Hydraulic Tyre Killers

ISO 9001: 2008
EN ISO 14001: 2004
www.optima-engineering.com
SECURITY SYSTEMS
Tyre Killers
INSTALLATION INSTRUCTIONS
HYDRAULIC TYRE KILLERS
INDEX
Page
1. GENERAL INFORMATION........................................................................... 3
2. SYSTEM COMPONENTS .............................................................................. 4
2.1 Construction......................................................................................................................4
2.2 Control Cabinet .................................................................................................................8
2.3 Electrical and Electronics Components ................................................................................9
2.4 Hydraulic Unit ...................................................................................................................12
3. OPERATING INSTRUCTIONS ..................................................................... 15

4. MAINTENANCE ........................................................................................... 18
5. PRACTICAL TROUBLESHOOTING PROCEDURES ...................................... 19
6. HOW TO PUMP MANUALYY ....................................................................... 20
1. GENERAL INFORMATION
DU
IT
CONNECT TO
DRAINAGE
SYSTEM
1
50
MM
Hydraulic Tyre-Killer is one of the heavy duty and highest security vehicle access control
systems. The Tyre-Killer provides high security for sensitive areas (banks, military bases, airports,
embassies etc) against forced and unauthorized entry or exit of motor vehicles. Tyre-Killer works
rapidly, teeth raises from the road surfaces in a couple of seconds so tyres and rims of the
unauthorized vehicle will definitely be destroyed immediately when the entry or escape is attempted,
therefore the vehicle moves only a few more meters and is inactivated. The hardened teeth of the
Tyre-Killer move all together as they are connected on the same teeth bar. The Tyre-Killer is powered
by an hydraulic unit and operating hydraulics is installed nearby. OPTIMA hydraulic tyre killers raise
and lower its teeth fastly and smoothly. The cylinder is powered by a hydraulic pump installed in
control cabinet. Control electronics and hydraulic units are stored in a electrogalvanized metal control
cabinet adjacent to Tyre-Killer. With the help of PLC controlled electronics, raise/lower function can
be achieved by every kind of access control devices, card readers, biometric readers like fingerprint or
hand shape, radio control, on/off switch or keyswitch etc. Besides, safety accessories like loop
dedectors, photocells, flashing lights or red/green lights can be integrated to the control electronics
very easily.
HYDRAULIC HOSE CONDUIT 150 MM
DR
AIN
AG
E
CO
N
PROXIMITY SWITCH DATA CABLE CONDUIT 100 MM
3
4
CONTROL ROOM
ENTRANCE
Picture 1. General view of Tyre-Killer
1- Control Cabinet
2- Security Photocell(optional)
3- Red/Green Lights(optional)
4- Keyboard Data Cable

5- 3 Phase 380 VAC Cable
6- Hydraulic Tyre-Killer
Environmental Conditions and Power Requirement

Between -20 C and +75 C, % 95 non-condensing humidity,
380 V, 3 ph, 50~60 Hz or
220 V, 1 ph, 50~60 Hz (optional)
Optional Accesories
1.
2.
3.
4.
5.
6.
Flashing or red/green lights

Radio control receiver, transmitter and antenna
Safety photocell, stand and casing
Inductive loop dedector
Mechanical lock (Driven by 2 extra detectors and a hydraulic cylinder)
Card Reader System
7. Uninterrupted Power Supply(UPS) to raise/lower the road blocker few times in case of no
electricity.
2. SYSTEM COMPONENTS
2.1 Construction and Faundation
The Tyre-Killer is bolted into a reinforced concrete foundation and is designed to withstand 50
tons of axle load when closed. It is made of steel S235JR / RAEX 250 quality 37 at least. Main
mechanical elements forming the construction are build entirely of steel and the frame consisting of
100 mm I, U and 100x100x4 mm box beams. Splitting teeth utilized in tire killer is manufactured from
25mm steel. All steel plate components are cut using CNC controlled laser cutting machines. Teeth bar
on which the teeth are welded is attached to the frame by means of stainless steel and hardened
steel hinges, provided with bronze bearings to reduce friction and noises. The hydraulic cylinder
support brackets are alloy-bronze casting. Therefore both smooth operation and durability against
high axle loads is achieved. In case of power failure, it is possible to disarm the Tyre-Killer manually.
Parts forming the drive unit, namely, piston, piston rod, reservoir, solenoid or manual valves, etc. are
very precisely manufactured so that they can stand harsh environmental conditions. As it will generally
be installed outdoors all the parts are hot dip galvanized to thickness of 60 micrometers (60m) in
order to prevent rusting. Additionally the top plate and the teeth will be powder coated with a
thickness of at least 80 micrometers; RAL 9010 for top plates and RAL 3020 for the teeth. The
hydraulic unit cabinet is different than the tyre killer construction in order the limit the risk of injury
while carrying out maintenance activities. The tyre killer will be installed in reinforced concrete
foundation by M12 anchors.
TYRE KILLER MAIN PART
1
2
4
5
12345-
Teeth Bar Plate

Teeth
Teeth Bar
Top Plate
Frame
Tyre-Killer Dimensions (Approximate Values)
Height : 835 mm (underground+main frame height)

Width : 440 mm
Length : 2 m to 6 m in 500 mm increments
*The special hardened teeth rise 250-300 mm above the road surface when the device is
activated.
*Tyre-Killers can be installed side by side to protect extra wide openings; from 2000 to 8000
mm in width - breaks of 500 mm.
*Width of the blocking element +100 mm.
A
B
B
A
%3 SLOPE
200 PVC
SECTION A-A
SECTION B-B
Figure 4. Road Blocker Concrete Foundation View
Depth : 428 mm
Width : 1475 mm
Length : 5400
Wall thickness : 300 mm
Customer must request a layout drawing for each project from the manufacturer as dimension may
vary in every application.
2.2 Control Cabinet

IP 55 With fan cooling
Material:
2 mm thick sheet metal (electrogalvanized, RAL 7035 electrostatically(epoxy) powder coated

and furnaced) for water-resistant outdoor applications.
2.5 mm thick sheet metal (electrogalvanized, RAL 7035 electrostatically(epoxy) powder coated
and furnaced) for inside hydraulic and electric group carriages
Dimensions :
76.5 cm x 106 cm x 116 cm (Cabinet may be manufactured in different dimensions according
to requirements)
The cabinet is fitted with espagnolet fastening and half europrofile cylinder.
Picture 2. Control Cabinet Views
1- Cabinet Side Cover

2- Air Circulation Opening
3- Cabinet Front Cover
4- Open/Close Handle and Lock with Key

5- Gasket
6- Plate
2.3 Electrical and Electronics Components

Control electronics utilized in hydraulic tyre killers is PLC controlled. Raise/lower function can
be achieved by every kind of card readers, biometric readers like fingerprint or hand shape, radio
control, on/off switches or key switches etc. Besides, safety accessories like inductive loop detectors,
photocells, flashing lights or red/green lights can be integrated to control electronics very easily.
Power requirement of the hydraulic tyre killers is 380 V 50~60 Hz.
Figure 7. Cabinet Control Panel

Figure 8. Desktop Control Panel
1
Emergency Stop
Stops the operation of the tyre killers in case of emergency. If pressed,

the tyre killers is locked and no comment could be given. In order to
return to the normal mode of operation, turn the button clockwise until
the switch releases itself.
2
Auto Down
Lowers the tyre killers automatically. It is enough to push the button

ONCE in order to operate the tyre killers from Cabinet Control Panel. No
other comment could be given until the process is accomplished.
3
Auto Up
Raises the tyre killers automatically. It is enough to push the button

ONCE in order to operate the tyre killers from Cabinet Control Panel. No
other comment could be given until the process is accomplished.
4
Phase R
Shows the operation of the first phase cable of the three phases 380
VAC. If it does not light, no voltage on the first cable of the three phases
380 VAC on the terminal and maintenance is needed.
5
Phase S
Shows the operation of the second phase cable of the three phases 380
VAC. If it does not light, no voltage on the second cable of the three
phases 380 VAC on the terminal and maintenance is needed.

6
Phase T
Shows the operation of the third phase cable of the three phases 380
VAC. If it does not light, no voltage on the third cable of the three phases
380 VAC on the terminal and maintenance is needed.
7
Emergency Stop
Stops the operation of the tyre killers in case of emergency. If pressed,

the tyre killers is locked and no comment could be given. In order to
return to the normal mode of operation, turn the button clockwise until
the switch releases itself.
8
Local Enabled
Shows that current Desktop (Override/Guard House) Control Panel is in

charge for the operation of the road blocker if this light in ON.
9
Auto Up
Raises the tyre killers automatically. It is enough to push the button

ONCE in order to operate the tyre killers from Desktop (Override/Guard
House) Control Panel. No other comment could be given until the process
is accomplished.
10
Auto Down
Lowers the tyre killers automatically. It is enough to push the button

ONCE in order to operate the tyre killers from Desktop (Override/Guard
House) Control Panel. No other comment could be given until the process
is accomplished.
11
Local/Remote Switch
Depending on the priority of the Control Panel, this switch changes the
operating Control Panel. The priority is Override Desktop Panel, Guard
House Desktop Panel and Cabinet Control Panel from the most prior to
the least prior respectively.
12
Cabinet Control
Explained in the previous pages
Panel
13
Power Supply
AC/DC Converter. If the energy is supplied to the system from three

phases 220/380 VAC, this device changes the voltage to 24 VDC in order
to supply power to some of the components in the system.
14
UPS
If the energy from three phases 220/380 VAC is OFF, the UPS supply the
power needed only for the electronic components for a limited
time.
15
Terminal
Connects electric (energy) connection of the whole system.

A- 3 Phase 380 VAC input
B- Motor output
C- UPS input/output
D- Cabinet fan output
E- Cooler Fan Motor Output.
F- Solenoid valve output
G- Keyboard input
H- Proximity sensor input
I - Traffic Light output.
J - Loop antenna input
10
Figure 9. Control Cabinet Electrical Components
16
Fuses
A- For the UPS.

B- For the Telemechanic Zelio PLC Card.
17
Main Fuses
For the whole system.
18
Telemechanic Zelio PLC Card
24 VDC, Password protected, programmable software

operated PLC card user interface. 12 inputs and 8 outputs are
used. For the further additions and modifications of the
system, 4 inputs and 2 outputs is available. (Total 16 input/10
Output).
19
Relay Group
PLC output protection relays.
20
Thermic Magnetic Switch
Motor safety switch. If a problem occurs in the oil pump

inside the tyre killers, the switch becomes 0 (zero) and cuts
the energy of the oil pump motor to be available for the
maintenance.
21
Contactor
Drives the Motor
22
Loop Dedector Control Card
11
2.4 Hydraulic Components
There are two pumps in the hydraulic system: Electric motor coupled gear pump (17 cc) and
manual operated hand pump. The first one is the default used pump in the system. The hand pump is
installed in case the gear pump does not work. When the direction control valves are in tandem
positions, the oil is pumped back to the reservoir through the pressure relief valve.
The oil level in the hydraulic system could be checked with the help of the Oil Level Gauge
which must show full and oil could be added through Oil Reservoir Plug.
Figure 10. Hydraulic Group
12
1
Filter
2
Direction Control Valve (Manually by handle)
3
Pressure Relief Valve (Adjust pressure in the system)
4
Electric Motor
5
Oil Cooler Fan
6
Direction Control Valve (Solenoid Actuated)
7
Oil filter dirtiness gauge.
8
Manometer
9
Hand Pump
10
Oil Reservoir Plug (To fill the tank)
11
Tank
12
Oil Level Gauge
13
OPERATION
and
MAINTENANCE
14
3. OPERATION INSTRUCTIONS
3.1
1.
Taking the Tyre Killer Into Operation
Open the control cabinet. Meanuhile unscrew the 4 pcs of holding rings from the tyre killers top
plate.
Figure : 12/1
Figure :12/2
Figure : 12/3
Figure : 12/4
Figure : 12/5
15
2. Connect the hoses coming from the hydraulic cylinder with the hydraulic system in the
cabinet.
3. If there is a Drainage Pump in the Tyre Killer System, connect the electric power cable to
the terminal.
4. If there is a Red/Green Traffic Light in the Tyre Killer System, connect the electric power
cable of the Red/Green Traffic Light to the terminal.
5. If there is a Loop Detector in the Tyre Killer System, connect the antenna cables of the
Loop dedector to the terminal.
6. If there are Radio control receiver, transmitter and antenna in the Tyre Killer System,
connect the electric power cable of it to the terminal.
7. If there are Safety photocell, stand and casing in the Tyre Killer System, connect the
electric power and data cables of Safety Photocell to the terminal.
8. If there is a Card Reader System in the Tyre Killer System, connect the electric power and
data cables of Card Reader System to the terminal.
9. Make sure that fuses on the Cabinet Panel (Figure 9, No: 16 and 17) are ON (upward
position).
10. Make sure the emergency stop buttons on the Cabinet Control Panel and Guard House
Desktop Panel (Figure 7 No: 1; Figure 8 No: 7) are not pressed.
11. Initially, there will be no oil in the hydraulic system, therefore fill the oil reservoir with
Shell Thellus 46 or equivalent. Check oil level from the gauge (Figure 10, No: 12) on the
oil reservoir (Figure 10, No: 11). It must show full .
12. Make sure that Motor safety switch on the Cabinet Panel (Figure 9, No: 20) are ON.
13. Connect the three phase 380 VAC cables to the terminal.(Figure 9, Item 15-A)
14. Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the Cabinet
Control Panel (Figure 7, No: 4, 5, 6) are ON.
16
3.2
Operation of the Tyre Killer
Depending on the position of the Local/Remote Switch (Figure 8 No: 11) on the Override
Desktop Panel and Guard House Desktop Panel, either Override Desktop Panel or Guard House
Desktop Panel or Cabinet Control Panel could control the Tyre Killer. For each Tyre Killer, only ONE
panel could be in charge, i.e. two panels could not operate the tyre killer at the same time.
Case 1) The Guard House Desktop Control Panel is in Charge: If the Local/Remote Switch of
the.Desktop Control Panel is on the Enable position (switch is heading to the RIGHT) the
Local Enabled Light on the Guard House Desktop Control Panel becomes ON which
means that the Guard House Desktop Control Panel is in charge and Cabinet Control Panel
could not operate the Tyre Killer.
Case 2) The Cabinet Control Panel is in Charge: If the Local/Remote Switch of the Desktop
Control Panel is on the Disable position (switch is heading to the LEFT), the Cabinet Control
Panel is in charge.
For each case, the operation of the tyre killer is as follows:
Raising of the tyre killer is done automatically. In order to raise it automatically, push Auto
Up button (Figure 7 No: 3, Figure 8 No: 9) ONCE.
Lowering of the tyre killer is done automatically. In order to raise it automatically, push Auto
Down button (Figure 7 No: 2, Figure 8 No: 10) ONCE.
Unless a successive command is sent, the motor will stop in 4 seconds.
Depending on the customer desire, DEAD-MAN BUTTON could be added to the system. In
that case, in order to raise and lower the tyre killer, either automatically or manually, Guard
House Desktop Control Panel and the dead-man button MUST be pushed at the same time;
otherwise the tyre killer could not be operated from the guard house. This function is added
to the system in order to prevent the tyre killer from being operated by people other than the
guard staff in case of emergency.
Depending on the customer desire, inductive loop detector(s) could be added to the system.
These devices work on the PULSE ON EXIT or SAFETY LATCH principle, i.e. when the
vehicle leaves the loop detectors magnetic area, it sends the PLC controller a pulse in order to
inform it about the vehicles position or it sends a signal as long as there is a vehicle on the
loop antenna. According to the design of the control logic, the tyre killer could be raised and
lowered automatically even without using the desktop panels.
17
Depending on the customer desire, card reader system could be added to the system.
According to the design of the control logic, the tyre killer could be raised and lowered
automatically even without using the desktop panels with the help of the pulse sent by the
card reader system.
4. MAINTENANCE
Oil Check
Oil Used: Shell Thellus 46 or equivalent
First oil change to be made after 500 working hours, next changes to be made after every
5000 working hours.
Filters Check
Filters to be changed at every oil change.
Oil Leakage Check
System to be eye-controlled for oil leakage once in every 3 months.
Piston to be eye-controlled if there is any leakage once a year.
Pressure Check
Manometer pressure values must be checked at every leakage control to see if there is
any deviation from the values stated by the manufacturer.
Maintenance Staff
All system controls to be made by qualified technical staff only.
Only original equipment manufactured or recommended by the manufacturer to be used

at repair and/or maintenance procedures.
18
5. PRACTICAL TROUBLESHOOTING PROCEDURES
If there is no movement observed after pressing auto or manual raise/lower buttons;

Make sure the emergency stop buttons on the Cabinet Control Panel and Guard
House Desktop Panel (Figure 7 No: 1; Figure 8 No: 7) are not pressed.
Make sure that fuses on the Cabinet Panel (Figure 9, No: 17and 16) are ON (upward
position).
Make sure that Motor safety switch on the Cabinet Panel (Figure 9, No: 20) are ON.
Make sure that all three phase check lights (Phase R, Phase S, Phase T) on the
Cabinet Control Panel (Figure 7, No: 4, 5, 6) are ON.
If there are unexpected behaviors in system, quickly stop the system by pressing one of
the emergency stop buttons on the Cabinet Control Panel, Override Desktop Panel and
Guard House Desktop Panel (Figure 7 No: 1; Figure 8 No: 7).
In case of power failure, tyre killer could ONLY be controlled by the cabinet control panel
due to the battery in the cabinet supplies the needed power for the electronics and in
case of the battery power shortage, the hand pump is used to raise/lower the road
blocker manually.
19
6. HOW TO PUMP MANUALLY

Insert manual pump arm into the slot and pump manually (Figure 13).
Figure 13. Manual Pumping
If the system is not still running after all these controls, please contact with the
manufacturer.
20
DECLARATION OF CONFORMITY FOR MACHINES

(DIRECTIVE 98 / 37 EEC, ATTACHMENT II , PART B)
Manufacturer:
OPTMA MHENDSLK LMTED RKET

KERESTECLER SANAY STES
3. CADDE NO:8 SARAY 06980
KAZAN / ANKARA/ TRKYE
Declares that the products,
V 100, V 200, V 300, V 400, V 500 Series Tripod Turnstiles

M 100 Series Motorized Turnstiles
F 100 Series Full-Height Turnstiles
HH100 Series Half-Height Turnstiles
SWG200 Series Swing Gate Turnstiles
HTK SERIES HYDRAULIC TYRE KILLERS
are constructed to be incorporated in a machine or to be assembled with other

machinery to construct a machine considered modified by the directive 98 / 37 EEC
are in confirmity with the regulations of the following EEC directives.
Directive 98 / 37 EEC directive for machines

Directive 73 / 23 EEC and directive 93 / 68 EEC low voltage
Directive 89 / 336 EEC and directive 92 / 31 EEC and directive 93 / 68 EEC
electromagnetic compatibility.
And also are in confirmity with the following national standards.

-
TS EN 292-1
/ January 1996 Standard
TS EN 292-2
/ January 1996 Standard
TS EN 563
/ April 1997 Standard
TS EN 418
/ November 1995 Standard
TS EN 60204-3-1 / December 1995 Standard
TS EN 50082-1
/ April 1995 Standard
TS EN 50082-2
/ February 1998 Standard
TS EN 60000-4-2 / April 1997 Standard
4 April 2001
Ankara
TURKEY
smail Tamer LGEN

President
Mechanical Engineer, B. Sc.

Hydraulic Tyre Killers

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ISO 9001: 2008

EN ISO 14001: 2004

3. OPERATING INSTRUCTIONS ..................................................................... 15

HYDRAULIC HOSE CONDUIT 150 MM

PROXIMITY SWITCH DATA CABLE CONDUIT 100 MM

Picture 1. General view of Tyre-Killer

4- Keyboard Data Cable

Environmental Conditions and Power Requirement

Flashing or red/green lights

TYRE KILLER MAIN PART

Teeth Bar Plate

Tyre-Killer Dimensions (Approximate Values)

Height : 835 mm (underground+main frame height)

Figure 4. Road Blocker Concrete Foundation View

2.2 Control Cabinet

2 mm thick sheet metal (electrogalvanized, RAL 7035 electrostatically(epoxy) powder coated

Picture 2. Control Cabinet Views

1- Cabinet Side Cover

4- Open/Close Handle and Lock with Key

2.3 Electrical and Electronics Components

Figure 7. Cabinet Control Panel

Stops the operation of the tyre killers in case of emergency. If pressed,

Lowers the tyre killers automatically. It is enough to push the button

Raises the tyre killers automatically. It is enough to push the button

phases 380 VAC on the terminal and maintenance is needed.

Stops the operation of the tyre killers in case of emergency. If pressed,

Shows that current Desktop (Override/Guard House) Control Panel is in

Raises the tyre killers automatically. It is enough to push the button

Lowers the tyre killers automatically. It is enough to push the button

Explained in the previous pages

AC/DC Converter. If the energy is supplied to the system from three

Connects electric (energy) connection of the whole system.

Figure 9. Control Cabinet Electrical Components

A- For the UPS.

For the whole system.

Telemechanic Zelio PLC Card

24 VDC, Password protected, programmable software

PLC output protection relays.

Thermic Magnetic Switch

Motor safety switch. If a problem occurs in the oil pump

Drives the Motor

Loop Dedector Control Card

2.4 Hydraulic Components

Figure 10. Hydraulic Group

Direction Control Valve (Manually by handle)

Pressure Relief Valve (Adjust pressure in the system)

Oil Cooler Fan

Direction Control Valve (Solenoid Actuated)

Oil filter dirtiness gauge.

Oil Reservoir Plug (To fill the tank)

Oil Level Gauge

Taking the Tyre Killer Into Operation

Operation of the Tyre Killer

For each case, the operation of the tyre killer is as follows:

Unless a successive command is sent, the motor will stop in 4 seconds.

Oil Used: Shell Thellus 46 or equivalent

Filters to be changed at every oil change.

Oil Leakage Check

System to be eye-controlled for oil leakage once in every 3 months.

Piston to be eye-controlled if there is any leakage once a year.

All system controls to be made by qualified technical staff only.

Only original equipment manufactured or recommended by the manufacturer to be used

5. PRACTICAL TROUBLESHOOTING PROCEDURES