B&B CR-25E User Manual

MODEL CR-25E

Cable Beam Barrier

INSTALLATION AND OPERATIONS

MANUAL

B&B ARMR CORPORATION

CORPORATE AND TECHNICAL SUPPORT: FIELD SERVICE SUPPORT:

2009 CHENAULT DRIVE 1934 OLD GALLOWS ROAD SUITE 114 CARROLLTON, TX 75006 VIENNA, VA 22182 TELEPHONE: (800) 367-0387 TELEPHONE: (703) 752-6108 FAX: (972) 385-9887 FAX: (703) 752-6288

MADE IN THE USA

Installation & Operations Manual CR-25E Cable Beam Barrier Introduction ii

INTRODUCTION

Welcome

Congratulations on your purchase of a B&B ARMR warning gate. We have years of experience in all aspects of perimeter security and related disciplines, and our products are used throughout the world to control access and to protect people, equipment, and facilities. Your warning gate is designed to give you years of smooth, trouble-free operation.

In addition to providing detailed operating instructions, this manual describes how to install, maintain, and troubleshoot your vehicle barrier. To make it easy to locate the information you need, we've included a detailed Table of Contents immediately following this Introduction. All of this is important information, so be sure to keep the manual available for reference.

If you need help with any aspect of your vehicle barrier's installation or operation, please contact us. We offer a broad range of vehicle barrier and related security services, so you can also call on us for:

• Turnkey installations

• Routine barrier preventative maintenance or emergency repairs (including work on non-

B&B ARMR products)

• Spare or replacement parts

• Custom designs or special installations

• Equipment upgrades (modernize your old equipment with state-of-the-art hydraulics

and control systems)

• Ancillary security equipment (such as security guard enclosures, card readers, security

lighting, and so on)

Safety

Your safety is important to us. If you have any questions or are in doubt about any aspect of the equipment, please contact us. While B&B ARMR does not assume responsibility for injury to persons or property during installation, operation, or maintenance, we can provide verbal guidance, additional written instructions, or the services of a factory engineer. We're here to help you operate your vehicle barrier safely and effectively.

Installation & Operations Manual CR-25E Cable Beam Barrier Introduction iii

As the user, you are responsible for correct and safe installation, operation, and maintenance of this equipment. Users must follow the specific instructions and safety precautions located in this manual. In addition they must:

• Be aware of and follow the safety standards of the Occupational Safety and Health

Administration (OSHA), as well as other applicable federal, state, and local safety regulations and industry standards and procedures. For installation outside the United States, users must also follow applicable international, regional, and local safety standards.

• Engage only experienced staff, properly trained, to install, operate, and maintain the

equipment.

• Ensure that all repairs are performed correctly, using properly trained staff and the right

tools and equipment.

How to Contact Us

If you have any questions or experience any problems with your vehicle barrier—or if we can help you with any other facility security issues—please contact us directly at:

CORPORATE AND TECHNICAL SUPPORT: SERVICE SUPPORT:

2009 Chenault Drive 1934 Old Gallows Road Suite 114 Carrollton, TX 75006 Vienna, VA 22182 Telephone: (800) 367-0387 Telephone: (703) 752-6108 Fax: (972) 385-9887 Fax: (703) 752-6288

E-mail: info@bb-armr.com

Installation & Operations Manual CR-25E Cable Beam Barrier Table of Contents iii

Table of Contents

INTRODUCTION .......................................................................................................ii

Welcome........................................................................................................................................................ii

Safety...........................................................................................................................................................ii

How to Contact Us........................................................................................................................................iii

1. INSTALLATION, ADJUSTMENT AND MAINTENANCE............................4

1.1 CR-25E Installation Instructions (Reference Drawing: 0025-0050-A)....................................... 4

1.2 CR-25E Start Up Instructions...................................................................................................... 6

1.3 CR-25E Shut Down Instructions.................................................................................................. 6

1.4 CR-25E Emergency Operation Instructions................................................................................ 6

1.5 CR-25E Lubrication Instructions (Reference Drawing: 0025-0053-B)....................................... 7

1.6 Lubrication Replacement Instructions......................................................................................... 8

1.7 Recommended Replacement Oils for CR-25E ............................................................................. 9

1.8 Brake Assembly Instructions (Reference Drawing: 0040-0023-C) ........................................... 10

1.9 Motor Replacement Instructions................................................................................................ 11

1.10 Limit Switch Replacement Instructions...................................................................................... 12

1.11 Field Balancing Instructions..................................................................................................... 13

1.12 Gate Arm Balancing Instructions.............................................................................................. 14

1.13 Adjusting the Barrier Movement ............................................................................................... 15

2. SPECIFICATIONS..............................................................................................19

3. ACCESSORIES AND MAJOR COMPONENTS.............................................. 22

3.1 Housing Assembly – 0025-0050-A............................................................................................. 22

3.2 Operator Assembly – 0025-0053-B........................................................................................... 23

3.3 Brake Assembly – 0040-0023-C................................................................................................ 24

3.4 Limit Switch Assembly - 0040-0009-F....................................................................................... 25

3.5 Motor Cut Sheet......................................................................................................................... 26

4. SYSTEM DRAWINGS........................................................................................ 27

4.1 Installation – 22’ Clear Opening............................................................................................... 27

4.2 Installation – 14’ Clear Opening............................................................................................... 28

4.3 Wiring........................................................................................................................................ 29

5. WARRANTY ....................................................................................................... 30

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 4 of 31

1. INSTALLATION, ADJUSTMENT AND MAINTENANCE

1.1 CR-25E Installation Instructions (Reference Drawing: 0025-0050-A)

NOTE: Failure to install your barrier properly could cause damage to the

operating mechanism.

1. Read the instructions and review the drawings thoroughly. If you do not understand any part of these instructions, please contact the manufacturer.

2. Check the anchor bolt locations and prepare the foundation for the barrier. Set the barrier operator and be sure to seal the bottom with duct seal. Housing must be level. Anchor bolts must be tightened evenly.

3. Make sure the local power supply for the motor and control circuit are correct. *Reference the enclosed electrical drawing in the back of the handbook.

IMPORTANT: All conduit must be sealed and the housing grounded.

4. Using the hand crank, turn the drive crank 45 degrees noting rotation of the drive crank should be clockwise.

5. Open main disconnect switch (S1) and connect the power. Connect the control circuit if separate. If power is supplied from the motor circuit, check the connections at the terminals.

NOTE: At this point in the installation, no counterweights or arms should

have been installed.

6. "Bump" test barrier operator for correct motor rotation.

NOTE: The drive cranks should rotate upwards toward roadway to raise

barrier arm (viewing barrier operator from either drive crank side of the housing).

7. Run barrier operator (without arms or counterweights) through several complete cycles. Leave the barrier operator in the closed to traffic position and open the main disconnect switch.

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 5 of 31

NOTE: This barrier has been completely assembled and test run through 24

complete cycles under full power at the factory. If satisfactory operation is not displayed in step #7, recheck all electrical connections carefully. CONSULT FACTORY IF PROBLEM IS NOT FOUND.

8. Remove side arm tube cover plate (Item #2). Locate pillow block bearings (Item #12). Do not tighten set screws. Now center assembly with housing. When assembly is correctly centered, tighten bearing set screws.

9. Insert arm, with endlock intact, into the main arm tube base. Push tube far enough to make the cable, connections at the pivot. After cables have been securely bolted to the pivot mechanism, extend arm so that the endlock saddles satisfactorily over the anchor assembly (on the bollard). Slide lock coller into place and tighten allen bolts.

NOTE 6: If endlock fails to line up properly, loosen bearing bolts and rotate

laterally. Re-tighten bolts. Now tighten arm base bolts securely. Replace side arm tube cover plate (tighten bolts securely).

10. With the arm in the down position, install the allotted amount of counterweights (Item #3) on the side arm tube assembly. Tighten bolts securely.

11. Close the main disconnect switch (S1) and operate the control circuit. If all connections are made correct, barrier arm will operate to fully up or fully down. The limit switch will automatically stop the motor at the extreme 90-degree movement of the arm.

12. With the barrier in the lowered position, check endlock mechanism for any type of hindrance with bollard post and adjust accordingly if required.

IMPORTANT: IF THREE PHASE POWERE CONNECTIONS TO THE

MOTOR ARE REVERSED, THE LIMIT SWITCH WILL AUTOMATICALLY DISCONNECT THE MOTOR WHEN THE DRIVE CRANK HAS ROTATED ABOUT 30 DEGREES IN THE INCORRECT DIRECTION, DEPENDING ON THE POSITION OF THE CONTROLS, i.e., UP OR DOWN. DRIVE CRANK MUST THEN ROTATE BACK TO ORIGINAL (VERTICAL) POSITION USING HANDCRANK, IN ORDER TO RESET BARRIER.

If this problem occurs, phase must be reversed. The limit switch has

been set at the factory and should NOT REQUIRE ADJUSTMENT. Arm should be raised or lowered by lengthening or shortening of the connecting rod not by adjustment of the limit switch cams.

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 6 of 31

1.2 CR-25E Start Up Instructions

NOTE: These instructions assume installation has been completed. If

necessary, refer to the enclosed installation instructions.

1. Remove the rear operator door.

2. Connect power by flipping the disconnect switch to the "ON" position.

3. Test operate the barrier to be sure it is functioning properly.

1.3 CR-25E Shut Down Instructions

1. Remove the rear operator door.

2. Disconnect power by flipping the disconnect switch to the "OFF" position.

1.4 CR-25E Emergency Operation Instructions

1. Remove the rear operator door.

2. Disconnect power by flipping the disconnect switch to the "OFF" position.

3. Locate the hand-crank mounted inside the housing.

4. Slip the hand-crank onto the shaft extending through the brake. The brake will automatically release.

5. Turn the hand-crank to raise or lower the barrier, as needed. A tag on the brake indicates crank direction for opening or closing the barrier. (Clockwise for “Close”, counter clockwise for “Open”).

6. Remove the hand-crank.

7. Flip the disconnect switch back to the "ON" position to resume powered

operation.

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 7 of 31

1.5 CR-25E Lubrication Instructions (Reference Drawing: 0025-0053-B)

Mechanism lubrication should be checked at least once per month.

Transmission (Item 5 on Assembly drawing): First gear drive box ( High speed housing):

1. Remove the front door of the housing (roadway side).

2. Check oil by removing the oil level plug located on the left-hand vertical

surface of the transmission a few inches below the motor.

Note: Some barriers may have site glasses.

a. If oil is visible, oil level is adequate - replace plug and go to next section. b. If oil is not visible, go to step 3.

3. Remove fill plug of first gear box located on top of gear box facing door).

4. Fill the case to the level plug or site glass (removed in step two) with multi-

grade Mobil SHC 629 or a direct replacement. (See recommended replacement oils on the following page.)

5. Replace plugs.

Final drive gear box (Low speed housing):

1. Remove the back door of the housing (counterweight side).

2. Check the oil level by removing the oil level plug located on the left-hand

vertical surface of transmission. Note: Some barriers may have site glasses.

a. If oil is visible, oil level is adequate - replace the plug and go to next section.

b. If oil is not visible, go to Step 2.

2. Remove oil fill plug on final gear box, on the left-hand vertical surface,

top.

3. Fill the case to the level plug or site glass (removed in step one) with

multi-grade Mobil SHC 629 or a direct replacement. (see recommended replacement oils on the following page)

4. Replace plugs.

Pillow Block Bearings:

1. Grease with Texaco Marfak 2 or equal.

2. Wipe off excess.

NOTE: 1 pillow block bearing is located inside unit on main shaft.

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 8 of 31

Connecting Rod Ends (Items11 & 13):

1. Grease with Texaco Marfak 2 or equal.

2. Wipe off excess.

Limit Switch Drive Chain (Item 8):

1. Spray chain with any good aerosol chain lube.

2. Wipe off excess.

1.6 Lubrication Replacement Instructions

Lubricate mechanism every 12 months with a manufacturer approved lubricant.

First gear drive box ( High speed housing):

1. Standing in front of the operator (roadway side) remove the door.

2. Locate drain plug on the bottom horizontal surface of the gear change box directly under the motor. (Motor is horizontally mounted).

3. Position catch pan under drain plug.

4. Remove the oil fill plug on the top of gear box facing door.

5. Remove the drain plug until the oil is completely drained, then replace plug.

6. Remove the oil level plug.

7. Refill gear change box until oil flows from the oil level hole. Replug the oil fill hole and the oil level hole.

Final drive gear box (Low speed housing):

1. Remove back door. Oil fill plug is located on the left-hand vertical surface, top. Remove oil fill plug.

2. Standing in front of the operator (roadway side), remove the door.

3. Locate drain plug on the vertical surface of the final output gear box.

4. Position catch pan under drain plug.

5. Remove the drain plug until the oil is completely drained, then replace plug.

6. Remove the oil level plug.

7. Refill final output box until oil flows from the oil level hole. Replug the oil fill hole and the oil level hole.

Installation & Operations Manual CR-25E Cable Beam Barrier Installation, Adjustment & Maintenance 9 of 31

1.7 Recommended Replacement Oils for CR-25E

Direct replacement of oils is very complicated and should be considered carefully when doing so. The following oils are recommended by the manufacturer of the transmissions on the warning gates and barriers.

The multi-grade Mobil SHC 629 synthetic oil is the manufacturers first choice. If this oil is not available, Exxon Terrestic SHP 150 can be used as a direct replacement. The temperature range is -30°F to 165°F.

If neither of the two above mentioned oils is available, almost any ISO Grade 150 or AGMA Lubricant #4 with a pour point of -40°F or less & a viscosity of approx. 726 (SUS@100°F) is acceptable.

The following grease is recommended by the manufacturer of the flange type bearings used on both the warning gates and barriers.

Texaco Marfax or Texaco Starplex grease is the manufacturers first choice. If this grease is not available, consult your local supplier for an equivalent.

+ 21 hidden pages