Hormann AWB Automatic Wheel Blocking System

About These Instructions

This manual is a translation of the original manual, in compliance with European Directive 2006/42/CE and the Supply of Machinery (Safety) Regulations 2008, No. 1597 (United Kingdom). It is valid for the AWB wheel blocking system with control unit.

Other Documents: Refer to the operating instructions for the levelling ramp and door.

Symbols Used:

• Warning of danger: Indicates important information for safe handling.
• Important notice: To avoid personal and material damage.
• Tighten screws firmly: Indicates to tighten screws securely.
• Slight tightening: Indicates to tighten screws lightly.
• Components optional: Indicates optional components.
• Check: Indicates to check components.
• Prohibited activity: Indicates activities that are not permitted.
• Correct activity: Indicates permitted activities.
• Refer to text: Indicates to refer to the text for more information.
• Refer to illustrations: Indicates to refer to the illustrations for more information.
• Remove and dispose of component or packaging: Indicates to properly remove and dispose of parts.
• Refer to separate installation instructions: Indicates to consult separate instructions for control units or additional electrical controls.

Abbreviations Used: Color codes for cables, individual conductors, and components correspond to the international color code according to IEC 757.

• RD: Red
• YE: Yellow
• BN: Brown
• WH: White
• GN: Green
• BK: Black
• BU: Blue

Denominations:

• AWB: Automatic Wheel Blocking System
• PCB: Plate
• DAP: Support for coupling

Safety Instructions

WARNING: Danger of injury due to non-compliance with operating instructions. These instructions contain important information for safe product handling. Pay special attention to potential hazards arising from its use.

• Read these instructions carefully.
• Observe the safety instructions in these instructions.
• Keep these instructions in an accessible place.

2.1 Appropriate Use

This product is intended for industrial use and for the following purposes:

• Coupling at loading and unloading stations for trucks.
• Blocking of vehicle wheels against unintentional rolling and slipping (skidding): resistant to an extraction force of up to 115 kN.
• Depending on the equipment: assistance for regulating and monitoring loading and unloading and coupling processes.

The AWB is a purely support system. The driver's responsibility for caution does not change.

The control unit is only intended for connection with the components indicated in these instructions.

2.2 Inappropriate Use

The product is not suitable for reliably preventing premature departure or theft of the vehicle.

It is forbidden to use the AWB to move vehicles.

2.3 Personnel Qualification

Do not allow anyone to work on the product unless authorized and trained by the user. This applies to fitters, maintenance personnel, and users.

2.3.1 User

The user is responsible for the following tasks:

• Instruct users.
• Make documentation available and ensure it is followed.
• Ensure the product is always in perfect technical condition.

2.3.2 Technical Personnel

Technical personnel are responsible for the following work areas:

• Assembly
• Commissioning
• Maintenance
• Dismantling and recycling

Note:

• Work must be carried out exclusively by qualified personnel familiar with assembly techniques and relevant safety regulations.
• Assembly includes mechanical and electrical work.
• Special work required for assembly must be performed by qualified professionals from specialized companies. This includes work on building statics or ventilation systems.
• Electrical installations must only be carried out by qualified electricians.

2.3.3 User

Users can undertake tasks related to product operation and care.

User Requirements:

• Must have received direct product instruction from the user.

2.4 Danger from AWB Modifications

WARNING: Danger of injury from structural changes. Changing components or adding additional components can disable important safety components and cause fatal injuries. Modifications to the structure may only be made after agreement with the manufacturer.

2.5 Corrosion and Short Circuit from Contact with Liquids

Liquids can damage components through corrosion and short circuits. Protect the following components from contact with liquids:

• Components subject to electrical voltage.
• Hydraulic unit.

2.6 Safety Instructions for Electrical Work

DANGER: Danger of death from mains voltage. Contact with mains voltage poses a risk of fatal electric shock. Entrust electrical connection work to a qualified electrician. Observe applicable protective regulations. Disconnect the power supply. Secure the installation against unauthorized reconnection.

WARNING: Danger from incorrect assembly. Improper actions during assembly can cause danger to persons or damage to the installation. Observe all safety instructions. Follow all installation instructions. If in doubt, consult the manufacturer.

CAUTION: Damage from external voltage. External voltage at the connection terminals of the control unit plate can destroy all electronics. Plug system cables into the housing from below. Close unused connections with blind plugs.

CAUTION: Damage from tensile forces. Pulling on the connection cables of electrical components destroys the electronics. Avoid tensile forces on the connecting cables of the control unit plate.

Product Description

The AWB is an automatic wheel blocking system for loading and unloading stations that prevents slipping and skidding. The system automatically positions the blocking unit and extends the blocking arm. The system includes sensors, a control unit for monitoring and release, and connections for additional components.

Supply and Transport

DANGER: Danger of injury from falling wheel blocking system. Falling material can cause personal injury. Do not stand under the load. Transport a maximum of 4 AWBs simultaneously. The drive unit support has a lifting eye. Transport individual drive units with a lifting strap.

Assembly

Refer to the illustrations starting on page 10.

5.1 Assembly Requirements

• Consider the site plan.
• The arrangement of components is reversed for left-hand traffic. This reversed arrangement may also be necessary if space is limited.
• Prepare a wheel guide for the opposite side, e.g., a Hörmann WBM1900 steel wheel guide.
• If a wheel guide is already available: Position the wheel guide according to the site plan.

5.2 Safety Instructions for Assembly

WARNING: Risk of injury from non-observance of assembly instructions. Failure to follow the assembly instructions in this manual poses a risk of injury. Read this chapter carefully before proceeding with assembly. Follow the safety instructions. Observe all local regulations regarding structure and safety.

CAUTION: Damage from liquids. Contact with liquids can cause short circuits. If the dock and levelling ramp assembly is exposed to the risk of flooding, mount the drive unit in a higher, suitable position.

Assembly and electrical work should only be performed by qualified professionals (see chapter 2.3 Personnel Qualification).

Ensure the following conditions are met during assembly:

• Access to the work area is restricted within a wide radius.
• The wheel blocking system is undamaged and in good condition.
• Cables are not bent, crushed, or damaged.
• Do not mount the drive unit or control unit in a potentially explosive area.
• Ensure the drive unit and control unit are within a temperature range of -20 °C to +50 °C.

5.3 Preparation

Assembly of the wheel blocking system can only be carried out if the mounting location meets the specified requirements. Ensure at least one of the following conditions is met:

• Position of final door position CLOSED: via a magnetic switch in the guide rail (see illustration 8C), or alternatively in the automation control unit.
• Levelling ramp in rest position message: via the proximity switch on the levelling ramp.

5.3.1 Mounting the Drive Unit

• Route the connection cable and data cable through the PVC pipe (on-site) into the interior.
• For the interior drive unit, select a suitable mounting height for operation. If multiple drive units are mounted one above the other, ensure good operability. Mount the drive unit preferably above the control unit for levelling ramps or doors.
• For the power supply, it is recommended to connect to the control unit for the levelling ramp. If mounted separately, the drive unit must have its own main switch "L" (see page 4).
• Set the main power switch to position "0".
• There must be no mains voltage present for connecting components.

Mounting Types:

• On concrete or sheet steel: using the supplied anchors, sheet metal screws, and shims.
• On steel beams: using M4 / M5 screws and shims.

Commissioning

Connect the power supply.

Operation

7.1 Meaning of Messages

Control Lamp on Control Unit:

• Off: AWB is not blocking any vehicle.
• Solid: Vehicle blocked, door opening authorized.
• Rapid flashing: Fault.
• Slow flashing: Control not functioning (key switch is in the off position).

Control Lamp on AWB Blocking Unit:

• Off: AWB is not moving.
• Yellow light flashing: AWB is active in motion. The flashing light starts 3 seconds before the first movement.

Acoustic Signal Tone:

• Alarm: AWB is active in motion. The tone starts 3 seconds before the first movement.

Exterior Signal Lamp RD / YE / GN with corresponding equipment:

• RD illuminated: Vehicle coupling or uncoupling is not permitted.
• YE illuminated: Coupling position almost reached (in conjunction with the coupling support system).
• GN illuminated: Vehicle coupling or uncoupling is not permitted.

Alarm: In case of faults, the acoustic signal warns of safety risks.

• The AWB does not find a wheel.
• Unlock the AWB with the door open.
• The automatic door is open without the AWB blocking the vehicle.
• The data connection between the control unit and the exterior drive unit has been interrupted.

7.2 Sequence of Functions

Refer to image 10.

WARNING: Danger of entrapment. During the blocking process, persons can become trapped. Ensure that no persons are in the movement area of the blocking unit and the blocking arm. Do not step on the telescopic profile.

NOTICE: Valid for installations with inflatable dock shelter or electric roller blind door after coupling and automatic positioning of the AWB:

• First, put the dock shelter into the working position (automatically if the corresponding equipment is available).
• Then, open the door (automatically with the corresponding equipment).
• After each loading process, wait until the AWB has fully returned to its rest position. This prevents a collision with a truck during the next coupling.

Maintenance

8.1 Cleaning and Care

User Activity: Once a day. Check that the following areas are free of snow and dirt: movement area of the blocking unit, roadway in the movement area of the blocking unit.

8.2 Maintenance

Only qualified professional personnel may carry out checks and maintenance (see 2.3.2). Exception: tasks to be performed specifically by the user.

NOTICE: Depending on the type of maintenance, the interior drive unit generates an error message and triggers an alarm.

Acoustic warning signal contamination can be avoided by deactivating the piezoelectric signal generator via the DIL SWITCH ZUMBADOR during work.

User Activity: Once a week. Perform a visual check for possible mechanical and electrical damage.

Technical Personnel Activity: Once a year, or twice a year for intensive use (> 8 times per day). Perform a functional check (see chapter 7 Operation). Check the mobility of moving parts. Check safety and control functions: operation of signal lamps, operation of control lamps for AWB and control unit, operation of the emergency stop switch. For this, use the configuration options in the service interface. Check cables for breaks. In case of failure, immediately disconnect the power. Replace defective cables. Check the function of the main switch on the exterior drive unit. Ensure connections and fastenings are firm. Check for wear on the following components: guide profiles, hydraulic hose, cable chain. Immediately rectify any possible damage.

8.3 Service Interface

The service interface is a mobile website with:

• Information on control software and user data.
• Adjustment possibilities.

The service interface is only available in English. If you have difficulty understanding, contact the manufacturer or supplier.

Establishing the Connection

You need a device with WiFi enabled, e.g., a laptop or mobile phone.

1. Open the housing of the exterior control unit.
2. Set the DIL switch OTA on the top plate to the ON position.

The WiFi connection is established. The AWB electronics are no longer ready for operation.

OTA: On / Off

If you have finished using the Service Interface application, set the DIL switch OTA on the plate back to the OFF position.

3. Connect your personal computer or mobile phone to the desired WiFi network:

• Drive unit (interior): Control WB Hörmann****
• Control unit (exterior): Master WB Hörmann****
• Password: AWB-WIFI

If the browser does not load automatically, enter the following IP address directly in the browser bar: 192.168.1.1. This accesses the Hörmann WB data page. Here you will find information on the control software version and user data.

Service Interface Start Page

From the menu (top right), you can access the following pages:

• Data page
• Firmware update
• Settings
• Errors

8.3.1 Reading and Changing Configuration: Settings Page

• Select the Settings page.
• Possible settings: System reset, Plate type (when replacing), Check connected equipment, Set control lamp brightness on the control unit, Connect or disconnect manual operation, Connect or disconnect coupling support (DAP), Behavior of the door release function in case of failure, Modify timer values.

A message appears in the menu as soon as an adjustment has been successfully modified.

8.3.2 Control Unit Reset

The menu item "Reset this device" allows you to reset the system. User settings are retained. The WiFi connection is re-established with the corresponding device configuration.

8.3.3 Adjusting Door Operation or Levelling Ramp Unlock Behavior in Case of Failure (only when the door is connected)

You can choose between two configurations:

• a. Door operation is enabled in case of failure. Select this configuration for the following cases of failure: the AWB is not in the "vehicle blocked" state, the door is open, and the alarm is triggered. The door can be closed. The alarm stops. After resolving the cause of the fault, operation can be resumed.
• b. Door operation is blocked in case of failure. Select this configuration for the following cases of failure: when the AWB triggers an alarm with the door closed, the door cannot be opened for safety reasons. The door can only be opened after the fault has been rectified.

The current configuration is indicated.

To change the configuration, select the corresponding menu item:

• a. Door operation enabled in case of failure
• b. Door operation blocked in case of failure

8.3.4 Setting Timeout Values

You can adjust the configuration of various timers.

8.3.5 Manual Jog Mode

You can switch to manual mode of the AWB as follows:

• Turn the key switch of the interior drive unit to the AWB OFF position.
• Set the DIL switch OTA of the exterior control unit to the ON position.
• Connect via WiFi.
• Connect manual operation via the menu item "Turn on manual jog mode".
• Now, move the AWB with the exterior control unit. The front panel indicates which movement each key activates.

To disconnect manual operation:

• via the menu item "Turn off manual jog mode" or
• set the DIL switch OTA of the exterior control unit to the OFF position.

Remember to turn the key switch of the interior drive unit back to the AWB ON position.

Dismantling and Recycling

8.3.6 Software Update: Exterior Drive Unit or Control Unit

Select the "Firmware Update" page.

The "Update" menu item accesses a page that allows software updates. The corresponding file must be available on the personal computer or mobile phone.

8.3.7 Error Log

Select the "Errors" page. The "Errors" menu item accesses a page that displays the latest error messages.

8.4 Wear Parts

• Check the material thickness of the guide profile: Replace the guide profile if the material thickness is less than 6 mm.
• Check if the guide profile screws are tight or tighten them if necessary to a torque of 20 Nm.

8.5 Faults and Troubleshooting

Only qualified personnel can rectify faults and failures (see chapter 2.3.2). In case of a fault, first check if it is a mechanical damage or if a component is stuck. Only check the causes listed below after checking and ruling out those possibilities.

Check:

• control lamps and tone generators of the AWB and interior drive unit
• the connection of the control unit plate
• the wiring to the signal transmitters
• the immediate surroundings for interference

High-frequency electromagnetic radiation can affect the switching of outputs, e.g., high-frequency welders.

To rectify faults, the mentioned adjustment work is described in the chapter "Checking and Maintenance".

• Control lamp on the control unit flashes rapidly. The alarm sounds. The AWB has moved fully forward. The blocking arm is not extended: The AWB does not find a wheel. Press the reset key, move the AWB to the rest position using the "Unlock" key.
• Control lamp on the control unit flashes rapidly. The alarm sounds. The AWB is in the intermediate or rest position. An automatic door has moved without the AWB blocking a vehicle: Close the door. Press the reset key, move the AWB to the rest position using the "Unlock" key. Block the truck with the AWB. If the fault persists, check the error message in the service interface.
• Control lamp on the control unit flashes slowly: No fault: the key switch is in the OFF position. Control function is deactivated. Contact the station operator.
• The AWB key does not light up and does not function after the levelling ramp is in the rest position and the door is closed: The final position message for the CLOSED door is faulty. Check the wiring to the magnetic switch or the final position message of the door control. Refer to the corresponding technical documentation.
• The final position message of the levelling ramp is faulty: Check the wiring to the levelling ramp sensor. Refer to the corresponding technical documentation.
• No illumination of the pushbuttons is active (no active pushbutton).
• OTA activated in the exterior box.
• DAP does not detect any vehicle.

Overview of Error Messages in the Service Interface (Errors): For connection to the service interface, see chapter 8.3.

If the indicated measures do not solve the problem: check the sensors and wiring.

Dismantling and Recycling

Dismantling the AWB is done in the reverse order of assembly. For correct disposal, separate the AWB into individual components after dismantling. Dispose of everything in compliance with local regulations.

Technical Data

10.1 AWB

• Length: 8000 mm (from the front edge stop)
• Width: 680 mm
• Height: 335 mm
• Blocking height: 300 mm
• Weight: Total weight 607 kg (with oil), weight without motor unit: 545 kg
• Maximum vehicle extraction force: 115 kN
• Working area: 2825 mm (continuous positioning of the blocking unit along the roadway)
• Roadway reach: 370 mm

10.2 Complete System

• Connection voltage of the drive unit: 400 V AC, 50/60 Hz
• Connection voltage of the control unit: 24 V DC in the exterior control unit
• Maximum power consumption: 3.1 kW
• Required power supply: via residual current protection switch (RCD) with a pre-installed fuse of 16 A.

NOTICE: A control unit for automation and, if applicable, a door control unit can be connected to the power supply via the main switch of the control unit for levelling ramps. Consult the operating instructions for the control unit for levelling ramps and doors.

Check if adaptations are necessary due to additional current consumption:

• the pre-installed fuse
• the power supply cables for the control unit for levelling ramps

• Protection class: IP 65
• Overvoltage category: Category of overvoltage 3
• Maximum installation height (to ensure minimum required air pressure): 1000 m above sea level, relative humidity ≤ 93%, no condensation.
• Maximum ambient temperature during operation: -20 °C to +60 °C
• Maximum ambient temperature for transport and storage: -25 °C to +60 °C

Declaration of Conformity

EC Declaration of Conformity (EU) pursuant to the Machinery Directive 2006/42/CE, Annex II, Part 1 A

Manufacturer: Hörmann KG Verkaufsgesellschaft, Upheider Weg 94 - 98, D-33803 Steinhagen. Address: Axel Becker

The manufacturer hereby confirms under its sole responsibility that this product: Hörmann AWB Wheel Blocking System corresponds, according to its concept and design in the version marketed by us, to the relevant essential requirements of the following directives, provided that it is used appropriately:

• 2006/42/CE Machinery Directive
• 2014/35/UE EU Directive on Low Voltage
• 2014/30/UE EU Directive on Electromagnetic Compatibility
• 2011/65/UE (RoHS) EU Directive on the Restriction of the Use of Certain Hazardous Substances

Applied Standards and Specifications (if the date is not indicated, the latest edition of the publication, including modifications):

• EN ISO 13849-1, Safety of machinery – Safety-related parts of control systems: Performance Level "c"
• EN 60204-1 Safety of machinery – Electrical equipment of machines
• EN 61000-6-2 Electromagnetic compatibility – Immunity to interference
• EN 61000-6-3 Electromagnetic compatibility – Emission

If one of the combinations described above has been assembled and commissioned according to our instructions, the installation complies with the mentioned standards. In case of an unauthorized modification of the product, this declaration becomes invalid.

The person authorized to compile the technical documentation is the management of the manufacturer indicated above.

Steinhagen, 01/04/2025

ppa. Axel Becker, General Manager, Sales and International Marketing, Hörmann KG Verkaufsgesellschaft