GRAB-300 Combined Manual _ENG.pdf

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OWNER/OPERATOR & MAINTENANCE MANUAL

GRAB®-300

GROUND RETRACTABLE AUTOMOBILE BARRIER

K12/ASTM M50

innOvAtiOn • integRitY • quALitY • cLient seRvice

GRAB

GRAB®-300

NOTICE OF CONFIDENTIAL INFORMATION

This Owner/Operator/Maintenance Manual (“Manual”), including the information and drawings contained in this manual, is confidential and is the exclusive property of Smith & Wesson Security Solutions™. This Manual is provided to, and intended solely for use by, current owners and/or prospective purchasers of the GRAB® (“intended recipient”).

This Manual contains confidential information, proprietary information, and trade secrets, and is provided to the intended recipient in the strictest confidence. Any unauthorized duplication, replication, or transmis-sion of this Manual to any other person(s), in whole or in part, without the prior expressed written consent of Smith & Wesson Security Solutions is strictly prohibited. Smith & Wesson Security Solutions reserves the right to recall any or all copies of this Manual in their entirety at any time at Smith & Wesson Security Solutions’ expense.

As the intended recipient, upon reception of this Manual, you agree to maintain the Manual and its contents in strictest confidence, and you agree that you will NOT:

(1) Disclose or transmit this Manual, or any of its contents, to any person who is not an intended recipient.

(2) Copy, reproduce, or duplicate this Manual, or any of its contents, in whole or in part.

(3) Use any information and/or drawing contained in the Manual for any purpose other than those expressly agreed to in writing by Smith & Wesson Security Solutions.

If you have come into possession of this Manual and you are not its intended recipient, you must contact Smith & Wesson Security Solutions immediately to arrange for its immediate return. Failure to do so could result in criminal charges, civil prosecution, and/or other legal action against you.

© 2011 Smith & Wesson Security Solutions, All Rights Reserved. GSA # GS-07F-5792R.

WARNING: THE EXPORT OR RE-EXPORT OF THE GRAB, OR THIS MANUAL, MAY BE

SUBJECT TO U.S. EXPORT ADMINISTRATION REGULATIONS (EAR) AND OTHER GOVERNMENTAL

EXPORT CONTROL POLICIES OR RESTRICTIONS.

© 2011 SMIth & WeSSoN SecuRIty SolutIoNS. All RIGhtS ReSeRved. 2011-07-GRABMM

TABLE OF CONTENTS

GRAB-300 overview

Component Description Purpose Features & Specifications

Safety

Hazard Definitions & Safety Labels Safety Label Locations GRAB Shutdown Protective Ground General & Operational Safety General Maintenance & Traffic Safety.. 10 Entrapment & Tripping Hazards operation

Guard Booth Panel Master Control Panel Maintenance/Local Panel Overwatch Panel orientation visual operation

Resetting the GRAB-300

Manual Raising and lowering of the GRAB tools

Maintenance

Weekly Maintenance Monthly Maintenance Net Encasement Maintenance Annual Maintenance Maintenance Schedule Maintenance Record

Spare Parts Guide

Dept. of Defence Certification contact Information component description

1. Foundation

2. Anchor Stanchions/Clevis Assembly

3. Pistons

4. Net Lifting Arm Assembly

5. Net

6. Net Pads

7. Safety Equipment –

(Traffic lights Audible Alarm, and Horn/Safety Beacon)

8. Barrier Control Panel

9. Net Encasements

10. Cable Bumpers

Figure 1

GRAB-300

OVERVIEW

GRAB®-300 OVERVIEW

the GRAB-300 system is designed to be an access control point and an emergency barrier against unwanted vehicles. It is easy to maintain and safe to operate.

As an access control point, the barrier’s net serves as a gate to allow approved traffic into your facility. The net is lowered into the deep grooves of the rubber net pads. This protects the net and can handle frequent and heavy traffic.

During normal access point operations a simple and easy to follow schedule of maintenance is included in the Maintenance Manual. It will keep the barrier operating optimally throughout the warranty period and minimize maintenance replacement beyond.

GRAB-300

OVERVIEW

GRAB®-300 OVERVIEW (continued)

The GRAB-300 is a reduced risk, energy absorbing, K-12 certified crash barrier. It was the world’s first ASTM M50 certified, non-hydraulic barrier.

Due to its flexible design, the GRAB-300 has dominated the security barrier industry. Unlike rigid wedge barriers, the GRAB-300 is a reduced risk solution to keep your perimeter safe while protecting resources and lives.

Specifications:

• K-12 and ASTM M50 Crash Certified Barrier (15,000 lb vehicle travelling at 50 mph)

• Energy Absorbing Technology

• Reduced Risk to Vehicle Occupants and Facility

• Vehicle Occupants are Stunned so they can be Apprehended

• GRAB can be Reset and Back in Operation within Minutes of an Impact

• Cost Efficient: Replaces Multiple Barriers with One GRAB System

• Flexible Design Suitable for Access Control or Final Denial Applications

• Reusable System: Interchangeable Parts for Quick and Easy Replacement

• No hazardous Materials

• Certified by the US Department of Defense to Protect all Road ways from Single Lane to Over 60’ with a Single Barrier.

• Traffic Control Devices Integrated into Barrier Design

• Low Maintenance Requirements

• All Weather Operation: Will operate in up to 6” of standing water

• Custom Covers Available to Match Facility Design Standards

• Green: All Electric Operation

• Bidirectional (In/Out) Operation

Features:

• Shallow Mount Foundation

• Flexible Power Supply

• Two Second Operation

• Capable of Over 1.2 Million Up/Down Cycles per Year

• Custom Programmable Controls

• The GRAB Barrier has passed testing and certification for the following standards:

- DoS(March 2003), FHWA, ASTM, DoD and ACoE

GRAB-300

SPECIFICATIONS

AND FEATURES

GRAB®-300 SPECIFICATIONS AND FEATURES

WARNING: Personnel intending to operate the GRAB® should have completed the S&W operators training. You must understand all warnings, controls, and labels included on your barrier before operating maintenance on this product. Failure to do so can result in serious injury or death.

For your safety and to prolong the life of your equipment, understand and heed the following safety words that may be seen throughout this manual:

dANGeR:

Danger is used to indicate the presence of a hazard which will cause severe injury, death or substantial property damage if the warning is ignored.

WARNING:

Warning is used to indicate the presence of a hazard which can cause severe injury, death or substantial property damage if the warning is ignored.

cAutIoN:

Caution is used to indicate the presence of a hazard which will or can cause injury or property damage if the warning is ignored.

Safety labels are located on your barrier to alert you to possible hazards.

Make sure you understand the information and follow the instructions before using the system. If the labels become illegible, damaged, or fall off the equipment, call S&W for replacements. Do not deface the labels or remove them from the equipment.

the following is a guide to where the safety decals are found on your barrier:

• (A) A “No Step” decal is on each lifting arm and each motor cover.

• (B) A “Moving Parts” decal is on each lifting arm and each motor cover access panel.

• (c) A “High Voltage” decal is on each motor cover access panel.

• (c) A “High Voltage” decal is located on the exterior of the Barrier

Control Panel door.

• (d) The GRAB Model number sticker is on the inside of the

Barrier Control Panel and can be used as a reference when ordering parts.

HAZARD DEFINITIONS

SAFETY LABELS

SAFETY

(A)

(B)

(c)

(d)

SAFETY LABELS

(THE BACK OF THE LIFT ARM)

SAFETY LABELS

(THE FRONT OF THE LIFT ARM

AND MOTOR COVER)

SAFETY LABELS

(THE TOP OF THE MOTOR

COVER)

SAFETY (continued)

Only S&W approved, qualified electricians or authorized technicians should be allowed to work on electrical components. Qualified personnel should know the location of all electrical shut-off boxes, disconnects and similar devices and be sure these are kept dry. If you suspect there is an electrical system failure, shut off power to the equipment and call S&W for guidance. If your GRAB system includes the UPS/Battery Backup System, it must be de-energized as well otherwise your system could still have power.

oShA Regulation 1910.147(c)(1) states that the employer shall establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative.

Qualified personnel must follow the lockout / tagout procedures established by the Employer as required by OSHA.

the following minimum NFPA steps must be taken to ensure an electrically safe work condition:

1. Determine all sources of energy by reviewing up-to-date drawings.

2. Disconnect all sources of energy by operating adequately rated disconnecting means.

3. Inspect, whenever possible, energy-isolating devices for visible breaks in the power conductors.

4. Perform a voltage test to determine the absence of voltage.

5. Install grounding devices, if determined necessary.

6. Install locks and tags per facility lockout / tagout procedures.

SAFETY LABELS

(continued)

ELECTRICAL SAFETY

SAFETY (continued)

OSHA REQUIREMENTS

NFPA GUIDELINES

SAFETY (continued)

WARNING: When performing maintenance on the GRAB Barrier, be sure to check for 120 Volts AC from the UPS per the prints. Prints could be located in the BBU or in the Barrier Control Panel.

WARNING: When performing maintenance on the GRAB Barrier, have a clear understanding that even though the main power may be shut off at the breaker, the system still has power via the UPS/Battery Backup System. As a result, de-energize the Battery Backup System before performing any maintenance by performing the following steps:

1) Turn off Breaker (A) (these breakers supply the DC Bus voltage to the Variable Frequency Drives).

2) Turn off Breaker (B) (this breaker supplies AC power to Booster Module).

3) Turn off the 120 volt Uninterruptible Power Supply unit.

4) Use a voltage meter to ensure that no DC voltage is present between terminals +1PC & -1PC. (c)

5) Use a voltage meter to ensure that no DC voltage is present between terminals +2PC & -2PC. (d)

6) Use a voltage meter to ensure that no AC voltage is present between Terminals 2032 & 2039. (e)

7) When no voltage is present on the terminals in steps 4,5 & 6, the system has been successfully shut down.

WARNING: In the event of a power failure or while equipment is being serviced, be sure all switches are locked in the OFF position following lock-out/ tag-out procedures. Accidental start-up could result in serious injury or death.

GRAB SHUTDOWN

WITHOUT

BATTERY BACKUP

GRAB SHUTDOWN

WITH

BATTERY BACKUP

The Barrier Control Panel has HIGH VOLTAGE inside. NEVER work inside the Barrier Control Panel with the power on.

Perform the following step to shut down the GRAB without battery backup present:

Turn the main disconnect located in the BCP to the “OFF” position.

Earth Ground

NEVER disconnect the grounding wire from the GRAB control panel.

The ground wire, attached to a copper rod driven into the ground and connected to the barrier control panel, provides protection against unequal potential between panel components and the surface on which a maintenance technician may stand while working in the control panel.

While the voltage at this connection point may rise above zero volts-to-earth-ground under fault conditions, the entire system will also rise at the same rate to the same voltage. This helps minimize any circulating currents between components from lightning or power surges.

The removal of this conductor or wires to/from the conductor will impede the protection for which it is designed to provide.

GRAB SHUTDOWN

WITHOUT BATTERY

BACKUP

(continued)

PROTECTIVE GROUND

or EARTH GROUND (Protective Earth)

This manual should be read and understood by the person operating the equipment. Extra copies are available from the manufacturer.

WARNING: Do not modify the equipment in any way. Modifications made to this equipment can be dangerous and could result in serious injury or death. Making changes to the equipment also voids the equipment warranty.

• NeveR defeat a safety guard or device to make a task easier.

• When operating the equipment, always wear proper apparel. Loose clothing could get caught in moving parts.

• Never operate equipment with guards or covers removed. Moving parts can cause severe injury. Keep hands, feet, hair, jewelry and clothing away from all moving parts.

• Keep walking and driving surfaces around the barrier clean and uncluttered to prevent a slip or trip hazard.

Never operate the equipment if you are under the influence of drugs, alcohol or medications that may make you less alert or affect your judgment.

• Make sure all mechanical guards and safety devices are in place and are working properly.

• Check that all hardware, fasteners, etc. are in good condition and tightly fastened. Replace any worn or damaged items with replacements supplied by the manufacturer.

• Personnel who are not required to be in the work area should be kept away. NeveR operate the equipment unless you are absolutely certain that all personnel are clear of the barrier and are made aware it is about to move.

• hoRN: Follow the recommended start-up procedure described in your operations manual. The horn operates is adjustable to operate between 78 dB-103 dB. Prolonged exposure to this level may require the use of ear protection.

GENERAL SAFETY

OPERATIONAL

SAFETY

TRAFFIC SAFETY

WARNING: Do not remove any guards while power is ON at the control panel.

WARNING: Before work is performed, be sure power is off and the main ON/OFF switch or button is locked in the OFF position. The main disconnect is always located on the primary control panel. For exact location, check the drawings for the unit.

• Following maintenance work, ensure all mechanical guards and other safety devices are installed and are in proper working order.

• NeveR clean, lubricate or adjust the equipment while any parts are moving or while the equipment power is ON.

consult Property owner / Manager:

• In the event of operating the barrier outside normal sequence of operation, contact owner to verify proper procedure for controlling or rerouting traffic at the barrier.

• The property owner or manager must have full knowledge of traffic plans to reroute traffic, or of plans for a complete roadway shutdown.

Consult facility traffic control plans to ensure that one-way, two-way, or other forms of traffic control are performed in accordance with established safety standards.

Stop or Detour Traffic

• Ensure that safety cones are properly utilized to effectively stop or detour traffic around the barrier while maintenance is being performed.

• Ensure that the properly sized cones are utilized given the site conditions and time of day/night.

Be aware of vehicle traffic when working on the GRAB-sp barrier system.

Always wear reflective clothing/vest. Use orange cones when available.

SAFETY (continued)

GENERAL

MAINTENANCE

SAFETY

ENTRAPMENT

HAZARDS

TRIPPING

HAZARDS

NeveR stand on the net pads or near the lifting arms. When the barrier is down, it could raise under you causing a fall. When the barrier is up, it could lower quickly and trap you.

There are many trip hazards near the GRAB barrier system. Watch your step.

Red Illuminated “eFo” Push Button: emergency Fast operate Used to deploy the barrier in an emergency situation. When pressed, the barrier will cycle through traffic light sequence and barrier will deploy after the vehicle safety loops are clear.

Red eFo light

• Illuminated: An EFO button has been pressed

• Flashing: THIS EFO has been pressed

• Extinguished: No EFO button has been pressed

Red “oveRSPeed” Pilot light

• Illuminated: Overspeed vehicle has been detected.

• Extinguished: No overspeed vehicle detected.

Red “WRoNG WAy” Pilot light

• Illuminated: A vehicle traveling the wrong way has been detected.

• Extinguished: No wrong way detected.

“AlARM”

• Sounds when a fault is detected, overspeed vehicle or wrong way vehicle detected.

GUARD BOOTH

PANEL (TYPICAL)

(GB)

OPERATIONS

“GuARd Booth ARMed” Pilot light

• Illuminated: The Guard Booth has been armed by both the Master switch and the Power Key Switch and the Security Booth station is operational.

• Extinguished: The Guard Booth is either disabled by the Master Key Switch or the Power Key Switch.

Black “lAMP teSt” Push Button Used to test all LED lights on the Guard Booth Station. When pressed, all pilot lights should illuminate on the panel. If any of the lights do not illuminate after pressing the “LAMP TEST” pushbutton, the LED needs to be replaced in that light.

GUARD BOOTH

PANEL (TYPICAL)

(continued)

OPERATIONS (continued)

Red Illuminated “BARRIER UP” Push Button (“TEST” mode only) Used to raise the barrier in a non-emergency situation (“TEST” mode only)

• Flashing: The Pilot light will flash when the push button is pressed.

It will continue to flash until the barrier is completely in the up position. Once in the fully up position the light will turn solid.

• Illuminated: Barrier is in the fully up position. Road is Closed.

• Extinguished: The light extinguishes as soon as the “BARRIER DOWN” button is pushed. The barrier is either in the process of going down or in the fully down position

Green Illuminated “BARRIER DOWN” Push Button (“TEST” mode only) Used to lower the barrier in a non-emergency situation (“TEST” mode only)

• Flashing: The pilot light will flash when the push button is pressed.

It will continue to flash until the barrier is completely in the down position. Once in the fully Down position, the light will turn solid.

• Illuminated: Barrier is in the fully down position. Road is open.

• Extinguished: The light extinguishes as soon as the “BARRIER UP” button is pushed. The barrier is either in the process of going up or in the fully up position.

MASTER CONTROL

PANEL (TYPICAL)

(MCP)

Amber “eFo Mode” Pilot light

• Illuminated: The Master Control Panel is in EFO Mode. All EFO’s are active; The Maintenance Panel is disabled; The Master Panel “BARRIER UP/DOWN” pushbuttons are disabled.

• Extinguished: The Master Control Panel is either in Maintenance/ Local or Test Mode. EFOs are not active.

Red Illuminated “eFo” Push Button: emergency Fast operate Used to deploy the barrier in an emergency situation. When pressed, the barrier will cycle through traffic light sequence and barrier will deploy after the vehicle safety loops are clear.

Red eFo light

• Illuminated: An EFO button has been pressed

• Flashing: This EFO has been pressed

• Extinguished: No EFO button has been pressed

“PoWeR oN” / disarmed/Armed Key Switches This is the master switch controlling all Guard Booths and the Master Control Panel. This switch has the ability to either enable or disable all guard booths to function. If in the “ON” state, each individual guard booth can then be armed or disarmed. If in the “OFF” state, none of the security booths can be activated and the Master Control Panel lights, pushbuttons, and Maintenance Panel will not operate.

“PoWeR oN” Pilot light

• Illuminated: All guard booth switches have been enabled and each are operational to function on their own. All Master Control Panel controls are functional.

• Extinguished: All security booths switches are disabled.

None are operational. The Master Control Panel is not operational.

Guard Booth (X) Panel “No/yeS” Key Switch Used to allow operation: Either arms or disarms Guard Booth (X). The Master “POWER ON” key switch must be on for this key switch to function.

Guard Booth (X) “yeS” Pilot light

• Illuminated: The Guard Booth has been armed by both the Master “POWER ON” Key Switch and the Guard Booth (X) Panel “NO/YES” Key Switch and the Guard Booth station is operational.

• Extinguished: The Guard Booth is either disarmed by the “Power On” Key Switch or the Guard Booth (X) Panel “NO/YES” Key Switch.

Note: Also applies to overwatch Panel (if installed)

MASTER CONTROL

PANEL (TYPICAL)

(continued)

“oveRSPeed” Pilot light

• Turns on when an overspeed condition has been detected by ODDS

“WRoNG WAy” Pilot light

• Turns on when a wrong way condition has been detected by ODDS

“duReSS” Illuminated Push Button

• Used to alert an external system that a duress condition exists

Red “looP oN” Pilot light

• Turns on when a barrier loop has been on longer than 15 seconds.

(Time is adjustable).

Red “tRouBle” Pilot light

• Turns on when there is a problem with the barrier (motion fault, power supply fault, Battery low voltage fault for battery backup systems)

“locAl/eFo/teSt” Keyswitch

• local Mode (Barrier Mode Switch) - only the barrier up/down illuminated push buttons at the Maintenance Panel are operational

• eFo mode - only the barrier EFO illuminated push buttons are operational;

• test mode- only the Master Operator Panel barrier up/down illuminated push buttons are operational

“AlARM”

• Sounds when the barrier is in motion or if there is a power supply fault

“SIleNce AlARM” Pushbutton

• Used to silence the Alarm

“lAMP teSt” Pushbutton

• Tests the functionality of all the pilot lights on the panel

OPERATIONS (continued)

MASTER CONTROL

PANEL (TYPICAL)

(continued)

“eFo/locAl” System Key Switch

• LOCAL: Only the Maintenance Panel controls the operation of the barrier. The Master Panel, and if present: card reader, and loop detectors do not function.

• EFO: When in EFO mode, the barrier will respond to an EFO button when pressed, and can be operated by a card reader if present. Neither the Maintenance/Local Panel nor the Master Control Panel can operate the barrier.

Red “tRouBle” Pilot light

• Illuminated: Exists when a hard fault occurs and stops the operation of equipment.

• Extinguished: No faults exist.

Red Illuminated “BARRIeR uP” Push Button (in “LOCAL” mode) Used to raise the barrier in a non-emergency situation in “LOCAL” mode.

• Flashing: The pilot light will flash when the push button is pressed.

It will continue to flash until the barrier is completely in the up position. Once in the fully up position, the light will turn solid.

• Illuminated: Barrier is in the fully up position. Road is closed.

• Extinguished: The light extinguishes as soon as the “BARRIER DOWN” button is pushed. The barrier is either in the process of going down or in the fully down position.

MAINTENANCE/LOCAL

PANEL (TYPICAL)

(MP)

Green Illuminated “BARRIeR doWN” Push Button (in “LOCAL” mode) Used to lower the barrier in a non-emergency situation.

• Flashing: The pilot light will flash when the push button is pressed.

It will continue to flash until the barrier is completely in the Down Position. Once in the fully down position, the light will turn solid.

• Illuminated: Barrier is in the fully down position. Road is Open.

• Extinguished: The light extinguishes as soon as the “BARRIER UP” button is pushed. The barrier is either in the process of going up or in the fully up position.

Amber “locAl Mode” Pilot light

• Illuminated: The Maintenance Panel and Master Control Panel has been turned to “LOCAL” mode.

• Extinguished: The Maintenance Panel is in “EFO” mode.

“BARRIeR MotoRS dISABle/eNABle” Key Switch Interrupts the circuit between the power and the motor for wedges and bollards. This feature is a safety lockout to disable the barrier.

• Disable: The barrier motors are locked out and will not operate. The switch disables the system so that maintenance can be performed without accident. This is a safety switch.

• Enabled: The barrier is in normal operating conditions. Motion can occur.

MAINTENANCE/LOCAL

PANEL (TYPICAL)

(continued)

Red “BARRIeR uP” Pilot light Used only to indicate if the barrier is coming up. This is not a button.

• Flashing: The Pilot Light will flash when the push button is pressed at the Maintenance/Local Panel or the Master Control Panel. It will continue to flash until the barrier is completely in the up position.

Once in the up position, the light will turn solid.

• Illuminated: Barrier is in the fully up position. Road is closed

• Extinguished: The light extinguishes as soon as the “BARRIER DOWN” button is pushed. The barrier is either in the process of going down or in the down position.

Green “BARRIeR doWN” Pilot light Used only to indicate if the barrier is going down. This is not a button.

• Flashing: The Pilot Light will flash when the push button is pressed at the Maintenance/Local Panel or the Master Control Panel. It will continue to flash until the barrier is completely in the down position.

Once in the down position, the light will turn solid.

• Illuminated: Barrier is in the down position. Road is open.

• Extinguished: The light extinguishes as soon as the “BARRIER UP” button is pushed. The barrier is either in the process of going up or in the up position.

Red “eFo ARMed” Pilot light

• Illuminated: The Overwatch Panel has been armed at the Master Control Panel.

• Extinguished: The Overwatch Panel is disarmed.

OVERWATCH

PANEL (TYPICAL)

(OW)

OVERWATCH

PANEL (TYPICAL)

(continued)

Red Illuminated “eFo” Push Button: emergency Fast operate Used to deploy the barrier in an emergency situation. When pressed, the barrier will cycle through traffic light sequence and barrier will deploy after the vehicle safety loops are clear. The Maintenance/Local Panel must be in “EFO” mode for this EFO button to operate.

Red eFo light

• Illuminated: An EFO button has been pressed

• Flashing: THIS EFO has been pressed

• Extinguished: No EFO button has been pressed

“overspeed” Pilot light

• Turns on when an overspeed condition has been detected by ODDS

“Wrong Way” Pilot light

• Turns on when a wrong way condition has been detected by ODDS

“duress” Illuminated Push Button

• Used to alert an external system that a duress condition exists

“Alarm”

• Sounds when the barrier is in motion or if there is a power supply fault

BARRIER NET

Constructed from steel cable.

TURNBUCKLE

Used to tension the net.

CABLE BUMPER

Keeps cables off the concrete, which reduces wear on the cables.

NET ENCASEMENT

(optional) Aids in preventing small wheels/tires from dropping into net pads.

BARRIER ORIENTATIONBARRIER ORIENTATION

NET PADS

Used to recess the net into the road surface.

LIFT ARMS

Used to lift the net.

ANCHOR STANCHIONS

Tie back point for the net used to absorb impact energy.

BARRIER ORIENTATION (continued)

PISTONS

Used to absorb impact energy and slow-down impact.

TRAFFIC LIGHTS

(optional) Used for traffic control around barriers.

HORN

Sounds when barrier is in motion (adjustable to operate between 78 dB-103 dB)

SAFETY LOOPS

(optional) Used to detect presence of vehicle over the barrier.

BARRIER ORIENTATION (continued)

Check that the net (B) Figure 3 goes up and down in a continuous motion and that the arms (A) travel in unison.

Barriers are activated by control buttons located at operator’s stations and main panel. Consult your facility’s specific layout for functions of control panel and sequence of operation.

In any of the above cases, if a system is not functioning properly, call your S&W representative.

OBSERVE AND

INSPECT OPERATION

OF EQUIPMENT

Figure 3

VISUAL OPERATION

Verify that safety warning equipment is working properly.

Inspect foundation for cracks.

Perform a visual inspection on the net pads to see if any are raised up due to sediment under the mat.

Perform visual inspection of the net cable bumpers. They should be positioned to keep the portion of cable that would touch the ground in the lowered position from touching the ground during the raising and lowering of the GRAB.

If the net encasement becomes cracked or damaged, replace the encasements necessary using the steps supplied in the S&W Maintenance Manual.

VISUALLY CHECK

OPERATION OF

SAFETY DEVICES

FOUNDATION

NET PADS

CABLE BUMBERS

NET ENCASEMENT

VISUAL OPERATION (continued)

Detail from Figure 3

(A) on Page 24

Red Strobe

Signal Lights

CORRECT ALLIGNMENT

INCORRECT ALIGNMENT

Verify the net is properly tensioned. The ideal tension is 1” to 1-1/2” of sag for every 10 feet of road span. For example, a 40-foot barrier should have 4” to 6” of sag.

Figure 4

Refer to the steps in the S&W Maintenance Manual. Address any maintenance or repair necessary to correct any discrepancies listed above.

ARM ALIGNMENT

MONTHLY INSPECTION

OF NET TENSION

VISUAL OPERATION (continued)

Ground Retractable Automobile Barrier (GRAB-300) system is designed to be an access control point and an emergency barrier against unwanted vehicles. It is easy to maintain and safe to operate.

As an access control point, the barrier’s net serves as a gate to allow approved traffic into your facility. The net is lowered into the deep grooves of the rubber net pads. This protects the net and can handle frequent and heavy traffic. During normal access point operations a simple and easy-to-follow schedule of maintenance included in this manual will keep the barrier operating optimally throughout the warranty period and minimize maintenance replacement beyond.

Should the net be deployed to stop a moving vehicle, perform the Following steps to reset the GRAB-300. Immediately call USR if you are unable to perform any of the steps.

1. Shut down the GRAB-300 as instructed in the Maintenance Manual to ensure that the system is de-energized prior to resetting the

GRAB-300.

2. Ensure that traffic control procedures and safety protocols are immediately put into effect per facility guidelines.

3. Ensure that the area is clear of any pieces of debris which may have broken off of the vehicle or any fluids which may have leaked out of the vehicle during the strike.

In an emergency event, upon impact, the net breaks free from four turnbuckles. Each turnbuckle is secured to the net with one shear pin (as shown here).

RESETTING THE

GRAB-300

FOLLOWING

AN IMPACT

Figure 5

RESETTING THE GRAB®-300

4. Check the entire GRAB-300 concrete foundation for any signs of impact fatigue cracks or anchor bolts pulled from the concrete;

repair immediately.

On the GRAB-300, the net is anchored to four pistons that absorb the energy during an impact. The pistons are pulled as needed by the force on the net and can swing on the stanchions to follow the direction of pull of the restrained vehicle. Each piston contains four (4) socket head cap screws that will shear if the piston is pulled from the housing during impact.

RESETTING THE

GRAB-300

FOLLOWING

AN IMPACT

(CONTINUED)

Figure 6

RESETTING THE GRAB®-300 (CONTINUED)

The un-extended GRAB-300 pistons look like those in Figure 7. Also note the location of the socket head cap screws (SHCS). There are four socket head cap screws, which are located under plastic protective caps, for each piston.

6. Examine the pistons to see if they have extended during the impact.

If there has been an impact and it’s not clearly obvious that the pistons have extended as in Figure 6, you can take a measurement from the end of the piston to the housing. The distance should be 8.0” as shown in Figure 7.

7. Check the condition of all netting and net encasements.

a. Damaged net encasements should be replaced as discussed in the “Net encasement Maintenance” section on page 29 of the Maintenance Manual.

b. Damaged netting should be replaced immediately.

8. Before re-installing the net, check the condition of the swivel/ turnbuckle. Replace as necessary.

9. Check the lifting arm. Examine the steel pin that connects the swivel/turnbuckle to the lift arm. Replace as necessary.

10. Once thorough inspections has been done, you may proceed in re-installing the net.

11. Remove the four socket head cap screws from each piston that has been extended.

12. Push each piston back into place and install new socket head cap screws.

RESETTING THE

GRAB-300

FOLLOWING

AN IMPACT

Figure 7

RESETTING THE GRAB®-300 (CONTINUED)

13. Ensure that the piston arms are rotated into position, parallel with the roadway

Figure 8

14. Place the net into the net pad recesses to ensure the net rests centered in the grooves of the net pad when it is in the down position (A). Adjust the turnbuckles as required to make sure the net is centered. The net here is shown without the net encasements for illustration purposes.

cAutIoN: Follow all OSHA and facility guidelines when moving the net pads. Net pads range from 100 to 140 lbs. per section.

15. Install new shear pins (B) to secure the turnbuckles to the lifting arms as shown here.

16. Install new steel pin into shear pin to secure shear pin.

17. Re-energize the system and raise the net into position to check the sag.

A

B

RESETTING THE GRAB®-300

RESETTING THE

GRAB-300

FOLLOWING

AN IMPACT

RAISING AND

LOWERING THE

GRAB

RAISE THE BARRIER

Remove the rear cover access panel on motor cover.

Remove the plate.

Attach the 9/16”deep well socket to a drill and rotate clockwise while pulling the brake release toward you.

LOWER THE BARRIER

Remove the rear cover access panel on motor cover.

Pull the brake release toward you to lower the barrier.

MANuAl RAISING ANd loWeRING oF the GRAB®

Note to maintenance technician: In order to assist with scheduling maintenance, a digital cycle counter is located inside the control panel.

Tools needed for the following maintenance tasks include:

• Grease gun for arm bearings and turnbuckles.

• Bearing Grease Note: Bearing grease should be purchased from USR as it meets strict penetration testing, operating temperature guidelines and provides the necessary mixes of detergents and lubricants to keep the GRAB- 300 components operating at optimal levels.

• Two-foot rebar (rebar diameter may vary) and/or a spud crescent wrench can be used for tensioning the net turnbuckles.

TOOLS

TOOLS

• 18” and 24” pipe wrenches for sleeves

• 15/16” or 1-1/8” wrench or socket (depends on unit installed) for arm bearing dust cover

• 24mm or 30mm wrench or socket (depends on unit installed) for the gearbox

• 3/4” hex key for the arm shaft collars

TOOLS

(continued)

TOOLS (continued)

• 9/16” deep well socket for the motor cover anchors

• Phillips Head Screw Driver or 7/16” nut driver for motor cover access panels

• 1-1/2” wrench for Arm Anchors

TOOLS

(continued)

TOOLS (continued)

• 15/16” or 1-1/8” wrench or socket (depends on unit installed) for arm bearing dust cover

• 24mm or 30mm wrench or socket (depends on unit installed) for the gearbox

• 3/4” hex key for the arm shaft collars

• 9/16” deep well socket for the motor cover anchors

OPERATIONAL

MAINTENANCE

Red Strobe

Signal Lights

WEEKLY MAINTENANCE (or every 1,000 cycles)

Figure 6

Inspect foundation for cracks. Fill with suitable concrete crack filler if cracks are present.

Net Pads Raise the net to the “UP” position.

cAutIoN: Before proceeding, ensure that all power is removed from the system and that proper lockout-tagout procedures are followed.

Perform a visual inspection on the net pads to see if any are raised up due to sediment under the mat. If sediment is present, remove the net pads and thoroughly sweep the sediment out from the net pad depression. Follow OSHA or facility safety guidelines for lifting.

Replace the net pads. Remove the safety lockouts and apply power to the system. Lower the net into the net pads.

Refer to pages 29-33 for Net Encasement Maintenance.

Net cable Bumper Alignment While the net is in the lowered position, ensure that safety precautions are taken to remove power from the system and ensure that all lockout/tagout procedures are in place.

The net cable bumpers should be positioned to keep the portion of cable that would touch the ground in the lowered position from touching and scraping the ground during the raising and lowering of the GRAB.

If adjustment is necessary, loosen the retaining screw, viewable from the side of the bumper, reposition the bumper on the cable and retighten the retaining screw.

FOUNDATION

NET PADS

NET ENCASEMENT

NET CABLE BUMPERS

MONTHLY MAINTENANCE (or every 3,000 cycles)

Touch up paint as required.

Inspect the intake fan filter located on the barrier control panel and battery backup panel. Replace clogged filter as required. Never operate system without proper filters in place. To access the fan filter, remove the ten (10) screws and fan filter cover as shown.

Slide the filter out for inspection, remove and replace if necessary.

Perform this on the filter located on battery backup is so equipped.

Ensure that you replace the filter cover and reinstall all ten screws.

Test fans and thermostat operation by adjusting thermostat throughout its limits. The fans should turn on when the temperature is set lowest and off when the temperature is set highest. Return the thermostat to its normal setting of 80-degrees.

PAINT

BARRIER CONTROL

PANEL

Inspect the stanchions (A) Figure 7a for loose bolts and wrench-tighten until snug.

Inspect the pistons (B) Figure 7a for loose bolts and wrench-tighten until snug.

Inspect the pistons for leaks. If the pistons were to leak, the most likely place would be at the rod seal (c) Figure 7b on front of the piston. If the pistons are leaking, call your S&W representative.

STANCHIONS

PISTONS

Figure 7a

Figure 7b

Grease the four arm bearings. Each arm has two bearings as shown in Figure 8a. Each bearing has one grease fitting.

Use high-grade lithium grease. Pump in the grease until it comes out of the side of the bearing. Ensure that the tip of the grease gun is securely held in place on the fitting while pumping as shown in Figure 8b.

NET LIFTING ARMS

Figure 8a

Figure 8b

Inspect the gearbox for leaks. If leaks are found coming from the gearbox, contact S&W.

Inspect the net lifting arms for loose bolts and tighten as needed.

Grease the turnbuckle bearings (A) Figure 8c. Use high-grade lithium grease. Pump in the grease until it comes out of the bearing. Ensure that the turnbuckle lock nut (B) Figure 8c is tight.

Figure 8c

NET LIFTING ARMS

TURNBUCKLES

Verify the net is properly tensioned. The ideal tension is 1” to 1-1/2” of sag for every 10 feet of road span. For example, a 30-foot barrier should have 3” to 4½” of sag.

Measure the sag by running a string (see dotted line in Figure 8d) between the two net lifting arm pad eyes, Figure 8d, and measure the difference between the string and the center of the net as shown

Figure 8d

If the sag is outside the recommended parameters, perform the following steps to ensure that the net is properly tensioned at all four turnbuckles:

1. Position the net into the “lowered” position; remove power from system and ensure that all lockout/tagout procedures are in-place.

2. Loosen all four turnbuckle locking nuts.

3. Relieve tension on the net by loosening all four turnbuckles.

4. Ensure the net is centered in the net pads.

5. Evenly tighten all four turnbuckles by hand while net is in the net pad.

6. Once the turnbuckles are hand-tightened, return power to the barrier and engage the barrier into the “raised” position.

7. Remove power from system and ensure that all lockout/tagout procedures are in-place.

8. Measure the net sag again. At this time, the net sag should exceed the 1” to 1-1/2” per 10 feet of net recommendation.

9. Tighten the four turnbuckles ½ turn at a time, using a bar inserted into the adjustment hole, shown in Figure 9, in the turnbuckle until the recommended 1” to 1-1/2” per 10’ of net is achieved. This should place the same amount of tension at each of the four turnbuckle’s shear\pins.

NET TENSION

10. Retighten the locking nuts on the turnbuckles.

11. Re-energize the barrier system and ensure that the net fits into the net pads when lowered.

Shown below is the detail involved with adjusting the net tension to ensure the net rests centered in the grooves of the net pad when it is in the down position as shown in Figure 10.

Move the net pad (A) right or left or adjust turnbuckles to center the net in the grooves as shown in Figure 10. The net is shown without the net encasement option.

cAutIoN: Follow all OSHA and facility guidelines when moving net pads.

Net pads range from 100 lbs to 140 lbs per section.

NET TENSION

(continued)

Figure 9

Figure 10

If the net encasements become cracked or damaged, replace the encasements as necessary using the following steps:

Note: Ensure that traffic is properly controlled during all maintenance activity in coordination with the owner/manager.

1. Raise the net into the “UP” position.

2. Ensure power to the system is disengaged and all safety procedures are followed to prevent accidental startup during the net encasement maintenance.

3. The net encasement consists of (4) stainless steel rods, the encasement top, and the encasement bottom. See detail A for a breakaway.

NET ENCASEMENT

REMOVAL

NET ENCASEMENT MAINTENANCE

Detail A

4. The ends of the stainless steel rods are bent 90 degrees to secure them in place. Bend the ends straight and remove by pulling them straight up (top) or straight down (bottom).

NET ENCASEMENT

REMOVAL

(continued)

NET ENCASEMENT MAINTENANCE (continued)

Detail B

5. Separate top encasement from the U-shaped encasement.

6. Discard the old net encasement and proceed to “Net eNcASeMeNt ASSeMBly”.

NET ENCASEMENT

REMOVAL

(continued)

NET ENCASEMENT MAINTENANCE (continued)

Detail C

1. Make sure you have the matched pairs of net encasements (K8/K4, with or without logo, black or yellow).

2. With the net in the raised position, working on the side of the net that rests on the net pad when lowered, place the net encasement bottom over the vertical cable orienting the logo upright if present.

3. Place the net encasement top onto the bottom capturing the cable. The parts have features that interleave like a hinge. Ensure that the hinges are aligned and seated together. See detail c.

4. Insert the stainless steel rod into the hole in the top net encasement.

5. Work the stainless steel rod into the U-shaped lip of the bottom net encasement. Twist the stainless steel rod to help feed it through.

Continue until the stainless steel rod is completely inserted and bend both ends 90 degrees to secure them in the net encasement.

6. Repeat Step 5 with the other top side. See detail d.

NET ENCASEMENT

ASSEMBLY

NET ENCASEMENT MAINTENANCE (continued)

Detail D

7. Insert the bottom stainless steel rods in a similar manner as step 5.

At this time the net encasement should be fully installed and held firmly in-place around the net, as shown below.

NET ENCASEMENT

ASSEMBLY

(continued)

NET ENCASEMENT MAINTENANCE (continued)

Every year or 36,000 cycles, the SHEAR PINS (P) Figure 12 should be removed and replaced in each of the turnbuckles.

cAutIoN: Use only the S&W replacement shear pins. Do not substitute any other material for these parts. Doing so may cause the barrier to become inoperable if an impact occurs and voids the warranty on the equipment.

To replace the pins:

1. Contact owner to verify proper procedure for controlling or rerouting traffic at the barrier scheduled to be serviced.

2. Lower the net down and turn power off to the unit.

3. Before loosening the tension, legibly mark the position of the turnbuckles on their threaded posts.

4. Loosen all four turnbuckles using a piece of rebar or a spud wrench.

5. Remove the cotter pins and then shear pins and discard the old shear pins.

6. Replace the shear pins with the proper replacements available from S&W.

7. Replace the cotter pins and tighten all four turnbuckles back to the mark on the threaded posts.

8. Check the net tension and net sag. If necessary, tension the net as described in the Monthly Maintenance section.

9. Ensure that net is centered in net pads.

SHEAR PINS

ANNUAL MAINTENANCE (or every 36,000 cycles)

Figure 12

Period Weekly Monthly yearly Test safety detection and warning equipment l

Check that net movement is continuous and that both arms move in unison l

Test all buttons at operator stations l

Visually inspect for missing, torn, or illegible safety labels l

Visually inspect concrete for cracks l

If necessary, clean net pads l

If necessary, clean net pits l

Visually inspect net encasements and re-place if necessary l

Visually inspect protective net bumpers (placement and condition) l

Check net tension; adjust if necessary l

Check net position in net pads; adjust if necessary l

Check stanchions and net lifting arms for loose bolts and worn hardware l

Visually inspect pisotns and net arm gearbox for leaks l

Grease the four (4) turnbuckles l

Grease the four (4) arm bearings l

Inspect and replace if necessary Barrier Control Panel Filters l

Test operation of Barrier Control Panel fans and thermostat l

Touch-up paint as required l

Replace shear pins and cotter pins & retension the net l

Replace shear pins and cotter pins & re-tension the net l

MAINTENANCE SCHEDULE

Month cycles (from digital counter) Signature date

MAINTENANCE RECORD

Item Number description usage K Rating- Net length (ft)

Qty

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 8 ft.

GRAB-300 10 ft.

GRAB-300 12 ft.

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 14 ft.

GRAB-300 16 ft.

GRAB-300 18 ft.

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 20 ft.

GRAB-300 22 ft.

GRAB-300 24 ft.

GRAB-300 26 ft.

GRAB-300 28 ft.

GRAB-300 30 ft.

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 32 ft. 4

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 34 ft.

GRAB-300 36 ft.

GRAB-300 38 ft.

GRAB-300 40 ft.

GRAB-300 42 ft.

GRAB-300 44 ft.

GRAB-300 46 ft.

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 48 ft.

GRAB-300 56 ft.

GRAB-300 58 ft.

GRAB-300 60 ft.

GRAB-300 62 ft.

- CONTACT S&W FOR SPECIFIC SHEAR PIN INFO GRAB-300 64 ft.

GRAB-300 66 ft.

GRAB-300 68 ft.

GRAB-300 70 ft.

001235 TURNBUCKLE- ASSM 1X23” w/

STATIONARY JAW FOR

5/8 (0.63) SHEAR PIN

GRAB-300 8 ft.

GRAB-300 10 ft.

GRAB-300 12 ft.

GRAB-300 14 ft.

GRAB-300 16 ft.

GRAB-300 18 ft.

GRAB-300 20 ft.

GRAB-300 22 ft.

GRAB-300 24 ft.

GRAB-300 26 ft.

GRAB-300 28 ft.

GRAB-300 30 ft.

SPARE PARTS GUIDE

The following is a list of spare parts which, if ordered, are specific to the model of GRAB-300 at your facility and specific to any customizations made throughout the life of the project. If you have questions regarding which part(s) you should order, please contact S&W.

Item Number description usage K Rating- Net length (ft)

Qty

001236 TURNBUCKLE- ASSM 1X23” w/

STATIONARY JAW FOR

7/8 (0.88) SHEAR PIN

GRAB-300 32 ft.

GRAB-300 34 ft.

GRAB-300 36 ft.

GRAB-300 38 ft.

GRAB-300 40 ft.

GRAB-300 42 ft.

GRAB-300 44 ft.

GRAB-300 46 ft.

GRAB-300 48 ft.

GRAB-300 56 ft.

GRAB-300 58 ft.

GRAB-300 60 ft.

GRAB-300 62 ft.

GRAB-300 64 ft.

GRAB-300 66 ft.

GRAB-300 68 ft.

GRAB-300 70 ft.

000191 IMPACT SOCKET 15/16” HEX

X 3/4” DRIVE

Used on the motor and shaft to manually lift the arm

000030 WEDGE STEEL ANCHOR 3/8 -16X5

MAGNI

Anchors used for the motor covers and as net pad retention

000269 FAN FILTERS - 5 PACK Replacements for Control Panels so Equipped

000198 COTTER PIN - 3/16 DIA X 1.50 ~18-8 SS Used when replacing sheer pins 4 000007 STROBE LIGHT Red strobe bulb replacement 1 000012 USR SAFETY YELLOW PPG W43597 Safety Yellow Paint 1

000027 HORN - 350 WB-120 Safety Warning Device 1

000040 RED 22mm PILOT LIGHT Illuminates 22mm Red pilot light on control station

000041 GREEN 22mm PILOT LIGHT Illuminates 22mm Green pilot light on control station

000056 RENO LOOP DETECTOR Loop detector for vehicle detection over inductive loop

000062 GREASE Grease for stanchions, lifting, arms and turnbuckles 1

000150 SCREW - 1/4- 20 UNC X .75 SET SCREW

~SS (100 QTY)

Top & Bottom Net Verticals 30

000151 SCREW -1/4-20 UNC X .50 SET SCREW

~SS (100 QTY)

Center Cable of Net 30

000232 WHITE 22mm PILOT LIGHT Illuminates 22mm white pilot light on control station

000269 FAN FILTERS Replacement Air Filter 1 000400 REFLECTOR (bottom of net encasement) Replacement reflector for bottom of net encasement

000401 REFLECTOR (top of net encasement) Replacement reflector for top of net encasement

SPARE PARTS GUIDE (continued)

Item Number description usage K Rating- Net length (ft)

Qty

001162 8” Green LED 8” replacement Green LED for signal light

000446 8” Red LED 8” replacement Red LED for signal light

000448 8” Yellow LED 8” replacement Yellow LED for signal light

000862 12” Green LED 12” replacement Green LED for signal light

000163 12” Red LED 12” replacement Red LED for signal light

000164 12” Yellow LED 12” replacement Yellow LED for signal light

000490 PROXIMITY SWITCH Replacement proximity switch for net arm

000806 LOOP SEALANT Sealant to cover vehicle detection loop 1

001179 STAINLESS STEEL RETAINER ROD Replacement retainer rod for one net encasement

500094 NET ENCASEMENT (TOP) Replacement for Top portion of Net Encasement

000896 CABLE BUMPERS Placed on cables to decrease wear and tear 1

SPARE PARTS GUIDE (continued)

Item Number description usage K Rating- Net length (ft)

Qty

001162 8” Green LED 8” replacement Green LED for signal light

000446 8” Red LED 8” replacement Red LED for signal light

000448 8” Yellow LED 8” replacement Yellow LED for signal light

000862 12” Green LED 12” replacement Green LED for signal light

000163 12” Red LED 12” replacement Red LED for signal light

000164 12” Yellow LED 12” replacement Yellow LED for signal light

000490 PROXIMITY SWITCH Replacement proximity switch for net arm

000806 LOOP SEALANT Sealant to cover vehicle detection loop 1

001179 STAINLESS STEEL RETAINER ROD Replacement retainer rod for one net encasement

500094 NET ENCASEMENT (TOP) Replacement for Top portion of Net Encasement

000896 CABLE BUMPERS Placed on cables to decrease wear and tear 1 dePARtMeNt oF the ARMy uS ARMy coRPS oF eNGINeeRS

PRotectIve deSIGN ceNteR 1616 capitol Avenue, Suite 9000 oMAhA, NeBRASKA 68102-4901

September 22, 2008

Protective Design Center

Mr. Wes Foss Vice President Universal Safety Response, Inc.

277 Mallory Station Road, Suite 112 Franklin, TN 37067

Dear Mr. Foss:

Based on the vehicle crash tests at the Texas Transportation Institute (TTI), in College Station, Texas, on July 2, 2008 and July 3, 2008, and the measured penetration distance, and the provisions of ASTM F 2656-07, the GRAB-300 62-foot and GRAB-300 14-foot Barrier Systems have been determined to meet the Department of Defense (D0D) crash performance criteria for active vehicle barriers. In accordance with ASTM F 2656 – 07, the TTI Test Director has recommended a rating of M50 P2 for both the GRAB-300 62-foot and GRAB-300 14-foot barrier systems. Provisions of ASTM F 2656 – 7 also include the interpolation of vehicle barrier width between identical, tested barrier systems of differing width. Under the provisions of ASTM F 2656-7 the Protective Design Center certifies the GRAB-300 as M50 P2 for widths of 14 to 62 feet.

The GRAB-300 will be placed on the DoD list of certified vehicle barriers…