CENTURION SYSTEMS SECTOR II User manual

SECTOR II TRAFFIC BARRIER
INSTALLATION MANUAL
TRAFFIC BARRIERS
Centurion Systems (Pty) Ltd
www.centsys.com

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multi-language
Technical Support
Monday to Friday
from 07h00 to 18h00
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Manufactures to
international
quality standard
ISO 9001:2008
100%
testing of
products
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R&D
development
team
Centurion Systems (Pty) Ltd reserves the right to make changes to the products described in this
manual without notice and without obligation to notify any persons of any such revisions or changes.
Additionally, Centurion Systems (Pty) Ltd makes no representations or warranties with respect to
this manual. No part of this document may be copied, stored in a retrieval system or transmitted in any
form or by any means electronic, mechanical, optical or photographic, without the express prior written
consent of Centurion Systems (Pty) Ltd.
1986 1990 1995 1999 Today
Sales and technical support
to Africa, Europe, Asia,
the Americas, Australia
and the Pacic
Company Prole

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SAFETY
FIRST IMPORTANT SAFETY INSTRUCTIONS
1. Glossary of terms
2. Product identication
2.1 Internal components
2.2 External components
2.3 Electronics tray
2.4 Hardware unpacking
3. Physical installation
3.1 Orientation of the SECTOR II
3.2 Preparation of the cabinet plinth
3.3 Mounting the cabinet
3.4 Fitting and levelling the boom pole
4. Onsite electrical wiring
4.1 AC and DC power isolation
4.2 Earthing the unit
4.3 Wiring AC power to the SECTOR II Trac Barrier
4.4 Installing loop detectors
4.4.1 Installing a single FLUX SA loop detector
4.4.2 Installing dual FLUX SA loop detectors
5. Basic controller setup
5.1 Powering up the SECTOR II
5.2 Programming the controller
6. Installation handover
7. Advanced controller setup
7.1 Menu navigation map
Installation ow diagram: Center-fold pull-out
8. Maintenance
8.1 How and when to do maintenance
8.2 Site related issues
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Contents

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8.3 Basic adjustments
8.4 Basic checks for the CLAWS Roadway Spikes
9. Troubleshooting
9.1 Diagnostics
10. Appendices
10.1 SECTOR II specications
10.1.1 Unit specications
10.1.2 Barrier boom pole specications
10.1.3 Fuse protection
10.1.4 Certicate of compliance
10.2. Changing the SECTOR II to a left-hand conguration
10.3 Adjusting limits for Fail-safe Mode
10.4 11-pin loop detector installations
10.4.1 Installing a single FLUX 11-pin loop detector
10.4.2 Installing dual FLUX 11-pin loop detectors
10.5 Safety beam installation
10.6 Wiring diagrams for installation modes
10.6.1 Simplex Mode
10.6.2 Complex Mode (Option 1)
10.6.3 Complex Mode (Option 2 - Ticket vendors)
10.6.4 Uni-directional trac
10.6.5 Bi-directional trac
10.7 Factory Default Settings (South Africa only)
10.8 Terminal descriptions
10.9 Ancillary installation equipment
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CONTENTS
Icons used in this manual
This icon indicates tips and other
information that could be useful
during the installation.
This icon denotes variations
and other aspects that should be
considered during installation.
This icon indicates warning,
caution or attention! Please
take special note of critical
aspects that MUST be adhered
to in order to prevent injury.
This icon indicates areas
where mechanical crushing
may occur

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ATTENTION
To ensure the safety of people and possessions, it is important that you
read all the following instructions.
Incorrect installation or incorrect use of the product may cause
serious harm to people and / or property.
The installer, being either professional or DIY, is the last person
on the site who can ensure that the operator is safely installed, and that
the whole system can be operated safely.
IMPORTANT
SAFETY INSTRUCTIONS
Warnings for the installer
CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS before beginning to install
the product.
• All installation, repair, and service work to this product must be carried out by a
suitably qualied person
• Do not activate your barrier unless you can see it and can determine that its area of
travel is clear of people, pets, or other obstructions
• NO ONE MAY CROSS THE PATH OF A MOVING BARRIER. Always keep people
and objects away from the barrier and its area of travel
• NEVER LET CHILDREN OPERATE OR PLAY WITH THE BARRIER CONTROLS
• Secure all easily-accessed barrier controls in order to prevent unauthorised use of the
barrier
• Do not in any way modify the components of the automated system
• Do not install the equipment in an explosive atmosphere: the presence of ammable
gasses or fumes is a serious danger to safety
• Before attempting any work on the system, cut electrical power to the operator and
disconnect the batteries
• The mains power supply of the automated system must be tted with an all-pole
switch with contact opening distance of 3mm or greater. Use of a 5A thermal breaker
with all-pole circuit break is recommended
• Make sure that an earth leakage circuit breaker with a threshold of 30mA is tted
upstream of the system
• Never short-circuit the battery and do not try to recharge the batteries with power
supply units other than that supplied with the product, or manufactured by
Centurion Systems (Pty) Ltd
• Make sure that the earthing system is correctly constructed, and that all metal parts
of the system are suitably earthed
SAFETY INSTRUCTIONS

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• Safety devices must be tted to the installation to guard against mechanical
movement risks, such as crushing, dragging and shearing
• It is recommended that at least one warning indicator light be tted to every system
• Always t the warning signs visibly to the inside and outside of the barrier
• The installer must explain and demonstrate the manual operation of the barrier in
case of an emergency, and must hand over the user guide to the user
• Explain these safety instructions to all persons authorised to use this barrier, and be
sure that they understand the hazards associated with trac barriers
• Do not leave packing materials (plastic, polystyrene, etc.) within reach of children as
such materials are potential sources of danger
• Dispose of all waste products like packing materials, worn-out batteries, etc.
according to local regulations
• Always check the obstruction detection system and safety devices for correct
operation
• Neither Centurion Systems (Pty) Ltd, nor its subsidiaries, accepts any liability caused
by improper use of the product, or for use other than that for which the automated
system was intended
• This product was designed and built strictly for the use indicated in this
documentation. Any other use, not expressly indicated here, could compromise the
service life/operation of the product and/or be a source of danger
• Anything that has not been specied in these instructions may be considered a risk
to your safety, and the safety of others. If you are unsure of an installation matter,
please contact your nearest distributor
SAFETY INSTRUCTIONS

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SECTOR II 3, 4.5 or 6m trac barrier manufactured by
Centurion Systems (Pty) Ltd
Boom Aluminium pole used to close o roadway or section
thereof
Loop Inductive loop manufactured to sense a vehicle when it
passes over the loop. Minimum 2.5m wide by 1m
Counterbalance assembly A spring-assembly to balance the boom pole
Hold down bracket Bracket used to clamp the cabinet in position
CP84 SM 2A Charger Battery charger
Camlock Cabinet-type lock, (60198 Keyed-alike)
DIP switch Selectable binary switches (two-position)
Modes of Operation Selection that dictates how the SECTOR II barrier will
react to external stimuli
Duty cycle Percentage per unit time within which the barrier can
operate, i.e. 48 minutes in an hour
Collision-sensing operation The ability of the boom to detect an obstruction and reverse
direction
Manual Operation Allows emergency manual operation of boom without
utilising the manual-override
TABLE 1
GLOSSARY OF TERMSSECTION 1
1. Glossary of Terms

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1. Electronics tray
2. Gearbox assembly (3m, 4,5m and 6m)
3. Spring assembly locating washer
4. Spring assembly bolt
5. Spring-washer
6. Spring assembly bush
7. Counterbalance assembly
8. Taper roller
9. Tension-bar nut
10. Hold down bracket
11. AC Mains terminal block
FIGURE 1. PRODUCT IDENTIFICATION - INTERNAL COMPONENTS
5
6
4
1
2
3
8
9
10
11
7
PRODUCT IDENTIFICATIONSECTION 2
2. Product Identication
2.1. Internal Components

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1. Barrier lid
2. Boom pole (3m, 4.5m and 6m)
(not supplied)
3. Manual override (6mm Allen key)
4. Boom pole coupler
5. Barrier enclosure
6. Door
7. Boom pole retainer
1. CP4 7Ah battery
2. Barrier controller
3. CP84 SM 2A charger
4. Wiring channels
5. FLUX SA loop detector – single (optional)
FLUX SA loop detector – double (optional)
6. FLUX 11-Pin loop detector – single (optional)
FLUX 11-Pin loop detector – double (optional)
FIGURE 2. PRODUCT IDENTIFICATION - EXTERNAL COMPONENTS
FIGURE 3. PRODUCT IDENTIFICATION - ELECTRONICS TRAY
76
5
5
4
6
2
2
4
3
3
1
1
2.2. External components
2.3. Electronics tray
PRODUCT IDENTIFICATIONSECTION 2

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1. M8 Nuts
(for boom pole retainer)
2. M8 Spring Washers
(for boom pole retainer)
3. M12 Heavy duty washers
(for the Hold Down Bracket)
4. Hold down bracket
5. Boom pole retainer
6. 6mm Allen key (for manual override)
FIGURE 4. PRODUCT IDENTIFICATION - HARDWARE
2.4. Hardware unpacking
When unpacking the SECTOR II, neccessary harware can be found attached to the
enclosure. The hardware is as follows:
1
2
3
4
5
6
PRODUCT IDENTIFICATIONSECTION 2

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PHYSICAL INSTALLATIONSECTION 3
3. Physical Installation
3.1. Orientation of the SECTOR II
The SECTOR II can be installed in dierent congurations. It is important to fully
understand the site requirements before purchasing the unit. The following steps detail
the dierences between the orientations:
Step 1
Look at the site and decide where the unit will be positioned.
Step 2
Determine which direction the pole will face. This will enable you to ascertain whether a
right-hand or left-hand barrier is needed for the installation.
Left-Hand Barrier Right-Hand Barrier
• A left-hand barrier is a unit that is
installed on the left-hand-side of
the road from which the vehicle
approaches. The door always faces the
approaching vehicle
• If a left-hand unit is required, it may
be necessary to convert the barrier to
a left-hand barrier(see next point)
• A left-hand congured SECTOR II
is available from Centurion Systems
(Pty) Ltd upon request. Please note
that left-hand congurations may
require longer lead times
• A right-hand barrier is a unit that
is installed on the right-hand-side
of the road from which the vehicle
approaches. The door always faces
the approaching vehicle
• All units are manufactured as right-
hand units, unless otherwise specied
• It is always recommended to mount
the barrier with the access-door facing
the oncoming trac. This ensures
that if a vehicle hits the pole, the
pole is knocked away from the barrier
housing
FIGURE 5
Right-hand orientated
SECTOR II trac barrier
Left-hand orientated
SECTOR II trac barrier
Direction of trac
Direction of trac
TABLE 2

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It is assumed that all details discussed in the document “SECTOR II pre-installation
buyers' guide” are complete and physical installation of the system onsite is about to
start.
If Section 5 of the Pre-installation Buyers' guide has not been followed, for convenience
we have repeated what is requires to prepare the plinth before mounting the cabinet.
Install an earth-spike and
hold down studs (if not
using rawl bolts), as shown
in Figure 5 and Figure 6
before casting the plinth.
Step 6
Using medium strength concrete
(25Mpa), cast the plinth with
dimensions as shown in Figure 6 and
Figure 7. Allow to dry.
Ensure that 30mm of
conduit protrudes above
the concrete, and that the
mains wires will emerge
within the cabinet at least
400mm in length.
Should a 33Ah battery need to be installed, the studs need to be cut to length
subsequent to the SECTOR II being secured to the plinth.
FIGURE 6. PLINTH DIMENSIONS
FIGURE 7
Recommended
minimum height
Earth-spike
(Not supplied)
M12 Throughbolt
rawlbolts or
Chemical anchors
(Not supplied)
Earth spike
(Not supplied)
M12 Throughbolt rawlbolts
or Chemical anchors
(Not supplied)
Conduit
290mm
Underground
300mm
80mm
Concrete plinth
Recommended
minimum depth
284.5mm
420mm
150mm
20mm
180mm
50mm90mm
420mm
FRONT OF UNIT
274mm
Concrete plinth
Conduit
SECTOR II
PHYSICAL INSTALLATIONSECTION 3
3.2. Preparation of the Cabinet Plinth

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Step 1
Remove the lid before removing the
door.
Step 2
Pull the door release to open the
door (1). The door is then removed
by lifting it up and away (2).
FIGURE 8
FIGURE 9
Camlock
Camlock
key
SECTOR II lid
SECTOR II
door
Door release
2
1
The lid is not attached
to the barrier enclosure.
Hold the lid securely
while pivoting it up, and
removing the lid.
The Controller, Battery,
Charger Unit, and Loop
Detectors are all accessable
once the lid of the
SECTOR II has been
removed.
3.3. Mount the cabinet
PHYSICAL INSTALLATIONSECTION 3
Step 3
Position the unit on the pre-installed
plinth.
Step 4
Ensure that the unit is level and that
the conduit and cables have suitable
clearance from moving parts.
FIGURE 10
Plinth
SECTOR II
enclosure
Barrier
hold-down
stud
Conduit
Mains
cable

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Step 5
Ensure the hold-down bracket is the
right way up before securing it in
position (Figure 11).
Bolt the hold-down bracket in
position to clamp the barrier onto
the plinth (Figure 12).
If there is a need to install
the SECTOR II barrier in the
left-hand conguration and
it has not been pre-ordered,
keep the barrier bolted in
place. Refer to Appendix 2 -
Changing a unit to a
left-hand conguration
FIGURE 11
FIGURE 12
Barrier
hold-down
stud
Nut
Heavy duty
Washer
(Supplied)
Hold-down
bracket
PHYSICAL INSTALLATIONSECTION 3
3.4. Fitting and levelling the boom pole
FIGURE 13
3.4.1. Fitting the pole
Step 1
Carefully remove the end cap from
one end of the boom pole.
Step 2
Use the retainer assembly to mark a
line along the pole.
Step 3
From the edge of the pole, mark and
centre punch the hole positions at
65mm and 175mm (Figure 13).
Marking pen
Boom poleBoom pole retainer
65mm
175mm

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FIGURE 14
FIGURE 15
Step 5
Insert the boom pole retainer and
locate the threaded studs in the
drilled holes.
Drilling machine
8.5mm drill bit
Boom pole
Boom pole retainer
Step 4
Drill two 8.5mm holes.
Holes must be drilled
through only one wall of
the boom pole.
PHYSICAL INSTALLATIONSECTION 3
FIGURE 16
Step 6
Fasten the boom pole as shown and
replace the end cap (Figure 16).
Boom pole
M8 Nut
M8 Spring
washer
Threaded
stud
Coupler
in vertical
position
End Cap

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FIGURE 17
3.4.2. Leveling the boom pole
Step 1
Using the manual override, move the
boom pole to the lowered position.
Step 2
If the pole is not horizontal,
loosen both lock nuts on the
adjustment link using 2x 17mm
spanners (Figure 17).
Step 3
Adjust the adjustment link to achieve
a level boom. Use a spirit level on
the boom pole, then tighten the lock
nuts using 2x 17mm spanners.
Drive arm
Adjustment
lock nuts
(1x LH, 1x RH)
Output
shaft plate
Adjustment
link
Mechanical crushing
may occur
Figure 17 shows a right-hand conguration. Although the left-hand conguration
looks dierent, the levelling procedure remains the same.
PHYSICAL INSTALLATIONSECTION 3
FIGURE 18
FIGURE 19
3.4.3. Coarse adjustment of the
spring tension
The spring tension is adjusted at the
factory. Should the spring tension
need to be adjusted, follow the steps
below.
Step 5
Manually override the boom pole so
that it rests under the tension of the
spring.
Step 6
Use a 24mm socket (4.5m and
6m boom) or a 17mm socket (3m
boom) to adjust the spring so that
the boom pole rests at an angle of
approximately 45˚. The optimal
position will be determined by the
electronics when the unit is set up.
Tension
bar nut
Ratchet
spanner

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Before commencing with wiring, ensure that all power to the SECTOR II
is OFF.
Lightning Protection
The S-SERIES electronic controller utilises the same proven surge protection philosophy that is
used in all products from Centurion Systems (Pty) Ltd. While this does not guarantee that the
unit will not be damaged in the event of a lightning strike or power surge, it greatly reduces the
likelihood of such damage occurring. The earth return for the surge protection is provided via the
mains power supply earth.
In order to ensure that the surge protection is eective, it is essential
that the unit is properly earthed.
FIGURE 20
4.1. AC and DC power isolation
Step 1
Switch o both the AC and DC isolators (Figure 20)
Step 2
Install and connect the 12V, 7.5Ah battery.
DC Isolator
switch - 'OFF'
position shown
AC Isolator
switch - 'OFF'
position shown
ONSITE ELECTRICAL WIRINGSECTION 4
4. Onsite Electrical Wiring

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FIGURE 23
Earth
Neutral
Live
4.3. Wiring AC power to the
SECTOR II trac barrier
Route and connect the 220V AC
Mains cable (Figure 23).
Mains
supply
4.2. Earthing the unit
Connect the earth spike (Figure 21)
to the designated earth point
(Figure 22) using 5mm2copper-
weave conductor and the self-
tapping screw provided.
FIGURE 21
Earth spike
(Not supplied)
FIGURE 22
Designated
Earthing point
ONSITE ELECTRICAL WIRINGSECTION 4

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4.4. Installing loop detectors
The SECTOR II can use various
types of loop detector.
Centurion Systems (Pty) Ltd
recommends using the FLUX SA
(standalone) loop detector, as the
unit is easily clipped into place and
wired.
Loop detector variations:
• Single FLUX SA
• Dual FLUX SA
• Single FLUX 11-pin (Appendix 4)
• Dual FLUX 11-pin (Appendix 4)
4.4.1. Installing a single
FLUX SA loop detector
Step 1
Clip the FLUX SA into the electronics
tray.
Step 2
Wire the FLUX SA to the controller
using the supplied harness as per
the wiring diagram (Figure 27).
Step 3
Run the TWISTED loop wires up
inside the enclosure through the
wiring clips to the FLUX SA
(Figure 26). Connect the twisted
loop wires to the FLUX SA.
FIGURE 24
FIGURE 25
FIGURE 26
FLUX SA
DIP switch
access cover
FLUX SA
FLUX SA
Twisted
loop wires
Wiring clips
Connection
terminals
Twisted
loop wires
running
through
opening
ONSITE ELECTRICAL WIRINGSECTION 4

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FIGURE 27. WIRING A SINGLE FLUX SA AS A CLOSING / SAFETY LOOP
Closing / safety loop
Black Earth Yellow Red
Earth point
NOTE: For safety loops,
Perm Presence must be turned 'ON'
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RELAY
RELAY
ONSITE ELECTRICAL WIRINGSECTION 4