Nova Technology International, LLC Lock-Up User manual

Vehicle Restraint
Installation Manual
Manual No. MF4-158-000 - September 2018© 2018 Nova Technology International, LLC

1Manual No. MF4-158-000 - September 2018
NOVA Lock-Up™Installation Manual
PRECAUTIONS ……............…………...………….....…..…………...…………………
INSTALLATION INSTRUCTIONS ……………....………....……………………………
WARRANTY……………………....………………………………………………………..
TABLE OF CONTENTS
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7
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3Manual No. MF4-158-000 - September 2018
NOVA Lock-Up™Installation Manual
PRECAUTIONS
Safety-Alert Symbol
The Safety- Alert Symbol is a graphic representation
intended to convey a safety message without the
use of words. When you see this symbol, be alert to
the possibility of death or serious injury. Follow the
instructions in the safety message panel.
DANGER
The use of the word DANGER signifies the presence
of an extreme hazard or unsafe practice which will
most likely result in death or serious injury.
WARNING
The use of the word WARNING signifies the presence
of a serious hazard or unsafe practice which could
result in death or serious injury.
CAUTION
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in minor
or moderate injury.
NOTICE
The use of the word NOTICE indicates information
considered important, but not hazard-related, to
prevent machine or property damage.
SAFETY INSTRUCTIONS
Indicates a type of safety sign, or separate panel on
a safety sign, where safety-related instructions or
procedures are described.
Read and understand the Owner’s/User’s Manual and
become thoroughly familiar with the equipment and its
controls before operating the transport vehicle restraint.
Never operate a transport vehicle restraint while
a safety device or guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION
signs, Placards or Decals on the equipment unless
replacing them.
Figure 1
Do not start the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone (see Figure 1).
Remove any tools or foreign objects from the operating
zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
Recognize Safety Information General Operational Safety Precautions
WARNING: This product can expose you to chemicals including lead, which are known to the State of California to
cause cancer or birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

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Operational Safety Precautions
Learn the safe way to operate this equipment.
Read and understand the manufacturer’s
instructions. If you have any questions, ask
your supervisor.
DANGER
Stay clear of dock leveling device and restraint when
transport vehicle is entering or leaving area.
Do not move or use the dock leveling device and
restraint if anyone is under in front or near it.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Do not operate any equipment while under the
inuence of alcohol or drugs.
PRECAUTIONS
WARNING
Chock/restrain all transport vehicles. Never remove
the wheel chocks until loading or unloading is
finished and transport vehicles driver has been given
permission to drive away.
Do not use a broken or damaged restraint device.
Make sure proper service and maintenance
procedures have been performed before using.
If the NOVA Lock-Up™vehicle restraint does not
operate properly using the procedures in this manual,
BE CERTAIN TO CHOCK THE VEHICLE WHEELS
BEFORE LOADING OR UNLOADING. Contact NOVA
or your local representative for service.

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NOVA Lock-Up™Installation Manual
Maintenance Safety Precautions
PRECAUTIONS
WARNING
ALWAYS disconnect electrical power source and
ground wire before welding on restraint.
DO NOT ground welding equipment to any electrical
components of the restraint. Always ground to the
restraint frame.
WARNING
DO NOT grind or weld if hydraulic fluid or other
flammable liquid is present on the surface to be
ground or welded.
DO NOT grind or weld if uncontained hydraulic fluid
or other flammable liquid is present. Stray sparks
can ignite spills or leaks near the work area. Always
clean up the oil leaks and spills before proceeding
with grinding or welding.
Always keep a fire extinguisher of the proper type
nearby when grinding or welding.
DANGER
Electrical power must be OFF when servicing the
equipment. For maximum protection, use an OSHA
approved locking device to lock out all power
sources. Only the person servicing the equipment
should have the key to unlock the device.
WARNING
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the unit before maintenance is
complete.

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7Manual No. MF4-158-000 - September 2018
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MOTOR COVER
LEFT SPRING COVER
RIGHT SPRING COVER
ROLLER TRACK
ASSEMBLY
CARRIAGE RETURN
SPRINGS (QTY 4)
CARRIAGE ASSEMBLY
SLOPE EXTENSION
ROLLER ASSEMBLY
(QTY 4)
LOWER SPRING BAR
OUTSIDE LIGHT
CONTROL BOX
PLACARD
OUTSIDE SIGN
INSIDE SIGN
FIGURE A—LOCK-UP COMPONENTS DESCRIPTION
INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
A NOVA Lock-Up™vehicle restraint may be installed on
docks with or without levelers; consult NOVA for proper
application.
Follow the simple installation procedures below:
• Inspect NOVA Lock-Up™vehicle restraint parts.
• Install roller track.
• Install NOVA Lock-Up™vehicle restraint into roller
track.
• Install electrical components.
• Install safety & instruction signs.
• Test operation.
INSPECT NOVA LOCK-UP™ PARTS
Open packaging and inspect all parts and materials—
see Figure A above. Immediately report any damage
or missing materials to factory. Review the component
assemblies to determine their correct locations.
DANGER
Post safety warnings and barricade work area,
at dock level and at ground level, to prevent
unauthorized use of the dock position.
NOTICE
A 4” thick bumper is required regardless of whether
or not there is a leveler. DO NOT install a NOVA
Lock-Up™vehicle restraint on docks without 4” thick
bumpers. For thicker bumpers consult factory.

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INSTALLATION INSTRUCTIONS (continued)
INSTALL ROLLER TRACK
Install roller track onto dock face at specied location
by welding to an embedded steel plate or by using the
fteen (15) concrete anchors provided in conjunction
with welding to pit steel and a leveler frame. Refer to
Figures B and C.
If you have questions, contact NOVA Technical Support
at [phone].
NOTICE
The roller track must be plumb with dock face. If
not, use and weld (6) shims 2” wide x 25 5/8” long.
If shims are over 1/2” thick use longer anchors. If
shims need to be 1” thick or more, contact NOVA.
If the dock face is not perpendicular, contact
NOVA Technical Support at [phone].
The carriage roller track cannot be bent or
deformed. Straighten or replace if necessary.
NOTE: Trim roller track, as necessary, up to a
maximum of 5” from the bottom.
NOTE: Some mechanical dock levelers have an
adjusting nut access hole in the leveler front subframe.
If the NOVA Lock-Up™vehicle restraint roller track
interferes with the access hole, the roller track must be
cut to allow access.
NOTE: Some levelers are slightly recessed within the
pit and thus require a shim to be inserted between the
roller track and the leveler front subframe and welded
in place.
NOTICE
Fifteen (15) concrete anchors are provided with
each NOVA Lock-Up™vehicle restraint. An
anchor must be installed in each roller track hole
except for those plug-welded to embedded steel.
ANCHOR INSTALLATION INSTRUCTIONS
1. Put roller track in place.
2. Drill hole of 5/8” diameter and minimum of 4-5/8”
deep. Clean out hole.
3. Insert anchor and drive ush with roller track, making
sure that the threaded wedge is inserted rst. Do
not disassemble anchor prior to installation.
4. Install all anchors and torque to 60 ft-lbs. See
gure B.
FIGURE B—ANCHORING ROLLER TRACK

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WELDING INSTALLATION INSTRUCTIONS
If the installation being worked on is a retrot or
replacement situation, the following electrical
connections must be disconnected prior to welding.
LOCKOUT/TAGOUT the power at the fused disconnect,
then remove the motor and limit switch connections
from the control harness located in the outside junction
box. Once all welding has been completed, reconnect
all the wires.
NOTES:
a. Never install the NOVA Lock-Up™vehicle restraint
directly onto concrete block or brick dock face.
b. When welding the NOVA Lock-Up™vehicle
restraint, disconnect power and ground leads to
leveler.
c. Due to actual conditions, total mounting height may
be different.
d. Plug weld all holes that are in contact with the
embedded mounting plate. All fteen (15) holes
must be either plug welded or anchored. See gure
C.
e. Shims must be the full length of the roller track.
Minimum electrode must be 1/8” 7018 or better.
See gure D.
INSTALLATION INSTRUCTIONS (continued)
NOTICE
Never weld on the NOVA Lock-Up™vehicle
restraint after the motor is wired into the control
box and power to the control box is on. Electrical
current from the welder can loop back through
the circuit and damage the motor and other
components.
FIGURE C—WELDING ROLLER TRACK FRONT VIEW
(WITH EMBEDDED PLATE)
FIGURE D—WELDING ROLLER TRACK SIDE VIEW

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INSTALL VEHICLE RESTRAINT INTO
ROLLER TRACK
INSTALLATION INSTRUCTIONS (continued)
CAUTION
Use lifting device (e.g. crane, jack) when lifting
carriage (approx. 110 lbs.). Lifting by hand may
cause back injury.
• Attach the four (4) springs to the lower spring bar.
• Pull springs upward and slide over top spring mount
on the roller track.
• Slide the carriage assembly into the roller track.
Refer to Figure E.
• Install right and left spring cover with clip nuts and
at head screws provided.
• Position and bolt the lower spring bar to the bottom
of the NOVA Lock-Up™vehicle restraint carriage.
• Install the motor cover and spring covers.
• Install slope extension.
FIGURE E—INSTALLING CARRIAGE ASSEMBLY INTO
ROLLER TRACK

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If the incoming electrical power for the NOVA Lock-
Up™vehicle restraint is taken from a nearby electrical
appliance, e.g., overhead door opener, verify that the
amperage is in accordance with local and federal codes.
The NOVA Lock-Up™vehicle restraint 1/10 HP motor
requires 120V, single phase power, 60 Hz power and 10
amps of current to operate properly.
Two (2) NOVA Lock-Up™vehicle restraints can be
connected into one (1) 20 amp branch circuit breaker
per the 1999 National Electrical Code Paragraph 430-
53.
If you have questions, contact NOVA Technical Support
at [phone].
INSTALLATION INSTRUCTIONS (continued)
DANGER
Make sure that the power source has been locked
out and tagged according to OSHA regulations
and approved local electrical codes.
NOTICE
Where indicated, all components must be
connected to a SAFETY EARTH GROUND that
conforms to the 1999 National Electric Code
Section 250-50 section (a) or section (c) for a
grounding electrode system.
The NOVA Lock-Up™vehicle restraint assembly
includes a 63” long exible wiring harness, the control
box with lights and the outside signal light box. The
outside junction box, conduit ttings and wire are
provided by others; be sure to use a qualied installer
utilizing quality materials. Refer to Figures F and G.
Refer to Figure H, page 13 for component location
information. Electrical schematics for wiring information
can be found inside the control box.
CONTROL BOX INSTALLATION
GUIDELINES—TEMPERATURE
CONTROLLED APPLICATIONS.
1. Route the conduit to enter through the side or
bottom of the enclosure. If the conduit could ll with
water, a drip leg may be needed.
2. Seal the conduit in any location where the conduit
crosses over temperature zones that could produce
condensation.
3. Install spacers between the wall and enclosure to
provide temperature insulation and air ow.
INSTALL ELECTRICAL COMPONENTS

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INSTALL ELECTRICAL COMPONENTS (continued)
FIGURE G—OUTSIDE LIGHT WIRING
INSTALLATION INSTRUCTIONS (continued)
GREEN
LIGHT
RED WIRE
FROM LIGHT BOX
BLACK WIRE
FROM LIGHT BOX
RED WIRE FROM LIGHT BOX
(MARKED WITH "GREEN LIGHT" TAG)
RL
-V
GL
RED LIGHT
GREEN LIGHT
LIGHT BOX COVER
TO
CONTROL
BOX
OUTSIDE LIGHT WIRING
OUTSIDE JUNCTION BOX
(SUPPLIED BY OTHERS)
TO LOCK-UP
GROUND IN BOX
SAFETY EARTH GROUND
REQUIRED FOR PROPER
OPERATION
FROM OUTSIDE
LIGHT BOX
3/4" CONDUIT AND FITTINGS
(SUPPLIED BY OTHERS)
CONTROL HARNESS
#14 GAGE WIRE - (TYP.)
(SUPPLIED BY OTHERS)
WIRE NUT CONNECTION (TYP.)
NEMA 4 J.I.C. BOX
(WATERPROOF)
4" X 4" X 3" SUGGESTED
SIZE (3" MAX.
PROJECTION FROM
WALL ALLOWABLE)
ORANGE
WIRE NUT TERMINATION
G
G
G
M1
M1
N
N
M2
M2
WHITE
-V
RED
WHITE/BLACK
LS3
BLACK
BLUE
LS2
RED/BLACK
LS1
GRD
IMPORTANT: ALL COMPONENTS
MUST BE CONNECTED TO A
SAFETY EARTH GROUND WHERE
INDICATED. THIS GROUND MUST
CONFORM TO 1996 N.E.C.
SECTION 250-81 PAR. (a) AND
PAR. (c), FOR GROUNDING
ELECTRODE SYSTEM.
FIGURE F—OUTSIDE JUNCTION BOX

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There is one (1) driver warning sign and one (1) inside
operator sign supplied with each NOVA Lock-Up™
vehicle restraint. (Mounting hardware supplied by
others.) Mount outside sign as shown in Figure H.
Mount the inside sign next to the control box. Attach
placard to control box with zip tie supplied or mount
next to the control box. Install all signs provided.
NOTES:
• Some docks may have dock/truck seals or shelters
which are larger than standard. The outside light,
sign location, and mounting should be studied
before proceeding to avoid interference.
• If necessary, signs may be trimmed for fit. However,
DO NOT cut or eliminate sign letters or words.
• Attach signs with concrete anchors or screws. Do
not use nails.
• NEVER put conduit in front of signs. A clear view
must be maintained at all times of the exterior and
interior signs.
INSTALLATION INSTRUCTIONS (continued)
15 "
15 "
58 "
18 "
5 "
48 "
80 "
DOCK SEAL
"NOVA LOCK-UP"
3/4" CONDUIT OR
DIAMETER PER
LOCAL CODE
(SUPPLIED BY OTHERS)
JUNCTION BOX
MOUNTED ON
DOCK FACE,
NOT TO EXTEND
OUT MORE THAN 3"
(SUPPLIED BY OTHERS)
WIRE HARNESS
INSIDE LIGHT
AND CONTROL
BOX
DISCONNECT
(SUPPLIED BY OTHERS)
OUTSIDE LIGHTS
PLACE CONTROL BOX WHERE BEST SUITED, WITHIN
ARMS REACH, AT EYE LEVEL, NEAR DOOR OPENING
INSIDE SIGN
C
L
OF DOCK AND
"NOVA LOCK-UP"
OUTSIDE
SIGN
FIGURE H—SUGGESTED COMPONENT LOCATION

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CONTROL BOX STATUS
INSIDE LIGHTS
RED LIGHT
FLASHING
TEST OPERATION
This test operation is specically for the installation instructions to verify the Lock-Up™
is working properly. If the Lock-Up™does not work properly, contact NOVA Technology.
1. Power-Up
a. Unlatch metal clips on the right side of control box holding the cover on.
b. Open the cover of the control box.
c. Turn on the circuit breaker by ipping switch upward.
FIGURE I—CIRCUIT BREAKER
FIGURE J—STANDARD PLC SCREEN
d. Close the cover of the control box.
e. Re-latch the metal clips to secure the cover.
f. Remove protective lm from PLC display.
g. Verify PLC screen shows “Lock-Up™” as shown
in gure J.
h. Verify the red light on the control box is ashing.
i. Verify the outside green light is ashing.
FIGURE K—STORE POSITION/NO VEHICLE PRESENT
INSTALLATION INSTRUCTIONS (continued)

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2. Test Restrain Function
a. There should be no object holding down Rear Impact Guard or RIG sensor.
b. Depress “RESTRAIN” (#1 button).
c. Verify the vertical barrier has risen.
d. Verify the red light on the control box is ashing.
e. Verify the alarm beeping at 1 second intervals.
f. Verify the outside red light is ashing.
RESTRAINT POSITION
CONTROL BOX STATUS
INSIDE LIGHTS
RED LIGHT
FLASHING
FIGURE L—RIG SENSOR IN UP POSITION
FIGURE M—RESTRAIN OPERATION
INSTALLATION INSTRUCTIONS (continued)
FIGURE N—RESTRAIN LOCKED, ALARM SOUNDING

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c. Enter default Over-Ride code, 5528, then press “ENTER” as shown.
i. If the wrong code was entered, the “Wrong PW: Reenter or Wait” display will appear. On this display,
repeat steps 3a through 3c to enter horn over-ride.
ii. Or, if no further input is completed within 30 seconds, the “Wrong PW: Reenter or Wait” display will clear
and the screen will return to last display.
FIGURE O—ENGAGING HORN OVER-RIDE
FIGURE P—ENGAGING HORN OVER-RIDE CONTROL BOX LIGHT INDICATION
3. Test Horn Over-Ride Function
a. Depress the “HORN OVER-RIDE” button (#0 button).
CONTROL BOX STATUS
INSIDE LIGHTS
RED LIGHT
FLASHING
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
PW
:
Lock-Up
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
PW
: 5528
Lock-Up
 
INSTALLATION INSTRUCTIONS (continued)
b. Verify the red light on the control box is ashing.
FIGURE Q—ENTERING HORN OVER-RIDE DIAGRAM
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
Lock-Up

17Manual No. MF4-158-000 - September 2018
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f. Use a weight, clamp or other means to temporarily depress the RIG sensor plate on the unit until the end of
this test.
i. Leave object on top of RIG sensor plate until test operation is complete.
FIGURE R—HORN OVER-RIDE LIGHT INDICATION
RESTRAINT POSITION
FIGURE S—DEPRESSED RIG SENSOR PLATE
CONTROL BOX STATUS
INSIDE LIGHTS
RED AND GREEN
LIGHTS FLASHING
FIGURE T—OVER-RIDE STATE, RIG SENSOR PLATE DEPRESSED OUTSIDE LIGHT
INSTALLATION INSTRUCTIONS (continued)
d. Verify the red and green lights on the control box are ashing.
e. Verify the outside red light is ashing.
g. Verify the outside red light continues to ash.

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FIGURE U—DISENGAGING HORN OVER-RIDE
FIGURE V—EXITING HORN OVER-RIDE DIAGRAM
4. Turn off Horn Over-Ride Function
a. Verify the red and green lights on the control box are ashing.
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
PW
:
Lock-Up
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
PW
: 5528
Lock-Up
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
Lock-Up
 
1
4
7
3
6
9 0
INFO
ENTER
HORN OVER-RIDE
CODE
BACK
NEXT
RELEASE
RESTRAIN
2
5
8
NOVA IntelliDock
Lock-Up
CONTROL BOX STATUS
INSIDE LIGHTS
RED AND GREEN
LIGHTS FLASHING
CONTROL BOX STATUS
INSIDE LIGHTS
GREEN LIGHT
FLASHING
FIGURE W—ENGAGED STATE LIGHT INDICATION
INSTALLATION INSTRUCTIONS (continued)
c. Enter default Over-Ride code, 5528, then press “ENTER”.
i. If the wrong code was entered, the “Wrong PW: Reenter or Wait” display will appear. On this display,
repeat steps 4a through 4c to exit horn over-ride.
ii. Or, if no further input is completed within 30 seconds, the “Wrong PW: Reenter or Wait” display will clear
and the screen will remain in horn over-ride.
e. Verify the green light on the control box is ashing.
f. No horn should be sounding.
g. Verify the outside red light is ashing.
b. Depress the “HORN OVER-RIDE” button (#0 button).