FAAC 615BPR Automatic Barrier

Introduction

The FAAC 615BPR is an automated barrier system designed for vehicle access control. It features an aluminum beam with reflex reflectors and a steel upright with a cataphoresis treatment and polyester paint finish. The upright houses the hydraulic operator and electronic control unit. The operator utilizes a hydraulic power pack and a double-acting cylinder. The system includes an adjustable torque limitation system, a beam stopping device, and a manual release command for power outages or faults.

Note: The beam and balancing spring must be ordered separately based on the sales price list. This system is intended solely for vehicle access control.

1. Description and Technical Specifications

Fig. 1: Components

• ① Foundation plate
• ② Barrier upright
• ③ Control board
• ④ Emergency release
• ⑤ Torque adjustment screws
• ⑥ Double-acting piston
• ⑦ Travel limit screw
• ⑧ M12 nut blocking the tie rod
• ⑨ Rocker
• ⑩ Oil filling plug
• ⑪ Breather screw
• ⑫ Balancing spring
• ⑬ Spring adjustment tie-rod
• ⑭ Hydraulic power pack
• ⑮ Travel limit sensors
• ⑯ Travel limit magnets

1.1 Maximum Use Curve

The curve illustrates the maximum work time (T) based on use frequency (F). For example, the 615BPR can operate continuously at a 50% use frequency. To ensure efficient operation, stay within the curve's operating range. Note that direct sun exposure can reduce use frequency to 20%. The calculation of use frequency is the percentage of effective work time (opening + closing) compared to the total cycle time (opening + closing + pause times).

Calculation Formula: %F = (Ta + Tc) / (Ta + Tc + Tp + Ti) x 100

Where:

• Ta = opening time
• Tc = closing time
• Tp = pause time
• Ti = interval time between one complete cycle and another

2. Electric Preparations (standard system)

Fig. 2: Connections

• ① Operator 615BPR
• ② Photocells
• ③ Key-operated push-button
• ④ Flashing lamp
• ⑤ Receiver
• ⑥ Loop Detector

Important Notes:

• Use adequate rigid and/or flexible tubes for laying cables.
• Always separate low-voltage accessory connection cables from 230V~ cables. Use separate sheaths to prevent interference.

3. Dimensions

Fig. 3: Dimensions

All dimensions are in millimeters.

4. Installing the Automated System

4.1 Preliminary Checks

Ensure the following conditions for safe and efficient operation:

• The beam must not encounter obstacles or overhead cables during movement.
• The soil must provide sufficient stability for the foundation plinth.
• Ensure no pipes or electrical cables are present in the plinth excavation area.
• If the barrier body is exposed to vehicle traffic, install protective measures against accidental impact.

4.2 Masonry for Foundation Plate

Fig. 4: Foundation Plate Installation

1. Create a foundation plate as shown in Fig. 4.
2. Install the foundation plate as shown in Fig. 4, including sheaths for electrical cables. Use a spirit level to ensure the plate is perfectly level and allow cement to set.

4.3 Installing the Upright

Fig. 5: Upright Installation

1. Remove the cover by unscrewing the securing screws.
2. Secure the upright to the foundation plate using the provided nuts and washers, as shown in Fig. 5. Ensure the upright hatch normally faces the building.

4.4 Installing the Beam

Fig. 6, 7a, 7b: Beam Installation

The 615BPR is supplied in the right-hand version. For left-hand installation, refer to section 5.5.

1. Ensure the piston rod secured to the rocker is fully extended (corresponding to the beam's vertical position).
2. Remove and store the breather screw as shown in Fig. 6.

Important: Moderately tighten the pocket securing screw (max 30Nm).

4.5 Installing and Adjusting the Balancing Spring

Fig. 8: Balancing Spring Installation

1. Verify that the balancing spring matches the installed beam type (see Chapter 5).
2. With the beam in a vertical position, assemble the tie rod and spring as shown in Fig. 8.
3. Release the operator (Chapter 7) and position the beam at 45°. Adjust the tie rod and spring to balance the beam's weight in this position.
4. Restore normal operation as described in Chapter 7.

5. Balancing Springs

The 615BPR system requires a balancing spring, ordered separately. The spring type varies based on beam length and type (rigid, skirt, or articulated). Consult the tables below for spring matching.

5.1 Springs for Rectangular Beams with Skirt

5.2 Springs for Rectangular Beams with Foot and with Skirt and Foot

5.3 Springs for 615BPR Rapida

5.4 Springs for Round Bars

5.5 Transformation from Right to Left Version

Fig. 9: Right to Left Conversion

1. Release the operator.
2. Loosen the connection (Fig. 9, ref. A).
3. Provisionally remove the piston securing screw (Fig. 9, ref. B) and the seeger ring (Fig. 9, ref. C).
4. Rotate the rocker.
5. Position the piston from the left side and secure it with the screw (Fig. 9, ref. D) and seeger (Fig. 9, ref. E).
6. Tighten the connection (Fig. 9, ref. F).
7. Re-lock the operator.
8. Dismantle the control unit container and reinstall it on the left of the hood using the existing holes.
9. Change the connectors of the travel-limit sensors (J6 and J9 on the 596/615BPR board).

6. Start-Up

6.1 Adjusting the Transmitted Torque

Fig. 10: Torque Adjustment

To set the hydraulic system's transmitted power, turn the two by-pass screws (Fig. 10). The red screw controls closing movement torque, and the green screw controls opening movement torque. Turn screws clockwise to increase torque and counter-clockwise to decrease torque.

6.2 Adjusting the Mechanical Travel Limits

Fig. 11: Travel Limit Adjustment

Adjust the beam's position for maximum closing and opening using the mechanical travel stops (Fig. 11, ref. 1).

6.3 Adjusting the Magnetic Travel Limits

The slow-down point of the automated system can be modified by moving the magnetic cylinder within the rocker's arms in the motion unit (Fig. 11, ref. 2).

6.4 Automated System Test

Fig. 12: System Test

1. After installation, apply the danger warning sticker to the top of the upright (Fig. 12).
2. Check the operating efficiency of the automated system and all connected accessories.
3. Provide the client with the "User's Manual", explain correct operation and use, and highlight potentially dangerous areas.

7. Manual Mode Operation

Fig. 13: Manual Operation

In case of power failure or system fault, use the release device as follows:

1. Insert the standard triangular key (Fig. 13) into the lock and turn it counter-clockwise by one turn.
2. Manually open and close the barrier.

8. Restoring Normal Operation Mode

Before restoring normal operation, switch off the system's power. Turn the triangular key clockwise until it stops, then remove it. This prevents involuntary activation during the maneuver.

9. Available Accessories

Skirt Kit

Fig. 14: Skirt Kit

The skirt kit enhances beam visibility and is available in lengths from 2 to 3 meters. If a skirt kit is installed, the balancing spring must be readjusted.

Fork Support

Fig. 15: Fork Support

The fork support has two functions:

• It prevents the beam from bending or splitting when closed if stressed by external forces.
• It allows the beam to rest when closed, preventing downward bending.

Positioning the Fork Support Foundation Plate with Rectangular Beam

Fig. 16: Fork Support Plate Positioning (Rectangular Beam)

Dimensions are in millimeters.

Refer to Fig. 16 for positioning the foundation plate:

• P1 = Barrier foundation plate
• P2 = Fork support foundation plate
• L = Beam length (mm)
• A = L - 195 (mm)

Positioning the Fork Support Foundation Plate with Round Beam

Fig. 16A: Fork Support Plate Positioning (Round Beam)

Dimensions are in millimeters.

Refer to Fig. 16A for positioning the foundation plate:

• P1 = Barrier foundation plate
• P2 = Fork support foundation plate
• L = Beam length (mm)
• A = L - 375 (mm)

Articulation Kit

Fig. 17: Articulation Kit

The articulation kit allows a rigid beam to be articulated for a maximum ceiling height of 3 meters (refer to specific instructions). If the articulated kit is installed, the balancing spring must be adapted.

End Foot

Fig. 18: End Foot

The end foot supports the beam when closed, preventing downward bending. If a foot is installed, the balancing spring must be readjusted.

10. Maintenance

During maintenance, always check:

• Correct settings of the by-pass screws.
• System balancing.
• Efficiency of safety devices.

The automated system does not require oil top-ups.

11. Repairs

For any repairs, contact FAAC's authorized Repair Centres.

CE Declaration of Conformity for Machines

Manufacturer: FAAC S.p.A.

Address: Via Calari, 10 - 40069 Zola Predosa BOLOGNA - ITALY

Declares that the Barrier mod. 615BPR:

• Is built to be integrated into a machine or assembled with other machinery to create a machine under Directive 2006/42/EC.
• Conforms to the essential safety requirements of other EEC directives: 2006/95/EC (Low Voltage Directive) and 2004/108/EEC (Electromagnetic Compatibility Directive).

Furthermore, FAAC declares that the machinery must not be put into service until the machine into which it is integrated has been identified and its conformity to Directive 2006/42/EEC and subsequent modifications has been declared.

Date: Bologna, 01-02-2010

Signed: A. Marcellan, The Managing Director

Warnings for the Installer - General Safety Obligations

1. ATTENTION! Read all instructions carefully to ensure people's safety. Incorrect installation or use can cause serious harm.
2. Read instructions thoroughly before installation.
3. Keep packing materials away from children.
4. Store instructions for future reference.
5. This product is designed for the indicated use only. Any other use may compromise its condition or be dangerous.
6. FAAC is not liable for improper or unintended use.
7. Do not install in explosive atmospheres.
8. Mechanical parts must comply with Standards EN 12604 and EN 12605 (and national regulations for non-EU countries).
9. FAAC is not responsible for poor workmanship or deformation of closing elements.
10. Installation must comply with Standards EN 12453 and EN 12445 (and national regulations for non-EU countries).
11. Always cut electrical power before working on the system.
12. The mains power supply must have an all-pole switch with a contact opening distance of at least 3 mm. A 6A thermal breaker is recommended.
13. Ensure a differential switch with a threshold of 0.03 A is fitted upstream.
14. Ensure the earthing system is perfect and all metal parts of the closure are earthed.
15. The system has an anti-crushing safety device (torque control). Check its tripping threshold as per point 10.
16. Safety devices (EN 12978) protect against mechanical risks like crushing, dragging, and shearing.
17. Use at least one indicator light (e.g., FAACLIGHT) and a warning sign.
18. FAAC is not liable for safety or operation if non-FAAC components are used.
19. Use only original FAAC spare parts for maintenance.
20. Do not modify system components.
21. Provide the user with information on manual operation and the warnings handbook.
22. Do not allow people to stay near the product while operating.
23. Keep remote controls away from children to prevent accidental activation.
24. Transit is permitted only when the automated system is idle.
25. Users must not attempt repairs; contact qualified personnel only.
26. Check system efficiency, especially safety devices, every 6 months.
27. Anything not expressly specified in these instructions is not permitted.