate the barrier. Except "Emergency Stop" no
other comment could be given until the process is accomplished.
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Keyboard OFF/ON: When the switch is at "ON" position, keyboard
buttons are activated. When the switch is at "OFF" position, the
buttons are deactivated.
Keyboard OFF/ON (Indicator): Shows that current "Desktop Control
Panel" is in charge for the operation of the barrier if this light in ON.
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2.4. HYDRAULIC COMPONENTS
There are two pumps in the hydraulic system: Electric motor coupled gear pump and manual
hand pump. The first one is the default used pump in the system. The hand pump is used in case
there is no power.
Pic.4. Hydraulic Unit
1. Electric Motor 4. Hydraulic Oil Tank
2. Fixing Part of Unit 5. Oil Reservoir Plug
3. Valve Plate
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HYDRAULIC ARM BARRIER
OPERATION
AND
MAINTENANCE
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3. OPERATION INSTRUCTIONS
3.1. TAKING THE BARRIER INTO OPERATION
1) Open the cabinet door.
Fig.3. Opening Steps for Cabinet Door
2) Make sure that connection of loop antennas are made correctly. Refer to the related "Loop
Detector Connection Diagram & Instructions". Loop Detector antenna "MUST" be connected
to the terminal if "Loop Detector Module" is inserted to its base. If Loop Detector will not be
used, Loop Detector Module should be removed. The system will still be working although
there is no safety precautions.
3) Make sure that connection of input power cables are made correctly.
4) Make sure that desktop control panel cables are made correctly.
5) Make sure that safety photocell cables are made correctly.
6) Make sure that fuses on the Cabinet Panel are ON (upward position).
7) Make sure that Thermic Magnetic Switch on the Cabinet Panel are ON.
8) Make sure the emergency stop buttons on the Guard House Desktop Control Panel is not
pressed.
9) Initially, there will be no oil in the hydraulic system, therefore fill the oil reservoir with SHELL
THELLUS S2V68 or MOBIL DTE10EXCEL68 hydraulic oil. Check oil level from the gauge on the oil
reservoir. It must show "full".
10) Depending on the position of the Keyboard OFF/ON switch Keyboard Control Panel is
enabled.
• Raising of the barrier arm is done automatically. In order to raise it automatically, push “Auto
Up” button ONCE.
• Lowering of the barrier arm is done automatically. In order to raise it automatically, push
“Auto Down” button ONCE.
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4. HOW TO PUMP MANUALLY
In the event of a power failure, manual hand pump provides manual pumping to raising and
lowering of the barrier.
Pic.5‐A Raise Method of the Barrier Arm
To raise the barrier arm, firstly press the button at the front side of the solenoid valve as seen
Pic.3‐A. Then, move the bar up and down as seen Pic.5‐A.
Pic.5‐B Lower Method of the Barrier Arm
To lower the barrier arm, press the button at the back side of the solenoid valve as seen
Pic.3‐B. Then, move the bar up and down as seen Pic.5‐B.
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5. MAINTENANCE
Lubrication
•Lubricate hydraulic piston hinges with grease oil after every 2000 full‐cycle.
•Lubricate bearings with grease oil after every 2000 full‐cycle.
Oil Check
• Check oil level with a dipstick every month. If oil level is under level then desired, check oil leakage.
• First oil change to be made after 3 months. Then;
‐ 1500 Full Cycle Per day: Change the oil in every 3 months.
‐ 750 Full Cycle Per day: Change the oil in every 6 months.
‐ Less than 750 Full Cycle Per day: Change the oil in every 2 years
Filters Check
• Filters to be changed at every oil change.
• Clean dust filter of air circulation openings in every one year.
Oil Leakage Check
• System to be eye‐controlled for oil leakage once in a week.
• Hydraulic hoses to be eye‐controlled for deformation in every 3 months.
• Piston to be eye‐controlled in every week for oil leakage.
• Check hydraulic hose connections in every 6 months. Make sure that hydraulic hoses connection
points are not loose.
Manual Hand Pump
• Check Manual Hand Pump’s operations are working or not.
Electrical Check
• Check wiring connections between electrical components and terminals. If there is a loose
connection between them, fix cable connections.
• Check earth connection in every one year.
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Cleaning
• Mechanical and electrical components should be cleaned with high‐pressure air for removing
foreign materials like dust or sand in every 3 months.
Hydraulic Piston
• Check the tightness of counternut under the hydraulic piston’s top hinge. If the counternut is
loose, tighten it with the help of a wrench.
• Check the tightness of setscrew on hydraulic piston’s top caps. If the setscrew is loose, tighten it
with the help of an allen key.
Setscrew
Counter Nut
Fig.4. Hydraulic Piston
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.
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6. TROUBLESHOOTING
FAULT REASON ACTION
A) There is no 1)All fuses should be on .
power 2) Check main power.
1) If there is metal on loop remove it.
2) The loop antenna cable is not connected to loop
B) Safety Loop is detector module . Should be connected.
active(Green 3)If the loop detection system will not be used then
Channel lamp) remove the loop detector module from its base.
4) Check whether the loop antenna cable is twisted
properly.
1) Emergency Buttons (Keyboard) is pressed.
Release it.
Barrier is not
1 2) Keyboard is not connected. Make the terminal
raising
connections as in drawings
3) Keyboard ON/OFF selection switch should be ON and
C) Motor is not the ‘local enabled’ lamp should light.
Running 4) Keyboard is not connected properly. Check the wiring
diagram. On PLC screen “I1” should be bold when up
button is pressed.
5) There is no RUN indication on PLC screen. Check the
power supply connections. Measure the Power Supply 24
Volt DC output.
D) UP solenoid is Check socket connections and tighten the screw of socket.
not working If problem continues contact with the manufacturer.
A) There is no 1)All fuses should be on
power 2) Check main power
1) Emergency Buttons (Keyboard) is pressed.
Release it.
2) Keyboard is not connected. Make the terminal
connections as in drawings
3) Keyboard ON/OFF selection switch should be ON and
B) Motor is not the ‘local enabled’ lamp should light.
Barrier is not
2 Running 4) Keyboard is not connected properly. Check the wiring
lowering
diagram. On PLC screen "I1" should be bold when down
button is pressed.
5) There is no RUN indication on PLC screen. Check the
power supply connections. Measure the Power Supply 24
Volt DC output.
Check socket connections and tighten the screw of socket.
C) DOWN solenoid
If problem continues contact with the manufacturer.
is not working
A) Oil is not proper Oil should be SHELL THELLUS S2V68 or MOBIL DTE10EXCEL68.
Slowly
4 Tighten the screw of pressure relief valve to clockwise app.
Lowering
B) Pressure is low 90 degrees
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A) Oil is not proper Oil should be SHELL THELLUS S2V68 or MOBIL DTE10EXCEL68.
Does not
5
Lower Fully B) Hydraulic Lock is Loosen the screw by using allen key to clockwise app. 180
too tight degrees
Tighten the screw of pressure relief valve to clockwise app.
Does not raise A) Pressure is low
6 90 degrees.
fully
B) Oil is not proper Oil should be SHELL THELLUS S2V68 or MOBIL DTE10EXCEL68.
Noise from
A) Oil level is too
7 hydraulic Check the oil level. It should be above min level
low
pump
A) There is no Check the connection and fuse of the lamp. There should
power be 220 VAC on terminals
Traffic Light B) Socket is not Check the socket of the lamp on the traffic light
8
does not work connected
Change the lamp
C) Lamp is broken
1‐ When the barrier is at down position, proximity sensor
Traffic Light input should be bold on PLC screen. If not ,approach the
A) Proximity sensor
does not work sensor to metal. The distance between sensor and metal
is not detecting
properly block should be maximum 10 mm
9
(when it is 2‐ Check the connection of the sensor.
down green is B) The terminal Reverse operation occurs if the barrier is down and green
not lighting connections are is lighting. Similarly if red is lighting when the barrier is up,
wrong swap the terminal connections.
Hydraulic Lock is Tighten the hydraulic lock clockwise for 90 degrees
10 Quickly Down
loose
A) Keyboard
Unfunctional Check the connection of the keyboard
Connection is
Operation (up
wrong
11 button lowers,
B) Hydraulic hose
down button
connections are Change the connections.
raises)
wrong
A) Proper cable is
not used for 1 mm square antenna cable should be used
Loop detector antenna
does not B) Wrong Number In the cable channel the number of winding should be 3.
12
working of turns
properly C) Vibration Silicon should be applied to the cable to prevent vibration
Under , above or beside the loop antenna minimum
D) There is metal
distance to any metal should be 100 cm.
Manual Hand
Solenoid Rod is not
13 Pump is not When it is pressed, the spring resistance should be felt.
pressed
Running
If the system is not still running after all these controls, please contact with the
manufacturer.
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DECLARATION OF CONFORMITY FOR MACHINES
(DIRECTIVE 98 / 37 EEC, ATTACHMENT II , PART B)
7. CE DECLARATION OF CONFORMITY
Manufacturer: OPTİMA MÜHENDİSLİK LİMİTED ŞİRKETİ
KERESTECİLER SANAYİ SİTESİ
3. CADDE NO:8 SARAY 06980
KAZAN / ANKARA/ TÜRKİYE
Declares that the products,
HAB SERIES HYDRAULIC ARM BARRIER
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 conformity 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 conformity 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 İsmail Tamer ÜLGEN
TURKEY President
Mechanical Engineer, B. Sc.
GUARANTEE CERTIFICATE
The product that you have bought is under guarantee for any kind of manufacturing and material defects for 1 (one) year from the
beginning of the bill date. Installation and usage damages are out of guarantee.
OPTIMA ENGINEERING Co.Ltd.
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8. ISO9001:2008 CERTIFICATE
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