Appendix B - K12 Operation and Maintenance Manual.pdf

SENTINEL

OPERATION AND

MAINTENANCE MANUAL

402 McKinney Parkway, Lillington NC 27546 Phone: (910) 814-5200 Fax: (910) 814-5299

SENTINEL 1

ATG Access Inc. Version : 03/2009 402 McKinney Parkway, Lillington, NC 27546

(910) 814 5200, Fax: (910) 814 5299 www.atgaccessinc.com

1 PREFACE

WARNING

Improper use of this equipment constitutes negligence and may result in serious injury or death.

CAUTION

Warranty requires that the operation and maintenance requirements and instructions described in this manual be followed and records of all maintenance activities be kept.

Records should be available upon request and may be required for warranty claims.

Failure to operate and maintain the equipment constitutes improper use and may void the warranty. Failed components and/or damaged parts requiring warranty service must be returned to ATG Access Inc. as requested.

ATG Access Inc. reserves the right to change and update the information and specifications contained within this manual at any time without notice.

No part of this document may be used or reproduced in any form or by any means, or stored in a database or retrieval system, without prior written permission of ATG Access Inc. Copying or directly reproducing any part of this manual for any purpose other than the original owner’s or purchaser’s use is a violation of United States copyright laws. For more information and assistance in obtaining additional copies of this manual, contact ATG Access Inc.

Manufacturing site:

ATG Access Inc.

402 McKinney Parkway, Lillington, NC 27546,

(910) 814 3800, Fax: (910) 814 3899.

Copyright

This manual has been written and published by ATG Access Inc. It is provided to customers, engineers and dealers of ATG Access Inc.. All rights reserved. The information contained in this manual is the property of ATG Access Inc. Transferring this information to third parties without prior consent of ATG Access Inc. is prohibited.

Operation and Maintenance Manual 2

Version : 03/2009

TABLE OF CONTENTS

1 PREFACE

2 SAFETY WARNINGS AND CAUTIONS

2.1 SAFETY WARNING AND CAUTION OVERVIEW

2.2 MAINTENANCE, SERVICE AND REPAIR WARNINGS

2.3 PEDESTRIAN AND PERSONNEL SAFETY WARNINGS

2.4 VEHICLE SAFETY WARNINGS

2.5 INTRUSION INCIDENT DAMAGE CAUTION

2.6 GENERAL SAFETY PRECAUTIONS

2.6.1 High Voltage Electrical Supply

2.6.2 Do Not Service or Adjust Alone

2.6.3 Equipment Lock-Out/Tag-Out

2.6.4 Hydraulic Fluid Health Hazard

2.6.5 Use of Fluids and Lubricants

2.6.6 Hydraulic Fluid Leakage and Spills

2.6.7 Hydraulic Fluid and Filter Element Disposal

2.6.8 High Pressure Hydraulic Lines

2.6.9 High Pressure Gases

2.6.10 Lifting and Handling Heavy Objects

2.6.11 Hot Surfaces

2.6.12 Enclosure Doors, Covers and Guards

2.6.13 Barrier System Set-up

2.6.14 Barrier System Operation and Testing

2.7 WORKING UNDER EQUIPMENT WARNINGS

2.8 ELECTRICAL SAFETY WARNINGS

2.9 HYDRAULIC SAFETY WARNINGS

2.10 HYDRAULIC SYSTEM RELATED CAUTIONS

2.11 ACCUMULATOR RELATED SAFETY WARNINGS

2.12 HYDRAULIC POWER UNIT (HPU) RELATED CAUTIONS

2.13 ELECTRONIC EQUIPMENT CAUTIONS

2.14 COLD WEATHER CAUTIONS

2.15 VEHICLE SPEED CAUTIONS

2.16 OWNER/OPERATOR RESPONSIBILITIES

3 OVERVIEW AND GENERAL DESCRIPTION

3.1 BARRIER SYSTEM OVERVIEW

3.1.1 Barrier System Options

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3.1.2 Sentinel Series Vehicle Barriers

3.1.3 Hydraulic Power Unit (HPU)

3.1.4 HPU Exterior Enclosure (Optional)

3.1.5 Interconnecting Hydraulic Lines

3.1.6 Electrical Enclosure

3.1.7 Master Operator Control Panel

3.1.8 Remote Operator Control Panel (Optional)

3.1.9 Interconnecting Electrical Conduits and Wiring

3.2 EQUIPMENT CHARACTERISTICS

3.2.1 Vehicle Barrier Characteristics

3.2.2 HPU Characteristics

4 THEORY OF OPERATION

4.1 HYDRAULIC CIRCUIT DETAILS

4.1.1 HPU Circuit

4.1.2 Manual Valve States

4.1.3 Emergency Fast Operate Hydraulic Circuit (Optional)

4.1.4 Barrier Cylinder

4.2 ELECTRICAL AND CONTROL CIRCUIT DETAILS

4.2.1 Operator Control Panel Control Circuit Details

4.2.2 Electrical Enclosure Circuits

4.2.3 Vehicle Detector Loop Circuits (Optional)

4.2.4 Traffic Light Circuits (Optional)

5 OPERATING INSTRUCTIONS

5.1 GENERAL OPERATING CONSIDERATIONS

5.2 SAFE-STATE (DE-ENERGIZED) CONDITION

5.3 START-UP AND PREPARATION FOR OPERATION

5.3.1 Pre-Op for Vehicle Barrier

5.3.2 Pre-Op Check for the HPU and Electrcial Enclosure

5.3.3 Pre-Op Check for the Master Operator Control Panel

5.3.4 Pre-Op Check for the Remote Operator Control Panel

5.4 BARRIER SYSTEM OPERATION

5.4.1 Emergency STOP

5.4.2 Raising a Barrier

5.4.3 Lowering a Barrier

5.4.4 Emergency Fast Operate (EFO)

5.4.5 EFO Reset

5.4.6 Arming and Unarming Operator Control Panels

5.5 NORMAL SHUT-DOWN

5.6 AUTOMATIC FAULT SHUT-DOWNS

5.7 MANUAL OVERRIDE OPERATION

5.7.1 Valve Override

5.7.2 Hand Pump Operation

6 MAINTENANCE INSTRUCTIONS

6.1 GENERAL

6.2 MAINTENANCE RESPONSIBILITY

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6.3 MAINTENANCE DATA SHEETS AND RECORDS

6.4 TOOLS AND SUPPORT EQUIPMENT

6.4.1 Standard Tools

6.4.2 Support Equipment

6.4.3 Overhaul Tools

6.5 SERVICE SUPPLIES

6.6 SPARE PARTS

6.7 MAINTENANCE AND INSPECTION INTERVALS

6.8 INSPECTION REQUIREMENTS

6.9 HYDRAULIC MAINTENANCE REQUIREMENTS

6.9.1 Hydraulic Cleanliness

6.9.2 Hydraulic Fluid Filling

6.9.3 Accumulator Gas Pre-Charging

6.9.4 Hydraulic Fluid Cleanliness Requirements

6.10 COMPONENT ADJUSTMENT

6.10.1 Adjustable Component Set-Points

6.10.2 Low Pressure Switch Adjustment

6.10.3 Dual Pump Pressure Switch Adjustment (Optional)

6.10.4 High Pressure Switch Adjustment

6.10.5 Safety Relief Valve Pressure Adjustment

6.10.6 Meter Out Flow Control Valve Adjustment

6.10.7 Meter In Flow Control Valve Adjustment

6.10.8 EFO Needle Valve Adjustment (Optional)

6.10.9 Non-Adjustable Components (Reference Only)

6.11 TOUCH-UP PAINTING

6.12 PREPARATION FOR DISASSEMBLY

6.13 REMOVING COMPONENTS AND ASSEMBLIES

6.14 GENERAL OVERHAUL INSTRUCTIONS

6.15 HOSE REPLACEMENT

6.16 SEAL REPLACEMENT

6.17 REASSEMBLING COMPONENTS AND ASSEMBLIES

6.18 POST MAINTENANCE, SERVICE AND REPAIR CHECK-OUT

7 TROUBLESHOOTING

7.1 BARRIER OPERATION

7.2 ELECTRICAL CIRCUITS

7.3 HYDRAULIC CIRCUIT

8 REFERENCE INFORMATION

8.1 ABBREVIATIONS AND ACRONYMS

8.2 TORQUE VALUES FOR FASTENERS

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8.2.1 SAE Grade 8

8.2.2 Metric Grade 8.8

8.2.3 Metric Grade 10.9

8.3 TORQUE VALUES FOR FITTINGS AND PLUGS

8.3.1 SAE Straight Thread O-Ring Boss Fittings

8.3.2 Tubing Nut, Hose & Adapter Fittings

8.3.3 Internal (Allen) Hex Plugs

8.3.4 Hex Head Plugs

8.4 TORQUE VALUES FOR SUBPLATE COMPONENT BOLTS

8.5 HYDRAULIC FLUID PROPERTIES

8.5.1 Citgo Aquamarine Hydraulic Fluid Properties

TABLES

Table 1, Vehicle Barrier Characteristics 24 Table 2, HPU Characteristics 25 Table 3, HPU Operating Environment and Limitations 26 Table 4, HPU Storage Environment and Limitations 27 Table 5, Manual Valve States 33 Table 6, Maintenance and Inspection Intervals 55 Table 7, Sentinel Accumulator Gas Pre-Charge Pressures (PSIG) 62 Table 8, Sentinel Accumulator Gas Pre-Charge Pressures (kPa) 63 Table 9, Adjustable Component Set-points 67 Table 10, Non-Adjustable Component Set-points 76 Table 11, Barrier Operation Troubleshooting 83 Table 12, Electrical Circuit Troubleshooting 87 Table 13, Hydraulic Circuit Troubleshooting 93 Table 14, SAE Grade 5 Torque Values 103 Table 15, SAE Grade 8 Torque Values 104 Table 16, Metric Grade 8.8 Torque Values 105 Table 17, Metric Grade 10.9 Torque Values 106 Table 18, SAE Straight Thread O-Ring Boss Fitting Torque Values 107 Table 19, Tubing Nut, Hose & Adapter Fitting Torque Values 108 Table 20, Internal (Allen) Hex Plug Torque Values 109 Table 21, Hex Head Plugs Torque Values 110 Table 22, Citgo Aquamarine Hydraulic Fluid Properties 111

Operation and Maintenance Manual 6

2 SAFETY WARNINGS AND CAUTIONS

2.1 SAFETY WARNING AND CAUTION OVERVIEW

Safety precautions must be observed at all times, during operating, maintaining, servicing and/or repairing of the equipment. Additional warnings and cautions may be provided throughout this manual and will immediately precede the text or procedural step to which they apply. Failure to strictly adhere to these safety precautions may result in injury to personnel and/or damage to the equipment.

Observance of all safety precautions is mandatory. All personnel associated with the operation and maintenance of this equipment must be familiar with the system.

To ensure safety, and to prevent damage to equipment, all of the safety devices within this system must be properly maintained.

Because the following safety precautions apply to normal operating conditions, supervisors or others in authority may find it necessary to issue supplementary or special precautions in order to cover local conditions and/or unusual circumstances.

Furthermore, if in the opinion of the supervisor such conditions still renders the equipment unsafe, none of these safety precautions are to be construed as an authorization for work to proceed nor for further operation of the system.

Attention must be directed to all Caution and WARNING notices that may appear throughout this manual.

WARNING notices are used to protect personnel. Failure to comply may result in severe injury or even loss of life.

Caution notices are used to warn personnel in regards to protecting the Barrier System equipment. Failure to comply may result in damage to equipment or the Barrier System.

2.2 MAINTENANCE, SERVICE AND REPAIR WARNINGS

Operators must not maintenance, service, repair and/or adjust barrier equipment. In the event that maintenance, service, repair and/or adjustment is required, or if the equipment is malfunctioning and/or non-operational, these activities must be performed by a trained and qualified Service Technician.

If a local Service Technician is not available, contact ATG Access Inc. Inc. for on-site support.

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2.3 PEDESTRIAN AND PERSONNEL SAFETY WARNINGS

The Operator and/or Service Technician is responsible for the safe operation of barrier equipment at all times.

Do not operate barrier equipment when pedestrians or personnel are in close proximity to the equipment, and especially if standing on the equipment. Serious injury or even death may result. Operation includes both raising and lowering of the barrier equipment.

The Operator and/or Service Technician must be particularly careful when using the Emergency Fast Operation (EFO) feature, when provided. Barriers move at very fast, forceful speeds which can cause serious injury or even death. Each site must have a clearly defined policy on when, and under which circumstances this feature can or should be used. Each Operator must be trained and understand the consequences of using the EFO feature.

When lowering Sentinel Series equipment, numerous pinch and shear points are present. Ensure that all pedestrians and personnel are away from the equipment to prevent serious injury or even death.

2.4 VEHICLE SAFETY WARNINGS

The Operator and/or Service Technician is responsible for the safe operation of barrier equipment at all times.

Do not operate barrier equipment when there is normal oncoming vehicle traffic, and especially if a vehicle is on, or directly over or under the equipment. Vehicle occupants may sustain serious injury or even death if a vehicle crashes into or impacts the barrier at any speed. In addition, substantial damage can occur to any vehicle striking the barrier equipment, or if the barrier equipment raises up into the vehicle, or lowered down onto the vehicle.

The Operator and/or Service Technician must be particularly careful when using the Emergency Fast Operation (EFO) feature, when provided. Barriers move at very fast, forceful speeds which can cause serious injury or even death, or substantial vehicle damage. Each site must have a clearly defined policy on when, and under which circumstances this feature can or should be used. Each Operator must be trained and understand the consequences of using the EFO feature.

When raising Sentinel Series equipment, substantial lifting forces are present.

Ensure that no vehicle is on and/or over the barrier equipment when the barrier is raised. Substantial damage can occur to the vehicle.

2.5 INTRUSION INCIDENT DAMAGE CAUTION

Barrier equipment is intended to be deployed under site-defined circumstances to prevent vehicle intrusion and/or prevent a deliberate attack.

In some incidents, vehicles may crash into or impact the barrier equipment.

Depending on the speed and weight of the vehicle, the barrier equipment may sustain any where from little to severe damage. In some instances, the barrier equipment may be destroyed, or so badly damaged that it is rendered completely inoperable after a intrusion incident.

Operation and Maintenance Manual 8

ATG Access Inc. Inc. recommends that barrier equipment be thoroughly inspected by a trained and qualified Service Technician before attempting reset of the equipment after an intrusion incident, especially if visible damage is apparent.

Under certain emergency situations relating to the incident (such as needing the traffic lane open for emergency response vehicles), it may be necessary to attempt a reset before the barrier equipment can be inspected. Any vehicle wreckage should be completely cleared off of the barrier equipment prior to attempting reset of the equipment. Then ensure that all personnel are completely away from the equipment and at a safe distance while attempting the reset.

Do not continue to operate the barrier equipment after an intrusion incident, until the barrier equipment has been thoroughly inspected and determined safe for operation.

2.6 GENERAL SAFETY PRECAUTIONS

The following are general safety precautions that may not be related to any specific procedure, but should be adhered to when operating, maintaining, servicing and/or repairing the equipment. All applicable safety precautions relative to the equipment supported by this manual must be adhered to prevent accidental injury to the Operator and/or the and/or Service Technician. These are the minimum precautions that personnel must understand and apply at all times.

2.6.1 High Voltage Electrical Supply

Personnel must observe all safety regulations at all times. Do not replace components nor make mechanical adjustments with electrical power turned on. To avoid injury to personnel, always remove electrical power and then use test equipment to confirm that an electrical circuit is at ground potential or zero volts before performing maintenance, service and/or repair.

2.6.2 Do Not Service or Adjust Alone

Under no circumstances shall any person perform potentially dangerous maintenance, service and/or repair tasks, except in the presence of someone who is capable of rendering aid.

2.6.3 Equipment Lock-Out/Tag-Out

Prior to performing maintenance, service and/or repair on the equipment, ensure that the system has been properly locked-out and tagged-out at the Facility.

Lockout shall include the blocking the flow of energy from a power source to the equipment. Power sources on the Barrier System include, but are not limited to:

Electrical Power

High Pressure Gases

Pressurized Fluid, including accumulators

Vessels and/or Lines Containing Pressurized Fluid

Thermal Power

Gravity and/or External Loads

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Lockout must be accomplished by installing a lockable device, such as a padlock, at the energy source, so that equipment cannot be powered-up, started, moved and/or operated. The lock and key must be controlled, and assigned to authorized personnel.

Tag-out shall include the placing of an identification tag on the power source, preferably directly on the lockout. The tag must indicate a warning not to restore power and clearly indicate Do Not Operate Equipment. Identification of the person and/or group applying the tag-out is highly recommended.

Both the lock-out and tag-out must be strong enough to prevent unauthorized removal, and to withstand the environment in which it is applied, without damage.

Personnel performing the lockout and tag-out of equipment must know how to properly shutdown the equipment, isolate the equipment, and locate and apply lock-out/tag-out devices. Personnel must also know how to safely release any stored energy, properly check and ensure that all energy and power has been removed, such that a safe state exists for maintenance and/or service activities. Upon completion of maintenance or service, the service personnel must know how to remove lock-out/tag-out devices, properly and safely re-apply energy and power sources, check and ensure that equipment is clear and ready to safely run and then finally safely start-up the equipment.

2.6.4 Hydraulic Fluid Health Hazard

Prolonged contact with hydraulic fluid may be injurious to health. If clothing becomes soaked in hydraulic fluid, personnel should wash thoroughly with soap and water and change immediately into dry clothing. Oil-soaked clothing must be decontaminated or properly disposed of.

2.6.5 Use of Fluids and Lubricants

Observe all cautions and warnings on containers when using consumables, such as hydraulic fluid, lubricants and cleaning solvents. When applicable, wear necessary protective gear during handling and use. Cleaning solvents may affect the skin, eyes and respiratory tract. Use only in a well ventilated area. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact.

If a consumable is flammable, make certain the consumable and its vapors are kept away from heat, spark and/or flame. Make certain equipment is properly grounded and suitable fire-fighting equipment is readily available prior to use.

For additional information on toxicity, flash-point and flammability of chemicals, refer to Material Safety Data Sheets (MSDS).

2.6.6 Hydraulic Fluid Leakage and Spills

Hydraulic fluids and lubricants are a potential fire hazard and an environmental concern. Know the location and proper use of fire extinguishers. Know the location and proper use of spill containment and absorbent materials.

Hydraulic fluids and lubricants on surfaces will be slippery and may cause personnel to fall. Avoid breathing vapors from hydraulic fluids, and wear appropriate respiratory (breathing) protection during clean-up when vapors are present. Clean up hydraulic fluid and lubricant leakage or spills immediately. Investigate and correct all causes of leakage.

Operation and Maintenance Manual 10

Prior to servicing and disconnecting hydraulic components and/or lines, place proper waste containers and oil absorbent materials to catch any spills.

2.6.7 Hydraulic Fluid and Filter Element Disposal

Used or contaminated hydraulic fluid must be disposed of properly as a waste material or recycled. Do not dump hydraulic fluid on the ground or down sewers. In addition, dispose of used filter elements and/or materials used to absorb spills properly.

2.6.8 High Pressure Hydraulic Lines

Hydraulic fluid under high pressure is used to operate the equipment. To avoid injury to personnel, always ensure that system hydraulic pressure is removed and at zero pressure before performing maintenance, service and/or repair tasks on the equipment.

Always wear appropriate eye protection when the hydraulic system is operating.

To avoid personal injury and prevent connection rupture, do not tighten hydraulic fittings or components when under pressure. Remove hydraulic pressure before tightening or torqueing connections and/or components.

Refer also to the HYDRAULIC SAFETY WARNINGS section 2.9. for additional precautions and details.

2.6.9 High Pressure Gases

High pressure gases are very hazardous if not contained. Use approved personal protective equipment, such as goggles or face shields when using compressed gases. Protect yourself from flying particles. Do not direct any gas stream toward yourself or other personnel.

Refer also to the ACCUMULATOR RELATED SAFETY WARNINGS section 2.11. for additional precautions and details.

2.6.10 Lifting and Handling Heavy Objects

The equipment, elements and components may include heavy items. Ensure lifting slings and hoist equipment have proper load ratings prior to use. To prevent personal injury, do not attempt to lift heavy equipment without using lifting devices.

Do not use chain to lift heavy equipment, use wire rope or braided slings.

In addition, to prevent personal injury, wear thick leather gloves when handling wire rope, wire rope slings or crane lines.

2.6.11 Hot Surfaces

To prevent personal injury or burns, do not handle or touch hot parts with bare hands or exposed skin. Use thermal insulated or thick leather gloves when handling hot equipment and components, —or— allow the equipment to cool-down prior to performing maintenance, service and/or repair on the equipment.

Be careful and pay particular attention for hot parts after an over-load or over-temperature shutdown condition occurs.

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When provided, a Hydraulic Power Unit heat exchanger cooler may be hot. To avoid personal injury or burns, avoid handling or touching the heat exchanger when hot.

On some equipment operating in cold temperatures, the equipment may be equipped with heaters which can be hot. To avoid personal injury or burns, avoid handling or touching heating elements when hot.

2.6.12 Enclosure Doors, Covers and Guards

Secure enclosure doors, component covers and equipment guards immediately after completion of maintenance, service, repair and/or adjustment. Do not operate equipment with enclosure doors open, or component covers or equipment guards removed.

2.6.13 Barrier System Set-up

Ensure the Barrier System, Hydraulic Power Unit and Operator Control Panels are properly mounted and secured prior to operating the equipment. Ensure mounting bolts, fasteners, hardware and related accessories are properly rated for the intended operation.

For the Barrier Systems, ensure that no binding or misalignment occurs. When possible, start and operate Barriers at low pressures and at slower speeds during initial commissioning and/or after major service or repair, to ensure proper operation of the Barrier System.

Ensure all electrical and signal cables are connected properly, as required. Do not attempt to hook-up electrical connections to the Barrier System equipment with power applied. High voltage electrical shock could cause injury or even death.

Ensure all power wiring and conduits are properly secured, especially against vibration.

Ensure all hydraulic lines are properly connected and leak-free prior to Barrier equipment operation.

Ensure all tools, loose articles, lifting devices, and other items are clear of the Hydraulic Power Unit prior to operation.

2.6.14 Barrier System Operation and Testing

Operators and/or Service Technicians must be trained, qualified and familiar with all operational characteristics of the Barrier System equipment, including the functions and operation of the Hydraulic Power Unit and Operator Control Panel Controls.

Ensure all ATG Access Inc. Inc. procedures are followed and in the proper sequence.

Do not operate Barriers Systems above rated capacity (such as at excessive speeds or pressures), or during improper environmental conditions (such as extreme hot or cold temperatures).

All personnel must stand clear of Barrier equipment during operation and/or testing.

2.7 WORKING UNDER EQUIPMENT WARNINGS

WARNING

When working under Barrier equipment, always ensure that raised equipment is secured and that no movement can occur. Use of approved mechanical lock bars

Operation and Maintenance Manual 12

(Safety bar) is mandatory prior to performing any maintenance, service, repair and/or adjustments.

For the Sentinel Series equipment, never crawl under a raised unit, nor allow any body parts between the top and side plates unless the equipment is properly secured against movement.

Never perform work under equipment until the equipment has been locked-out and tagged-out, and the Accumulator is at zero pressure.

Never disconnect or attempt to service, repair and/or adjust the barrier cylinder unless the equipment is properly secured against movement.

As with any mechanical and construction related work, always wear a hard hat during maintenance, service, repair and/or adjustments.

2.8 ELECTRICAL SAFETY WARNINGS

WARNING

Electrical shock can result in serious injury or death. Ensure all electrical power is disconnected from the equipment prior to servicing.

Ensure that the following safety practices are observed when working with electrical equipment:

Personnel must be fully informed of the hazards and dangers of electrical work.

Only trained and qualified personnel should perform electrical work.

Do not tamper with any electrical interlocks or safety devices.

Do not alter, disable, or bypass system safety devices.

Turn off all electrical circuits at the main electrical disconnect before working on any electrical circuit. Place warning tags and lockouts on open circuits and disconnect devices to prevent accidental application of power during maintenance, service and/or repair procedures.

Wear suitable clothing while working within four feet of exposed electrical equipment.

Do not wear rings, wristwatches or clothing with exposed metal buttons, zippers or fasteners.

Avoid working on electrical circuits near water or when wet conditions exist.

2.9 HYDRAULIC SAFETY WARNINGS

Hydraulic pressure can result in serious injury or death.

When dealing and working with hydraulic equipment, ensure that the following safety practices are observed:

Always verify that line pressure is zero before disconnecting hydraulic lines.

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Always block and restrain equipment, prior to disconnecting the hydraulic cylinder or lines.

Never tighten leaking connections or fitting while lines are pressurized.

Failure to comply may rupture the line and cause personal injury.

Suitable clothing, eye glasses and ear protectors must be worn at all times when operating or troubleshooting hydraulic systems.

Escaping fluid under pressure can penetrate skin causing serious injury.

Relieve pressure before disconnecting hydraulic components or lines. Use eye protection and leather gloves when checking for leaks. Use a piece of paper around suspected areas to assist in searching for leaks. Especially keep hands and body away from pinhole leaks, which eject fluids under high pressure. If for any reason fluid is injected into the skin or punctures the skin, it must be surgically removed immediately within a few hours by a doctor to prevent blood poisoning.

2.10 HYDRAULIC SYSTEM RELATED CAUTIONS

Caution Improper servicing of hydraulic equipment can damage the equipment.

When servicing hydraulic equipment, ensure that the following methods and practices are observed:

To ensure proper operation of the hydraulic circuits and also for long term, reliable operation, ensure all forms of contaminants are prevented from entering the hydraulic circuits, including, but not limited to dust, dirt, metal shavings, water and moisture.

To prevent lint or other contaminants from entering the hydraulic circuits, do not use common shop rags nor paper towels on the hydraulic circuits or hydraulic components. Loose fibers and lint can contaminate the hydraulic circuits. Use only special lint-free wipes. Also ensure absolute cleanliness when servicing, repairing and/or maintaining the hydraulic circuits, especially during filter element change-out, filling and bleeding of the hydraulic circuits.

Particles and contamination can be induced into the hydraulic circuits when changing a filter element or replacing a component. Contamination can cause hydraulic circuits malfunctions, failures and reduce component life.

Use care when changing filter elements to ensure the hydraulic circuits remains clean when ―open‖. Do not change filter elements when dust or sand is visible in the air or wind.

To prevent erratic and uncontrolled movement of the hydraulic cylinder, ensure that all air is bled from the hydraulic circuit components and lines after maintenance, service and/or repair.

Do not lay new or unprotected components on the decking or the ground.

Layout components on lint-free wipes. Avoid touching ―internal‖ surfaces with dirty hands or contacting other objects before installation.

To prevent contamination of hydraulic circuits, properly dispose or recycle hydraulic fluid drained from hydraulic circuits. Do not return the hydraulic fluid to the HPU reservoir. Always use new filter elements and do not attempt to clean filter elements.

Operation and Maintenance Manual 14

To avoid damaging components and/or manifolds, do not over-tighten pipe thread connections.

When performing work on or around the extended hydraulic cylinder, protect the rod surfaces to avoid damage to the sealing surface.

2.11 ACCUMULATOR RELATED SAFETY WARNINGS

Observe the following precautions when working on hydro-pneumatic accumulators and/or related hydraulic circuits. The correct procedures for maintenance are provided in detail under the ACCUMULATOR GAS PRE-CHARGING section 6.9.3.

High pressure gases and/or pressurized fluid can result in serious injury or death.

When dealing with hydraulic circuits utilizing accumulators, ensure that the following safety practices are observed:

Ensure that the accumulator fluid side is discharged and bled-down to near zero pressure prior to performing any maintenance, service and/or repair.

Ensure that all pre-charge gas is discharged and bled-down to near zero pressure prior to performing any disassembly and/or repair on the accumulator.

WARNING Never fill an accumulator with oxygen! An explosion and/or fire may result if oil and oxygen are mixed under pressure.

Never fill an accumulator with air. When air is compressed, water vapor in the air condenses and can cause rust. Rust on the accumulator bore may damage seals, cause excessive gas leakage and ruin the accumulator. In addition, if air leaks into the hydraulic fluid, the fluid may become oxidized and break down.

Always fill an accumulator or gas bottle with inert, dry nitrogen gas.

Commercial grade nitrogen gas is free of both water vapor and oxygen which makes it harmless to parts and safe for use.

Use an accumulator gas pre-charge kit for gas charging the accumulator.

Before using, become completely familiar on how to use the adapter in the kit and all safety precautions of this section.

Do not stand up gas charging cylinders, nor allow gas cylinders to be unrestrained. If the gas bottle falls over the valve may break off and cause the gas cylinder to act like a missile as high pressure gas escapes. Always lay gas cylinders down and/or secure gas cylinders in use and especially during transportation.

Never pre-charge an accumulator to a pressure more than that recommended by the manufacturer. Only charge the accumulator to the pre-charge pressure specified. Gas expands at higher temperatures and will cause higher pressures in a contained vessel. Measure the ambient air temperature prior to charging an accumulator and before selecting a gas pre-charge pressure.

Never charge an accumulator while the HPU is running or when hydraulic pressure is present. Release all hydraulic fluid pressure before charging.

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Failure to release pressure is dangerous and also a true gas charge pressure reading cannot be obtained.

When venting or discharging gas from accumulators or gas bottles, wear eye protection, such as goggles or face shields. Protect yourself from flying particles. Do not direct any gas stream toward yourself or other personnel.

Do not allow gas to escape fast, as the expanding gas may freeze up the gas valve and may not allow all pressure to be fully and completely discharged.

Before removing an accumulator or gas bottle from the hydraulic circuit, discharge all hydraulic and gas pressures.

Before you lift or transport an accumulator for removal from the hydraulic circuit, re-check that there is no (zero) gas pressure.

Unless removal is impractical, do not field service accumulators, accumulator seals and/or accumulator bladders. Remove and replace the accumulator and send the entire accumulator back to the factory for repairs whenever possible.

Do not allow high pressure gas fittings to become loose during maintenance and charging procedures, especially at the nitrogen gas fill valve and at the charging gas cylinder regulator.

During gas charging, to avoid damage to the charging gas regulator and to prevent inadvertent over-pressurization of the accumulator, do not open the gas cylinder shutoff valve with the regulator screwed in. Always back out the regulator before opening the gas cylinder shutoff valve.

Always replace protective gas caps on the gas charging valve. Dust and dirt can be injected into the accumulator during the next maintenance charging which may damage seals and cause the accumulator to fail. Use extreme caution and wear eye protection if a charging valve or charging accessory needs to be cleaned of dust, dirt or other contamination.

Never disconnect any hydraulic fitting, connection, valve or other hydraulic component before discharging the hydraulic pressure from all accumulators.

Accumulators can generate very high, nearly instantaneous flow rates.

2.12 HYDRAULIC POWER UNIT (HPU) RELATED CAUTIONS

Caution Improper servicing of the HPU can damage the equipment.

When servicing a HPU, ensure that the following methods and practices are observed:

To avoid damage to the hydraulic pump, do not start or operate the HPU until the hydraulic fluid temperature is above 50°F (10°C) —or— as specified by the limits established by the pump manufacturer.

If the hydraulic fluid is cold, the HPU should go through a warm-up cycle.

Apply power to the HPU and allow it to run idle until the fluid reaches operating temperature, prior to operating any hydraulic cylinders.

To ensure fluid levels are correct in the HPU reservoir, do not fill the reservoir while the HPU is running, especially since the hydraulic circuit is equipped with accumulators.

To prevent damage to the hydraulic pumps, do not allow the fluid level in the reservoir to fall to a level which would allow air to be drawn into the pump suction inlet or run dry.

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To avoid damage to the electric pump motor, do not operate the motor in a thermal overload condition nor bypass the overload protection circuitry.

For HPUs that are equipped with an air-to-oil heat exchanger or cooler (option), the heat exchanger/cooler has thin metal cooling fins which must remain separated for air flow through the heat exchanger to ensure proper hydraulic circuit cooling. Avoid damage to the heat exchanger cooling fins, and also avoid contact with the fins to prevent crushing and puncturing of the tubes.

For HPUs that are equipped with an air-to-oil heat exchanger or cooler (option), to prevent hydraulic circuit over-heating, ensure that the heat exchanger cooling fins are free of dirt and debris. Clean fins if required.

On units with thermal insulation and/or noise abatement insulation (option), oil soaked insulation constitutes a potential fire hazard. If the insulation becomes soaked with oil due to a hydraulic leak, replace the insulation.

2.13 ELECTRONIC EQUIPMENT CAUTIONS

Caution Improper servicing and/or repair of the control system electronics can result in damage to the equipment.

Ensure that the following methods and practices are observed when servicing electronic equipment:

To prevent damage to electronic equipment due to shorting, remove power to circuits prior to service. When adjusting or tuning, use insulated tools that have insulation down to the tool tip. Ensure that terminals and wires are not bridged, touched together, and/or shorted during service and/or calibration.

Do not remove electronic or Programmable Logic Controller (PLC) modules or cards with power applied.

Do not remove electronic connectors to electronics, sensors and/or switches with power applied.

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2.14 COLD WEATHER CAUTIONS

Caution Snow, sleet and/or ice packed in the Sentinel base can result in damage to the equipment.

Excessive loads can be applied to the equipment if vehicles drive over the roadway deck if the barrier is not fully down.

During cold weather storms, snow, sleet and ice may accumulated in the Sentinel base, especially if the Barrier is left in the raised position for extended periods of time.

In addition, even with small amounts of snow accumulating in the base, the snow can be come hard-packed or turn into an ice block if the Barrier is continuously operated up and down.

It is important that a snow pack or ice block not be allowed to accumulate in the base.

Ensure that the following methods and practices are observed when operating the equipment during cold weather conditions:

To prevent damage to equipment due to snow, sleet and/or ice packed in the base, remove and clear accumulation prior to lowering the barrier.

Utilize non-corrosive snow melting chemicals when applicable.

Utilize ATG Access Inc. Inc. frame heater (option) to assist in keeping base free of accumulation.

If accumulation has not been cleared, do not allow a vehicle to drive over the roadway deck resting on a snow pack or ice accumulation.

2.15 VEHICLE SPEED CAUTIONS

Caution Excessive vehicle speeds/loads under adverse conditions can cause dangerous driving conditions.

Vehicle speed over Barriers shall not exceed the safe driving speed for the existing roadway and weather conditions. Barrier roadway surface is non-skid diamond plate steel. Under certain conditions this surface can be dangerous at high speeds and/or loads, especially if snow and ice are present. Limit speeds to safe velocities.

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2.16 OWNER/OPERATOR RESPONSIBILITIES

The Owner/Operator is responsible for performing the following during operation, service and/or maintenance of the equipment:

The Owner/Operator shall properly maintain, service and repair equipment, and keep records of all work. Maintenance shall be performed at scheduled intervals.

1. Maintenance, service and/or repair of equipment shall be performed by trained and experienced Service Technicians only, familiar with the equipment specific requirements, ratings and limitations.

2. Operators and/or Service Technicians shall be properly trained in the use and operation of the equipment.

3. Equipment or components which have failed, are malfunctioning, are improperly adjusted, are worn or in disrepair, shall be repaired prior to resuming operation.

4. Equipment in a malfunctioning or unsafe condition shall not be operated.

5. Safety interlocks and/or safety devices shall not be bypassed and/or overridden during operation of equipment.

6. All components requiring replacement shall be replaced with identical components, including, but not limited to materials and seals. If substitution of a component is required, the Owner/Operator shall verify that the substitution is acceptable with ATG Access Inc. Inc. prior to use.

7. All equipment shall be used within component and equipment ratings and acceptable limits.

8. All adjustable components and equipment shall utilize set-points within ratings and acceptable limits.

9. Filter elements shall be changed when filter dirty warnings are indicated, and the system shall not be continuously operated in a warning condition.

10. ATG Access Inc. Inc. recommends that the hydraulic fluid cleanliness and properties be maintained, and checked at scheduled intervals. Corrective action or fluid replacement must be performed if hydraulic fluid is not in good condition.

11. The proper type of hydraulic fluid shall be used. Hydraulic fluids from two manufacturers shall not be mixed, even if the manufacturers claim compatibility.

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3 OVERVIEW AND GENERAL DESCRIPTION

3.1 BARRIER SYSTEM OVERVIEW

This manual provides information and instructions for the Operation and Maintenance of a Sentinel Series Barrier System, designed and manufactured by ATG Access Inc. Inc.

The Barrier System consists of the following major elements:

1. Physical barrier, with hydraulic cylinder(s).

2. Hydraulic Power Unit (HPU).

3. HPU exterior enclosure (optional).

4. Interconnecting hydraulic lines (provided by the installer).

5. Electrical controls enclosure.

6. Master Operator Control Panel.

7. Remote Operator Control Panel (optional).

8. Interconnecting electrical conduits and wiring (provided by the installer).

The type of barrier and actual equipment is dependant on each site installation.

Refer to the Sentinel Barrier System drawings for specific details.

In addition, some sites may have multiple barriers installed. Control of these barriers can be individually actuated, or in groups, depending on the site layout.

Barrier Systems can be tailored to the site and security requirements. Some of the features discussed in this manual may vary slightly with each Barrier System installation.

3.1.1 Barrier System Options

This manual includes information on Optional equipment, that can be supplied with a Barrier System. Optional equipment is not provided, unless stated in a specification and/or contract document, or specifically requested by the Buyer, at the time the Barrier System order is placed.

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In addition, not all options can be added to Barrier Systems after initial manufacture.

The options listed here are not comprehensive, more options might be implemented in the installed product. Contact ATG Access Inc. Inc. for the availability of optional equipment and tailored Barrier System configurations.

The Sentinel barrier may be ordered with the following Options:

1. Emergency Fast Operate (EFO) feature (optional) — provides additional control valves and associated hydraulic circuit components for rapidly deploying the Barrier System. Also includes the associated EFO pushbutton switch on the control panel for activation of the EFO function.

2. Remote Operator Control Panel (optional) — provides one or more additional control and monitoring panels for operating the Barrier System. Also includes the associated Arming selector switch on the control panel for arming and disarming the remote panel. Note: this option requires a customer-supplied method of mounting the Remote Operator Control Panel.

3. Remote EFO Station (optional) — provides a single, additional EFO pushbutton switch in a pushbutton station for activation of the EFO function. Note: this option requires a customer-supplied method of mounting the Remote EFO Station.

4. Down position sensor — provides a down sensor to monitor when the Barrier is in the lowered position. Also includes the associated Position indicator lights on the control panel to indicate the status of the Barrier position.

5. HPU with dual (redundant) motor / pump (optional) — provides hydraulic pump (and motor), for redundant operation. Also includes an additional motor starter, and a pressure switch. The PLC control logic is enhanced to switch between the two motors to alternate starting, to balance the run-time between the two pumps.

6. HPU with multiple accumulators for power-out operation (optional) — provides one or more additional accumulators which stores hydraulic power. The stored hydraulic power allows raising and lowering of the Barrier for a pre-determined number of cycles, even if the hydraulic pumps are not operating.

7. HPU exterior enclosure (standard included, optional excluded) — provides an exterior enclosure for the HPU, which provides outdoor protection against sun and weather. The HPU enclosure includes access doors with locks.

Note: This option requires a customer-supplied concrete mounting pad, and anchoring of the exterior enclosure.

8. Vehicle Detector Modules and control logic (optional) — provides one or more vehicle detector modules for detecting the presence of a vehicle on either side of a Barrier System. Note: This option requires placement, configuration and connection of customer-supplied roadway (antenna wire) loops, and addition interconnecting electrical conduits and wiring between the roadway loops and the HPU electrical enclosure.

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9. Traffic Lights (optional) — provides one or more traffic lights to signal vehicles to stop, or proceed with caution through the Barrier. Traffic lights include two light (red and green, or red and yellow) selections and an eight (8) foot tall mounting pole. Traffic lights can be configured for the in-coming (entry) traffic direction, out-going (exit) traffic direction or both. Note: This option requires a customer-supplied Facility mounting pad (i.e. rebar foundation), and addition interconnecting electrical conduits and wiring between the light poles and the HPU electrical enclosure.

10. Battery back-up Power Supply – 24 hour (optional) — provides a battery pack connected to the control system, which supplies control power in the event of electrical power loss, for control of up and down barrier actuation only. The PLC, lights, heaters and other features / accessories will not be available during power out operation.

11. EFO Reset (with EFO option) — provides a pushbutton switch on the Control Panel to allow the barrier to be reset after actuation of the Emergency Fast Operate (EFO) feature. When the EFO Reset is provided, the EFO valve will remain energized (latched) until an EFO Reset is performed.

12. Cold weather HPU hydraulic reservoir heater (optional) — provides an electrical immersion heater in the HPU reservoir to keep the fluid at an acceptable operating temperature. Also includes an associated thermostat switch for turning the heater on and off at a pre-set temperature.

Additional options are available, contact a ATG Access Inc. Inc. representative for additional information and availability.

3.1.2 Sentinel Series Vehicle Barriers

The ATG Access Inc. Inc. Sentinel Series is a wedge-type, shallow vehicle barrier system based on an opening ―clam-shell‖ design.

Each vehicle barrier includes a mechanical barrier mechanism and hydraulic cylinder.

Hydraulic fluid is supplied to the hydraulic cylinder to raise the barrier. All vehicle barriers can block and withstand intentional vehicular attacks when deployed, to help prevent intrusion.

Vehicle barriers are installed in a permanent concrete foundation. The foundation anchors the barrier and becomes part of the blocking method. Interconnecting hydraulic lines and hoses, and electrical conduit and wiring are installed between the vehicle barrier and the Hydraulic Power Unit. Interconnecting electrical conduit and wiring are also installed between the Hydraulic Power Unit and the Master and Remote Operator Control Panels for controlling the barrier.

The following paragraphs provide a general description of the major assemblies and elements of the Sentinel Series Barrier System.

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3.1.3 Hydraulic Power Unit (HPU)

The Barrier System includes a Hydraulic Power Unit (HPU) that provides a source of hydraulic fluid power for raising the vehicle barrier.

Typically, the Hydraulic Power Unit is located in relatively close proximity to the vehicle barriers. When multiple vehicle barriers are installed, hydraulic fluid power may be distributed to each barrier location from a single hydraulic supply.

The HPU provides a hydraulic fluid reservoir, pumps and motors, circuit manifolds, hydraulic lines, control valves, flow and pressure controls, hydro-pneumatic accumulators, hand pump, sensor switches, and all other necessary hydraulic circuits and hydraulic components as required to operate the barrier. All hydraulic components are integral with HPU.

This HPU equipment is an open-frame construction with all hydraulic components centrally mounted in one location.

Refer also to the HYDRAULIC CIRCUIT DETAILS section 4.1. for additional information and details on functions and operation.

3.1.4 HPU Exterior Enclosure (Optional)

The HPU must be located either indoors, or under cover if located outdoors. The HPU must not be installed unprotected. If an outdoor installation is required, an optional HPU exterior enclosure can be provided by ATG Access Inc. Inc. This enclosure fits over the HPU similar to a shed, and includes access doors for maintenance and service entry.

3.1.5 Interconnecting Hydraulic Lines

Two hydraulic lines are interconnected between the HPU and the vehicle barrier cylinder. One line raises the vehicle barrier and the other line lowers the barrier or allows it to lower due to gravity.

Note: During initial installation, or after major repair, it is important to coordinate the control functions with the hydraulic lines connected to the cylinder. Switching of the hydraulic lines would cause reverse operation that could damage the barrier.

For most installations, the interconnecting hydraulic lines will be hydraulic hoses run in an underground conduit to each vehicle barrier. Some installations may use buried piping or tubing lines.

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3.1.6 Electrical Enclosure

An electrical enclosure is provided for controlling the pump motors and valves on the HPU, monitoring the HPU sensors, and for interfacing with the Operator Control Panel control switches and indicator lights.

The Electrical Enclosure may include, but is not limited to:

13. Control transformer and/or DC power supply.

14. Pump motor starters.

15. Electrical circuit protection.

16. Programmable Logic Controller (PLC) and/or control relays.

17. Vehicle Loop Detector Modules (optional).

The Electrical Enclosure is typically mounted on the HPU, in close proximity to the control valves and sensors.

When a PLC is used, the PLC provides pre-programmed electrical control and monitoring logic for operating the Barrier System.

The enclosure is a painted steel enclosure with a hinged door for easy access to the interior. All electrical components and wiring are mounted on an interior panel.

3.1.7 Master Operator Control Panel

Typically the Master Operator Control Panel is located in a master control room, security guard shack or…