VBR-600 Dok-Lok Vehicle Restraint Installation Manual

Transcription

1 VBR-600 Dok-Lok Vehicle Restraint Installation Manual MADE IN U.S.A. This Manual Covers Restraints Built After Serial Numbers: VB and up PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO JANUARY 2014

2 NOTES 2 Pub. No January 2014

3 TABLE OF CONTENTS INTRODUCTION SAFETY WARNINGS INSTALLATION WIRING DIAGRAM FOR STAND ALONE DOK-LOKS ELECTRICAL SCHEMATIC FOR STAND ALONE DOK-LOKS WIRING DIAGRAM FOR COMBINATION POWER UNIT DOK-LOKS ELECTRICAL SCHEMATIC FOR COMBINATION POWER UNIT DOK-LOKS HYDRAULIC SCHEMATIC WARRANTY BACK COVER INTRODUCTION Read and understand this manual before attempting to install or operate any DOK-LOK vehicle restraint. For best results, have this product serviced by your authorized Rite-Hite representative. The VBR-600 DOK-LOK vehicle restraint by Rite-Hite is intended to provide a safer workplace for workers in shipping and receiving dock areas. The VBR-600 DOK-LOK vehicle restraint is a hydraulic restraint device that, when properly installed and operated, retains a secure connection between the truck and dock. Signal lights and signs provide instructions to the truck driver and DOK-LOK vehicle restraint operator that a safe condition exists. The DOK-LOK vehicle restriant is operated by pressing push buttons on an inside control panel. NOTICE TO USER Your local Rite-Hite representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative or Rite-Hite at The Rite-Hite products in this manual are covered by one or more of the following U.S. patents: 5,271,183; 5,323,503; 5,546,623; 5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 6,065,172; 6,070,283; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,276,016; 6,311,352; 6,318,947; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,499,169; 6,505,713; 6,524,053; 6,634,049; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 6,892,411; 7,032,267; 7,062,814; 7,134,159; 7,213,285; 7,216,391; 7,363,670; 7,380,305; 7,503,089; 7,533,431; 7,546,655; 7,584,517; 7,681,271; 7,841,823; 7,877,831; 7,823,239; 8,006,811; 8,065,770; 8,141,189 and pending U.S and foreign patent applications. RITE-HITE, THINMAN TM, SAFE-T-LIP, HYDRACHEK, EEL-LOK TM, DOK-LOK, DUAL-DOK, SAFE-T-STRUT TM, DOK-COMMANDER, JUMBO TM, HYDRA-RITE TM, SAFE-T-GATE, RITE-VU TM LIGHT COMMUNICATION SYSTEM and SMOOTH TRANSITION DOK SYSTEM TM, are trademarks of Rite-Hite. Pub. No January

4 SAFETY WARNINGS When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. DO NOT OPERATE XXXXXXXXXXXX XXXXXXXXXXX FIGURE 1 - LOCKOUT/TAGOUT LOCKOUT/TAGOUT PROCEDURES The Occupational Safety and Health Administration requires that, in addition to posting safety warnings and barricading the work area, the power supply has been locked in the OFF position or disconnected. It is mandatory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout procedure requires that the person responsible for the repairs is the only person who has the ability to remove the lockout device. In addition to the lockout device, it is also a requirement to tag the power control in a manner that will clearly note that repairs are under way and state who is responsible for the lockout condition. Tagout devices have to be constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or become unreadable. Rite-Hite Corporation does not recommend any particular lockout device, but recommends the utilization of an OSHA approved device (refer to OSHA regulation ). Rite-Hite Corporation also recommends the review and implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These regulations are available through OSHA publication This is the highest level statement. Failure to follow the listed instructions will most likely result in severe injury or death. The statements used with this level of warning deal with a safe operating procedure. If the procedure is ignored, the possibility of personal injury may exist. This is a statement of serious hazard. Failure to follow the listed instructions could place the individual at risk of serious injury or death. IMPORTANT is used to draw attention to a procedure that needs to be followed to prevent machine or property damage. 4 Pub. No January 2014

5 INSTALLATION INSTRUCTIONS (No Hydraulic Leveler Present in Pit) This Bolt May Need To Be Removed To Improve Access RITE-HITE VBR-600 DOK-LOK Installation Manual Shim from top of cylinder support to underside of cylinder clevis 1" Approx. INSTALLATION Dock Leveler Cylinder Clevis Leveler Pit Floor VBR-600 Insert Assembly 3/16-16 Bolt w/jam Nut, Qty (2) Torque To 200 In-Lbs (17 Ft-Lbs) Ensure Tabs On Insert Are Under Tabs In Pan As Shown And Install And Tighten (2) Bolts With Jams Nuts. FIGURE 2 - PLACEMENT Install And Torque (6) Nylock Nuts Securing Insert To Pan. Torque To 260 Ft-Lbs 1. Install VBR6 insert (if removed during pit work) and tighten (6 ea.) nylock nuts on back face and (2 ea.) jam nuts on base. See figure 2 2. Install hydraulic dock leveler per dock leveler installation instructions. 3. Manually raise and strut dock leveler. FIGURE 3 - CYLINDER SUPPORT HYDRAULIC CYLINDER SUPPORT (Dock Leveler) 4. If the base clevis of the hydraulic cylinder on the dock leveler is over the opening of the Dok-Lok, cylinder support must be placed centered on cylinder clevis and shimmed to support hydraulic dock leveler. See figure If the base clevis of the hydraulic cylinder on the dock leveler is not over the opening of the Dok-Lok, cylinder clevis needs to be shimmed to pit floor to support hydraulic dock leveler. 6. Route Dok-Lok hydraulic hoses thru the back opening of the Dok-Lok pit. See figure 4. Pub. No January

6 INSTALLATION CONT. 4 x 4 x 3 NEMA 4 (Waterproof) Juction Box (Supplied By Others) Alternate Hose Routing Shown Main Cylinder #6 Hose Prefered Hose Routing Behind Cylinder Support Wire Tie Hoses These Locations Positioning Cylinder #4 Hose Stored Sensor Switch Spring Adjustment Nut ELECTRIC AND SIGN INSTALLATION 7. Mount a waterproof junction box and stand alone power unit, if equipped, to the pit floor near Dok-Lok pit. See figure 4 & Route and secure (SW2) stored sensor cable with the Dok-Lok hydraulic hoses. Terminate into junction box. See figure Route and secure (SW1) R.I.G. sensor cable leaving a minimum loop of 20. Secure with stored switch and hoses. Terminate into junction box. Ensure that the switch cable has enough slack to travel with the barrier through the entire locking range. See figure 4. FIGURE 4 - ROUTING RIG Sensor Switch (Min 20" Loop) Attach Main Cylinder (#6 Hose) Here Attach Positioning Cylinder (#4 Hose) Here FIGURE 5 - PUMP AND HOSE ROUTING 6 Pub. No January 2014

7 INSTALLATION CONT. place control box where best suited within arms reach at eye level near door opening 15" disconnect (supplied by others) 5" Ref. inside sign inside light & control box outside lights dock seal 18" mirror image outside sign 1" Warning Decal standard outside sign 80" 96" drive approach 20" 48" of dock and DOK-LOK FIGURE 6 - SUGGESTED COMPONENT LOCATION 10. Mount all signs and electrical components as shown in figure 6. When drilling holes in the box, DO NOT allow the drill to go too deeply into the box. Damage to the control systems may occur. DO NOT turn control box upside down to drill any access holes. Cover internal electrical components prior to drilling - this will prevent debris from contacting the internal electrical components. CONTROL BOX AND CONDUIT INSTALLATION PROCEDURES. 11. Install the control box on a wall adjacent to the overhead door at approximately 48" above the floor level. See Figure Drill a hole for the power supply conduit (by others) in the bottom of the control box. All holes drilled through the control box must be through the bottom of the box. Remove all debris from box using a shop vacuum. NEVER use air to blow debris from the control box. Pub. No January

8 INSTALLATION CONT. b. Seal the conduit in any location where the conduit transitions temperature zones that may produce condensation. The control box and all wiring should be installed by a qualified electrician in accordance with all national and local electrical codes. If rigid conduit is installed, bonding must be maintained between conduit connections by using ground bushings and a jumper wire. c. Spacers should be installed between the enclosure and the wall to provide tempature insulation and air flow. 13. Connect wiring as indicated by the Electrical Schematic and Wiring Diagram. See figures 7 & 8 or figures 9 & To complete installation see page 12, Fill and Bleed Hydraulic System section. Control Box Installation Guidelines - Temperature Controlled Applications. a. Conduit should be routed to enter through the bottom or side of the enclosure. A drip leg may be needed if the conduit could fill with water. 8 Pub. No January 2014

9 WIRING DIAGRAM - STAND ALONE POWER UNIT DETAIL - "A" OUTSIDE LIGHT BOX (SUPPLIED BY RITE HITE) 40 ITE WIRE 42 RED WIRES RED TO POWER SOURCE 30 AMP RATED FUSED DISCONNECT (SUPPLIED BY OTHERS) 41 GREEN ITE WIRE SIDE VIEW OF COVER FROM CONTROL BOX (3) 14 GA. WIRES INSIDE LIGHT & CONTROL BOX OUTSIDE LIGHT BOX SEE DETAIL - "A" WIRE TO POWER UNIT PIT MOUNTED JUNCTION BOX SEE DETAIL - "B" WIRE TO POSITION CYLINDER FLOAT SOLENOID (SOL 2) RIG SENSOR WIRE (SECURE TO PIT FLOOR AND LEAVE 20" OF SLACK SO BARRIER CAN TRAVEL FULL RANGE) STORED SENSOR WIRE (SECURE TO PIT FLOOR) TO RIG SENSOR (SW1) WIRE TO POSITION CYLINDER EXTEND SOLENOID (SOL 1) FROM CONTROL BOX (10) 14 GA. WIRES GND SW1+ SW1- +V1 SW2+ SCOM SOL1 SOL2 MCOM M1 GRN BLK BLK GRN 3/4" CONDUIT & FITTINGS (BY OTHERS) SEE NOTE #2 WIRE NUT CONNECTIONS (TYP) TO POWER UNIT NOTES: TO STORED SENSOR (SW2) DETAIL - "B" JUNCTION BOX (IN LEVELER PIT) (SUPPLIED BY OTHERS) 1. All Conduit & fittings to be 3/4 min. If 1 or larger is used, DO NOT use outside light box center knockout. 2. Wire per local electrical codes. 1 conduit may be required. 3. Refer all installation and service to qualified personnel. BLK GRN NEMA 4 JIC ENCLOSURE (WATERPROOF) 4" X 4" X 3" SUGG. SIZE (3" ALLOWABLE MAX HEIGHT) FIGURE 7 - WIRING DIAGRAM BLK GRN BLK GRN TO POSITION CYLINDER EXTEND SOLENOID (SOL 1) TO POSITION CYLINDER FLOAT SOLENOID (SOL 2) ENCLOSURE GROUND LUG 4. All components must be connected to a safety earth ground where indicated. This ground must conform to latest edition of NEC Section Par.(a) & Par.(c) for grounding electrode. 5. For non-metallic enclosures, use grounding bushings on all conduit entering the control box. Install pre manufacturer s specifications. Use 8AWG green copper wire, 65 /75 C minimum to ground. Bushings in enclosures where multiple conduit entrances are required. Pub. No January

10 4 AMP RITE-HITE VBR-600 DOK-LOK Installation Manual ELECTRICAL SCHEMATIC - STAND ALONE POWER UNIT Connects to Ground Terminal on back panel in control box To Customer Power Supply 120v, 1PH, 60Hz, 30 Amp. Fused Disconnect With 15 Amp. Dual Element Time Delay Fusing (Supplied By Others) (G) (L1) (L2/N) (1) MCom Motor -.75 H.P. 115v. 1Ph. 50/60 Hz F.L.A. (2) MRun M (10) SCom ISA2 PUSH BUTTON BOARD R LOCK UNLOCK G R G Inside Lights, Horn and Push Button Wiring Harness HS #1 HS #2 HS # Orange ISR 12 VDC,.54A Green ISG 12 VDC,.54A Power Module Service Button CPU module 4 Amp Automotive Fuse + 12VDC Red + 12VDC Red Ambr Lt Cntrl Yellow OSR Sense White/Orange OSG Sense White/Green GND Black GND Black HS #3 Violet HS #2 Brown HS #1 Gray Lock Blue Unlock White PB3 PB2 PB1 LOCK UNLOCK SW1 ISA ISR ISG HORN SW2 SW3 OSG OSR +V1 SW1+ SW1- +V2 SW2+ SW1- (5) (6) (7) SCOM 250v. 1A Fast Blow CR4 CR5 SOL2 L1 L 2 MCOM M 1 OSPWR OSG OSR SOL1 M 1 CR3 CR2 CR1 250v. 15A Slow Blow SOL1 SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (8) Sol1 (9) Sol2 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock Solenoid 1 Position Cyl. Extend (BLK) (T) 120 VAC, 0.23 AMPS Solenoid 2 Position Cyl. Float (BLK) (T) 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF ON Red +12V H Horn White/Black Horn - 12 VDC, 0.03A white white mech./ FA interconnect hydraulic interconnect raise photoeye interconnect White/Red Horn + black black R.I.G. Sensor Switch (SW1) STORED Sensor Switch (SW2) red (42) Outside Light Power LEGEND lable LED lamp denotes field wiring NOTE: Use included female spade connectors for installation. white (41) white (40) G R Outside Light Green 12VDC, 2.1A Outside Light Red 12VDC, 2.1A FIGURE 8 - ELECTRICAL SCHEMATIC 10 Pub. No January 2014

11 WIRING DIAGRAM - COMBO POWER UNIT DETAIL - "A" OUTSIDE LIGHT BOX (SUPPLIED BY RITE HITE) 40 ITE WIRE 42 RED RED WIRES TO POWER SOURCE 30 AMP RATED FUSED DISCONNECT (SUPPLIED BY OTHERS) 41 GREEN ITE WIRE SIDE VIEW OF COVER FROM CONTROL BOX (3) 14 GA. WIRES INSIDE LIGHT & CONTROL BOX OUTSIDE LIGHT BOX SEE DETAIL - "A" WIRE TO DIVERT SOLENOID (SOL 3) PIT MOUNTED JUNCTION BOX SEE DETAIL - "B" WIRE TO LIP BLOCK SOLENOID (SOL 4) NOTES: RIG SENSOR WIRE (SECURE TO PIT FLOOR AND LEAVE 20" OF SLACK SO BARRIER CAN TRAVEL FULL RANGE) STORED SENSOR WIRE (SECURE TO PIT FLOOR) DETAIL - "B" JUNCTION BOX (IN LEVELER PIT) (SUPPLIED BY OTHERS) TO RIG SENSOR (SW1) TO STORED SENSOR (SW2) WIRE TO POSITION CYLINDER EXTEND SOLENOID (SOL 1) NEMA 4 JIC ENCLOSURE (WATERPROOF) 4" X 4" X 3" SUGG. SIZE (3" ALLOWABLE MAX HEIGHT) 1. All Conduit & fittings to be 1 min. If 1 or larger is used, DO NOT use outside light box center knockout. 2. Wire per local electrical codes. 3. Refer all installation and service to qualified personnel. FROM CONTROL BOX (10) 14 GA. WIRES GND SOL1 SW1+ SW1- +V1 SW2+ SOL2 SCOM MCOM SOL3&4 GRN BLK BLK GRN BLK GRN BLK GRN BLK GRN BLK GRN WIRE TO POSITION CYLINDER FLOAT SOLENOID (SOL 2) 3/4" CONDUIT & FITTINGS (BY OTHERS) SEE NOTE #2 WIRE NUT CONNECTIONS (TYP) TO DIVERT SOLENOID (SOL 3) TO LIP BLOCK SOLENOID (SOL 4) ENCLOSURE GROUND LUG TO POSITION CYLINDER TO POSITION CYLINDER EXTEND SOLENOID FLOAT SOLENOID (SOL 1) (SOL 2) FIGURE 9 - WIRING DIAGRAM - COMBINATION POWER UNIT 4. All components must be connected to a safety earth ground where indicated. This ground must conform to latest edition of NEC Section Par.(a) & Par.(c) for grounding electrode. 5. For non-metallic enclosures, use grounding bushings on all conduit entering the control box. Install pre manufacturer s specifications. Use 8AWG green copper wire, 65 /75 C minimum to ground. Bushings in enclosures where multiple conduit entrances are required. Pub. No January

12 4 AMP T RITE-HITE VBR-600 DOK-LOK Installation Manual ELECTRICAL SCHEMATIC - COMBO POWER UNIT FROM 120V CONTROL VOLTAGE 3X1(RD) FIXED TIMER DELAY ON BREAK (11) Sol3 Solenoid 3 Divert (BLK) (T) X1(RD) 16FU1 2X1(RD) 3.0 AMP. 250 v. DUAL ELM TIME DELAY 6 5 INITIATE INPUT 1 2 LOAD R 4 3 X2() 2X1(RD) (12) Sol4 (13) Sol Com B 120 VAC, 0.23 AMPS Solenoid 4 Lip Block (BLK) (T) 120 VAC, 0.23 AMPS Power Module 2X1(RD) SCOM L1 L2 MCOM M1 250v. 1A 250v. 15A Fast Blow Slow Blow To Motor Contactor (10) Sol Com A Solenoid 1 Position Cyl. Extend (BLK) (T) Inside Lights, Horn and Push Button 3X1(RD) Wiring Harness CPU module PUSH BUTTON BOARD 4 Amp Automotive R G Fuse ISA2 LOCK UNLOCK R G HS #1 HS #2 HS # Orange ISR 12 VDC,.54A Green ISG 12 VDC,.54A + 12VDC Red + 12VDC Red Ambr Lt Cntrl Yellow OSR Sense White/Orange OSG Sense White/Green GND Black GND Black HS #3 Violet HS #2 Brown HS #1 Gray Lock Blue Unlock White PB3 PB2 PB1 LOCK UNLOCK SW1 ISA ISR ISG HORN SW2 SW3 OSG OSR Service Button +V1 SW1+ SW1- +V2 SW2+ SW1- (5) (6) (7) CR4 CR5 SOL2 OSPWR OSG OSR SOL1 M1 CR3 CR2 CR1 SOL1 SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (8) Sol1 (9) Sol2 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock 120 VAC, 0.23 AMPS Solenoid 2 Position Cyl. Float (BLK) (T) 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF ON Red +12V H Horn White/Black Horn - 12 VDC, 0.03A white white mech./ FA interconnect hydraulic interconnect raise photoeye interconnect White/Red Horn + black black R.I.G. Sensor Switch (SW1) STORED Sensor Switch (SW2) red (42) Outside Light Power LEGEND lable LED lamp denotes field wiring NOTE: Use included female spade connectors for installation. white (41) white (40) G R Outside Light Green 12VDC, 2.1A Outside Light Red 12VDC, 2.1A FIGURE 10 - ELECTRICAL SCHEMATIC - COMBINATION POWER UNIT 12 Pub. No January 2014

13 HYDRAULIC SCHEMATIC Locking Cylinder Positioning Cylinder M (Main) P (Position) Shuttle Valve Solinoid Valve (SOL2 - Position Cylinder Float) Check Valve T (Tank) Solinoid Valve (SOL1 - Position Cylinder Extend) RO (Ramp Out) LO (Lip Out) Solinoid Valve (SOL4 - Lip Block) NOTE: Only Used With Combination Power Unit System Relief 500 PSI Solinoid Valve (SOL3 - Divert Valve) NOTE: Only Used With Combination Power Unit LI (Lip In) RI (Ramp In) FIGURE 11 - HYDRAULIC SCHEMATIC Fill and Bleed Hydraulic System 13. Fill Reservoir using supplied MIL-H5606-A hydraulic fluid. 14. Apply power to control box. 15. Ensure front of barrier is unobstruted and can extend freely. 16. Press and hold the service button inside the control box until the horn chirps. Service button is located on the CPU module. See figure Controls are now in Fill Mode. 18. Press and Hold the LOCK button until the main cylinder extends. Release LOCK button, cylinder will retract. 19. Press and Hold the UNLOCK button until the main and positioning cylinders extend. Release unlock button, main cylinder will retract. 20. Tighten lift spring adjustment nut completly. See figure 4. Pub. No January

14 VALVE BLOCK ASSEMBLY NOTE: COMBINATION VALVE BLOCK SHOWN DOK-LOK Position Cylinder Extend Solenoid (SOL 1) DOK-LOK Main Cylinder Port Leveler Lip Cylinder Out Port DOK-LOK Position Cylinder Port Leveler Lip Block Solenoid (SOL 4) Leveler Ramp Cylinder Divert Solenoid (SOL 3) DOK-LOK Position Cylinder Float Solenoid (SOL 2) Leveler Ramp Cylinder Out Port Leveler Lip Block Solenoid (SOL 4) Leveler Lip Cylinder In Port Leveler Ramp Cylinder In Port Return To Tank Port Leveler Ramp Cylinder Out Port DOK-LOK Position Cylinder Float Solenoid (SOL 2) TOP/FRONT/ RIGHT SIDE VIEW FIGURE 12 - VALVE BLOCK DETAIL BOTTOM/BACK/ RIGHT SIDE VIEW 21. Cycle the Dok-Lok LOCK and UNLOCK several times to remove air from system. Add remaining hydraulic fluid as needed. Stop cycling once the main and positioning cylinders operate without hesitation. 22. Press service button to exit Fill Mode. 23. Test operation according to Owners Manual to complete installation. 14 Pub. No January 2014

15 NOTES Pub. No January

16 RITE-HITE STANDARD WARRANTY Rite-Hite warrants that its products will be free from defects in design, materials, and workmanship for a period of 365 days from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can, with reasonable care, be detected and in no event no more than 30 days after the warranty has expired. In order to be entitled to the benefits of this warranty, the products must have been properly installed, maintained, and operated within their rated capacities and/or specified design parameters, and not otherwise abused. Periodic lubrication and adjustment is the sole responsibility of the owner. This warranty is Rite-Hite s exclusive warranty. RITE-HITE EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Non-standard warranties, if any, must be specified by Rite-Hite in writing. In the event of any defects covered by this warranty, Rite-Hite will remedy such defects by repairing or replacing any defective equipment or parts, bearing all the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract, negligence, or strict liability. LIMITATION OF LIABILITY RITE-HITE SHALL NOT IN ANY EVENT BE LIABLE FOR ANY LOSS OF USE OF ANY EQUIPMENT OR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, ETHER FOR BREACH OF WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Global Sales & Service Office: RITE-HITE 8900 N. Arbon Drive P.O. Box Milwaukee, Wisconsin Phone: Representatives in all Major Cities 16 Pub. No January 2014