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RSSI RSS-3000 Series Maintenance Manual

Electric drop beam vehicle barrier
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Maintenance Manual
Maintenance Manual
RSS-3000 Series Electric Drop Beam Vehicle Barrier
RSSI Barriers, LLC
6530 East Highway 22
Panama City, Florida 32404
850-871-9300/Fax 850-871-4300
Web Site:
www.rssi.com
May 2021
Page 1 of 60

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Summary of Contents for RSSI RSS-3000 Series

  • Page 1 Maintenance Manual Maintenance Manual RSS-3000 Series Electric Drop Beam Vehicle Barrier RSSI Barriers, LLC 6530 East Highway 22 Panama City, Florida 32404 850-871-9300/Fax 850-871-4300 Web Site: www.rssi.com May 2021 Page 1 of 60...
  • Page 2 Maintenance Manual Contents Page 3 Introduction Page 3 General Page 3 Before you Begin Page 3 How to Obtain Factory Support Page 4 Hazard Alert Message and Symbol Page 4 General Safety Page 5 Barrier Maintenance Page 5 Emergency Manual Operation Page 9 Troubleshooting Procedures Page 11...
  • Page 3 HOW TO OBTAIN ADDITIONAL FACTORY SUPPORT If you have any issues or questions, on-site personnel are highly encouraged to contact RSSI’s Service department. Normal office hours are 7:00 AM Central Standard Time to 3:30 WE CAN HELP YOU! PM Central Standard Time, Monday - Friday.
  • Page 4 ● Never operate this equipment when a vehicle, person or any obstruction is in the way of full operation of the RSS-3000. ● Prior to start-up of the RSS-3000 series electric Drop Beam vehicle barrier system, all electrical connections to the barrier will be isolated (disconnected) IAW local Lock Out Procedures.
  • Page 5 Maintenance Manual Lowering Barrier (Close Roadway) 1. Remove Fiberglass Cowling from barrier Fiberglass Cowling, RSS-3000 2. Visually inspect for debris that could interfere with operation WARNING Remove power from barrier (Barrier Control Panel) 3. Disconnect power to the barrier by turning off the Main Disconnect and lock out with a wire tie or IAW local lockout procedures.
  • Page 6 Maintenance Manual 5. Hand turn the 15/16 nut clockwise while applying light pressure to engage the manual drive downward, tabs inside the notch goes down to Locking Ring. The Brass Ring will lower as you screw down revealing the notch to lock in Manual Drive. Manual Drive 6.
  • Page 7 Maintenance Manual NOTE The Manual Nut is equipped with an internal clutch. It will engage at max physical limits or if the load is too great. WARNING Improper operation of manual screw will damage actuator 8. To release Manual Drive, slide the brass ring down and turn locking nut (counterclockwise) out of notches.
  • Page 8 Maintenance Manual move upward and pop when fully disengaged. DO NOT OPERATE BARRIER UNTIL MANUAL BRAKE OVERDRIVE IS FULLY DISENGAGED. Warning Label Place top plate back in place and install screws, start all screws before tightening (anti-seize) After condition requiring Emergency Manual Operation has been corrected (power restored or components repaired, reinstate power to the barrier by turning on the Main Disconnect Main Power Disconnect Push in drive fuse(s) in BCP...
  • Page 9 Servo Drive in Barrier or call RSSI E14 trending in Intermittent Loss of Check Ethernet cable from Ethernet switch Contact RSSI if Alarm History with communication to Servo Drive to servo drive in BCP, replace if bad. conditions still exist.
  • Page 10 BBP at CB1. If less than 208v, alarm page or in incoming power is too low. If confirmed and condition alarm history. still exists, Call RSSI Contact Electric provider to provide 208-240v Barrier stops in mid Motion E10 Bus overvoltage...
  • Page 11 Verify voltage on Heat wires in Power J-box Retest heat, if the Condition heating up still exists Call RSSI. NOTE If you encounter an issue not listed or want to discuss with a technician, please contact the factory. See page 3, HOW TO OBTAIN ADDITIONAL FACTORY SUPPORT.
  • Page 12 Maintenance Manual FUNCTIONAL CHECKOUT 1. Turn OFF CB1 and Contactor C1 should de-energize (pop out) and Contactor C2 should energize (pull in) simultaneously. Note: if BBU is connected and powering BCP from CB 4, check to see if power stayed on during the switchover and that the PLC generates "Loss of normal power"...
  • Page 13 Maintenance Manual • Ethernet and Device Testing Procedures The following table identifies all devices in the RSSI Barrier Network. IP ADDRESS DEVICE/LOCATION 192.168.1.10 PLC in BCP 192.168.1.11 Servo Drive Inside Barrier 192.168.1.12 Maintenance Touch Screen in BCP 192.168.1.13 Point I/O in Primary Touch Screen Controls 192.168.1.22...
  • Page 14 Maintenance Manual Component Repair/Replacement Procedures If there is a component to repair/replace that is not covered in this manual, contact the RSSI Service Manager for assistance (see page 3, HOW TO OBTAIN ADDITIONAL FACTORY SUPPORT). • Repairs should only be performed by a factory trained technician.
  • Page 15 Maintenance Manual 1- B TTACHMENT ARRIER ONTROL FROM MAINTENANCE TOUCH SCREEN 1. From the MAIN MENU, press the BARRIER CONTROL button. Main Menu Inside the BARRIER CONTROL menu use the MOVE CLOSED/OPEN buttons to operate the barrier a few cycles, Ensure the Beam is resting firmly in the Receiving Buttress in the CLOSED (DOWN) and ensure the OPEN(UP) position is all the way out of the traffic lane.
  • Page 16 2. At the Main Screen, go to the LOGIN box and login: “RSSI” password: “32404”. 3. Once you have logged in at the Main screen, select the HOME box and then at the HOME menu press the red HOME button.
  • Page 17 Maintenance Manual 2. Inside the BARRIER CONTROL menu use the MOVE CLOSED/OPEN buttons to operate the barrier a few cycles, Ensure the Beam is resting firmly in the Receiving Buttress in the CLOSED (DOWN) and ensure the OPEN(UP) position is all the way out of the traffic lane. Locking Tab at end of Beam isn’t in traffic lane.
  • Page 18 NOTE If you’re unsure of the impact of changing a setting, please contact RSSI. See page 3, HOW TO OBTAIN ADDITIONAL FACTORY SUPPORT. 1. ALARM Screen: Clear Active alarms before proceeding) Primary/Secondary Touch Screens must be connected before alarms can be cleared.
  • Page 19 OK, attempt to HOME again. If it doesn’t complete Homing a 2 time, pressing the abort homing button will stop HOMING procedure. Contact RSSI for assistance. 5. JOG/TEACH screens: use JOG to position barrier–then TEACH open/closed lane positions. Closed position should read around 3.5 and open position should read 290 depending on roadway.
  • Page 20 Maintenance Manual CAUTION DO NOT change any other settings on this screen without FIRST contacting RSSI. Doing so may change the operating characteristics of your barrier. 6. MOVE screen: using accel/decel to select speed of barrier 7. Barrier Control Screen: run barrier through a series of open/close movements while monitoring the AMP indicator.

  • Page 21: Preventative Maintenance Checklist

    HECKLIST Make copies of this checklist for maintenance activity for each barrier and maintain a copy in the maintenance binder for the Warranty/Historical Record. For assistance, please call RSSI’s service department at (850) 871-9300 or email service@rssi.com. Name of Person Performing Maintenance:...
  • Page 22 Maintenance Manual  Inspect Spring and Actuator Clevis Brackets, Bolts, and Retaining Bolt for improper wear or damage. Lubricate all clevis’ and bolts.  Check reflectorized tape and safety lights. Look for damage or improper operation. May 2021 Page 22 of 60...
  • Page 23 Replace the Cowling Cover and remove traffic safety cones  Report any deficiencies to the onsite supervisor  Complete this checklist, maintain a copy in files and forward a copy to RSSI for Warranty purposes  Return barrier to NORMAL Operations.
  • Page 24 Maintenance Manual 4 - R TTACHMENT EPLACE CTUATOR Tools needed: Always have these tools readily available 1. Cordless drill with adapter for 15/16 socket BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. WARNING ● Place traffic cones and block roadway from traffic to ensure worker safety. ●...
  • Page 25 Maintenance Manual 3. Remove Fiberglass Cowling 4. Disconnect the power (orange) and control (green) cables from actuator, taking care not to contaminate connectors with dirt, debris and water. Protect if necessary. Engage and adjust the manual adjustment screw (review Manual Operating Procedures on Page 8) on top of actuator until you can easily remove the connecting bolt at the actuator rod end.
  • Page 26 Maintenance Manual WARNING DO NOT OVER-TIGHTEN, DAMAGE TO SEAL MAY OCCUR. WARNING MANUAL ADJUSTMENT LOCKOUT SCREW MUST BE DISENGAGED BEFORE ACTUATOR IS MOVED ELECTRICALLY AGAIN OR DAMAGE WILL OCCUR. 10. Clear barrier of any tools. 11. Lubricate all clevis bolts and hardware. 12.
  • Page 27 Maintenance Manual 5 – R TTACHMENT EPLACE AFETY ENSOR TOOLS NEEDED 1. Phillips Head Screw Driver BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel 1 Turn off the power to the barrier you’re working on (24v power supply). 2 Remove the frequency plug with the wires from the safety loops.
  • Page 28 Maintenance Manual 7 Replace frequency plug and restore power to the barrier. Loop detector should flash red/green and then go to solid green indicator light. NOTE Ensure safety loops are clear before powering safety loop detectors. 8 Conduct a test of safety loops for functionality. 9 Return barrier to operation.
  • Page 29 Maintenance Manual 6 – R IR S TTACHMENT EPLACE ENSOR TOOLS NEEDED: 1. 1 1/2 inch open end wrench or crescent wrench BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. NOTE Before replacing, clean the IR Sensor lens and recheck for operation Replace IR Sensor 1.
  • Page 30 Maintenance Manual 3. Turn off the power to the barrier controls you’re working on (24v power supply). 4. Disconnect the IR Sensor cable connector and the 1-1/2” retaining nut, holding sensor to the bracket. 5. Install new IR Sensor and tighten the cable connector and retaining nut. 6.
  • Page 31 Maintenance Manual 7 – R TTACHMENT EPLACE PRING TOOLS NEEDED: 1. One electric or air impact drill 2. 1-1/8 inch socket and 1-1/8 inch open or boxed end wrench. 3. Swivel socket adapter BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel WARNING ●...
  • Page 32 Maintenance Manual 6. Once all tension is off of the springs, un-hook broken spring from bracket then replace with new spring. 7. Once new spring is installed, tighten tension bolts until plates are touching. May 2021 Page 32 of 60...
  • Page 33 Maintenance Manual 8. Reinstate power to the barrier by turning on the Main Disconnect 9. Open the Barrier Control Panel and turn ON the Servo Drive of the affected barrier by re- engaging the Servo Drive fuse. 10. Conduct an operational test…exercise barrier 8-10 cycles while observing spring assembly functionality.
  • Page 34 Maintenance Manual 8 - R TTACHMENT EPLACE ERVO RIVE TOOLS NEEDED: None BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel 1. Servo Drive Fuse closed 2. Disconnect power to the barrier by turning off the Main Disconnect and lock out with a wire tie or IAW local lockout procedures.
  • Page 35 Maintenance Manual 4. Remove old Fuse and replace with new one 5. Reinstate power to the barrier by turning on the Main Disconnect 6. Re-engage Servo Drive Fuse Holder (FU1) 7. Servo Drive should power up 8. Return barrier to service. May 2021 Page 35 of 60...
  • Page 36 Maintenance Manual 9 – R LED T TTACHMENT EPLACE RAFFIC IGHT TOOLS NEEDED 1. Phillips Head Screwdriver 2. Pliers BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. Turn off the power to the barrier you’re working on (24v power supply is on CB5). 1.
  • Page 37 Maintenance Manual 4. Remove wires for old LED Light from interior terminal block. 5. Remove old LED light and replace with new LED light. 6. Rewire new LED light to interior terminal block. 7. Tighten Tabs holding lens in place with a Phillips Head Screw Driver. 8.
  • Page 38 Panel unit and reconnected to the new Servo Drive Panel unit. WARNING The Servo Drive Panel should ONLY be opened at the RSSI factory. It is considered a “LRU” Line Replacement Unit. Opening this box VOIDS THE WARRANTY.
  • Page 39 Maintenance Manual 1. Disconnect power to the barrier by turning off the Main Disconnect and lock out with a wire tie or IAW local lockout procedures. 2. Remove fiberglass cowling then remove cowling from buttress. CAUTION DO NOT FORCE CONNECTORS TOGETHER, they are keyed in and must be aligned correctly, hand tighten only 3.
  • Page 40 Maintenance Manual NOTE Use dielectric grease to protect connectors. 13. Install Ethernet cable to sealed unit – 14. Install power cable to sealed unit (tighten then push connector in and tighten again) it may take a few times to FULLY SEAT the power connector to seal unit 15.
  • Page 41 Maintenance Manual 11 - R TTACHMENT EPLACE ERVO RIVE IN ANEL TOOLS NEEDED 3. Phillips Head Screw Driver 4. Small Electronics (Flathead) Screw Driver BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel WARNING ● Place traffic cones and block roadway from traffic to ensure worker safety when operating barriers.
  • Page 42 Maintenance Manual 2. Carefully remove Orange (Power) Cable from Drive by first disconnecting bonding plate from cable then pulling U/V/W Wiring Harness. Disconnect Brake wires (MBRK+ and MBRK-) from Terminal Block. Place Cable securely to the side. 3. Carefully remove Green (Encoder) Cable from Drive by unscrewing 2 small screws on connector then unplugging from Drive.
  • Page 43 Maintenance Manual 8. Connect Shunt harness, L1/L2 wire harnesses, and Ethernet Cable back to new Drive. 9. Install Orange Cable back to drive by placing cable under bonding plate then securing. Then connect U/V/W wiring harness and terminate MRBK + and – wires back to Terminal Block. 10.
  • Page 44 Maintenance Manual 12 - R LED L TTACHMENT EPLACE SSEMBLY IGHTS TOOLS NEEDED: 1. Phillips Head Screw Driver 2. Wire Cutters/Stripper 3. Water proof Butt Splices and Electrical Tape (in Spare Parts Kit) 4. Heat Gun BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel WARNING ●...
  • Page 45 Maintenance Manual 5. Rewire LED Lights, terminate with a waterproof butt splice and tape connection. 6. Reinstate power to the barrier by turning on the Main Disconnect 7. Conduct a test to verify LED Lights are functioning properly. Return barrier to operation. May 2021 Page 45 of 60...
  • Page 46 Maintenance Manual 13 - R TTACHMENT EPLACE URGE ROTECTION ODULE IN TOOLS NEEDED: None BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. NOTE Surge Protection Module is equipped with RED indicators on the front of device to inform you if the device has Failed.
  • Page 47 Maintenance Manual new pluggable module into Surge Protection Device. Ensure tabs are lined up and Install module is seated securely. 4. Turn ON CB1, wait 4 seconds for transfer switch, then turn on CB2, & CB3. Then monitor Surge Protection Module to ensure it does not Fail once power is turned on. Return barrier to normal operation May 2021 Page 47 of 60...
  • Page 48 Maintenance Manual 14 - R TTACHMENT EPLACE ELAY ELAY IN TOOLS NEEDED: None BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. 1. Disconnect power to the barrier by turning off the Main Disconnect and lock out with a wire tie or IAW local lockout procedures.
  • Page 49 Maintenance Manual 4. Grasp Time Delay Relay with thumb and finger then pull straight out. 5. Ensure Time Delay Relay dip switches are set properly (out of the box, all dip switches are set to the left; adjust the top dip switch to right and leave the remaining three to the left) 6.
  • Page 50 Maintenance Manual 15 - R TTACHMENT EPLACE OLTAGE ONITOR IN TOOLS NEEDED: None BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. 11. Disconnect power to the barrier by turning off the Main Disconnect and lock out with a wire tie or IAW local lockout procedures.
  • Page 51 Maintenance Manual 14. Note and Diagram existing wiring for installation of new Relay. 15. Grasp Voltage Monitor Relay while releasing from Dinrail with small screwdriver. 16. Disconnect all wires and discard defective unit. 17. Reconnect existing wires on new unit then attach to Dinrail by reversing procedure in step 5. 18.
  • Page 52 Maintenance Manual 16 - R 24 VDC P TTACHMENT EPLACE OWER UPPLY IN TOOLS NEEDED: 1. Small Phillips Head Screwdriver 2. Small Straight Head Screwdriver 3. Volt Meter BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel. 1.
  • Page 53 Maintenance Manual 4. Remove Power Supply from the Panel railing by pulling down tab on the bottom of the Power Supply, then pulling out and up from the bottom of the Power Supply. 5. Install the new Power Supply onto Panel railing by reversing step 4 above. 6.
  • Page 54 Maintenance Manual 17 – R TTACHMENT EPLACE AND ETUP OUCHSCREENS Replace Touchscreens BEFORE YOU INITIATE MAINTENANCE OPERATIONS All Maintenance Operations must be coordinated with site personnel 1. Remove (unplug) 24vdc power and Ethernet patch cable 2. Locate 4 black plastic locking clips on rear of screen May 2021 Page 54 of 60...
  • Page 55 Maintenance Manual 3. Remove by rotating plastic clips until they release 4. Replace with new touchscreen 5. Attach 4 black plastic locking clips by rotating until snug against faceplate May 2021 Page 55 of 60...
  • Page 56 Maintenance Manual CAUTION Do not over tighten clips, this will cause sensitivity issues on touchscreen 6. Replace (plug in) the 24vdc and Ethernet patch cable 7. Complete steps below “Changing IP address and choose program” section Setup Replacement Touchscreen Set IP Address 1.
  • Page 57 Maintenance Manual 1. Choose Touchscreen Program and From menu, select Load Application [F1]. 2. Then choose desired program from the list and press Load [F2]. 3. If asked “Do you want to replace the terminal’s current communication…configuration?”, select Yes [F7]. May 2021 Page 57 of 60...
  • Page 58 Maintenance Manual 4. After a few moments the run program button and other buttons will light up on Main menu. Select, Terminal Settings [F4] 5. Next, select Startup Options 6. Then select Run Current Application and press the Run Options [F3] button. May 2021 Page 58 of 60...
  • Page 59 Maintenance Manual 7. In the Run Options Menu. a. Set Replace RSLinx Enterprise Communications [F1] to Yes. b. Set Delete Log Files On Every Power Cycle [F2] to NO and Press Ok [F7]. 8. Press OK [F7] 9. Press Close [F8] May 2021 Page 59 of 60...
  • Page 60 Maintenance Manual 10. Press Reset [F7] to reboot touchscreen. 11. Return barrier to service. May 2021 Page 60 of 60...