OPERATOR S MANUAL RSS-3000 MSB MOBILE SURFACE BARRIER RSSI Barriers, LLC 6530 East Highway 22 Panama City, Florida 32404 850-871-9300/Fax 850-871-4300 Web Site: www.rssi.com
Table of Contents 1 GENERAL... 3 1.1 PURPOSE... 3 1.2 NEXT GENERATION SERVO EM TECHNOLOGY... 3 Figure 1-1, MPAI-Series Cutaway... 3 1.3 LIMITED WARRANTY... 4 1.4 SAFETY SUMMARY... 5 1.4.1 General Safety Instructions... 5 1.4.2 Safety Instructions... 5 1.5 OPERATOR RESPONSIBILITIES... 6 2 SPECIFICATIONS... 6 2.1 GENERAL SPECIFICATIONS... 6 2.2 OPERATING SYSTEM SPECIFICATIONS... 7 2.3 SAFETY FEATURES... 7 2.3.1 RSS-3000 MSB:... 7 2.3.2 Trailer... 8 3 OPERATING PROCEDURES... 8 3.1 TOW PROCEDURES.... 8 3.1.1 Conduct a walk around and ensure general condition.... 8 Figure 3-1, RSS-3000 MSB Safety Items... 8 Figure 3-2, Drop Beam Safety Pin... 9 Figure 3-3, Transition Plate Safety Pin... 9 Figure 3-4, Top Plate Safety Bolts... 9 3.2 PLACEMENT OF MSB.... 10 3.2.1 FORKLIFT.... 10 Figure 3-5, Drop Beam Safety Pin... 10 Figure 3-6, Transition Plate Safety Pin... 10 Figure 3-7, Stabilize MSB... 11 Figure 3-8, Trailer Jack Lock... 11 Figure 3-9, Connect Push Button Operator Controls... 11 3.2.2 MSB TRAILER JACK SYSTEM.... 12 3.3 OPERATING INSTRUCTIONS. THE FOLLOWING STEPS OUTLINE THE OPERATOR ACTIONS FOR THE RSS-3000 MSB.... 19 3.3.1 Sequence of Operation.... 19 3.3.2 Standard Push Button Operator Controls, Normal Operations... 19 Figure 3-25, Standard Push Button Operator Controls... 19 3.3.3 Manual Operation... 20 Figure 3-26, Access Cowling... 20 Figure 3-27, Manual Brake Overdrive... 20 4 OPERATOR MAINTENANCE... 21 QUARTERLY MAINTENANCE CHECKLIST... 22
1 GENERAL The RSS-3000-MSB is an all-electric mobile surface vehicle barrier that is designed to stop or disable vehicles and provide significant protection during special events or during periods of increased threats. It is designed to be quickly deployed and to be completely functional within 30 minutes. The RSS-3000 MSB provides a 12 foot access control point for event control or in areas requiring increased security access control. On unpaved or uneven road surfaces, the jack system serves as stabilizers to allow for a smooth transition from the roadway to the barrier surface. Additional reinforcement can be provided by placing jersey barriers adjacent to the jack system. All MSB Vehicle Barriers are fully operational and self-contained when shipped from the factory ready to use. The simple design of the RSS-3000-MSB requires very little maintenance even when there are high traffic volumes. 1.1 Purpose This manual provides basic information on the operation and preventative maintenance of the RSS-3000 MSB Electric Mobile Surface Barrier and is designed to assist the Owner/User and Systems Integrators. 1.2 NEXT GENERATION SERVO EM TECHNOLOGY The MPAI-Series Servo Actuator designed by Allan Bradley for RSSI products represents a leap ahead in electric motor technology. It uses roller screw technology, which has 15 times the travel life of an equivalent size ball screw. The MPAI-Series actuator functions in the same manner as a brushless servomotor. The servo drive rotates the motor at controlled speeds and torque, for a controlled number of revolutions and move times. This rotary motion translates into linear motion by use of the internal planetary roller screw mechanism of the MPAI-Series actuator. Figure 1-1, MPAI-Series Cutaway Figure 1-2, GSX40 Servo Actuator in RSS-3000 MSB
All actuators have IP-67 DIN Connectors (water resistant) and a manual overdrive for the brake that allows for the manual operation of the barrier UP or DOWN using a cordless drill with the proper attachment. The MPAI-Series actuator incorporates an absolute encoder as the primary rotary feedback device. If power is lost the barrier retains its position so as power is restored; no homing or calibration is required. The MPAI-Series Servo Actuator has an internal holding brake. Whenever there is not power to the brake, the armature is held in place preventing the inverted roller screw from turning and prevents the output rod from back driving, which in turn prevents the output rod from moving 1.3 Limited Warranty Figure 1-2, MPAI Series Servo Actuator in RSS-3000 MSB Barrier RSSI Barriers, LLC. warranties the RSS-3000 Series of Barriers to be free of defects in workmanship and materials for a period of 3 years for electrical and 5 years for mechanical components PARTS ONLY. Warranty will begin from the date of shipment from the factory or if installed by RSSI Barriers, LLC, from the date of installation unless otherwise noted on the bottom of this form. RSSI Barriers, LLC reserves the right of final determination as to the existence and causes of any defect or failure. Any part or parts found to be defective and that are returned to RSSI Barriers, LLC within the warranty period, shall at our option be repaired or replaced free of charge F.O.B. the factory. The warranty will not apply to the following circumstances that are beyond our control. Misuse, vandalism, accident, neglect, unauthorized repairs or modifications, acts of God (lightning, floods, insect damage, etc...), power surges, incorrect installation, or application. The warranty set forth above is entirely exclusive and no other warranty whether written or oral, is expressed or implied. RSSI Barriers, LLC specifically disclaims any and all implied warranties, merchantability or fitness for a particular purpose. It is the purchaser s sole and exclusive responsibility to determine whether or not the equipment will be suitable for a particular purpose. In no event shall RSSI Barriers, LLC be held liable for direct, indirect, incidental, special, consequential damages or loss of profits whether based on contract, tort, or any other legal theory during the course of the warranty or at any time thereafter. The end user agrees to assume all responsibility for all liability involving the use of this product, releasing RSSI Barriers, LLC of all liability. All RSSI barriers require minimal maintenance; however, there are some tasks that need to be performed after the barrier is installed to insure compliance with the warranty provided. When the RSSI barrier is installed and not accepted by the end user until a later date, the quarterly preventive maintenance tasks located in Attachment 1 of the Operator s Manual must be accomplished until acceptance by the end user. Likewise, after acceptance the end user is required to conduct these quarterly preventive maintenance tasks to ensure the warranty is valid. IN ORDER TO USE THE VEHICLE BARRIER, YOU MUST UNDERSTAND AND BE IN FULL UNCONDITIONAL AGREEMENT WITH ALL STIPULATIONS OUTLINED ABOVE. IF YOU ARE NOT IN FULL AGREEMENT, DO NOT PUT UNIT INTO OPERATION. PLACING THE VEHICLE BARRIER INTO
OPERATION WILL BE CONFIRMATION THAT YOU ARE IN FULL UNCONDITIONAL AGREEMENT WITH ALL OF THE ABOVE. 1.4 Safety Summary 1.4.1 General Safety Instructions This manual describes physical operation and maintenance procedures. Please NOTE the procedures may cause injury or death to personnel, or damage to equipment if NOT properly followed. Prior to performing any task, the WARNINGS, CAUTIONS, and NOTES included in that task shall be reviewed and understood. 1.4.1.1 Warnings, Cautions and Notes WARNINGS and CAUTIONS are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements that are considered essential to protection of personnel (WARNING) or equipment (CAUTION). WARNINGS and CAUTIONS immediately precede the step or procedure to which they apply. WARNINGS and CAUTIONS consist of three parts: heading (WARNING, CAUTION, or NOTE); a statement of the hazard; minimum precautions and possible result if disregarded. NOTES are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements that are not essential to protection of personnel or equipment. NOTES may precede or follow the step or procedure, depending upon the information that it pertains to. The headings used and their definitions are as follows. HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION, STATEMENT, ETC. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO, OR DEATH OF, PERSONNEL OR LONG TERM HEALTH HAZARDS. HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION, STATEMENT, ETC, WHICH, IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS. HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, CONDITION, OR STATEMENT. 1.4.2 Safety Instructions Operators of the RSS-3000 MSB MUST comply with the following important safety instructions PRIOR TO and DURING the operation of the RSS-3000 MSB. Read and comply with all safety rules in this manual before operating the barrier. A fully trained maintenance person must perform all maintenance work. In the case of an unmanned gate operation, vehicles must remain clear of the barrier during the raising and lowering of the Drop Beam Assembly. Be sure to post signs warning of the barrier operation.
If this unit is placed in a main traffic area, place traffic safety cones and make every attempt to divert or stop traffic before maintenance is started. Do not put any objects under a raised Drop Beam and keep all obstructions clear of the vicinity of the barrier Do not operate this equipment when you are distracted or under the influence of drugs, alcohol or medication causing diminished control. Prior to accessing the RSS-3000 MSB cowling, the main electrical disconnect to the barrier will be isolated (follow local lock out procedures). Never operate this equipment when a vehicle, person or any obstruction is in the way of full operation of the RSS-3000 MSB. 1.5 Operator Responsibilities The owner/user of the RSS-3000 MSB should be aware that they must: Not operate the vehicle barrier without receiving prior certification training, including reading this Operator Manual. Follow all safety rules, warnings and caution statements outlined in this Operator Manual. Retain a copy of this Operator Manual with the vehicle barrier controls. Prominently display warning signs on both sides of the vehicle barrier as required. Always be certain that the barrier area is clear of vehicles before operation. Discontinue use if the vehicle barrier fails to operate properly. Contact a trained barrier maintenance technician to maintain and repair the barrier. 2 SPECIFICATIONS 2.1 General Specifications All steel construction, primed and painted frame, post, and beams. MSB: The main MSB is 8 feet wide, 20 feet long, and 27 inches tall. The MSB trailer is 54 inches wide, 23 feet long, and 34 inches tall. Beam Dimensions: 3/8 steel tubing, 3 inches wide by 6 inches tall. Beam Height: 27 inches to the top of beam from steel plate drive surface. Shipping Weight: MSB; 10,500 lbs. at 12 foot lane coverage; MSB trailer 1,380 lbs.; Total weight MSB & Trailer 11,880 lbs. Operating System: Servo EM Actuator w/ patented roller screw technology and a Spring Assist Assembly. Electromechanical Cycle Time: Standard operation is less than 8 seconds. Operating Temperatures: Operational speeds are constant in temperatures ranging from -20 degrees to 200 degrees Fahrenheit without the use of heat on the operating systems. Figure 2-1, RSS-3000 MSB Electric Mobile Surface Barrier
2.2 Operating System Specifications The barrier is operated by a Servo MP Series Heavy Duty Electric Cylinder and a Spring Assist Assembly. Main Power The Servo Electromechanical motor operates on 120/208-240V single-phase (three-wire) power. Loss of Commercial Power Operation An optional Battery Back-up System can provide over 200 continuous cycles in the event of primary power loss. Control of the barrier is accomplished through normal operating controls. Manual Operation Barriers can be manually operated with a cordless drill fitted with the proper drive. Controls - The following circuits and controls shall be furnished. EPU/Control Panel - A control panel shall be provided to interface between all operator controls and barrier locations. This control panel shall contain all control circuits necessary for barrier operation. Voltage - The control circuit shall operate from 120/208-240V single-phase (three-wire) 50/60 Hz power supply. The control panel shall be mounted in a general-purpose NEMA 4 metal enclosure. All device interconnect lines shall be run to terminal strips. Operator Controls Barrier is supplied with push button operator controls to operate the MSB UP and DOWN. The Operator Controls are kept inside the control panel when not in use. 2.3 Safety Features 2.3.1 RSS-3000 MSB: Each unit is equipped with two safety LED lights, one mounted on each side of the Drop Beam. Figure 2-2, LED Safety Light Reflective red and white striped material is placed along the Drop Beam on both sides and on two sides (outside corners) of the Trailer Jacks. Figure 2-3, Reflective Safety Tape There are two RED/GREEN Traffic Lights mounted on the rear buttress of the MSB to advise drivers when they should stop or proceed.
2.3.2 Trailer Figure 2-4, Traffic Lights Trailer is equipped with electric brakes wired into the standard trailer wiring harness. Trailer has standard Stop Lights and Turn Signals. There is a large center pin in the center of the trailer for mounting the MSB. This center pin aligns four large bolts that are used to secure the MSB during transport. 3 OPERATING PROCEDURES 3.1 Tow Procedures. The following are guidelines to explain steps used to prepare to tow the MSB. Personnel should always use their locally approved tow procedures. 3.1.1 Conduct a walk around and ensure general condition. 3.1.1.1 The following items should be inspected on the Trailer. Tires inflated, brake lights, safety chains, and the trailer wiring harness all intact. Figure 3-1, RSS-3000 MSB Safety Items If any of these items are defective, correct before attempting to tow the MSB
3.1.1.2 The following items MUST be present on the MSB. Safety Pin on the MSB located near front of Drop Beam. Safety Pins in the MSB transition plate. Figure 3-2, Drop Beam Safety Pin Figure 3-3, Transition Plate Safety Pin Safety Bolts in four corners of the MSB plate, used to keep the MSB secured to the trailer during transportation. Figure 3-4, Top Plate Safety Bolts
3.2 Placement of MSB. If any of these items are defective, correct before attempting to tow the MSB There are two options for placing the MSB. 3.2.1 FORKLIFT. If a forklift is available, it is the most expeditious way to place the MSB into service. Remove the four (4) Top Plate Safety Bolts used to secure the MSB during transport. Using at least a 15K forklift, lift the MSB from the trailer and place it in the roadway. Ensure to position MSB so the Control Panel is on the side of roadway that has the electrical power service. Remove the safety pin from the front of the MSB Beam. Figure 3-5, Drop Beam Safety Pin Remove the transition plate pins and lower transition plate. Figure 3-6, Transition Plate Safety Pin
Using the manual jack handles lower the MSB trailer jacks to raise the MSB and stabilize it due to any unevenness in the roadway (road crown). Figure 3-7, Stabilize MSB If the manual jack handle seems to bind when attempting to use, ensure the jack spindle is not locked, push/pull to lock/unlock. Figure 3-8, Trailer Jack Lock Open the Control Panel and remove the Yellow Push Button Operator Control and cord. Remove the connector cover and connect the push button cord to the control panel. Figure 3-9, Connect Push Button Operator Controls
Connect the electrical power service to the Control Panel. Figure 3-10, Connect Electrical Power Ensure a certified electrician connects the power service to the disconnect switch on the exterior of the control panel. The MSB is ready for use, see paragraph 3.3 for operating instructions. 3.2.2 MSB TRAILER JACK SYSTEM. The MSB design allows it to be deployed from the trailer if a forklift is not available. Two people can perform this operation. Pull the vehicle towing the MSB trailer in the middle of the roadway, centering it. Figure 3-11, Position MSB Trailer
Stop the vehicle so the center pin in the MSB trailer is in the location you want the MSB. This is the pivot point. Figure 3-12, MSB Pivot Pin Remove the four (4) Safety Bolts used to secure the MSB during transport and place them on the trailer frame near their hole so they don t drag on the ground when the trailer is moved. Figure 3-13, Remove Top Plate Safety Bolts
Two individuals can then push on the MSB trailer jack system on opposite corners. The MSB will pivot on the trailer from the center of the roadway to a position across the roadway. See below figures. Figure 3-14, Position MSB in Roadway Using the manual jack handle or a power drill, lower the trailer jacks until they touch the roadway to stabilize the MSB. Figure 3-15, Stabilize MSB If the manual jack handle seems to bind when attempting to use, ensure the jack spindle is not locked, push/pull to lock/unlock.
Figure 3-16, Trailer Jack Lock Then working from the same end, two individuals using the manual jack handles, raise the MSB working as a team approximately 3-4 inches. They should then move to the other end of the MSB and raise that end approximately 3-4 inches. Repeat this process until the MSB Plate clears the center pin on the trailer. Figure 3-17, Raise MSB Off Trailer Pull the vehicle and trailer forward. Replace and screw safety bolts into holes before storing trailer so they don t drop from trailer and get damaged. Figure 3-18, Pull MSB Trailer Clear
Don t replace the safety bolts before pulling trailer from under the MSB. Doing so may result in the bolts striking the bottom of the MSB when the trailer is pulled forward. After the trailer has been safely removed from the area, the MSB can begin to be lowered in place to the roadway surface. Working from the same end, two individuals using the manual jack handles or power drills, lower the MSB working as a team approximately 10-12 inches. They should then move to the other end of the MSB and lower that end approximately 10-12 inches. Repeat this process until the MSB Plate is lowered to the roadway surface. Adjust MSB and stabilize it due to any unevenness in the roadway (road crown). Figure 3-19, Lower MSB to Roadway
Remove the safety pin from the front of the MSB Beam. Figure 3-20, Remove Drop Beam Safety Pin Remove the transition plate pins and lower transition plate. Figure 3-21, Lower Transition Plates
Open the Control Panel and remove the Yellow Push Button Operator Control and cord. Remove the connector cover and connect the push button cord to the control panel. Figure 3-22, Connect Push Button Operator Control Connect the electrical power service to the Control Panel. Figure 3-23, Connect Electrical Power Ensure a certified electrician connects the power service to the disconnect switch on the exterior of the control panel.
If the traffic lights and LED Safety Lights do not illuminate when the disconnect switch is activated, ensure the main breakers inside the EPU Control Panel are ON. Figure 3-24, MSB Circuit Breakers The MSB is ready for use, see paragraph 3.3 for operating instructions. 3.3 Operating Instructions. The following steps outline the operator actions for the RSS-3000 MSB. 3.3.1 Sequence of Operation. The RSS-3000MSB has a very simple sequence of operation. When the MSB Drop Beam is in the DOWN position, the LED safety lights located in the center of the beam are Flashing and the traffic Lights are solid RED. When the MSB Drop Beam is in the UP position, the LED safety lights are OFF and the traffic lights are GREEN. Whenever the MSB Drop Beam is moving between the fully UP or DOWN position, the LED safety lights flash and the Traffic Lights Flash RED. 3.3.2 Standard Push Button Operator Controls, Normal Operations Figure 3-25, Standard Push Button Operator Controls 3.3.2.1 To OPEN the traffic lane press the UP push button. The traffic light turns from solid RED to RED flashing, the barrier raises, LED safety lights continue to flash until the barrier reaches the fully UP position. The traffic light changes to GREEN and the LED safety lights stop flashing.
3.3.2.2 To CLOSE the traffic lane press the DOWN push button. The traffic light turns from GREEN to RED flashing, the barrier lowers, LED safety lights flash until the barrier reaches the fully DOWN position. The traffic light changes to solid RED and the LED safety lights continue flashing. 3.3.3 Manual Operation 3.3.3.1 Manually Lower Barrier Place necessary traffic safety cones to help insure worker safety. Remove the Access Cowling ( and 8 screws) to gain access to the actuator Figure 3-26, Access Cowling Tools needed; a 7/8 inch socket, a ratchet, and cordless drill. Remove the Metal Cover from the Manual Brake Overdrive. Figure 3-27, Manual Brake Overdrive Tools needed; a 7/8 inch socket, and cordless drill. Remove metal cylinder cover from Manual Brake Overdrive. Then switch to a cordless drill and set the drill on the slowest RPM setting and turn 7/8 nut clockwise to engage the manual drive downward lining up the notches while going down. Once notches are lined up and Manual Drive is down, turn locking nut (right below 7/8 nut) clockwise to Lock in Manual Brake Overdrive in place. Lower the barrier by keeping firm pressure on the drill and operating it on reverse setting (counterclockwise) on the slowest RPM setting until it reaches the full down position. DO NOT OVERDRIVE.
To release Manual Drive slide the slip nut down and turn locking nut out of notches, then turn 7/8 nut counterclockwise to disengage Manual Drive. DO NOT OPERATE BARRIER UNTIL MANUAL BRAKE OVERDRIVE IS FULLY DISENGAGED. FAILURE TO FOLLOW THESE PROCEDURES COULD SEVERELY DAMAGE THE BRAKE OVERDRIVE AND INVALIDATE THE WARRANTY Replace the Access Cowling, remove traffic safety cones, and contact site supervisor. 3.3.3.2 Manually Raise Barrier Tools needed; a 7/8 inch socket, a ratchet, and cordless drill. Remove metal cylinder cover from Manual Brake Overdrive. Then switch to a cordless drill and set the drill on the slowest RPM setting and turn 7/8 nut clockwise to engage the manual drive downward lining up the notches while going downward. Once notches are lined up and Manual Drive is down, turn locking nut (right below 7/8 nut) clockwise to Lock in Manual Brake Overdrive in place. Raise the barrier by keeping firm pressure on the drill and operating it forward (clockwise) on the slowest RPM setting until it reaches the full up position. To release Manual Drive slide the slip nut down and turn locking nut out of notches, then turn 7/8 nut counterclockwise to disengage Manual Drive. DO NOT OPERATE BARRIER UNTIL MANUAL BRAKE OVERDRIVE IS FULLY DISENGAGED. FAILURE TO FOLLOW THESE PROCEDURES COULD SEVERELY DAMAGE THE BRAKE OVERDRIVE AND INVALIDATE THE WARRANTY Replace the Access Cowling, remove traffic safety cones, and contact site supervisor of problem. 4 OPERATOR MAINTENANCE The simple design of the RSS-3000 MSB requires very little maintenance. If your vehicle barrier needs repair or maintenance at any time, please contact your site supervisor. Robotic Security Systems, Inc. Technical Service contact numbers: Toll Free (866) 249-1029 or (850) 871-9300. A maintenance checklist is provided in Attachment 1.
Quarterly Maintenance Checklist Make copies of this checklist for maintenance activity for each barrier and maintain a copy in the maintenance binder for the Warranty/Historical Record. Location: Unit Serial #: Barrier Cycle Count: Name of Person Performing Maintenance: 1. Turn power on to unit check for proper voltage. Unit Model #:RSS-3000-MSB Voltage: 120/240 V Single Phase, 30 Amp Date of Maintenance: 2. Check operation of unit. Operate 5 to 6 times. Ensure that the Drop Beam operates smoothly (8 seconds). 3. Make sure the Drop Beam Barrier is in the OPEN (Drop Beam Up) position and power is turned off. 4. Place necessary traffic safety cones to insure worker safety. 5. Remove Cowling Cover. 6. Check Actuator brackets. If these connections are not kept tight, it might cause loose motion that could result in excessive wear.
7. Inspect Spring and Actuator Clevis Brackets, Bolts, and Retaining Pin for improper wear or damage. 8. Check reflectors and safety lights. Look for damage or improper operation. 9. Check Roller Bearing Bolts. Make sure these are tight. A loose fit might cause excessive wear and improper Drop Beam operation. 10. Check and Grease Roller Bearings. Use a standard bearing grease in a grease gun applying grease until it is visible at any point along either edge of the bushing and the shaft. 11. Check all painted parts and touch up as needed.
12 Replace the Cowling Cover and remove traffic safety cones. 13. Report any deficiencies to the onsite supervisor. 14. Complete this checklist, maintain a copy in files and forward a copy to RSSI. NOTES: