Manuel Roadblocker PDF

Operating Manual
Wedge II
Read the instructions

prior to performing any
task!
Perimeter Protection Germany GmbH

Johann-Reineke-Str. 6 10
33154 Salzkotten (Germany)
Telephone: +49 (0) 5258/500-70
Telefax:
+49 (0) 5258/4164
Email:
info@perimeterprotection.de
Internet:
www.perimeterprotection.net
Translation of the original operating manual

Document: 2092581
Version:
Created:
23.04.2014
Amended:
05.03.2015
Date 05.03.2015
Wedge II
Page 2 of 61
Table of contents
List of tables..................................................................................................... 5
List of pictures ................................................................................................. 5
Index ................................................................................................................. 6
1.
General ................................................................................................. 7
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
Information on this manual ...................................................................................... 7

Explanation of symbols ........................................................................................... 7
Limitations of liability ............................................................................................... 7
Copyright................................................................................................................. 8
Technical progress .................................................................................................. 8
Warranty terms........................................................................................................ 8
Customer service .................................................................................................... 8
2.
Safety .................................................................................................... 9
2.1.
2.2.
2.3.
2.3.1.
2.4.
2.5.
2.6.
2.7.
2.8.
Correct use in accordance to the instructions .......................................................... 9

Responsibility of the owner...................................................................................... 9
Personnel requirements ........................................................................................ 10
Qualifications......................................................................................................... 10
Personal protective equipment .............................................................................. 10
Basic dangers ....................................................................................................... 11
Safety devices ....................................................................................................... 12
Labelling................................................................................................................ 12
Spare parts ........................................................................................................... 13
3.
Technical data.................................................................................... 14
3.1.
3.2.
Model and areas of application .............................................................................. 14

Performance characteristics .................................................................................. 14
4.
Design and function .......................................................................... 15
4.1.
4.2.
4.3.
4.3.1.
4.3.2.
4.3.3.
4.3.4.
4.3.5.
4.3.6.
4.3.7.
Design ................................................................................................................... 15
Configuration options ............................................................................................ 16
Function of main components ............................................................................... 17
Base frame ............................................................................................................ 17
Blocking element ................................................................................................... 17
Safety skirt (optional)............................................................................................. 17
Scissor joint ........................................................................................................... 17
Spring pressure piston .......................................................................................... 18
Hydraulic cylinder .................................................................................................. 18
Drive cabinet ......................................................................................................... 18
5.
Transport and storage ...................................................................... 19
5.1.
5.2.
5.3.
5.4.
Safety instructions for transport ............................................................................. 19

Transport inspection .............................................................................................. 19
Transport............................................................................................................... 19
Storage ................................................................................................................. 20
6.
Installation and initial commissioning ............................................ 21
6.1.
6.2.
6.2.1.
6.2.2.
6.2.3.
6.2.4.
6.2.5.
6.2.6.
6.3.
6.3.1.
6.3.2.
Safety instructions for installation and initial commissioning .................................. 21

Installation ............................................................................................................. 21
Requirements for the place of installation .............................................................. 21
Installation material and tools ................................................................................ 21
Erection of foundation and assembly ..................................................................... 22
Hydraulic connection ............................................................................................. 22
Connection of power supply .................................................................................. 23
Cable connection .................................................................................................. 25
Initial commissioning ............................................................................................. 25
Commissioning...................................................................................................... 26
Changing of time parameters ................................................................................ 27
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6.3.3.
Adjustment of limit switches .................................................................................. 28
7.
Operation............................................................................................ 29
7.1.
7.2.
7.2.1.
7.2.2.
7.2.2.1
7.2.2.2
Safety instructions for operation ............................................................................ 29

Operation of the wedge ......................................................................................... 29
Normal operation ................................................................................................... 29
Operation during power failure .............................................................................. 30
System without accumulator .............................................................................. 30
System with accumulator ................................................................................... 31
8.
Maintenance ....................................................................................... 33
8.1.
8.2.
8.2.1.
8.2.2.
8.2.3.
Safety instructions for maintenance ....................................................................... 33

Maintenance schedule .......................................................................................... 33
Replacement of safety skirt ................................................................................... 34
Replacement of pressure spring piston ................................................................. 35
Replacement of bearing bushes for bearing points of blocking element ................ 36
9.
Faults .................................................................................................. 38
9.1.
9.2.
9.3.
Safety instruction for fault clearance ...................................................................... 38

Behaviour in event of faults ................................................................................... 38
Fault table ............................................................................................................. 38
10.
Spare parts ......................................................................................... 40
10.1.
Spare parts ordering.............................................................................................. 40
11.
Disassembly and disposal ............................................................... 41
11.1.
11.2.
Disassembly .......................................................................................................... 41
Disposal ................................................................................................................ 41
12.
Appendix ............................................................................................ 42
12.1.
12.2.
12.3.
12.4.
12.5.
12.6.
12.7.
Technical data of hydraulic drive unit .................................................................... 42

Required tools, measuring devices and auxiliary devices ...................................... 43
Pre-tensioning forces and tightening torques for screwed connections.................. 44
Spare parts list Wedge II ....................................................................................... 45
Hydraulic scheme wedge basic (example) ............................................................ 51
Wiring diagram for wedge basic (example) ............................................................ 53
Service strut for fixing of blocking element ............................................................ 59
13.
EC Declaration of conformity ........................................................... 60
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List of tables
Table 1: Surface options.......................................................................................................16
Table 2: Equipment options ..................................................................................................16
Table 3: Time parameter setting for control unit Easy 721-DC-TC .....................................27
Table 4: Maintenance schedule ............................................................................................33
Table 5: Fault clearance of the most common faults .............................................................38
Table 6: Electrical data of motor ...........................................................................................42
Table 7: Data of hydraulic drive ............................................................................................42
Table 8: Pre-tensioning force and tightening torque for regular thread .................................44
Table 9: Spare parts wedge II...............................................................................................45
Table 10: Component list for hydraulic diagram ....................................................................52
List of pictures
Picture 1: Design wedge II ....................................................................................................15
Picture 2: Drive cabinet for indoor installation .......................................................................16
Picture 3: Drive cabinet for outdoor installation .....................................................................16
Picture 4: Lifting points wedge ..............................................................................................20
Picture 5: Lifting points drive cabinet ....................................................................................20
Picture 6: Drive cabinet with hydraulic drive unit ...................................................................22
Picture 7: Connection of hydraulic lines inside the drive cabinet ...........................................23
Picture 9: Control box inside drive cabinet ............................................................................24
Picture 10: Connection of supply voltage ..............................................................................24
Picture 11: Overview of control unit ......................................................................................24
Picture 13: Open terminal box ..............................................................................................25
Picture 12: Terminal box inside the wedge ...........................................................................25
Picture 14: PLC Type Easy 721-DC-TC .............................................................................27
Picture 15: Position of inspection cover in wedge .................................................................28
Picture 16: Inspection opening for adjustment of limit switches ............................................28
Picture 17: Drive unit without accumulator (Standard) ..........................................................30
Picture 18: Drive unit with accumulator (for remote operation RO3 during power failure) .....31
Picture 19: Lowered blocking element ..................................................................................35
Picture 20: Removal of rear cover plates ..............................................................................35
Picture 21: Raising of blocking element ................................................................................35
Picture 22: Dismantling of front cover ...................................................................................35
Picture 23: Detaching of pivot axle .......................................................................................35
Picture 24: Lifting out of safety skirt ......................................................................................35
Picture 25: Preparation for disassembly ...............................................................................36
Picture 26: Detaching of upper fastening ..............................................................................36
Picture 27: Putting down of relieved pressure spring piston ..................................................36
Picture 28: Removal of locking ring and pulling out of bolt ....................................................36
Picture 29: Removal of rear cover plates ..............................................................................36
Picture 30: Dismantling of bearing bolt .................................................................................36
Picture 31: Raising of blocking element on bearing side .......................................................37
Picture 32: Steel winch for raising of blocking element .........................................................37
Picture 33: Removal of bearing bushes ................................................................................37
Picture 34: Example of type plate .........................................................................................40
Picture 35: Installation of service strut ..................................................................................59
Picture 36: Service strut .......................................................................................................59
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Index
C
Configuration options............................. 16
Copyright ................................................. 8
Correct use in accordance to the
instructions .......................................... 9
Customer service .................................... 8
Maintenance schedule ...........................33
D
Dangers, basic ...................................... 11
Design ................................................... 15
Dimensions ........................................... 14
P
Performance characteristics ...................14
Personal protective equipment ...............10
Personnel requirements .........................10
Protective clothing..................................10
Protective glasses ..................................11
Q
Qualified electrical technician .................10
Qualified person .....................................10
E
EC Declaration of conformity ................. 60
Electrical connection ............................. 23
Explanation of symbols............................ 7
R
Responsibility of the owner ..................... 9
Faults .................................................... 38
Foundations .......................................... 21
Safety ..................................................... 9
Safety shoes ..........................................11
Spare parts ............................................40
Spare parts ordering ..............................40
H
Hard hat ................................................ 11
I
Installation ............................................. 21
Installation material ............................... 21
L
Limitations of liability ............................... 7
T
Tools ......................................................21
Trained person.......................................10
Transport ...............................................19
Transport inspection ..............................19
Type plate ..............................................40
W
Warranty terms ....................................... 8
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Page 6 of 61
GENERAL
1. General
1.1. Information on this manual
This manual enables safe and efficient handling of the wedge II. This manual is an integral
part of equipment and must be kept in close proximity to the equipment where it is
permanently accessible to the personnel.
Before starting any work the personnel must have read the manual thoroughly and
understood its contents. Compliance with all specified safety instructions and operating
instructions is vital to ensure safe operation. In addition local accident prevention regulations
and general safety instructions must be observed for the operational area of the equipment.
Illustrations in this manual are intended to facilitate basic understanding and may differ from
the actual configuration.
1.2. Explanation of symbols

Safety instructions are marked with symbols in these instructions. The safety instructions are
always introduced by signal words which express the extent of danger.
DANGER!
This combination of symbol and signal word indicates an immediatelydangerous situation which could cause death or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a possibly-dangerous
situation which could cause death or severe injuries if not avoided.
CAUTION!
situation which could cause slight injuries if not avoided.
NOTICE!
situation which could cause property and environmental damage if it is not
avoided.
This symbol highlights useful tips and recommendations as well as information

designed to ensure efficient and smooth operation.
1.3. Limitations of liability

The wedge II has been safely engineered, manufactured and tested according to the stateof-the-art and has left the factory in technically faultless safe condition. All details and
instructions in this manual have been compiled under consideration of the valid standards
and regulations, the state-of-the art and our many years of knowledge and experience.
The manufacturer assumes no liability for damage in the following cases:
Non-observance of this manual
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GENERAL
Use deviating from the intended use

Assignment of untrained personnel
Unauthorised retrofitting
Technical changes
Use of non-approved spare parts.
For special models, additional ordering options or in cases where the most recent technical
changes have been implemented, the actual scope of delivery may deviate from the
explanations and representations described here.
The duties and obligations agreed upon in the delivery contract apply in full, as well as the
general terms and conditions, the terms of delivery of the manufacturer and the valid legal
regulations applicable at the time of conclusion of the contract.
1.4. Copyright
The manual must be treated with confidentiality. It is indented exclusively for people involved
with the product. The handing over of the manual to third parties is not allowed without
written permission from the manufacturer.
The information, texts, drawings, pictures and other illustrations are
copyrighted and are subject to industrial property rights. Any misuse of the
contents of this manual is in breach of copyright and liable to prosecution.
1.5. Technical progress

The manufacturer reserves the right to adjust technical data to the technical development
progress without special notification. The manufacturer will provide information about the upto-dateness as well as possible changes and extension of this operation manual.
1.6. Warranty terms

The warranty terms are included in the manufacturers Terms and Conditions.
1.7. Customer service

Our customer service is at your disposal for any questions and technical information
Johann-Reineke-Str. 6 10,
33154 Salzkotten (Germany)
info@perimeterprotection.de
Service hotline
Telephone: +49 5258 500 758
Fax: +49 5258 500 853
Date 05.03.2015
Wedge II
Page 8 of 61
SAFETY
2. Safety
This section provides an overview of all important safety aspects for the protection of people
as well as for safe and fault-free operation. Additional task-related safety instructions are in
the sections about the individual life phases.
Non-observance of the procedures and safety instructions in this manual can pose a
significant risk.
2.1. Correct use in accordance to the instructions

The wedge was designed and constructed as a barricade for road installation to prevent the
forceful entry of vehicles with up to 7.5t total weight travelling at 80 km/h for sites with a high
risk of terroristic attacks (i.e. embassies, military facilities, police stations or energy utilities).
The product is used in accordance with its intended purpose in outdoor installations to stop
and/ or separate traffic flows. The wedge is usually used to physically protect site access
points and is an integral part of the perimeter protection concept.
Correct use in accordance to the instructions includes observance of all specifications listed
in this manual.
Any additional or different use above and beyond the correct use in accordance to the
instructions is deemed as an incorrect use.
WARNING!
Danger due to misuse!
Non-intended or improper use or use by untrained or not instructed personnel
may result in dangerous situations for the user or third party and property
damage.
Do not use the wedge as lifting device for loads or vehicles

Do not climb over the wedge.
Do not use the wedge to regulate flow of pedestrian.
2.2. Responsibility of the owner

The term owner refers to the person who himself operates equipment for trade or
commercial purposes or who surrenders the equipment to a third party for use and who
bears the legal product liability for protecting the user, the personnel or third parties during
operation.
The equipment is used in the commercial sector. The owner of the equipment is therefore
subject to legal obligations pertaining to work safety.
In addition to the safety instructions contained in this manual the safety, accident-prevention
and environmental-protection regulations applicable to the field of application of the
equipment must be observed. The following applies in particular:
The owner must find out about the applicable health and safety regulations and conduct a
risk assessment of additional dangers due to the special conditions at the place of
application of the equipment based on which he must subsequently implement
appropriate instructions for the operation of the equipment.
The owner must verify over the entire life cycle of the equipment whether the instructions
issued by him are in compliance with the current status of regulations and adjust these if
necessary.
The owner must ensure that all staff who handle the equipment have read and
understood this manual. Additionally, he must train the personnel at regular intervals and
inform them of possible dangers.
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SAFETY
The owner must provide the required personal protective equipment.

The owner must clearly regulate and determine responsibilities for assembly, installation,
operation, configuration, and troubleshooting.
Additionally, the owner must also ensure that the equipment is always in perfect working
condition.
2.3. Personnel requirements

2.3.1. Qualifications
WARNING!
Risk of injury due to use of unsuitably qualified personnel!
If unqualified personnel work on the equipment then dangers arise which may
result in injuries and damage to property.
Special activities should therefore only be carried out by the personnel

named in the relevant chapter of the instructions.
Keep unqualified personnel away from the danger area.
The following personnel qualifications for the various areas of activity are listed within this
manual:
Trained person
was instructed by the owner of his/her assigned tasks and the possible risks and dangers
in case of improper use.
Qualified person
is due to his/her professional training, knowledge and experiences as well as knowledge
of the relevant standards and regulations able to carry out his/her assigned tasks and to
independently detect and avoid possible risks and dangers.
Qualified electrical technician
is due to his/her professional training, knowledge and experiences as well as knowledge
of the relevant standards and regulations able to correctly connect and commission
electrical equipment and to independently detect and avoid possible risks and dangers.
Authorised personnel is to be restricted to those persons who can be expected to carry out
their work reliably. Persons whose ability to respond is influenced, e.g. by drugs, alcohol or
medicine, are not authorized.
2.4. Personal protective equipment

Personal protective equipment must be worn during installation and maintenance to minimise
the risk of injuries.
To wear generally
Protective clothing
is tight-fitting work clothing with low
tensile strength, tight-fitting sleeves and
without protruding parts
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SAFETY
Safety shoes
as protection against heavy falling
objects, slipping on slippery surface and
injuries caused by nails left lying about.
To wear during special work (refer to separate notification in the instructions)
Hard hat
as protection against heavy falling or
flying objects.
Protective glasses
as protection of the eyes against flying
objects, dust and fluid splashing.
2.5. Basic dangers

The following section describes remaining risks which can arise from the device even with
proper use.
In order to reduce the risks of personal injury and avoid dangerous situations, the safety
instructions and warnings listed here and in the other sections of these instructions must be
followed.
Electrical current
DANGER!
Life-threatening danger from electrical current!
There is an immediate, life-threatening danger from electrical shock if live parts
are touched. Damaged insulation or single components can be life-threatening.
Date 05.03.2015
If the insulation is damaged then immediately disconnect the voltage supply

and have repairs carried out.
Only allow work on the electrical system to be performed by qualified
electrical technician.
If working on the electrical system disconnect the voltage supply and check
for absence of voltage.
Disconnect the voltage supply before carrying out maintenance, cleaning or
repair works and secure against unauthorised or unintended switching on.
Do not bridge or disable any fuses.
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SAFETY
Moving parts
WARNING!
Risk of injury due to moving parts!
Rotating and/or linear-moved parts may cause severe injuries.
Do not reach into or handle moving parts during operation.

Do not open covers during operation.
Take into account the after-run time:
Make sure that there are no moving parts before opening the covers.
2.6. Safety devices
WARNING!
Life-threatening danger due to non-functioning safety devices!
Safety devices ensure maximum safety during operation and must not be
disabled. Safety can only be guaranteed with intact safety devices.
Check if the safety devices are operational and correctly installed before
starting work.
Refer to chapter Design and function for detailed information regarding the
position of the safety devices.
The equipment is fitted with the following safety devices:

LED- strip on blocking element
optional safety skirt,
2.7. Labelling
The following symbols and instruction notices are found on and in the equipment. They refer
to the immediate area in which they are attached.
WARNING!
Risk of injury in case of illegible or missing labelling!
Over the course of time stickers and symbols on the machine become dirty or
unrecognisable in another manner so that danger is not recognised and
necessary operating instructions cannot be followed. As a result there is the
risk of injury.
Always keep all safety, warning and operating instructions on the machine
in easily legible condition.
Replace damaged signs or stickers immediately.
Follow operating instructions
Only use the marked object after reading the operating
instructions.
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SAFETY
Electric voltage
Only qualified electrical technicians are allowed to work
in this area.
Unauthorised persons must not enter the working area
or open the marked cabinet.
2.8. Spare parts
CAUTION!
Risk of injury due to use of incorrect spare parts!
Use of incorrect or faulty spare parts may result in dangers to the personnel as
well as damages, malfunctions or total failure.
Only use original spare parts from the manufacturer or approved by the
manufacturer.
Always contact the manufacturer in case of doubt.
Loss of guarantee
Use of non-approved spare parts results in loss of the manufacturers
guarantee.
Always purchase spare parts from an appointed dealer or directly from the manufacturer. For
contact details see Page 2.
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TECHNICAL DATA
3. Technical data
3.1. Model and areas of application
Design:
wedge barrier with shallow foundation and electrohydraulic drive unit in separate drive cabinet
Blocking height:
1.0 m
Blocking width:
2.0 m, 2.5 m, 3.0m, 3.5 m and 4.0 m
Operational safety:
monitoring by operator, safety skirt (optional), blocking

element with LED-strip (optional)
Maintenance effort:
low
Areas of application:
to prevent forceful entry of vehicles for sites with a high

risk of terroristic attacks (i.e. embassies, military
facilities, police stations or energy utilities).
3.2. Performance characteristics

Operating times:
raising approx. 3.5 sec, lowering approx. 3.5 sec

emergency fast operation (EFO): approx. 1 sec (with
optional accumulator)
Locking:
in final positions or hydraulically during power failure
Drive unit:
4.0 kW, 400 V (3-phase), 50 Hz
Supply voltage:
400 V (3Ph + N + PE), 50 Hz
Operation during power failure:
via hand pump, optional with accumulator for three

movements (RO3)
Wheel load:
100 kN according to SLW 60 (DIN 1072)
Opening and closing direction:
upwards and downwards, front face towards impact
Impact energy:
1852 kJ (7.5 t @ 80 km/h)
Certification:
according to PAS68 V/7500[N3]/80/90:0.0/20.7 and

IWA 14-1 V/7200[N3C]/80/90:0.0
(tested at 4.0 m blocking width)
Weight:
approx. 2000 kg (for 4.0 m blocking width)
Temperature range:
-20C 60C
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DESIGN AND FUNCTION
4. Design and function

4.1. Design
Picture 1: Design wedge II
1 Base frame
2 Blocking element
3 Safety skirt
4 Scissor joint
5 Pressure spring piston
6 Hydraulic cylinder
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DESIGN AND FUNCTION
4.2. Configuration options

Table 1: Surface options
Standard colour
Base frame
RAL 7030 stone grey
Blocking element and cover

RAL 7030 stone grey
plates
Scissor joints
RAL 3000 flame red
Safety skirt (optional)
RAL 3000 flame red
Optional colours
RAL9010 pure white / RAL3000 flame red

Striped cover plates and safety RAL1007 daffodil yellow / RAL9005 jet black
skirt (optional)
RAL-colour ____________
DB-colour ____________
Table 2: Equipment options
Drive cabinet with

200 mm socket l
Drive cabinet for indoor installation (Picture 2)
Drive cabinet for outdoor installation with rain cover and

outdoor coating RAL 7035 (Picture 3)
Drive unit without accumulator (standard)

Drive unit
Safety equipment
Drive unit with accumulator for emergency fast operation

(EFO)
Drive unit with accumulator for remote operation during
power failure (RO3). The accumulator is sufficient for

three movement cycles of the blocking element.
Safety skirt (recommended)
LED-strip (recommended)
Picture 2: Drive cabinet for indoor installation
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Wedge II
Picture 3: Drive cabinet for outdoor installation
Page 16 of 61
DESIGN AND FUNCTION
4.3. Function of main components

4.3.1. Base frame
The base frame is a welded assembly, which is
cast into the foundation. The base frame consists
of the bearing points for blocking element and
scissor joints and serves to transfer the impact load
into the foundation and soil.
Across the full blocking width the bottom of the
base frame comprises of perforated sheet at the
front and rear for drainage.
4.3.2. Blocking element
The blocking element is a welded assembly which is
connected with the base frame via five swivelling
bearing points. The blocking element is raised and
lowered by the hydraulic cylinder and the spring
pressure pistons. The blocking element absorbs the
energy in case of a vehicle impact and deflects it via
the base frame and scissor joints into the foundation.
Built-in parts are accessible from the outside via inspection covers.
4.3.3. Safety skirt (optional)
The safety skirt is a protective cover. It consists of
seven lamellae, which are movably linked to each
other.
The safety skirt collapses during lowering of the
blocking element and rests in a protected area inside
the wedge.
4.3.4. Scissor joint

The scissor joint transfers the load during impact
and connects the blocking element to the base
frame. A total of five scissor joints are installed.
The connection between blocking element and base
frame is made via pivot bolts.
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DESIGN AND FUNCTION

4.3.5. Spring pressure piston
The spring pressure piston supports the hydraulic
cylinder during the raising process. During lowering of
the blocking element the spring pressure pistons are
automatically tensioned and energy is thus stored. The
stored energy is released during the next raising
process.
4.3.6. Hydraulic cylinder

The hydraulic cylinder raises the blocking element and
is thus the actuator. In the raised position the hydraulic
cylinder keeps the blocking element in the end position.
The hydraulic cylinder is operated by means of the
hydraulic aggregate located in the drive cabinet.
4.3.7. Drive cabinet

The drive cabinet houses the hydraulic aggregate and
the control unit.
The drive cabinet is heated and ventilated and installed
at a maximum distance of 25 m from the wedge. The
connection between the hydraulic aggregate and
hydraulic cylinder is made via high pressure hydraulic
hoses which are installed in underground hollow pipes.
The drive cabinet is bolted onto a separate and
sufficiently sized foundation which must be erected on
site.
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TRANSPORT AND STORAGE
5. Transport and storage

5.1. Safety instructions for transport
NOTICE!
Property damage from improper transport!
Transport units can fall or topple over with improper transport. As a result, a
considerable extent of property damage can arise.
Proceed with caution when unloading the transport units at the time of
delivery as well as during inhouse transport and observe the symbols and
instructions on the packing.
Only use the attachment points provided.
Only remove packing briefly before assembly.
Components must only be transported with vehicles which are approved for
public traffic based on their load-bearing capacity. The Regulations for
Accident prevention (UVV), in particular as applicable to working with
suspended loads, must be observed.
Components must be securely fastened against shifting during transport by
means of wedges and lashing straps.
The more detailed safety instructions of the used transportation equipment
such as fork lift or crane must the observed.
5.2. Transport inspection

Immediately inspect the delivery for completeness and transport damage on receipt. Proceed
as follows in the event of externally apparent transport damage:
Do not accept the delivery or only accept it subject to reservation.

Note the extent of the damage on the transport documentation or the shippers delivery
note.
Initiate complaint procedures.
Issue a complaint in respect of each defect immediately following detection.
Damage compensation claims can only be asserted within the applicable
complaint deadlines.
5.3. Transport
The wedge is delivered fully assembled (exception: steel reinforcement to be supplied by
third party on site).
Normal transport is by means of a lorry or container with the wedge sitting on a wooden
pallet or square timber
Load and unload using a forklift truck or crane
The wedge is fitted with four lifting points (Picture 4) for safe transport. All four lifting points
must be used at any time.
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TRANSPORT AND STORAGE
Picture 4: Lifting points wedge
The drive cabinet is fitted with four lifting points which can be utilised for transport using eye
bolts.
Picture 5: Lifting points drive cabinet
5.4. Storage
Put down the wedge on any level surface using the supplied square timbers if it is not to be
placed onto the relevant foundation immediately upon delivery.
Transport the drive cabinet in an upright position and park it in a stable manner. The factory
packaging on pallet is sufficient for this purpose.
For extended periods of time store the drive cabinet in dry conditions with an ambient
temperature >0C.
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INSTALLATION AND INITIAL COMMISSIONING
6. Installation and initial commissioning

6.1. Safety instructions for installation and initial commissioning
WARNING!
Life-threatening danger due to incorrect installation and initial
commissioning!
Installation errors and improper electrical connection may result in lifethreatening situations or considerable extent of property damage.
Installation and initial commissioning must only be carried out by personnel

of the manufacturer or personnel approved by the manufacturer.
All electrical work must only be carried out by qualified electrical technicians.
Keep unqualified personnel away from the danger area.
Consult the manufacturer also in case of subsequent re-location.
Seal off the entire construction site to prevent access from unauthorised
persons during assembly and/or other work on the wedge.
During assembly all regulations and safety precautions for persons and
machines should be adhered to without fail.
Disconnect the voltage supply before carrying out any works and secure
against unauthorised or unintended switching on (exception: test run/function
test).
6.2. Installation
6.2.1. Requirements for the place of installation
Erection of the foundations
The soil must have the required load-bearing capacity and a strength of 110kN/m2
The subsoil must be able to absorb and drain surface water (to be checked on site if
necessary)
Conduits and cables between the wedge and the drive cabinet must be supplied and
installed on site (by third party)
If a roadway gradient is present a drainage channel is to be positioned above the wedge
over its entire blocking width as the wedge is not designed for drainage of the surrounding
surfaces.
6.2.2. Installation material and tools

The following is included in the scope of supply of the product:
Screws, nuts and compound anchors for fixation of the drive cabinet
Touch up paint
Installation instruction
Wiring diagram
These tools and auxiliary means are required for the installation and are not included in the
scope of supply:
Filler plates made of steel and aluminium in various thicknesses to level out small height
inaccuracies of the foundations
Typical bench tools (hammer, wrench, screw driver etc.)
Water level (ideally one fitted with magnets for fastening)
Pry bar or similar
Hammer drill with stone drill bit 18mm
Compressed air to blow out drill holes (e.g. hand-operated air pump)
Date 05.03.2015
Wedge II
Page 21 of 61

6.2.3. Erection of foundation and assembly
Prepare the foundation pit for the wedge according to the minimum dimensions as per
the manufacturers foundation drawing. If foundation drawing is not available, request it
from the manufacturer.
Excavate the foundation pit for the foundation of the drive cabinet.
Check the dimension against the foundation drawing
Check horizontal alignment and evenness of ground surface of the foundation pit
Place wedge into the prepared foundation pit
Make sure that surface water can drain completely from the base frame.
Connect hollow pipes for hydraulic hoses and electrical cables between the wedge and
drive cabinet
Place reinforcement according to manufacturers specification. The reinforcement steel
must be at least grade BSt500A DIN488.
Lay cables and hydraulic hoses between the wedge and drive cabinet through the hollow
pipes. Check the quantity, cross section and length of the cables! The cables must
protrude at least 3.5 m from the hollow pipe.
Align the base frame horizontally and vertically by placing filler plates below the wedge
Properly cast the concrete (voids in the finished concrete are not permitted). The
concrete quality must be at least C30/37 according to DIN1045-1.
Check concrete quality used (e.g. by means of test certificates or pressure strength test)
6.2.4. Hydraulic connection
Hydraulic drive unit

Drive cabinet
Control unit
Picture 6: Drive cabinet with hydraulic drive unit
Carry out the hydraulic connection inside the drive cabinet as follows:
Connect the hydraulic line marked with A to the connector marked with A (Picture 7)
Connect the hydraulic line marked with B to the connector marked with B (Picture 7)
Ensure after completing the hydraulic connection that the system is free of air.
Date 05.03.2015
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Page 22 of 61
Hydraulic line A
Hydraulic line B
Picture 7: Connection of hydraulic lines inside the drive cabinet
Picture 8: Closed position of ball valve at pressure gauge
The ball valve at the pressure gauge must be always in closed (horizontal)
position (see Picture 8). Open (vertical position) it only for measurement
purpose.
6.2.5. Connection of power supply

The largest permissible motor size to be connected is 4.0 kW. The supply voltage (400 V,
three phase) must be connected via a lockable main switch. Incoming earth must be
connected to the equipotential bonding rail.
Date 05.03.2015
Alteration of the factory-provided cabling or the connection of non-approved

accessories is not allowed and will void all warranties.
All optional access control devices included in the scope of delivery of the
wedge have already been wired and function tested in the factory.
The pulse duration of the access control devices for single release must not
exceed 500 ms.
Only potential free contact must be connected to the inputs of the control
unit.
Wedge II
Page 23 of 61
Main switch
PLC
Wiring diagram
Terminal strip
Cable gland
Picture 9: Control box inside drive cabinet
The supply voltage may only be connected by qualified persons.
Connect the cables according to the terminal connection plan (Chapter 12.6)
Protect the supply voltage to the control with 16 A (DIAZED or NEOZED) as a maximum
Connect the supply voltage via a lockable main switch
Connect the incoming earth to the equipotential bonding rail
The motor runs counter clockwise. Ensure that the rotating field direction is correct. Switch
two of the phases if the motor rotates in the wrong direction.
Picture 10: Connection of supply voltage
Picture 11: Overview of control unit
Date 05.03.2015
Wedge II
Page 24 of 61

6.2.6. Cable connection
NOTICE!
Damage due to improper cable bending radius.
The cable can be damaged if its minimal cable bending radius is not observed.
This can impair the functionality of the equipment.
Do not bend cable.

Ensure that the minimal cable bending radius is observed and that the
insulation of the cable is not damaged.
Loosen the screws of the cover plate at the rear side of the wedge (Picture 15)
Remove cover plate(s)
Take out the terminal box and open it
Pull out the cables and connect them as per the labelling on the terminal box (Picture 13)
and the wiring diagram
Close the terminal box and reinsert
Reinstall the cover plate(s) at the rear of the wedge
Connect cable to the respective terminal strip in the control box (as per wiring diagram)
Picture 13: Terminal box inside the wedge
Picture 12: Open terminal box
6.3. Initial commissioning
NOTICE!
Property damage from improper initial commissioning!
Improper intial commissioning can lead to damage to the wedge.
Date 05.03.2015
Initial commissioning must only be carried out by persons approved by the

manufacturer to maintain the right to claims under guarantee.
Verify by means of the wiring diagram that the connection of the supply
voltage was carried out correctly
Wedge II
Page 25 of 61
WARNING!
Risk of injury due to moving parts!
The unintentional raising or lowering of the wedge may cause severe injuries.
Operate the equipment only in deadman function prior to the completion of

the initial commissioning and correct adjustment of all safety devices.
The wedge may only be passed on foot or vehicle when the wedge is in the
completely lowered position.
NOTICE!
Damage by electrostatic discharge.
Electrostatic discharge can lead to damage of electrical components in the
control unit.
Conduct electrostatic discharge prior to carry out any works on the drive
cabinet.
Verify by means of the wiring diagram that the connection of the mains supply was
carried out correctly
Turn on the main switch
The assignment of the inputs and outputs, the available status notifications as
well as the description of function for the control depend on the selected control
unit configuration and can be found in the separate order-related
documentation (see description of function and wiring diagram).
6.3.1. Commissioning
Check state of display of the control unit (see Picture 14)

Check existence of wire bridges for unused safety inputs
Set time parameters (see Chapter 6.3.2)
Check the proper function of all components, control devices and specially of all safety
devices
Check for smooth and silent operation of the wedge
Close the control unit box
Hand over wedge to the end user, making reference to the Operating Instructions and the
intended use and proper operation of the equipment.
If one of the functions does not perform as expected check first whether power is supplied
and whether the fuses are in working order. Further information can be found in Chapter 9.
Date 05.03.2015
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Page 26 of 61

6.3.2. Changing of time parameters
Display
Cursor buttons
OK-button
ESC-button
Picture 14: PLC Type Easy 721-DC-TC
Turn on control. The word run will appear in the right hand bottom corner of the display.
Press OK-button to access main menu
Start the parameter display by selecting PARAMETER. All changeable time parameters
are now shown in the submenu parameter.
Select required time parameter with cursor buttons or and press OK-button to
confirm. The selected time parameter is now shown in the display with its values.
Select required value with cursor buttons or and press OK-button to confirm
Change decimal place with cursor buttons or and value of a decimal place with cursor
buttons or
Press OK-button to save value or ESC-button to retain previous setting
Press ESC-button to leave parameter display
After completion of all parameter changes press ESC-button repeatedly until the word
run reappears in the right hand bottom corner of the display.
Table 3: Time parameter setting for control unit Easy 721-DC-TC
Date 05.03.2015
Parameter
Description
Factory setting
T1
running time
15 sec
T2
reversal time
1 sec
T3
advance warning time raising
0 sec
T4
auto-closing after passage
2 sec
T5
follow-up time lower
1 sec
T6
follow-up time raise (w/o safety skirt)
1 sec
T6
follow-up time raise (with safety skirt)
0 sec
T9
advance warning time lower
1 sec
T10
auto-closing after no passage
20 sec
Wedge II
Page 27 of 61

6.3.3. Adjustment of limit switches
The end positions of the blocking element can be adjusted by means of two limit switches
inside the wedge. They can be accessed via an inspection opening in the blocking element
(Picture 15 + Picture 16).
Picture 15: Position of inspection cover in wedge
Remove the cover of the inspection opening

Adjust the horizontal limit switch for the blocked (raised) position
Adjust the vertical limit switch for the lowered position of the wedge
Limit switch for position raised
Limit switch for position lowered
Picture 16: Inspection opening for adjustment of limit switches
The illuminated LED on the limit switch indicates the proper detection of the
signal lever (i.e. for raised position) or the cover plate of the blocking element
(i.e. for lowered position) respectively.
Date 05.03.2015
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Page 28 of 61
OPERATION
7. Operation
7.1. Safety instructions for operation
WARNING!
Risk of injury due to improper operation!
Improper operation can lead to injuries and property damage.
Read this operating manual carefully before operating the wedge for the
first time
Carry out all operating steps in accordance with the instruction in this
manual
Make sure that all covers and safety devices are installed and operating
correctly before operating the wedge
By handing over the keys to the wedge and making reference to this
operating manual the owner authorises the recipient to operate the wedge.
Any liability claim against the manufacturer will become void in case of
improper operation of the wedge or in case of a forceful attempt to break
through the activated wedge.
Only qualified and/or certified persons are allowed to operate the wedge.
During operation no vehicles, goods or persons are allowed in the movement area of the
blocking element of the wedge barrier in order to avoid collisions and injuries.
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 wedges blocking element must be carefully monitored.
7.2. Operation of the wedge

7.2.1. Normal operation
The wedge can be operated using an optional push button raise-stop-lower.
Raising of wedge
Pushing the button raise on the push button starts the electro-hydraulic drive unit and the
wedge moves into its blocking position. The end position is automatically detected and the
drive unit is automatically turned off after reaching the end position.
Lowering of wedge
When pushing the button lower on the push button the wedge moves into its lowered
position without the support of the drive unit. The end position is automatically detected.
Stopping of wedge
When pushing the button stop on the push button the wedge stops immediately.
Emergency Operation or Emergency Fast Operation (EFO) (optional)
The Emergency Operation or Emergency Fast Operation (EFO) command via anti-terror
push button moves the wedge immediately with increased speed into the completely raised
position. If the command is given during a lowering operation of the wedge, the wedge will
reverse at once.
Date 05.03.2015
Wedge II
Page 29 of 61
OPERATION
The emergency (fast) operation command is a priority command which overrides all safety
functions of induction loops and light beams as well as the fire brigade command.
Operation of the wedge will not be possible as long as the control device is activated.
The emergency (fast) operation 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 (fast) operation.
The emergency fast operation command in connection with optional accumulator moves
the blocking element into the raised position at high speed.
NOTICE!
Risk of damage caused by Emergency (Fast) Operation command!
The emergency (fast) operation command is a priority command which overrides
all safety functions when activated. This can cause significant property damage.
Protect anti-terror push button for emergency (fast) operation against

accidental activation
Only activate anti-terror push button in situations where site security takes
precedence over personal safety (e.g. in case of an imminent terror attack).
7.2.2. Operation during power failure

The operation during power failure differs depending on the configuration of the equipment.
The following configurations are possible:
1. System without accumulator

2. System with accumulator
7.2.2.1 System without accumulator
7
7
6
1
12
8
11
9
10
Picture 17: Drive unit without accumulator (Standard)
Date 05.03.2015
Wedge II
Page 30 of 61
OPERATION
1. Oil infill
2. Ball valve
3. Hand pump
4. Oil gauge
5. Oil release
6. Pressure gauge
7. 2/2 Directional seated valve (2 nos.)
8. Oil filter
9. Pressure limit valve
10. Pressure switch
11. Temperature and oil level sensor
12. Pump lever
Raising of blocking element
Remove pump lever from the back wall of the drive cabinet and insert it into the hand
pump
Operate hand pump (3) (Picture 17) until the fully raised position has been reached
Reattach the pump lever to the back wall of the drive cabinet
Lowering of blocking element
Lower the wedge by opening the ball valve (2) (Picture 17) until the fully lowered position
has been reached
Close the ball valve again
7.2.2.2 System with accumulator

13.
14.
15.
Accumulator
Connector A
Connector B
13
14
15
Picture 18: Drive unit with accumulator (for remote operation RO3 during power failure)
Raising of blocking element
Remove pump lever from the back wall of the drive cabinet and insert it into the hand
pump
Operate hand pump (3) (Picture 17) until the fully raised position has been reached
Reattach the pump lever to the back wall of the drive cabinet
Date 05.03.2015
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Page 31 of 61
OPERATION
Lowering of blocking element
Lower the wedge by opening the ball valve (2) (Picture 17) until the fully lowered position
has been reached
Close the ball valve again
Independent of the filling level of the accumulator there will be more pumping movements
required in comparison to a system without accumulator
Date 05.03.2015
Wedge II
Page 32 of 61
MAINTENANCE
8. Maintenance
8.1. Safety instructions for maintenance
WARNING!
Risk of injury due to improperly conducted maintenance!
Improper maintenance can lead to severe injuries or property damage.
Allow for sufficient working space before starting work

Keep the working space neat and tidy! Tools and components which are
lying around are potential causes for accidents.
Pay attention to the correct installation of components after they have been
removed and comply with the required screw tightening torque
Protection of the environment

Remove leaking or excess grease from lubrication points and discharge in
accordance with the applicable local regulations to protect the environment
during maintenance operations.
8.2. Maintenance schedule

Conduct mainly visual inspections and function tests in order to establish the integrity, overall
condition and good working order of the components and safety devices. Carry out the
following tasks and note them in the inspection records/assembly reports.
Table 4: Maintenance schedule
Component
Maintenance work
Task
Interval
M*
Wedge in
general
Blocking
element
Scissor
joint
Base frame
Hydraulic
cylinder
Date 05.03.2015
Y*
Check for damages, corrosion and

deterioration
Visual check
Conduct test run
Functional check
Check completeness and tight fit of all screws
Visual check
Check bearing for damage and ease of

movement
Visual and
functional check
Check bearing bolt for correct fit
Visual check
Replace bearing bushes
Maintenance
Check for damages
Visual check
Check bearing bolt for correct fit
Visual check
Cleaning
Care
Function of drainage
Visual and
functional check
Grease joint head
Maintenance
Clean hydraulic cylinder
Care
Check for damage, corrosion etc.
Visual check
Wedge II
R*
Repair
x
x
Page 33 of 61
MAINTENANCE
Component
Maintenance work
Task
Interval
M*
Drive
cabinet
Safety
devices
*M
*J
*R
Y*
R*
Check oil level in oil tank
Visual check
Refill oil
Maintenance
Check for oil leakage
Visual check
Check system pressure of hydraulic
Visual check
Check condition of hydraulic aggregate
Visual check
Change oil
Maintenance
Check condition of control unit
Visual check
Conduct function test of control unit
Functional check
Check drive cabinet heater
Functional check
Replace relay or contactors
Maintenance
Clean drive cabinet
Care
Check light beams
Functional check
Check main switch
Functional check
Check LED-strip
Functional check
Check safety skirt for damages and wear and

tear
Visual check
Replace safety skirt
Maintenance
x
x
= monthly
= yearly or every 100.000 cycles (1 cycle = 1 x raising + 1 x lowering)
= if required
8.2.1. Replacement of safety skirt

The safety skirt is subject to general deterioration which depends on the operating conditions
(operating cycles, dirt, vandalism, etc.). This deterioration impairs the functioning of the
safety skirt and necessitates a replacement.
The mounting / dismantling requires two people and the following working steps:
Lower blocking element (Picture 19)

Remove rear cover plates (Picture 20)
Raise the blocking element approx. 20 cm by means of hand pump and secure against
lowering (Picture 21)
Dismantle front cover (Picture 22)
Detach pivot axle of the safety skirt on the rear side of the wedge (Picture 23)
Lift out the safety skirt to the front (Picture 24)
Date 05.03.2015
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Page 34 of 61
MAINTENANCE
Picture 19: Lowered blocking element
Picture 20: Removal of rear cover plates
Picture 22: Dismantling of front cover
Picture 21: Raising of blocking element
Picture 23: Detaching of pivot axle
Picture 24: Lifting out of safety skirt
8.2.2. Replacement of pressure spring piston

The pressure spring piston may be replaced only if the pressure spring is relieved.
Move wedge into the blocking position and secure against lowering with service strut
(Picture 25). The wedge may only be entered with this safeguard measure in place.
Detach the upper fastening of the pressure spring piston by turning and pulling out the
folding spring bolt (Picture 26)
Put down the relieved pressure spring piston (Picture 27)
Detach the locking ring of the lower fastening and pull out the bolt (Picture 28)
Remove the pressure spring piston
Conduct the assembly in reverse order
Date 05.03.2015
Wedge II
Page 35 of 61
MAINTENANCE
Picture 25: Preparation for disassembly
Picture 26: Detaching of upper fastening
Picture 27: Putting down of relieved pressure spring piston
Picture 28: Removal of locking ring and pulling out of bolt
8.2.3. Replacement of bearing bushes for bearing points of blocking element

The bearing bushes are subject to deterioration regardless of the conditions of use and
environmental conditions. They can be replaced without the use of a crane; a lifting device
with a stroke of at least 250 mm will be required. The pressure must be removed from the
hydraulic system prior to commencing work.
Only the three bearing points in the middle are fitted with bearing bushes. The two outer
bearing points do hence not require any replacement bearing bushes.
Remove rear cover plates (Picture 29)

Dismantle all five bearing bolts (Picture 30)
Raise blocking element on the bearing side (e.g. by of a steel winch) (Picture 31 +
Picture 32)
Remove bearing bushes (Picture 33)
Conduct the installation of the new bearing bushes in the reverse order
Picture 29: Removal of rear cover plates
Date 05.03.2015
Wedge II
Picture 30: Dismantling of bearing bolt
Page 36 of 61
MAINTENANCE
Picture 31: Raising of blocking element on bearing side
Picture 32: Steel winch for raising of blocking element
Picture 33: Removal of bearing bushes
Date 05.03.2015
Wedge II
Page 37 of 61
FAULTS
9. Faults
9.1. Safety instruction for fault clearance
WARNING!
Risk of injury due to improperly fault clearance!
Improper fault clearance can lead to severe injuries or property damage.
Allow for sufficient working space before starting work

Keep the working space neat and tidy! Tools and components which are
lying around are potential causes for accidents.
Pay attention to the correct installation of components after they have been
removed and comply with the required screw tightening torque
9.2. Behaviour in event of faults

In general, the following applies
Turn of the machine immediately if faults arise which pose an imminent risk for people
and property
Determine cause of malfunction
Inform the person in charge on site
Call in the manufacturers customer service if necessary
The fault table below provides details on who is authorized to rectify the fault.
9.3. Fault table

Table 5: Fault clearance of the most common faults
Fault
System is without
power
Power is present, but

motor does not run
Motor runs, but the

blocking element
does not move
Cause
Measure
Remedy
Power supply is
interrupted
Main or motor
protection switch is
switched off
Control fuse F2 is
faulty
Motor failure
Check mains supply
Restore power supply
Check main and motor

protection switch
Switch on main
and/or motor
protection switch
Replace control fuse
F2 (6A slow-blow)
Replace motor
Wedge is
mechanically
blocked
Malfunction of a
hydraulic valve
Rotating field
direction of motor
is incorrect
Operating
Operating pressure is pressure set at the
too low
pressure control
valve is too low
Date 05.03.2015
Check control fuse F2

Check for proper function
of motor
Identify the obstructing
object
Remove obstructing
object
Check valve function

(electrical and hydraulic)
Replace plug socket

or complete valve
Check rotating field

direction based on fan
wheel.
Increase pressure
Change two phases

of the mains supply
Wedge II
Adjust pressure
control valve
Page 38 of 61
FAULTS
Fault
System loses oil
Blocking element
does not fully raise
Hydraulic cylinder
makes noise during
operation
Blank LCD-display of
control unit
LCD-display of
control unit shows:
TEST: AC
TEST: EEPROM
TEST: DISPLAY
TEST: CLOCK
LCD-display of
control unit shows:
ERROR: I2C
LCD-display of
control unit shows:
ERROR: EEPROM
Date 05.03.2015
Cause
Measure
Remedy
Internal leakage
Close ball valve
Oil level is too low
Check if ball valve is fully

closed
Check oil level
Leaking hose
connection
Check hose connection for Seal connection, refill

leak tightness
oil
Hydraulic hose is
damaged
Check hydraulic hose for

damage
Refill oil level
Replace hydraulic
hose
Limit switches are Check limit switch

not properly
adjustments
adjusted
Operating
Check operating pressure
pressure is too low
Adjust limit switches
Blocking element
is mechanically
blocked
Piston rod sealing
rings are dry
Identify the blockage
Remove the blockage
Bearing is dry
Check bearing for

sufficient greasing
Check supply voltage
Power supply is
interrupted
Increase operating
pressure
Check condition of sealing Lubricate piston rod

rings
with hydraulic oil
Regrease
Switch on power
supply
LCD-display of
Easy is faulty
Replace control unit

Easy
Auto-test has been

aborted.
Internal error of
control unit

Easy
Memory card
removed
Memory card
inserted incorrectly
before saving
Memory card is
faulty
Control unit Easy
is faulty
Check presence of
memory card
Check proper fit of
memory card
Buffer memory or
memory of control
unit Easy is faulty
Wedge II
Insert memory card

Insert memory card
Replace memory card

Easy
Easy
Page 39 of 61
SPARE PARTS
10. Spare parts
WARNING!
Risk of injury due to use of incorrect spare parts!
Use of incorrect or faulty spare parts may result in damages, malfunctions or
total failure and may jeopardise the safe operation of the equipment.
Only use original spare parts from the manufacturer.
Purchase spare parts directly from the manufacturer. For contact details see chapter 1.7
Customer service.
10.1. Spare parts ordering

The following information must be quoted when ordering spare parts:
Kommissionsnummer/commission number (see type plate)

Position (see type plate)
Baujahr/year of manufacture (see type plate)
Produktbezeichnung/product name (see type plate)
Seriennummer/serial number (see type plate)
Picture 34: Example of type plate
Date 05.03.2015
Wedge II
Page 40 of 61
DISASSEMBLY AND DISPOSAL
11. Disassembly and disposal

The wedge must be dissembled and disposed of in an environmentally responsible manner
after its end of the useful life has been reached
11.1. Disassembly
Before starting the disassembly:
Switch off the machine and secure against switching on

Disconnect the machine from the entire power supply
Dismantle component groups and components considering the applicable local

environmental protection regulations.
11.2. Disposal
If no return or disposal agreement has been made, send the dismantled components for
recycling.
Scrap metallic material residues

Send electrical scrap such as control unit and motor for recycling
Dispose of oils and greases at approved collection points
NOTICE!
Danger to the environment due to incorrect disposal!
Incorrect disposal may pose risks to the environment.
Date 05.03.2015
Electrical scrap, electronic components, lubricants and other auxiliary

materials must be disposed of by authorized specialist companies
If in doubt, obtain information about disposal in accordance with the
environmental regulations from the local municipal authorities or specialist
waste companies.
Wedge II
Page 41 of 61
APPENDIX
12. Appendix
12.1. Technical data of hydraulic drive unit
Hydraulic accumulators and hydraulic hoses must be subjected to recurrent
testing. The owner defines the testing intervals for inner and outer inspection as
well as pressure test.
The recurrent internal inspection must be conducted at the latest after 10 years
according to the German Industrial Safety Regulation (BetrSichV).
Outer inspections of hydraulic accumulators should be conducted by a
competent person as per manufacturers recommendation every two years.
The normal life expectancy of hydraulic hoses depends on the operating

pressure and environmental conditions.
The hydraulic hoses should be replaced at the latest after six years to prevent
ageing effects.
Table 6: Electrical data of motor
Frequency Power
[Hz]
[kW]
Voltage
Current
[V]
[A]
Motor Operating
rotation
mode*
speed
Protection Power factor

class
cos
[1/min]
50
4.0
60
*S1 =
4.8
380-420
380-480
8.55
1430
Y 4.86
0.82
S1
10.26
IP55
1716
Y 5.83
0.82
Continuous operation; the motor is designed for continuous operation.
Table 7: Data of hydraulic drive
Drive
option
pump
size
system
pressure
[l/min]
[bar]
Standard
16.0
EFO*
RO3**
*
raising
lowering
EFO
remote power
failure
operations
140
3.5
3.5
16.0
180
3.5
3.5
1.0
16.0
180
3.5
3.5
1.0
Operating time [sec]
EFO emergency fast operation
** RO3 remote operation for 3 cycles in case of power failure

Oil Type:
Mineral Oil
Bio-degradable
HLP 22
Plantohyd 22 S NWG
Filling capacity of the hydraulic System:
Date 05.03.2015
approx. 35 l
Wedge II
0.2 l per meter of hydraulic line
Page 42 of 61
APPENDIX
12.2. Required tools, measuring devices and auxiliary devices

Tools
Open-ended and ring spanners
8 10 - 13 17 19 21 32 36
Torque wrenches
13 17 19 21 32 36
Allen wrenches
4 10
Screwdrivers (slotted/crosshead)
4 x 0.8 - 8 x 1.2 / size 2 size 3
Hammer drill 20 mm (auxiliary equipment for cleaning the drilled holes)

General tools for electric installation (as e.g. side cutter, stripping tool, etc.)
Fitter's hammer
Rubber hammer
Measuring devices
Tape measure, folding rulers
Spirit level 1 m (ideally with magnetic foot)
Leveller (recommended)
Mason line
Electric measuring and inspection equipment
Auxiliary devices
Crane
Slinging equipment (no chains)
Shims of different thickness
Square logs for supporting purposes
Date 05.03.2015
Wedge II
Page 43 of 61
APPENDIX
12.3. Pre-tensioning forces and tightening torques for screwed connections

Friction coefficient =0.14
Table 8: Pre-tensioning force and tightening torque for regular thread
Dimension
Strength
class
M5
Pre-tensioning force Fv (kN)
Tightening torque Ma (Nm)
4.6
5.6
8.8
10.9
12.9
4.6
5.6
8.8
10.9
12.9
2.1
2.79
6.4
9.3
10.9
2.0
2.7
5.9
8.7
10
M6
2.96
3.94
9.0
13.2
15.4
3.5
4.6
10
15
18
M8
5.42
7.23
16.5
24.2
28.5
8.4
11
25
36
43
M10
8.64
11.5
26
38.5
45
17
22
49
72
84
M12
12.6
16.8
38.5
56
66
29
39
85
125
145
M14
17.3
23.1
53
77
90
46
62
135
200
235
M16
23.8
31.7
72
106
124
71
95
210
310
365
M18
28.9
38.6
91
129
151
97
130
300
430
500
M20
37.2
49.6
117
166
194
138
184
425
610
710
M22
46.5
62
146
208
243
186
250
580
830
970
M24
53.6
71.4
168
239
280
235
315
730
1050
1220
M27
70.6
94.1
221
315
370
350
470
1100
1550
1800
M30
85.7
114.5
270
385
450
475
635
1450
2100
2450
All values are indicative.
Date 05.03.2015
Wedge II
Page 44 of 61
APPENDIX
12.4. Spare parts list Wedge II

Table 9: Spare parts wedge II
Photo
Article
Number
Comment
320677*
BW = 2.0 m
320677*
BW = 2.5 m
320677*
BW = 3.0 m
320677*
BW = 3.5 m
320677*
BW = 4.0 m
Scissor joint complete

with distance bush, bolt
and locking rings,
RAL 3000
357005
1
1
1
1
1
Safety skirt complete

320677*
320677*
320677*
320677*
320677*
Bearing block type LD30-N c/w axle holder

A-30 + bolt BA-30
318170
Igus bush GFM 2023-21

for pressure spring
piston
311196
Bearing bush for

pressure spring piston
357168
Bearing bolt for pressure

spring piston
357167
Pressure spring piston

complete
356822
Pressure spring 88/3/1
357209
Slide block for spring

pressure piston
357947
Folding spring bolt for

pressure spring piston
307376
Quantity
1
1
1
1
1
Date 05.03.2015
Description
Blocking element compl.
1980 x 1715 x 160
2480 x 1715 x 160
2980 x 1715 x 160
3480 x 1715 x 160
3980 x 1715 x 160
Wedge II
X
X
X
X
X
BW
BW
BW
BW
BW
= 2.0 m
= 2.5 m
= 3.0 m
= 3.5 m
= 4.0 m
Page 45 of 61
APPENDIX
Photo
Date 05.03.2015
Quantity
Description
Article
Number
10
Igus bush GFM 4550-25

for blocking element
357202
Axle blocking element,

welded, galvanised
362474
10
Distance bush for scissor

joint
357008
10
Pivot bolt 1 for scissor

joint (50x77)
362472
Pivot bolt 2 for scissor

joint (50x110)
362473
10
Bearing bush 1 for

scissor joint
357169
10
Bearing bush 2 for

scissor joint
357954
Hydraulic cylinder
S70/35, 2x dampened,
c/w rose ends, RAL 3000
357275
Aggregate with block,

version S1
357534
Standard
Aggregate with block

and 1x 3.5L
accumulator, version Q1
357535
for option EFO
Aggregate with block

and 2x 3.5L
accumulator, version C1
355799
for option RO3
1 or 2
Diaphragm accumulator
3.5L
318540
1 no. for option EFO,

2 nos. for option
RO3
Wedge II
Comment
Page 46 of 61
APPENDIX
Photo
Quantity
Article
Number
Comment
Screw-in check valve

RK 2
321932
Pressure control valve

DB4E 01X 350V
pressure pre-adjusted
to140 bar
356614
Standard
Pressure control valve

DB4E-012-CE0034.
ENISO4126.4L28.210
356610
for option EFO and /

or RO3
2-way ball valve NG 6
321934
2 or 3
2/2 directional seated

valve
321937
2 nos. for standard,

3 nos. for option
EFO or RO3
2 or 3
Solenoid plug socket 24

V AC/ DC, 3m cable
yellow IP 67
320269
2 nos. for standard,

3 nos. for option
EFO or RO3
Pressure gauge 63,

0 - 250 Bar
321936
Level gauge
321942
Pressure switch
8151-PL1-B
356609
Hand pump HP10-21
356607
Filter cartridge HC 9
321938
354746
310831
307413
1
2
2
Date 05.03.2015
Description
Level and temperature

switch UNS1000-BN18
Hydraulic oil HLP 22,
20 L
Hydraulic oil Plantohyd,
20 L
Wedge II
for option
mineral oil
for option biodegradable oil
Page 47 of 61
APPENDIX
Photo
Quantity
2
2
1
Hydraulic hose 25000

long, type 2SN DN16
EN 853, DKOL/DKOL
Proximity limit switch
IG 5357
Connection cable IFM
EVT 001, straight 5 m
cable for level switch
Article
Number
Comment
323126
distance wedge
drive cabinet: 25 m
320191
320819
Control EASY 721 DCTC with existing

programme
355083
for control
configuration Vario
Control EASY 512 DCTC with existing

programme
358281
for control
configuration
Standard
Control EASY 410-DCTE
322864
for option EFO

and/or RO3
Main switch on/off
113714
Circuit breaker B 6 A,
1-pole
201342
Motor protection switch

7.00-10.0 A
309470
Main contactor 11 kW
24 VDC
321714
Transformer
230/24 VDC, 6 A
202935
for standard + option

EFO
(without RO3)
Power supply unit

230/24 VDC, 5 A
323250
for option RO3
var
Auxiliary switch
24 VDC, 250V/8A,
2 change-over
305783
17 nos. standard
21 nos. EFO
22 nos. RO3
3-Phase monitoring relay
356156
for option RO3
Date 05.03.2015
Description
Wedge II
Page 48 of 61
APPENDIX
Photo
Date 05.03.2015
Quantity
Description
Article
Number
Comment
for option RO3
Rechargeable battery
pack NP7-12, 12V 7Ah
323073
Heater 500W 230V
311354
Hygros-thermostat
357204
Filter fan 230 VAC,

55 qm/h
352882
Outlet filter
352883
Hose-proof hood
352884
for option outdoor
Optional
1 no. for BW = 3.0 m
2 nos. for BW = 2.5 m
and 3.5 m
and 4.0 m
Optional
1 no. for BW = 2.5 m
up to 4.0 m
var
LED-Strip red, 24V DC,

595x18,4x19,7, IP67,
5m connection cable
324337
var
LED-Strip red, 24V DC,

1010x18,4x19,7, IP67,
5m connection cable
324336
var
Anti-terror push button

EFO
307845
optional
var
Push button Raise-StopLower
309352
optional
var
Push button Raise-StopLower with illumination
318829
optional
var
Light beam transmitter
353974
optional
Wedge II
Page 49 of 61
APPENDIX
Photo
Quantity
Description
Article
Number
Comment
var
Light beam receiver
353975
optional
Detector 2-channel
354832
optional
Receiver type EF 433-N

MINI 230V for plug-in
socket
34918
optional
Plug-in socket 11-pole

ES 12
83034
optional
Antenna ANSONIC
with 5 m connection
cable
85559
optional
Hand-held transmitter
Type SF 433-1E
90996
optional
var
B = Basic version (without safety skirt)

S = Version with safety skirt
BW = Blocking width
Var = variable
320677* = general article number Spare part assembly Wedge
Date 05.03.2015
Wedge II
Page 50 of 61
APPENDIX
12.5. Hydraulic scheme wedge basic (example)
Date 05.03.2015
Wedge II
Page 51 of 61
APPENDIX
Table 10: Component list for hydraulic diagram
Item
1
2
3
4
5
7.1
7.2
7.3
8
9
10
12
13
14
15
16
17
18
19
20
21
23
24
25
27.1
27.2
28
29
30
31.1
31.2
32
46
50
Date 05.03.2015
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
Description
Screw-in check valve RK 2
Pressure control valve DB4E 01X 350V
2-way ball valve NG 6
Pressure switch 8151-PL1-B
Pressure gauge 63 (0-250bar)
Tapped blockage plug
2/2 directional seated valve EM 31 V - X 24
2/2 directional seated valve EM 31 V - X 24
Tapped diverting plug
Filter cartridge HC 9
Hand pump HP10-21
Valve manifold (aluminium)
Hydraulic tank 30 litre
Tank cover
Bellhousing for gear pump
Coupling Spidex
Gear pump Z 16
E-Motor 4,0 kW, V1, 4-polig, 400/460 V- 50/60 Hz
Filler neck with breather
Level gauge
Pressure hose
Return pipe, double nipple
Nozzle
Nozzle
Level and temperature switch UNS1000-BN18
Nozzle
Screw connection for gear pump
Filter disc
Filter disc
Minime-coupling
Screw connection for valve manifold
Ball valve DN 6 L
Wedge II
Page 52 of 61
APPENDIX
12.6. Wiring diagram for wedge basic (example)

The wiring diagram in this manual is intended to facilitate basic understanding
and may differ from the actual configuration. An order-related wiring diagram
will be supplied as separate document.
Date 05.03.2015
Wedge II
Page 53 of 61
APPENDIX
Date 05.03.2015
Wedge II
Page 54 of 61
APPENDIX
Date 05.03.2015
Wedge II
Page 55 of 61
APPENDIX
Date 05.03.2015
Wedge II
Page 56 of 61
APPENDIX
Date 05.03.2015
Wedge II
Page 57 of 61
APPENDIX
Date 05.03.2015
Wedge II
Page 58 of 61
APPENDIX
12.7. Service strut for fixing of blocking element
Picture 35: Installation of service strut
Picture 36: Service strut
For service purpose the service strut must be placed on both sides of the wedge to ensure
that any unintentional movement of the blocking part is impossible.
Alternative a squared timber 10 cm by 10 cm with length 90 cm can be used.
The manufacturer recommends the service strut shown in Picture 35 and Picture 36.
WARNING!
Risk of injury due to moving blocking element!
Unintentional lowering of the blocking element may cause severe injuries.
Date 05.03.2015
For safety reasons the entering of the wedge without prior installation of a
mechanical support is strictly prohibited.
Wedge II
Page 59 of 61
EC DECLARATION OF CONFORMITY
13. EC Declaration of conformity
EC Declaration of Conformity
in compliance with EC-Machinery Directive (2006/42/EC, Annex II A)
Manufacturer:

Johann-Reineke-Strae 6-10
33154 Salzkotten
Description:
Road blocker
Type:
Wedge II
Serial number:
The object of the declaration described above fulfils all the relevant provisions of the
following European Community Directives:
EC-Machinery Directive (2006/42/EC)
EMC Directive (2004/108/EC)
Harmonised standards applied:
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1:
General requirements
EN ISO 4413:2010 Hydraulic fluid power - General rules and safety requirements for
systems and their components
Technical standards and specifications applied
Tested to PAS 68:2013 and IWA 14-1:2013 with 4.0 m blocking width
receiving PAS68 V/7500[N3]/80/90:0.0/20.7
and IWA 14-1 V/7200[N3C]/80/90:0.0
Salzkotten, _____________________
(Place and Date of Issue)
K. Hamborg, Managing Director
(Name, Position within the Company)
_____________________
(Signature)
This declaration of conformity is only valid if the subsequent annexed

declaration for installation and initial commissioning is completed and signed
by the installation company or owner.
Date 05.03.2015
Wedge II
Page 60 of 61
EC DECLARATION OF CONFORMITY
Annexed declaration for installation and initial commissioning

(Annex to manufacturers declaration of conformity)
The company:
____________________________________
____________________________________
____________________________________
____________________________________
hereby declares that the machinery described below
Description:
Type:
Serial number:
was installed and commissioned in compliance with all installations instructions as per the
manufacturers operating manual using auxiliary materials in accordance with the installation
site and building ground.
Place
Date 05.03.2015
Date
Signature/Position within the Company
Wedge II
Page 61 of 61

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Operating Manual

Read the instructions

Perimeter Protection Germany GmbH

Translation of the original operating manual

Information on this manual ...................................................................................... 7

Correct use in accordance to the instructions .......................................................... 9

Model and areas of application .............................................................................. 14

Design and function .......................................................................... 15

Transport and storage ...................................................................... 19

Safety instructions for transport ............................................................................. 19

Installation and initial commissioning ............................................ 21

Safety instructions for installation and initial commissioning .................................. 21

Adjustment of limit switches .................................................................................. 28

Safety instructions for operation ............................................................................ 29

Safety instructions for maintenance ....................................................................... 33

Safety instruction for fault clearance ...................................................................... 38

Spare parts ......................................................................................... 40

Spare parts ordering.............................................................................................. 40

Disassembly and disposal ............................................................... 41

Technical data of hydraulic drive unit .................................................................... 42

EC Declaration of conformity ........................................................... 60

Maintenance schedule ...........................33

1.2. Explanation of symbols

This symbol highlights useful tips and recommendations as well as information

1.3. Limitations of liability

Non-observance of this manual

Use deviating from the intended use

1.5. Technical progress

1.6. Warranty terms

1.7. Customer service

2.1. Correct use in accordance to the instructions

Do not use the wedge as lifting device for loads or vehicles

2.2. Responsibility of the owner

The owner must provide the required personal protective equipment.

2.3. Personnel requirements

Special activities should therefore only be carried out by the personnel

2.4. Personal protective equipment

2.5. Basic dangers

If the insulation is damaged then immediately disconnect the voltage supply

Do not reach into or handle moving parts during operation.

2.6. Safety devices

The equipment is fitted with the following safety devices:

optional safety skirt,

2.8. Spare parts

2.0 m, 2.5 m, 3.0m, 3.5 m and 4.0 m

monitoring by operator, safety skirt (optional), blocking

to prevent forceful entry of vehicles for sites with a high

3.2. Performance characteristics

raising approx. 3.5 sec, lowering approx. 3.5 sec

in final positions or hydraulically during power failure

4.0 kW, 400 V (3-phase), 50 Hz

400 V (3Ph + N + PE), 50 Hz

Operation during power failure:

via hand pump, optional with accumulator for three

100 kN according to SLW 60 (DIN 1072)

Opening and closing direction:

upwards and downwards, front face towards impact

1852 kJ (7.5 t @ 80 km/h)

according to PAS68 V/7500[N3]/80/90:0.0/20.7 and

approx. 2000 kg (for 4.0 m blocking width)

DESIGN AND FUNCTION

4. Design and function

Picture 1: Design wedge II