Gunnebo Wedge K12 Manual

Operation and Maintenance Instructions
Wedge K12

Dokument-No.:2013366 Version a page 2
Creation date: 28.11.2007
Table of Contents
1. OPERATION .........................................................................................................................3
2. OPERATION DURING POWER FAILURE ............................................................................4
2.1. S YSTEM WITHOUT A CCUMULATOR .........................................................................................4
2.2. S YSTEM WITH A CCUMULATOR ...............................................................................................4
3. CONTROL UNIT AND ELECTRICAL FUNCTION .................................................................5
3.1. G ENERAL .............................................................................................................................5
3.2. O PERATION CONTROLS AND INDICATORS ...............................................................................5
3.2.1. I NPUTS ..............................................................................................................................5
3.2.2. O UTPUTS ..........................................................................................................................7
3.2.3. P OTENTIAL FREE STATUS SIGNALS ......................................................................................7
3.3. C HANGE OF TIME PARAMETERS AT THE CONTROL UNIT “E ASY ”................................................8
4. MAINTENANCE.....................................................................................................................9
4.1. M ONTHLY M AINTENANCE ......................................................................................................9
4.1.1. B LOCKING E LEMENT AND U NDERGROUND H OUSING ............................................................9
4.1.2. H YDRAULIC D RIVE U NIT AND HYDRAULIC COMPONENTS .....................................................10
4.1.3. E LECTRICAL C ONTROL .....................................................................................................10
4.2. S EMI -A NNUAL M AINTENANCE ..............................................................................................10
4.2.1. B LOCKING ELEMENT AND U NDERGROUND H OUSING ...........................................................10
4.2.2. H YDRAULIC D RIVE U NIT AND HYDRAULIC COMPONENTS .....................................................10
4.2.3. E LECTRICAL C ONTROL .....................................................................................................10
4.3. M AJOR M AINTENANCE ........................................................................................................11
5. TROUBLE-SHOOTING........................................................................................................12

Dokument-No.:2013366 Version a page 3
Creation date: 28.11.2007
1. Operation
The WEDGE K12 Road Blocker is designed and built with the objective of preventing forceful
infiltration of vehicle. Any other use (e.g.: as a lifting device for loads or for jacking up vehicles) can
lead to unforeseen hazards to a third party or to damage and/or destruction of the blocker. It must
always be kept in the intended condition so that it does not become a possible cause of danger.
Any claim for manufacturer’s liability is barred if the blocker is used for any improper
operation or if a forceful attempt to enter the activated system is made.
(1) Only qualified and/or certified persons are allowed to operate the WEDGE K12 Road Blocker.
During operation no vehicles, goods or persons are allowed in the movement area of the
blocking element of the WEDGE K12 Road Blocker in order to avoid collisions and injuries.
(2) The system is to be operated in such a way that approaching vehicles have time to stop in
front of it. Every movement of the system’s blocking element must be carefully monitored.
(3) The tolerable impact load of the WEDGE K12 amounts to 1852 kJ. This is equivalent to the
impact force of an approx. 7.5 ton heavy vehicle with an initial speed of 80 km/h.
(4) The opening time of the blocking element averages about 4…5 seconds, the lowering time 4
seconds.
Optional: With the accumulator version the opening time is 1…2 seconds and the lowering
time 4 seconds.
(5) The standard control instructions are carried out using a push button switch “Open-Close-
Emergency stop”. Customer related controls are optional possible.
(6) The end positions of the blocking element are detected by proximity switches.
(7) The underground housing of the WEDGE K12 is certified for a wheel load of 100 kN
(correspond with 10 tons per wheel or 20 tons per axle) or alternative an area load of
33.3kN/m².
(8) The WEDGE K12 Road Blocker can be either operated using normal or manual operation via
hand pump. In normal mode it is operated with the help of a hydraulic drive which is fed by a
3 phase alternating current 230 / 400V 50 Hz.
(9) The WEDGE K12 is designed for outdoor operation and therefore can be used without
problem in outside temperature ranging from - 20°C to + 60°C. However attention needs to be
paid that the drainage of the housing (1) is assured in order to avoid damage or destruction of
the situated components. In winter during strong snowfall the area over the WEDGE K12
should be kept free of snow.
Drive cabinet:
1. cabinet
2. hydraulic drive
3. control unit

Dokument-No.:2013366 Version a page 4
Creation date: 28.11.2007
2. Operation during Power Failure
Raise the blocking element
1. Operate the Wedge using the hand pump (6) until the fully raised position is reached.
Lower the blocking element
1. Operate the Wedge using the ball cock (5) until the fully lowered position is reached.
2.1. System without Accumulator
4. oil infill
5. ball cock
6. hand pump
7. oil gauge
8. oil release
9. manometer
10. 2/2-way valve “raise”
11. oil filter
12. pressure limit valve
13. 2/2-way valve
14. minimess coupling
2.2. System with Accumulator
15. accumulator
16. pressure watcher accumulator
17. connector “A”
18. connector “B”

Dokument-No.:2013366 Version a page 5
Creation date: 28.11.2007
3. Control unit and electrical function
3.1. General
The control unit processes signals coming from outside via terminal strips.
It controls the commands for operation of the wedge, operates the solenoid valves of the hydraulic
unit and offers a variety of indications and control elements.
3.2. Operation controls and indicators
3.2.1.Inputs
Control device “stop”
After activation of a control switch “stop”, the Wedge stops immediately. A renewed movement of
the Wedge has to be started either by using the control switch “lower” or “raise”.
If the function “automatic raise” is active, the Wedge will automatically raise into its blocking
position after the pre-adjusted time T10 has expired.
Control device “lower”
The Wedge barrier moves into the completely lowered position after activation of the control switch
“lower“.
If the command “lower” is given during operation of the Wedge, it will stop and will only lower after
the pre-adjusted reversal time T2 has expired.
Control device “raise”
After activation of the control switch “raise” the Wedge barrier moves into the completely raised
position.
If the command “raise” is given during the lowering movement of the wedge, it will automatically
stop and will move into the raised position after the pre-adjusted T2 time has expired.
Control device “emergency raise”
The command “emergency raise” moves the Wedge barrier immediately into the completely raised
position. If the command is given during the lowering movement of the wedge, the direction of
movement reverses immediately.
The „emergency raise“-command is a priority command and overrides the safety function of the
induction loops, light barriers and the command for fire-brigade.
As long as the control switch is operated, no movement of the Wedge is possible.
The „emergency raise“-command is permitted even in case of a malfunction (oil temperature too
high or oil level too low). Afterwards no further movements are possible with activated input
“emergency raise”.
The optional “speed kit” with accumulator will move the blocking segment into its upright position
with increased speed.
Fire alarm system / fire brigade
The fire alarm system causes an automatic lowering of the Wedge, if the contact is opened by a
control device. Therefore this contact always must be closed.
The Wedge cannot be raised as long as the contact is open, neither automatically nor by control
switches. To go back to normal function the contact has to be closed again.
The “emergency raise”-function will override the fire alarm system.

Dokument-No.:2013366 Version a page 6
Creation date: 28.11.2007
Automatic on / off
In „automatic“-mode the Wedge barrier moves automatically into the blocking position after
expiration of the time pre-set T10, provided that the light barriers are not interrupted and the
induction loops are not occupied.
The function of control switches “lower”, “stop”, “raise”, induction loops and light barriers is always
independent of the automatic function.
Pulse contact control
If the controller is operated while the Wedge is in an intermediate position, the barrier moves into
the lowered position.
If the controller is operated while the Wedge is in the final position, the barrier moves into the
opposite direction.
Any operation of the controller stops the movement of the Wedge.
If the controller is operated several times during the movement of the Wedge, the following
switching sequence results: “raise“, “stop“ , “lower“, “stop“, “open“, etc.
Proximity switches “lowered” (S6) / “raised” (S7)
The limit switches indicates the final positions of the Wedge.
If the limit switch for the preselected direction is occupied, the respective valve, as well as during
raising the motor will be switched off after expiration of a pre-set time of one second.
Induction loop 1 A2.1 (close / safety) / Induction loop 2 A2.2 (safety)
After passing of both induction loops, and expiration of pre-set time T4, the Wedge raises.
If one of the loops is occupied again while the Wedge is raising, the barrier stops and lowers again.
It raises again if the loops are not occupied and after expiration of the pre-set time.
The function emergency raise will ignore an occupied induction loop.
Light barrier
After interruption of the light beam, the Wedge can’t be raised. If the light beam is interrupted while
the Wedge is raising, the barrier stops and moves back into the completely lowered position.
In „automatic“-mode the Wedge closes again after removal of the disturbance and expiration of the
pre-set time T4. In “manual”-mode a command raise or lower is expected.
If the light beam is not interrupted, the Wedge raises (if the loops are not occupied) after expiration
of the pre-set time T4.
The function “emergency raise” will ignore an interrupted light barrier.
Malfunction
Too high oil temperature, disengaged motor circuit switch, seized run time excess as well as a too
low oil level are faults. If an error occurs, the exit “disturbance” is set immediately.
An emergency stroke of the Wedge into the raised position is possible via the entrance
“emergency raise” except the motor circuit switch is disengaged.
Further electrically controlled movements of the Wedge are afterwards no longer possible! If
necessary, the Wedge can be lowered manually by opening the ball cock valve (5) positioned
directly at the aggregate.

Dokument-No.:2013366 Version a page 7
Creation date: 28.11.2007
3.2.2.Outputs
Hydraulic motor
The hydraulic engine runs only during the raising operation of the Wedge (Standard).
If the hydraulic drive unit is equipped with an accumulator (optional) the engine may running also to
refill the accumulator. This process is activated by a pressure watcher and is not depending on the
operation of the Wedge.
Lighting blocking element
The lighting flashes during lifting and lowering. If the fully raised position is reached, the light
shines continuous.
Solenoid valve “raise”
The solenoid valve “raise” is activated, in order to raise the Wedge.
Solenoid valve lowering
The solenoid valve “lower” is activated, in order to lower the Wedge.
Advance warning raise
The output is activated with the operation command “raise”. The Wedge raises after expiration of
the adjustable pre-set time T3.
During the expiration of the advance warning pre-set time a red traffic light flashes.
Traffic light
The traffic light indicates green only if the limit switch “lowered” is occupied.
If the command “raise“ is given in any position the traffic light will switch to red.
3.2.3.Potential free status signals
Wedge raised
If the Wedge is in the completely raised position, then the potential-free status signal is activated.
The contact is available as change-over switch.
Wedge down
If the Wedge is in the completely lowered position, then this potential free status signal is activated.
The contact is available as change-over switch.
Malfunction
The status signal “disturbance” is activated during run time excess, optionally too little oil, to high
oil temperature or disengaged motor circuit switch (contact is available as change-over switch).

Dokument-No.:2013366 Version a page 8
Creation date: 28.11.2007
3.3. Change of time parameters at the control unit “Easy”
The control is switched on and the word “run” will appear on the bottom at the right hand side of
the display.
With the ok key you enter the main menu.
Here you can confirm the menu option parameter selection (parameter flashes) by using the arrow
keys up/down and the ok key. Now you are in the submenu parameter, where all alterable times
are shown.
You can select a time parameter by using the arrow key up/down.
After the parameter (e.g. T1) is selected, confirm this with the ok key. The chosen time with its
values will appear on the display (screen). By using the arrow keys you can select the current
value which should be changed and confirm with the ok key.
Now you can move by using the arrow keys left/right in the line back and forth and increase or
decrease the value with the arrow keys up/down.
Changes of values must be confirmed with the ok key.
With the “Esc”-key you will jump back to the previous step.
After you finished your changes, repeatedly press the Esc key, until the word “run” appears again
at the bottom on the right hand side of the display.
Parameter
Description Factory setting
T1 running time 15 sec
T2 reversal time 2 sec
T3 advance warning time raising 1 sec
T4 auto-closing after passage 2 sec
T5 follow-up time lower 0 sec
T6 follow-up time raise 0 sec
T9 advance warning time lower 1 sec
T10 auto-closing after no passage 20 sec

Dokument-No.:2013366 Version a page 9
Creation date: 28.11.2007
4. Maintenance
The maintenance work may only be carried out by qualified persons. The maintenance work
consists of:
- General visual examination
- Examination of screws
- Examination of electrical and hydraulic connections
- Changing of the hydraulic oil
- Cleaning
Attention!
Before maintenance work can begin the main switch for the power supply must be switched off
and secured against inadvertent activation of the switch.
An inspection of the underground housing (1) is possible when the blocking element is in a fully
raised position. It is not necessary to enter the Wedge. In case there is a need for entering the
barrier fix the blocking element in the raised position to prevent any accidents.
The Wedge is an open steel structure. Depending on environmental conditions a more frequent
cleaning of the underground housing may be necessary.
4.1. Monthly Maintenance
4.1.1.Blocking Element and Underground Housing
(1) Outer visual examination of the entire system for damages, corrosion and deterioration. The
long-term corrosion protection used here includes full galvanisation of all steel components
and a plastic coating of TRI-PROTECT
®
.
Cold-hardening PVC or two-component material is used to repair any damaged areas of the
corrosion protection.
(2) Check the bearings(6), bolts and axle support(7) on the hydraulic cylinders (5) for tightness
and the chain element(3) for any damages.
(3) A tight fit of the proximity switch (8) for the position of the blocking element.
(4) Check the general condition of all functional parts.
(5) Clean the underground housing.
(6) Check the drainage of the housing (1).

Dokument-No.:2013366 Version a page 10
Creation date: 28.11.2007
4.1.2.Hydraulic Drive Unit and hydraulic components
(1) Press the selector switch “Flush” (Option) located in the control cabinet for at least 60 sec.
(2) Check for damage to the hydraulic lines.
(3) Check the hydraulic cylinder (hydraulic cylinders) (5) and all hydraulic screw connections for
oil leaks (tighten if necessary).
(4) Check the oil level in the oil tank and if necessary refill.
(5) Check the general condition of all functional parts.
(6) Check the system pressure and adjust to specified pressure if necessary.
(7) Clean the hydraulic unit and check the surrounding area for contamination and/or foreign parts
of any kind.
4.1.3.Electrical Control
(1) Visual examination of the terminal box inside the piston housing(4) and the terminal box inside
of the control cabinet.
(2) Functional test of the electrical heater of control cabinet.
Conduct a general functions test.
4.2. Semi-Annual Maintenance or in each case of 50.000 cycles
This maintenance needs to be performed half-yearly or in each case of 50.000 cycles (1Zyklus
corresponds once to lifting and lowering). The following work needs to be performed in addition to
the work which is required for the monthly maintenance:
4.2.1.Blocking element and Underground Housing
(1) Lubricate the joint head of the hydraulic cylinders (5).
(2) Lubricate the chain joints.
(3) Check that all functional parts are intact, if necessary replace.
(4) Remove the sand from the underground housing as well as the mechanical functional parts
with an industrial vacuum cleaner; clean-up any contamination and oil deposits.
4.2.2.Hydraulic Drive Unit and hydraulic components
(1) Remove oil filler neck and check for contamination, clean if necessary.
(2) Check the air and reverse-flow filters, clean or replace if necessary.
(3) Clean the sand and other contaminates out of the control box, all hydraulic components and
the motor, especially oil residues.
4.2.3.Electrical Control
Attention!
Examination of the electrical connections and system can only be made by an Electrician.
(1) Check the condition of the electrical control.
(2) Check that the contactors and relays function faultlessly.
Conduct a function test
Check the raising and lowering of the blocking element with a light test run. Pay attention if the
electrical operation makes any unusual noises and, if possible, determine the cause.

Dokument-No.:2013366 Version a page 11
Creation date: 28.11.2007
4.3. Major Maintenance
Major Maintenance should be carried out after 1,000 operational hours or at the very latest every 2
years.
This includes all work described in the monthly maintenance (see section 3.1). In addition to this
the following tasks are required:
(1) Examination of all functional parts, connections and screw connections for their intactness and
tight fit.
(2) Change the oil of the system. The same type of hydraulic oil must be used.
Total filling capacity: ca. 30 l + 0.2 l per meter length of hydraulic lines
(3) Clean the oil filter.
(4) Clean the filter insert or replace it.
(5) Conduct a function test.
Attention!
Only one type of hydraulic oil can be used in the system! A mixture of
hydraulic fluid can lead to the destruction of the system!

Dokument-No.:2013366 Version a page 12
Creation date: 28.11.2007
5. Trouble-Shooting
A malfunction which can cause the blocking element not to move can have several different
causes. The most frequent causes and their remedies are listed below.
—Cause: power is interrupted.
Remedy: check the electrical lines of the current entry. With power failure implement hand
operation (see section 2).
—Cause: power is present. Even so motor does not run.
Remedy: check motor for operability and if necessary replace the motor.
—Cause: power is present, motor runs but the blocking element does not move.
Remedy: check system pressure and the valve function.
— Cause: operating pressure is too low
Remedy: adjust the pressure limit valve (increase operating pressure).
—Cause: blocking element is mechanically blocked.
Remedy: check if a foreign object is blocking the blocking element. If necessary take off the
cover plate and remove the foreign object.
—Cause: blocking element is distorted.
Remedy: repair the blocking element and/or replace it.
Other malfunctions and their remedies:
—Blocking element moves too slowly.
Cause: hydraulic oil is too old and/or too thick.
Remedy: adjust the damping into open and closed position valve, regulating valve and the
pressure limit valve.
—blocking element does not reach the end position
Cause: proximity switches are misaligned
Remedy: align the proximity switches.
—hydraulic cylinder makes loud noises during operation.
Cause: piston rod glands are dry.
Remedy: lubricate the piston rod (piston rods).
—hydraulic pressure too low, e.g. due to a leak
Cause: screwed pipe joint is leaky
Remedy: tighten screw connection, correct oil level.
During all maintenance and repairs all regulations and safety
precautions for persons and machines are to be adhered to
without fail.