Centurion SECTOR Series User manual

SECTOR installation manual
HIGH-VOLUME
INDUSTRIAL
TRAFFIC
BARRIER
TM

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Contents
IMPORTANT SAFETY INSTRUCTIONS page 3
page 1
page 2
page 2
Mechanical Setup
Electrical Setup
Commissioning and Handover
1. Declaration of conformity
2. General description
Lightning protection
3. Specifications
Physical dimensions
Technical specifications
Barrier housing specifications
Barrier pole specifications
Fuse protection
4. Icons used in this booklet
5. Product identification
6. Required tools and equipment
7. Preparation of site
General considerations for the installations
8. Loop detectors and associated functionality
FLUX OB features
FLUX OB diagnostics
9. Selecting Operating Mode
Simplex Mode
Complex Mode
PLC Mode
10. Cabling requirements
Simplex Mode
Complex Mode (basic)
Free-exit for uni-directional traffic
Free-exit for bi-directional traffic
11. Orientation
Left hand
Right hand
12. Conversion from right hand to left hand
Remove the coupler
Fit the coupler
13. SECTOR installation
Enclosure positioning
page 5
page 6
page 6
page 7
page 7
page 7
page 8
page 8
page 8
page 9
page 10
page 11
page 12
page 12
page 13
page 13
page 15
page 17
page 17
page 17
page 18
page 19
page 19
page 19
page 19
page 20
page 21
page 21
page 22
page 23
page 24
page 25
page 26
page 26

Concrete plinth/foundation
Fitting the pole
Levelling the boom pole
Balancing the spring
Failsafe/Lock Mode
Manual release
14. Electrical setup
Connecting all wiring
15. Simple Mode: Option 1 (recommended) electrical connections
16. Simple Mode: Option 2 - electrical connections
17. Complex Mode: Option 1 (basic) electrical connections
18. Complex Mode: Option 1 (Tickect vend) electrical connections
19. Free-exit loop - electrical connections
20. Setting up the limits and features for the SECTOR barrier
Setting up the limits
21. SECTOR menu navigation
22. SECTOR controller features
23. Diagnostics
Diagnostic LEDs
LCD display
Buzzer feedback
24. Factory defaults schedule
25. Description of terminal functions
26. Faultfinders guide
Procedure A - Low battery voltage condition
Procedure B - False collision detection
27. Peripheral equipment
28. Installation handover
page 26
page 27
page 28
page 28
page 29
page 29
page 30
page 30
page 31
page 33
page 35
page 37
page 38
page 39
page 39
page 41
page 44
page 50
page 50
page 51
page 52
page 53
page 55
page 57
page 57
page 58
page 59
page 61

Mechanical setup
Heed necessary site considerations Page 12
Check cabling requirements Page 19
Gather required tools and equipment Page 11
Set the concrete foundation Page 26
SECTOR enclosure positioning Page 26
Fit the pole Page 27
Level the boom pole Page 28
Balance the spring Page 28
These abbreviated instructions are for the experienced
installer who needs a checklist to get a standard installation
up and running in the minimum of time.
Detailed installation features and functions are referred to
later in this manual.
Page 1

Connect all wiring Page 30
Page 39
Page 41
Page 61
step
9
Electrical setup
Page 2
step
10
Set the limits and features
step
12
Carry out professional
handover to client
Commissioning
and handover
step
11
Set additional features via the
menus, if required

Warnings for the installer
CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS
beforebeginningto install the product.
!All installation, repair, and service work to this product must
becarriedout bya suitably qualified 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
otherobstructions
!NO ONE MAY CROSS THE PATH OF A MOVING BARRIER
Always keep people and objects away from the barrier and its
areaoftravel
!NEVER LET CHILDREN OPERATE OR PLAY WITH THE
BARRIER CONTROLS
!Secure all easily accessed barrier controls in order to prevent
unauthorizeduseofthebarrier
!Do not in any way modify the components of the automated
system
!Do not install the equipment in an explosive atmosphere: the
presence of flammable gasses or fumes is a serious danger to
safety
!Before attempting any work on the system, cut electrical
powerto the operatoranddisconnectthebatteries
!The mains power supply of the automated system must be
fitted with an all-pole switch with contact opening distance of
3mm or greater. Use of a 5A thermal breaker with all-pole
circuitbreakis recommended
!Make sure that an earth leakage circuit breaker with a
thresholdof30mAis fitted 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 by Centurion Systems
IMPORTANT
Safety Instructions
ATTENTION
To ensure the safety of people, it is important that you
read all the following instructions. Incorrect
installation or incorrect use of the product could cause
serious harm to people.
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.
Page 3

!Make sure that the earthing system is correctly
constructed, and that all metal parts of the system are
suitably earthed
!Safety devices must be fitted 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 fitted to every system
!Always fit 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 the User Guide over to the user
!Explain these safety instructions to all persons authorized
to use this barrier, and be sure that they understand the
hazards associated with automated gates
!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 packaging materials,
worn out batteries, etc. according to local regulations
!Always check the obstruction detection system, and safety
devices for correct operation
!Centurion Systems does not accept 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
Everything not expressly specified in these instructions
is not permitted.
Page 4
MOVING BARRIER CAN CAUSE SERIOUS INJURY OR DEATH
KEEP AWAY! THE BARRIER MAY MOVE AT ANY TIME
DO NOT ALLOW CHILDREN TO PLAY IN THE AREA
OR OPERATE BARRIER

Page 5
1. Declaration of conformity
Manufacturer:
Declares that the product:
Conforms with the following specifications:
Standard to which conformity is declared:
Centurion Systems (Pty) Ltd
Unit 13 Production Park
Intersection Newmarket Road & Epsom Avenue
North Riding
Gauteng
South Africa
Product name: SECTOR Traffic barrier
Product options: All variants
Safety: IEC 61010-1:2001
Emissions: CISPR 22 CLASS B: Radiated emissions – 150MHz to 1GHz
CISPR 22 CLASS B: Conducted emissions – 150 KHz to 1GHz
Immunity: IEC 61000-4-2 – Electrostatic discharge
IEC 61000-4-3 – Radiated immunity – 80MHz to 1000MHz
IEC 61000-4-4 – Electrical fast transients/burst
IEC 61000-4-5 – Surge immunity test
IEC 61000-4-6 – Conducted immunity – 150KHz to 80MHz
IEC 61000-4-8 – Power frequency magnetic field
IEC 61000-4-11– Voltage dips and interruption
IEC 61010-1:2001 Safety
IEC 61000-6-3:2006 Emissions
IEC 61000-6-1:2005 Immunity
Signed at North Riding, South Africa on December 1, 2010
Ian Rozowsky
Research & Development Director.

The SECTOR barrier has been designed to safely and cost-effectively apply high-duty
vehicular access control to roadways between 3m and 6m wide. The battery backed up
system ensures continued operation in the event of a power failure. The failsafe position
and collision detection system has been designed and tested to set the standard in safety
of operation and to provide an unparalleled level of reliability and durability in operation.
The pole travel limits are managed by a sealed opto-electronic system that ensures
precise position and trajectory control. Accurate and reliable collision detection ensures
safe operation even under trying conditions. A precision die-cast gearbox and novel
speed and trajectory control algorithm ensures smooth and rapid operation even after
many years of service. The splined output coupler eliminates pole droop over time. The
SECTOR control card has been designed to be easy and intuitive to use with helpful
instructions on the status of the operation during and after installation.
Some of the advanced features offered by the SECTOR controller are:
!Interactive graphical user interface via a backlit LCD display to facilitate and simplify
the installation process
!Fully automated single button limit setup
!Independent Memory Input, Non-Memory Input, Barrier Raise and Barrier Lower Inputs
!Advanced closed-loop speed control to maintain safe and reliable operation in windy
conditions
!Independent control of Opening and Closing speeds
!Selectable and adjustable Autolower
!Selectable mains failure raise
!Smooth, adjustable start/stop (ramp-up and ramp-down)
!Multiple Operating Profiles
!Onboard CENTURION receiver with full channel mapping capability (limited to 500
buttons)
!A status LED output to indicate the barrier status remotely
!Advanced and proven lightning protection
The SECTOR electronic controller utilises the same proven surge protection philosophy
that is used in all CENTURION products. 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.
Lightning Protection
2. General description
Page 6
In order to ensure that the surge protection is effective, it is essential that the
unit is properly earthed.

3. Specifications
FIGURE 1. OVERALL DIMENSIONS
Technical specifications
Physical dimensions
Page 7
1167mm
285mm 437mm 304mm
20mm
890mm
Ø76mm
Input voltage
Motor voltage
Motor power supply
Battery charger
Current consumption (mains)
Boom pole length
Boom pole raise time (adjustable)
Manual override
Maximum number of operations per day
Duty cycle - mains present
Operations in standby with 7Ah battery
Half day
Full day
Collision sensing
Operating temperature range
Onboard receiver type
Receiver code storage capacity
Receiver frequency
220-240V AC ± 10%, 50Hz
12V DC
Battery driven (standard capacity - 7Ah)
CP84SM - 2A @ 13.8V
170mA
Allan key operated from outside unit
3000
80%
3000
3000
Electronic
-15°C to +65°C
CENTURION code-hopping multichannel
500 transmitter buttons
433MHz
SECTOR 3 SECTOR 4.5 SECTOR 6
3.0m
1.2 sec 3 sec3 sec
4.5m 6.0m
Can operate off a solar supply, consult Centurion Systems for assistance
Can increase battery capacity for longer standby times
Boom pole raise and lower times are both individually configurable to suit individual
installation requirements
Based on 25°C ambient temperature and unit not in direct sunlight
Based on an output torque of less than 50% of rated
Based on basic operator excluding closing loop detector Limited by daily usage

Page 8
Fuse protection
The following protection fuses are provided on the system:
Item Type Rating
Main controller
Motor circuit Automotive fuse ATO (25 x 7 mm) 30A
Light circuit 5 x 20mm 3A fast blow
Auxiliary supply Electronic limit 300mA
Charger
Mains input 5 x 20mm 3A fast blow
Not user serviceable
SECTOR 3
SECTOR 4.5 SECTOR 6
Barrier housing specifications
Application
Main housing surface
protection
Inland areas Coastal plains
-no airborne salt Marine areas
Zinc-passivated
mild steel with
epoxy coating
Grade 430 stainless
steel with epoxy
coating
Grade 316
brushed
stainless steel
SECTOR 3
Base frame surface
protection Mild steel, hot
dip galvanised Grade 316 brushed
stainless steel
Mild steel, hot
dip galvanised
Housing construction Sheet metal housing, 1.6mm wall thickness with
separate fabricated base frame, 3mm wall
thickness to raise housing above ground
Traffic yellow
Colour IP 55
Housing protection rating
Barrier pole specifications
Material and profile
Dimensions
Weight
Surface protection, colour
and markings
Aluminium, round profile with plastic end cap
Outside diameter: 76.2mm; Wall thickness: 1.27mm
800g/metre
Epoxy-coated white with
red reflective tape

4. Icons used in this manual
This icon indicates tips and other
information that could be useful
during the 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 denotes variations and
other aspects that should be
considered during installation
Page 9

5. Product identification
FIGURE 2. PRODUCT IDENTIFICATION
Page 10
1. SECTOR enclosure
2. Gearbox assembly (3m, 4.5m and 6m)
3. Spring locating washer
4. Spring bush (3m, 4.5m and 6m)
5. Counterbalance assembly (3m, 4.5m
and 6m)
6. Retaining bracket
7. Floor spacer
8. Boom pole (3m, 4.5m and 6m)
9. Boom coupler
10. Boom retainer
11. Door
12. Electronics assembly
1
2
3
4
5
6
7
8
9
10
11
12

6. Required tools and equipment
!Spanner – 17mm; 13mm
!Screwdriver – 3.5mm flat and 6mm Philips
!Hammer
!Electric drilling machine
!G-clamp x 2
!Pick
!Crimping tool and pin lugs
!Self-locking pliers (vice-grip)
!Pliers
!Side cutters
!Masonry bits – 6mm; 20mm; (for sites with rawlbolt foundation plates)
!Steel bits – 8.5mm; 5.0mm; 4.0mm
!Spade
!Spirit level
!Measuring tape
!Welding machine, including safety equipment and consumables
!Angle grinder
!Extension cord
!Marking pen/pencil and chalk
!Safety equipment, gloves, goggles, etc.
Page 11

7. Preparation of site
General considerations for the installation
!Consider the following checklist when determining the safety and suitability of the site:
!Check that all local authority requirements will be met
!Check that the usage (duty cycle) of the site and the length of the boom pole
required, are within the barrier specifications
!Check that there is sufficient clearance on the side of the roadway to mount the
barrier
!Check that a suitable foundation has been prepared for the barrier
!Check that the fitment of additional safety equipment has been catered for
!Check that no pipes or electrical cables are in the way of the intended installation
Page 12

Page 13
8. Loop detectors and associated functionality
FLUX OB onboard vehicle loop detector
Description
Certain SECTOR models provide an onboard single-channel inductive loop detector
known as the FLUX OB, eliminating the need for a separate detector. This highly sensitive
loop detector can be used for the connection of closing loops and does not require
additional relays and bases to be fitted, saving time and money.
A number of diagnostic LEDs are present on the termination board to allow for quick and
reliable loop installation, and a series of selectable dipswitches enables the individual
user to change settings as best suits the installation. In addition, the inclusion of
adjustable frequency settings provides excellent immunity to outside interference, and
adaptive self-tuning means unparalleled and uncompromising reliability.
12 3 4 5678 9 10 11
SAFETY BEAM COM MI COM NMI Lower Raise Status TVI TVI LCK AUX Out
FRX
LOOP
12345678
ON DIP
17 18
PWR
DIA
DETECTED
LEVEL 5
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
FAULT
RUN
FREQ HI/LO
ASB
PERM PRES
0 0 0 0 1 1 1 1
UNI-DIR FRX
0 0 0 0 1 1 1 1
0 0 0 0 1 1 1 1
- 12V Out +
12 13 14 15 16
FRX
LOOP
Free-exit loop detector 11 pin base Reset button Dipswitches
Diagnostic
LEDs
FLUX OB onboard
inductive loop detector
FLUX OB features
Reset button
!
results in the detector retuning the sensing loop and becoming ready for vehicle
detection. In addition, a 0.5S output pulse will be generated
Run switch
!If the switch is ON, the detector is in Run Mode, and functions normally. If OFF, the
detector halts, and the output relay defaults to the detected state. This is useful when
working on the SECTOR, as it will prevent the boom from lowering
Frequency selection switch
!The frequency of the loop is determined by the inductance of the loop and the
frequency switch setting. If the frequency switch is ON, the frequency is reduced by
approximately 25%. It may be necessary to change the frequency to prevent cross-
talk between adjacent loops
Pressing the reset button enables the detector to be manually reset at any time. This
FIGURE 3. FLUX OB ONBOARD VEHICLE LOOP DETECTOR

Page 14
Uni-directional Free-exit switch
!The switch is used to select between uni- and bi-directional traffic. If the switch is in
the ON position, the loop detector will generate a “raise” pulse whenever a vehicle is
detected on the Free-exit loop. If, however, the switch is in the OFF position, a raise
pulse will only be generated if a detect signal is received from the Free-exit loop only,
and never when a signal is received from the Free-exit loop and the closing loop
simultaneously (bi-directional traffic)
It is very important that the distance between the free-exit loop and the closing
loop is less than the length of one car
Automatic Sensitivity Boost (ASB) switch
!This option increases the sensitivity of the detector after initial detection of a vehicle.
This is useful to reliably detect vehicle and trailer combinations. Sensitivity returns to
the selected value once the vehicle has been undetected
Permanent presence switch
!If this switch is set to the ON position, detection will be maintained as long as a vehicle
remains on the loop. The danger in using this setting is that any change in the
environment (for example the introduction of metal into the vicinity of the loop) will not
automatically be tuned out without pressing the reset button. If not selected, the loop
will automatically tune out any permanent detection after five minutes
Adjustable loop sensitivity settings
&
Eight sensitivity settings are available
Sensitivity SENS1 SENS2 SENS3
High (0.03%) ON ON ON
0.06% ON ON OFF
0.1% ON OFF ON
0.2% ON OFF OFF
0.5% OFF ON ON
1% OFF ON OFF
2% OFF OFF ON
Low (4%) OFF OFF OFF
Power indicator LED
!This red LED is on when power is present, and the controller is functioning
Loop fault indicator LED
!This red LED is illuminated when there is a loop fault. If the loop is open circuit, the
Fault LED will flash continuously. If the loop is short circuit, it will remain on
Detection level indicator LEDs
!These five RED LEDs provide a visual indication of the Detection Level. Once all five
LEDs are on, the detection threshold is almost reached. This is a very useful feature to
determine if the loop is going to perform reliably. With no vehicle in the vicinity, all the
LEDs should be off

Page 15
FLUX OB diagnostics
The sense level LEDs
flash erratically
The detector
randomly detects,
even though there is
no vehicle present
The Loop Fault LED is
flashing
The Loop Fault LED is
permanently
illuminated
There may be a poor
connection in the loop or
loop feeder
The detector may be
experiencing crosstalk with
the loop of an adjacent
detector
Faulty loop or loop feeder
wiring
Movement of the loop in the
ground
The loop inductance is too
large, or the loop is open
circuit
The loop inductance is too
small, or the loop is short
circuited
Check all wiring. Tighten screw
terminals. Check for broken wires
Try changing frequencies using the
frequency switch. Put the detector
with the larger loop onto low
frequency and the detector with
the smaller loop onto high
frequency
Check the wiring. Tighten screw
terminals. Check for pinched or
bent wires. Is the feeder wire
twisted?
Check for cracks in the road
surface near the loop
Check that there is electrical
continuity on the loop. If the
inductance is too large then try
reducing the number of turns
Check that there is no short circuit
on the loop feeder wiring of the
loop. If there is no short circuit
then the inductance is too small
and more turns of wire should be
added to the loop
Symptom Possible cause Solution
Detect indicator LED
!This green LED indicator is illuminated when there is a vehicle detected. This LED can
also be used to determine the loop frequency. Reset or power up, count the number of
times the Detect LED flashes. Multiply this number by 10KHz. For example: if the LED
flashes eight times, then the loop frequency is approximately 80KHz
Commissioning the FLUX OB
1. With the loop connected, apply power to the SECTOR controller.
2. The green Power LED on the termination board will light up, and the green Detect
LED will flash until the loop has stabilised, and then turn off.
3. Once the loop has stabilised, only the green power LED should be on.
4. Bring a metal object towards the loop, and the Sense level LEDs will begin to light
up, indicating the detection range of the loop.
5. Once all five lights have lit up, the unit will enter detect, with the green detect
LED lit.
6. Configure the desired operational settings using the dipswitches.
7. Test the FLUX OB using a metallic object, or a vehicle.

Page 16
Separate loop detector module
!If your SECTOR vehicle traffic barrier has not been fitted with an onboard inductive
loop detector, it is possible to install an external detector using one or both of the bases
provided on the SECTOR termination board. Bases are provided for both Free-exit and
closing loop connections. Setup will be as per the individual detector. For more
information on the different configurations and Modes of Operation as well as
connecting closing and Free-exit loops, please refer to section 15, Electrical Setup
12V loop detectors MUST be used.
Tips for successful loop installation
!The loop and feeder should be constructed from XLPE (cross-linked polyethylene)
insulated multi-stranded copper wire with a minimum cross-sectional area of 1.5mm².
The feeder should be twisted at a rate of at least 20 turns per metre to improve
reliability (Remember that twisting the feeder will shorten its length, so ensure a long
enough feeder wire is used). Feeders which may pick up electrical noise should use
screened cable, with the screen earthed at the detector
!Joints in the wire are not recommended, but where required must be soldered and
made waterproof
!Faulty joints will lead to unreliable operation
!The loop should be either square or rectangular in shape with a minimum distance of
1m between opposite sides
!Two to six turns of wire are typically used in the loop – See table below:
Loop perimeter (metres)
3-4
4-6
6-10
10-20
>20
Number of turns
6
5
4
3
2
!When two loops are laid in close proximity to each other, it is recommended that
different numbers of turns are used in each loop to prevent cross-talk
!Cross-talk describes the interference between two adjacent loops, and can cause
reliability issues
!To minimise cross-talk, adjacent loops should be at least two metres apart, and
different frequency settings
!The most reliable form of loop is preformed and enclosed in conduit. This prevents
water ingress, and minimises the effects of vibration
!Where a pre-formed loop is not practical, slots should be cut into the road using a
masonry cutting tool. A 45° cut should be made across the corners to prevent damage
to the wire on the corners. The slot should be about 4mm wide and 30mm to 50mm
deep. Remember to extend the slot from one of the corners to the roadside to
accommodate the feeder. After the loop and feeder wires have been placed in the slot,
the slot must be filled with an epoxy compound or bitumen filler