INDEX 1. GENERAL INFORMATION SYSTEM COMPONENTS OPERATING INSTRUCTIONS MAINTENANCE... 18

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1 ISO 9001: 2008 EN ISO 14001: 2004 SECURITY SYSTEMS Tyre Killers INSTALLATION INSTRUCTIONS HYDRAULIC TYRE KILLERS

2 INDEX Page 1. GENERAL INFORMATION SYSTEM COMPONENTS Construction Control Cabinet Electrical and Electronics Components Hydraulic Unit OPERATING INSTRUCTIONS MAINTENANCE PRACTICAL TROUBLESHOOTING PROCEDURES HOW TO PUMP MANUALYY

3 1. GENERAL INFORMATION Hydraulic Tyre-Killer is one of the heavy duty and highest security vehicle access control systems. The Tyre-Killer provides high security for sensitive areas (banks, military bases, airports, embassies etc) against forced and unauthorized entry or exit of motor vehicles. Tyre-Killer works rapidly, teeth raises from the road surfaces in a couple of seconds so tyres and rims of the unauthorized vehicle will definitely be destroyed immediately when the entry or escape is attempted, therefore the vehicle moves only a few more meters and is inactivated. The hardened teeth of the Tyre-Killer move all together as they are connected on the same teeth bar. The Tyre-Killer is powered by an hydraulic unit and operating hydraulics is installed nearby. OPTIMA hydraulic tyre killers raise and lower its teeth fastly and smoothly. The cylinder is powered by a hydraulic pump installed in control cabinet. Control electronics and hydraulic units are stored in a electrogalvanized metal control cabinet adjacent to Tyre-Killer. With the help of PLC controlled electronics, raise/lower function can be achieved by every kind of access control devices, card readers, biometric readers like fingerprint or hand shape, radio control, on/off switch or keyswitch etc. Besides, safety accessories like loop dedectors, photocells, flashing lights or red/green lights can be integrated to the control electronics very easily. 1 CONNECT TO DRAINAGE SYSTEM 2 HYDRAULIC HOSE CONDUIT Ø150 MM PROXIMITY SWITCH DATA CABLE CONDUIT Ø 100 MM 6 5 DRAINAGE CONDUIT Ø 150 MM 3 4 CONTROL ROOM ENTRANCE Picture 1. General view of Tyre-Killer 1- Control Cabinet 2- Security Photocell(optional) 3- Red/Green Lights(optional) 4- Keyboard Data Cable 5-3 Phase 380 VAC Cable 6- Hydraulic Tyre-Killer 3

4 Environmental Conditions and Power Requirement Between -20 C and +75 C, % 95 non-condensing humidity, 380 V, 3 ph, 50~60 Hz or 220 V, 1 ph, 50~60 Hz (optional) Optional Accesories 1. Flashing or red/green lights 2. Radio control receiver, transmitter and antenna 3. Safety photocell, stand and casing 4. Inductive loop dedector 5. Mechanical lock (Driven by 2 extra detectors and a hydraulic cylinder) 6. Card Reader System 7. Uninterrupted Power Supply(UPS) to raise/lower the road blocker few times in case of no electricity. 2. SYSTEM COMPONENTS 2.1 Construction and Faundation The Tyre-Killer is bolted into a reinforced concrete foundation and is designed to withstand 50 tons of axle load when closed. It is made of steel S235JR / RAEX 250 quality 37 at least. Main mechanical elements forming the construction are build entirely of steel and the frame consisting of 100 mm I, U and 100x100x4 mm box beams. Splitting teeth utilized in tire killer is manufactured from 25mm steel. All steel plate components are cut using CNC controlled laser cutting machines. Teeth bar on which the teeth are welded is attached to the frame by means of stainless steel and hardened steel hinges, provided with bronze bearings to reduce friction and noises. The hydraulic cylinder support brackets are alloy-bronze casting. Therefore both smooth operation and durability against high axle loads is achieved. In case of power failure, it is possible to disarm the Tyre-Killer manually. Parts forming the drive unit, namely, piston, piston rod, reservoir, solenoid or manual valves, etc. are very precisely manufactured so that they can stand harsh environmental conditions. As it will generally be installed outdoors all the parts are hot dip galvanized to thickness of 60 micrometers (60µm) in order to prevent rusting. Additionally the top plate and the teeth will be powder coated with a thickness of at least 80 micrometers; RAL 9010 for top plates and RAL 3020 for the teeth. The hydraulic unit cabinet is different than the tyre killer construction in order the limit the risk of injury while carrying out maintenance activities. The tyre killer will be installed in reinforced concrete foundation by M12 anchors. 4

5 TYRE KILLER MAIN PART Teeth Bar Plate Teeth Teeth Bar Top Plate Frame 5

6 Tyre-Killer Dimensions (Approximate Values) 6

7 Height : 835 mm (underground+main frame height) Width : 440 mm Length : 2 m to 6 m in 500 mm increments *The special hardened teeth rise mm above the road surface when the device is activated. *Tyre-Killers can be installed side by side to protect extra wide openings; from 2000 to 8000 mm in width - breaks of 500 mm. *Width of the blocking element +100 mm. A B B A %3 SLOPE Ø200 PVC SECTION A-A SECTION B-B Figure 4. Road Blocker Concrete Foundation View Depth : 428 mm Width : 1475 mm Length : 5400 Wall thickness : 300 mm Customer must request a layout drawing for each project from the manufacturer as dimension may vary in every application. 7

8 IP 55 With fan cooling Material: 2.2 Control Cabinet 2 mm thick sheet metal (electrogalvanized, RAL 7035 electrostatically(epoxy) powder coated and furnaced) for water-resistant outdoor applications. 2.5 mm thick sheet metal (electrogalvanized, RAL 7035 electrostatically(epoxy) powder coated and furnaced) for inside hydraulic and electric group carriages Dimensions : 76.5 cm x 106 cm x 116 cm (Cabinet may be manufactured in different dimensions according to requirements) The cabinet is fitted with espagnolet fastening and half europrofile cylinder. Picture 2. Control Cabinet Views 8

9 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 tyre killers 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 tyre killers is 380 V 50~60 Hz. Figure 7. Cabinet Control Panel Figure 8. Desktop Control Panel 1 Emergency Stop Stops the operation of the tyre killers in case of emergency. If pressed, the tyre killers 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 tyre killers automatically. It is enough to push the button ONCE in order to operate the tyre killers from Cabinet Control Panel. No other comment could be given until the process is accomplished. 3 Auto Up Raises the tyre killers automatically. It is enough to push the button ONCE in order to operate the tyre killers 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 9

10 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 Emergency Stop Stops the operation of the tyre killers in case of emergency. If pressed, the tyre killers 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. 8 Local Enabled Shows that current Desktop (Override/Guard House) Control Panel is in charge for the operation of the road blocker if this light in ON. 9 Auto Up Raises the tyre killers automatically. It is enough to push the button ONCE in order to operate the tyre killers from Desktop (Override/Guard House) Control Panel. No other comment could be given until the process is accomplished. 10 Auto Down Lowers the tyre killers automatically. It is enough to push the button ONCE in order to operate the tyre killers from Desktop (Override/Guard House) Control Panel. No other comment could be given until the process is accomplished. 11 Local/Remote Switch 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 Cabinet Control Panel 13 Power Supply 14 UPS 15 Terminal Explained in the previous pages 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. If the energy from three phases 220/380 VAC is OFF, the UPS supply the power needed only for the electronic components for a limited time. Connects electric (energy) connection of the whole system. A- 3 Phase 380 VAC input B- Motor output C- UPS input/output D- Cabinet fan output E- Cooler Fan Motor Output. F- Solenoid valve output G- Keyboard input H- Proximity sensor input I - Traffic Light output. J - Loop antenna input 10

11 Figure 9. Control Cabinet Electrical Components 16 Fuses 17 Main Fuses 18 Telemechanic Zelio PLC Card 19 Relay Group 20 Thermic Magnetic Switch 21 Contactor 22 Loop Dedector Control Card A- For the UPS. B- For the Telemechanic Zelio PLC Card. For the whole system. 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). PLC output protection relays. Motor safety switch. If a problem occurs in the oil pump inside the tyre killers, the switch becomes 0 (zero) and cuts the energy of the oil pump motor to be available for the maintenance. Drives the Motor 11

12 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 which must show full and oil could be added through Oil Reservoir Plug. Figure 10. Hydraulic Group 12

13 1 Filter 2 Direction Control Valve (Manually by handle) 3 Pressure Relief Valve (Adjust pressure in the system) 4 Electric Motor 5 Oil Cooler Fan 6 Direction Control Valve (Solenoid Actuated) 7 Oil filter dirtiness gauge. 8 Manometer 9 Hand Pump 10 Oil Reservoir Plug (To fill the tank) 11 Tank 12 Oil Level Gauge 13

14 OPERATION and MAINTENANCE 14

15 3. OPERATION INSTRUCTIONS Taking the Tyre Killer Into Operation Open the control cabinet. Meanuhile unscrew the 4 pcs of holding rings from the tyre killers top plate. Figure : 12/1 Figure :12/2 Figure : 12/3 Figure : 12/4 Figure : 12/5 15

16 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 Tyre Killer System, connect the electric power cable to the terminal. 4. If there is a Red/Green Traffic Light in the Tyre Killer System, connect the electric power cable of the Red/Green Traffic Light to the terminal. 5. If there is a Loop Detector in the Tyre Killer System, connect the antenna cables of the Loop dedector to the terminal. 6. If there are Radio control receiver, transmitter and antenna in the Tyre Killer System, connect the electric power cable of it to the terminal. 7. If there are Safety photocell, stand and casing in the Tyre Killer System, connect the electric power and data cables of Safety Photocell to the terminal. 8. If there is a Card Reader System in the Tyre Killer System, connect the electric power and data cables of Card Reader System to the terminal. 9. Make sure that fuses on the Cabinet Panel (Figure 9, No: 16 and 17) are ON (upward position). 10. Make sure the emergency stop buttons on the Cabinet Control Panel and Guard House Desktop Panel (Figure 7 No: 1; Figure 8 No: 7) 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 (Figure 10, No: 12) on the oil reservoir (Figure 10, No: 11). It must show full. 12. Make sure that Motor safety switch on the Cabinet Panel (Figure 9, No: 20) are ON. 13. Connect the three phase 380 VAC cables to the terminal.(figure 9, Item 15-A) 14. Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the Cabinet Control Panel (Figure 7, No: 4, 5, 6) are ON. 16

17 3.2 Operation of the Tyre Killer Depending on the position of the Local/Remote Switch (Figure 8 No: 11) 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 Tyre Killer. For each Tyre Killer, only ONE panel could be in charge, i.e. two panels could not operate the tyre killer 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 Tyre Killer. 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 tyre killer is as follows: Raising of the tyre killer is done automatically. In order to raise it automatically, push Auto Up button (Figure 7 No: 3, Figure 8 No: 9) ONCE. Lowering of the tyre killer is done automatically. In order to raise it automatically, push Auto Down button (Figure 7 No: 2, Figure 8 No: 10) 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 tyre killer, either automatically or manually, Guard House Desktop Control Panel and the dead-man button MUST be pushed at the same time; otherwise the tyre killer could not be operated from the guard house. This function is added to the system in order to prevent the tyre killer 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 vehicle s position or it sends a signal as long as there is a vehicle on the loop antenna. According to the design of the control logic, the tyre killer could be raised and lowered automatically even without using the desktop panels. 17

18 Depending on the customer desire, card reader system could be added to the system. According to the design of the control logic, the tyre killer 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. 18

19 5. PRACTICAL 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 (Figure 7 No: 1; Figure 8 No: 7) are not pressed. Make sure that fuses on the Cabinet Panel (Figure 9, No: 17and 16) are ON (upward position). Make sure that Motor safety switch on the Cabinet Panel (Figure 9, No: 20) are ON. Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the Cabinet Control Panel (Figure 7, No: 4, 5, 6) 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 (Figure 7 No: 1; Figure 8 No: 7). In case of power failure, tyre killer 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 road blocker manually. 19

20 6. HOW TO PUMP MANUALLY Insert manual pump arm into the slot and pump manually (Figure 13). Figure 13. Manual Pumping If the system is not still running after all these controls, please contact with the manufacturer. 20

21 DECLARATION OF CONFORMITY FOR MACHINES (DIRECTIVE 98 / 37 EEC, ATTACHMENT II, PART B) Manufacturer: OPTÝMA MÜHENDÝSLÝK LÝMÝTED ÞÝRKETÝ KERESTECÝLER SANAYÝ SÝTESÝ 3. CADDE NO:8 SARAY KAZAN / ANKARA/ TÜRKÝYE 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 HTK SERIES HYDRAULIC TYRE KILLERS 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 / January 1996 Standard - TS EN / January 1996 Standard - TS EN 563 / April 1997 Standard - TS EN 418 / November 1995 Standard - TS EN / December 1995 Standard - TS EN / April 1995 Standard - TS EN / February 1998 Standard - TS EN / April 1997 Standard 4 April 2001 Ankara TURKEY İsmail Tamer ÜLGEN President Mechanical Engineer, B. Sc.

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