Alutech BV-5-868 Installation and operating instructions

05.2020
www.alutech-group.com
ASSEMBLY AND OPERATION MANUAL
BV-5-868 Boom Barrier
ENGLISH
MONTAGE-UND BETRIEBSANLEITUNG
Schranke BV-5-868 DEUTSCH
MANUEL D’INSTALLATION ET D’UTILISATION
Barrière levante BV-5-868 FRANÇAIS

BOOM BARRIER BV5868 11
ENGLISH
1. Warnings and safety rules ................................................2
1.1. General requirements ......................................................... 2
1.2. When performing the assembly .................................................. 2
1.3. When operating the device ..................................................... 4
2. Product description .....................................................5
2.1. Scope of delivery ............................................................. 5
2.2. Technical specications ........................................................ 5
3. Preparation for assembly ................................................7
4. Assembly ............................................................7
4.1. Assembling the barrier cabinet ................................................... 7
4.2. Installing the spring ........................................................... 8
4.3. Installing a RBN8 boom ........................................................ 9
4.4. Manual unlocking ............................................................ 9
4.5. Balancing the boom .......................................................... 9
4.6. Adjusting the boom position .................................................... 10
5. Mains connection and open-close setting ................................... 10
6. Electrical connections .................................................. 11
7. Setup .............................................................. 14
7.1. Radio control setup ........................................................... 15
7.2. Setting operation parameters .................................................... 23
7.3. Actory reset ................................................................. 28
7.4. Cycle counter data ............................................................ 28
7.5. Two-way trac signalization ..................................................... 29
8. Indication ........................................................... 30
9. Functional check and start-up operations ................................... 32
10. Service and maintenance ............................................... 33
11. Troubleshooting guide ................................................. 34
12. Storage, transportation, and disposal ...................................... 35
13. Warranty terms and conditions ........................................... 35
14. Commisioning certicate ............................................... 36
15. Information on the work performed ....................................... 37
16. Information on repairs during warranty period ............................... 38
CONTENTS

BOOM BARRIER BV586822
WARNINGS AND SAFETY RULES
1. WARNINGS AND SAFETY RULES
1.1 GENERAL REQUIREMENTS
Y
ATTENTION! This manual contains important information concerning safety. Prior to commenc-
ing assembly and operation read and understand all the information provided below. Save this
manual for future reference!
Comply with the health and safety requirements established by rules and regulations in force and
this manual. Failure to follow the rules and regulations may result in serious damage, injury or death.
Ensure compliance with the standards concerning construction, assembly and operation of boom
barriers (N 12604, N 12453), as well as other relevant local rules and regulations.
YATTENTION! Installation, connection, adjustment, commissioning, maintenance, disassembly
and disposal of the product must be carried out by qualied (professional) and trained personnel
(EN 12635), competent and specialized organizations. Assembly, programming, conguration
and operation of the product in violation of the requirements are prohibited, as this may result
in damages, injuries and cause losses.
Making any modications to any elements of the product structure and unintended use of the
product are prohibited. The manufacturer shall not bear any responsibility for any damages
caused by unauthorized modications or unintended use of the product.
When performing any operations (assembly, repair, maintenance, cleaning etc.) and connections
inside the barrier, disconnect the mains circuit. If the master switch is out of sight, then attach
asafety sign stating ‘Don’tturn on. Men at work’ and take measures to prevent the possibility
of accidental restoring the power supply.
The manufacturer and the supplier do not exercise direct control over the assembly of the barrier
and automatic devices, their maintenance and operation, and are not responsible for the safety
of assembly, operation and maintenance of the product.
The company reserves the right to introduce changes in this manual and the product design
without prior notication, but preserving the same functional capabilities and intended purpose.
The contents of this manual cannot be used as the basis for legal claims.
1.2 WHEN PERFORMING THE ASSEMBLY
YATTENTION! The condition of all components and materials must be t for purpose and comply
with applicable rules and regulations.The tools and materials used must be fully functional and
comply with the applicable safety regulations, standards and instructions.
The parameters of the barrier boom and the planned intensity of use of the barrier must be within
the permitted limits (section‘2.2. Specications’). The installation site should correspond to the
declared temperature operating range indicated on the marking of the barrier.
It is necessary to assess the impact of wind loads characteristic of the installation site (region)
on the barrier operation. The barrier boom kit must be selected correctly.
Prior to assembly, remove all unnecessary parts (cables, ropes, angles, chains, etc.) and switch
o all unnecessary equipment, disconnect the locking devices.
Loading, unloading, assembly and disassembly of the barrier must be carried out in accord-
ance with safety regulations taking into account the weight of the barrier. The barrier shall be
assembled by two persons.

BOOM BARRIER BV5868 33
WARNINGS AND SAFETY RULES
Make sure the soil is stable and solid enough to ll the foundation.There should be no obstructive
pipes or cables at the site where the foundation pit is dug. The foundation must be laid deeper
than the frost-line depth.
Make sure that there is no risk of ooding in the area where the barrier is installed, otherwise
make the foundation for the barrier 100–200 mm above ground level.
Select foundation materials (concrete, rebars, etc.) in accordance with building regulations and
process requirements. Asolid and stable foundation will ensure reliable and safe operation of
the barrier.
The foundation surface must be at and horizontal.
Ensure that there is sucient space for assembly and operation of the barrier system.The distance
from the barrier cabinet and the boom tip to the nearest stationary obstacle (wall, fence, etc.) must
be at least 500 mm. The space around the barrier should allow easy and safe manual unlocking.
Check that there will be no obstacles to the movement of the barrier boom when opening and
closing (trees, power lines, walls, fences, etc.). The boom movement should occur at adistance
of at least 5mfrom overhead power lines.
The barrier should not block the pedestrian passageways.
Make sure that the barrier and barrier system devices are protected from accidental impact by
passing vehicles. Otherwise, ensure that safeguards (fencing) are in place.
The surfaces of the sites where the barrier system components are installed must be robust
and used as areliable and rigid support. Otherwise, measures should be taken to reinforce the
installation sites.
For boom lengths exceeding 4m, we recommend installing asupport post (optional). The height
of the support post must be adjusted to the height of the boom.
In case of poor visibility of the boom, e.g. in the dark, it is necessary to attach reective stickers
(optional) to the boom.
Permanent control facilities should be located within the barrier’svisibility at aheight of at
least 1.5mand away from moving elements. Control facilities shall not be publicly accessible.
The electrical system must be provided with aprotective earth connection. The section of the
electrical system to which the product is connected must be equipped with ashort-circuit
protection device (circuit breaker or similar device). The distance between the terminals in the
protective switchgear must be at least 3mm.
The cables for control and safety devices should be laid separately from cables with mains voltage.
Protect cables from contact with any rough or sharp surfaces; use corrugated tubes, pipes and
cable ducts to lay the cables. When wiring the barrier system components, use adouble-insu-
lated multicore copper cable.
The parameters of the electric cables used (section, number of wires, length, etc.) should comply
with the wiring diagram, device power, laying distance, laying method and ambient conditions.
Check and, if necessary, adjust the barrier for safe operation (EN 12453), as incorrect adjustment
may pose ahazard. Proper and safe adjustment is carried out by trained and qualied specialists
from acompetent organization.
During operation, protection against squeezing, impact, trapping, dragging and other hazards
(EN 12453, EN 12604) must be ensured by installing safety devices, safeguards, and observing
safe distances and clearances.
When operating outside the barrier visibility area or when automatic barrier closing is activated
in the settings, photocells (or equivalent safety device) must be installed.

BOOM BARRIER BV586844
WARNINGS AND SAFETY RULES
1.3 WHEN OPERATING THE DEVICE
YATTENTION! The product must not be used by children or persons with physical, sensory or
mental disabilities, or by persons with insucient experience and knowledge who have not
been instructed to use the product.
Don’tlet children play with control elements. Keep the controls out of the reach of children.
Never grab the moving barrier boom or any other moving parts.
Before activating the barrier, make sure there are no people, animals, vehicles or objects in the
hazardous area. Monitor the movement of the barrier boom until it is fully opened or closed.
Passage is permitted when the barrier is open and the barrier boom is completely stopped and
not moving. Do not drive through when the barrier boom is moving.
Do not stay (stop) in the boom area. The automatic barrier can be activated unexpectedly!
Be careful when using manual unlocking (section ‘4.4. Manual unlocking’) as the boom may fall
down very quickly due to loosened or broken springs or loss of balance.
Perform regular checks of the barrier system and the barrier structure, in particular inspect the
cables, springs, and mountings for wear, damage or loss of balance. Do not use abarrier that
requires repair or adjustment as adefective installation or poor balancing may result in injury
or damage to the product.
Check the operation of security devices (photocells, Stops, etc.) every month.
When using the curve (lter type) A, the sound pressure level of the barrier should be ≤70 dB(A)
at adistance of 3m.
The product is not intended for use in acidic, salty or explosive environments.
No foreign objects or building debris should be present inside the barrier; no water or other
liquids should be present inside the control unit or other electrical devices of the barrier system.
Do not operate the equipment in such condition.
The control unit must not be removed and opened in the street in adverse weather conditions
(rain, snow, wind with sand, etc.)! Provide protection for the open control unit for making con-
nections and adjustments under adverse weather conditions.
Sources of heat and naked ame must be removed at an adequate distance from the barrier
and its components. Failure to do so may result in damage to the product, malfunctioning or
dangerous situations.
The barrier system and the barrier shall be subject to scheduled maintenance to ensure ecient
and safe operation. Maintenance and repairs should be documented by the persons performing
them, and the owner should keep these records.
Do not use the barrier if it needs repair!

BOOM BARRIER BV5868 55
PRODUCT DESCRIPTION
2. PRODUCT DESCRIPTION
BV-5-868 electromechanical barrier is designed to automatically restrict entry/ exit of vehicles to/
from acertain territory.When equipped with aRBN8 boom prole, the roadway width is limited to
5m. When equipped with aRBN6-K(optional) boom prole, the roadway width is limited to 6m.
The barrier is equipped with aDC motor with an encoder, agearbox, abalancing spring, asystem
of limit switches, an electronic control unit with an integrated radio receiver, and aLED signal
lamp. The barrier has aself-locking feature (when the barrier is locked, the boom cannot be
moved manually without damaging the barrier, boom or mounting). The barrier is powered from
~230 V/50 Hz mains. In case the mains power supply is temporarily unavailable, the manual
unlocking feature integrated in the barrier will allow moving the boom manually, or the barrier
may be powered by aspecial battery pack (optional).
2.1 SCOPE OF DELIVERY
The scope of delivery of the barrier is shown in Fig. 1.
Y
The boom kit (item 12, Fig.1) depends on the type of boom prole and roadway width.The boom
prole, as well as prole length and components (damping devices, etc.) are to be agreed upon
when ordering the barrier.
YThe barrier cabinet kit contains components for mounting the RBN8 boom prole.
Once you have received the barrier, make sure that the package is complete and the components
are free of visible damage. If any inconsistencies are found, please contact the supplier.
2.2 TECHNICAL SPECIFICATIONS
Table 1
DESCRIPTION VALUE
Maximum torque 230Nm*
Eective boom length (L1, Fig.2–4) 3–5 m (optional up to 6 m)
Power supply 230V (±10%) / 50Hz
Maximum power consumption 100 W*
Maximum power consumption in standby mode 10 W
Intensity of service 250cycles/h*
Maximum opening time 6s*
Rated electric motor voltage 24 V
Radio control 868.35±0.15 MHz / dynamic code /
max. 250 remote control
Protection class I
Protection degree IP54
Working temperature range −30…+65 °
Barrier weight (gross) 60 kg
* The above characteristics are valid for ambient temperatures +20° (±5°) in case of compliance with assembly
and operation rules.

BOOM BARRIER BV586866
PRODUCT DESCRIPTION
Barrier dimensions with installed RBN8 boom—see Fig. 2; with installed RBN6- round
boom—see Fig. 4. The use of RBN6-boom (optional) is recommended in the areas with high
wind loads.When installing asupporting post (Fig. 3), take into account that the eective boom
length (L1) will be reduced.
The service life of the barrier is 8years, but no more than 1.000.000 full cycles provided that
maintenance, installation and operating rules are observed. The operating life of the barrier de-
pends on the operating conditions. Use Table 2to determine the expected operating life (number
of complete cycles):
• Sum up the life cycle percentages that apply to your barrier operating conditions.
• Draw a vertical line on the chart from the point of the total value until it intersects the curve.
• Draw a horizontal line from the intersection point on the chart to the lifecycle value.
1 000 000
800 000
600 000
400 000
200 000
0 10 20 30 40 50 60 70 80 90 100 %
Table 2
OPERATING CONDITIONS LIFECYCLE PERCENTAGE, %
Eective boom length (L1) exceeds 5 m 5
Movable support is installed 10
Frequent interruptions of movement following the commands of security
devices or STOP control commands (heavy use facilities, parking lots,
checkpoints, residential roads, etc.)
15
Value 3.0. of P1–F1 setting
(section ‘7.2. Setting operation parameters’) 5
Movement speed value in settings exceeds 7
(section ‘7.2. Setting operation parameters’P6–F1 and P6–F2)10
Unstable power line voltage; voltage surges 5
Ambient temperature above +40° and below 0° 5
Presence of sand and dust (sand or dust storms), salt mist, etc. 10
High wind load (>20 m/s) 5

BOOM BARRIER BV5868 77
PREPARATION FOR ASSEMBLY
3. PREPARATION FOR ASSEMBLY
1. Refer to section 1‘Warnings and Safety Rules’. Make sure that all rules and requirements
are complied with.
2. Determine the places where each device of the barrier system will be installed.
Anexample of a typical road automation scheme is shown in Fig. 5 below.
3. Determine the wiring diagram according to which all electrical devices in the barrier
system will be connected.
4. Lay the electrical cables according to current regulations to the places where the barrier
system devices are to be installed (Fig. 5). The entire site for the barrier system installation
must be provided with ducts for the laying of electrical cables!
Recommended cable parameters
depending on cable and electric circuit length .............................1–20m ...... 20–50m
RX photocell receiver (pos. 1) 4×0.5mm 4×1mm
TX photocell transmitter (pos. 2) 2×0.5mm 2×1mm
Key switch (pos. 3) 2×0.5mm 2×1mm
Lamp (pos. 4) 2×0.5mm 2×1mm
Antenna (pos. 5) RG58, max. 20m
Network (pos. 6) 3G1.5mm 3G2.5mm
4. ASSEMBLY
4.1 ASSEMBLING THE BARRIER CABINET
If you do not have aready foundation to install the barrier:
1. Prepare the pit for the foundation. Recommended dimensions of the foundation bed for
installing the barrier cabinet are shown in the Fig. 6 below. Dig the pit at a depth where
the soil does not freeze. Select the location of the pit while being inside the area to be
secured by the barrier. The barrier can be installed on the right or left side of the roadway;
install the barrier so that the door of the barrier cabinet should be located inside the
secured area.
YThe foundation for the barrier must be provided with ducts (pipes) for laying the
electrical cables! The ducts exit points from the foundation must be located approx-
imately in the mid-point of the barrier cabinet installation site.
2. Attach the foundation hooks to the mounting base using washers and nuts (Fig.7). Screw
the lower nuts to the end of the thread, observing the size 40–60 mm.
3. Fill the foundation and install the assembled mounting base with hooks (Fig. 8).
YMake sure that the mounting base is aligned until the foundation is set! Clean the
surface of the mounting base from traces of concrete and other building materials.
4. Wait until the foundation is completely hardened and then remove the top nuts and
washers (Fig. 9).
5. Installing the barrier cabinet. Use the key to open the door lock, remove the barrier door
(Fig. 10) and carefully put it aside. Install the cabinet and secure it with the nuts and
washers. (Fig. 11).

BOOM BARRIER BV586888
ASSEMBLY
If you have aready foundation to install the barrier, then mark and drill four holes at the barrier
installation site (Fig. 12), install the anchor bolts (not included in the scope of delivery). Install
the barrier cabinet (Fig. 10, 11).
4.2 INSTALLING THE SPRING
Depending on which side of the roadway the barrier will be installed and on the opening direction
of the boom, determine on which side the spring will be installed relative to the lever (Fig. 13).
4.2.1. THE BARRIER IS INSTALLED ON THE LEFT SIDE OF THE ROADWAY,
THEBOOM OPENS TO THE LEFT. THE SPRING IS INSTALLED ON THE LEFT SIDE
Factory setting.To perform such installation of the barrier, determine the correct opening in
the spring lever (Table 3) and adjust the spring if necessary (Fig. 14).
YThe lever opening in which the spring is inserted by the manufacturer is not nal and must be
checked!
Table 3
BOOM EFFECTIVE LENGTH L1, m
3≤L1<4 4≤L1<5 5≤L1<6 L1=6
RBN8 boom
with damper
321
—
RBN6- boom
3321
4.2.2. THE BARRIER IS INSTALLED ON THE RIGHT SIDE OF THE ROADWAY,
THE BOOM OPENS TO THE RIGHT. THE SPRING IS INSTALLED ON THE RIGHT SIDE
To install abarrier in such away, you will need to invert the lever and the spring:
1. Disconnect the spring by unscrewing the spring mounting bolt on the lever (1) (Fig. 15),
and unscrew the lever mounting bolt on the output shaft (2).
2. Screw the spring mounting bolt into the lever (3).
3. Remove the lever by slowly screwing in the bolt (Fig. 16).
4. Turn the lever 90° and install it back. (Fig. 17).
5. Find the correct opening on the spring lever (see Table 3) and secure the spring to the
lever (Fig. 18).
6. Connect the spring to the barrier cabinet at the bottom (Fig. 19).