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INSTRUCTION & INSTALLATION

SOLID-STATE CROSSING CONTROLLER III PLUS

(SSCC III PLUS)

A91190 & A91195

September 2007

DOCUMENT NO. SIG-00-02-03

VERSION F

Safetran Systems Corporation, California Division 10655 7th Street, Cucamonga, California 91730

1-800-793-SAFE

Copyright © 2005 – 2007 Safetran Systems Corporation. All rights reserved.

Document No. SIG 00-02-03 Version: F Safetran® is a registered trademark of Safetran Systems Corporation. Microsoft® is a registered trademark of Microsoft Corporation.

Echelon® is a registered trademark of Echelon Corporation.

PROPRIETARY INFORMATION

SAFETRAN SYSTEMS CORPORATION has a proprietary interest in the information contained herein and, in some instances, has patent rights in the systems and components described. It is requested that you distribute this information only to those responsible people within your organization who have an official interest.

This document, or the information disclosed herein, shall not be reproduced or transferred to other documents or used or disclosed for manufacturing or for any other purpose except as specifically authorized in writing by SAFETRAN SYSTEMS CORPORATION.

WARRANTY INFORMATION

SAFETRAN SYSTEMS CORPORATION warranty policy is as stated in the current Terms and Conditions of Sale document. Warranty adjustments will not be allowed for products or components which have been subjected to abuse, alteration, improper handling or installation, or which have not been operated in accordance with Seller's instructions. Alteration or removal of any serial number or identification mark voids the warranty.

SALES & SERVICE AND TECHNICAL SUPPORT LOCATIONS

Technical assistance and sales information on SAFETRAN products may be obtained at the following locations:

SAFETRAN SYSTEMS CORPORATION SAFETRAN SYSTEMS CORPORATION

2400 NELSON MILLER PARKWAY CALIFORNIA DIVISION

LOUISVILLE, KENTUCKY 40223 10655 7th STREET

TELEPHONE: (502) 244-7400 CUCAMONGA, CALIFORNIA 91730

FAX: (502) 244-7444 TELEPHONE: (909) 987-4673

SALES & SERVICE: 1-800-626-2710 CUSTOMER SERVICE: 1-800-793-7233

WEB SITE: http://www.safetran.com TECHNICAL SUPPORT: 1-800-793-7233

FAX: (909) 945-2662

FCC RULES COMPLIANCE

The equipment covered in this manual has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

CHANGE NOTICE

The following changes have been incorporated into Revision F of the Instruction & Installation Manual for the Solid-State Crossing Controller III PLUS (SSCC III PLUS), Document No. SIG-00-02- 03.

09-10-07:

• Changed footers to reflect ‘Rev F’ changes

Page 4-38 and 4-39, paragraph 6.4

• Inserted two intentionally blank pages to support printing of Program and Configure Menus

Page4-58, paragraph 6.4

• Inserted blank page to correct pagination issues

Page 5-14, paragraph 5.2.1.3, Steps 5-7

• Changed MCF in bubbles to reflect current data

Page 6-2, paragraph 6.4

• Inserted new Paragraph 6.4, titled “Meter Reading Conversion Examples”

Page 7-1, paragraph 7.1

• Changed sentence to end of second paragraph to read “Return the unserviceable unit to

Safetran under the Return Material Authorization process, if applicable.”

Page 7-2

• Inserted blank page stating “This page intentionally left blank” to correct pagination issues

Page 7-3, Figure 7-14

• Replaced with new Troubleshooting Diagram dated 09-06-07

• Changed page size to 11 X 17 to make it easier to read the troubleshooting diagram

Page 7-4

• Inserted blank page stating “This page intentionally left blank” to correct pagination issues

Page 7-5, paragraph 7-3

• Changed the first paragraph to read: “The SSCC is continuously self-checking its hardware and software for faults. Fault conditions may be severe or informational. When a severe fault is detected, the LCD displays a SHUTDOWN #xxx message where xxx is the Error Code. The fault is entered into the summary log. If a fault occurs repeatedly, the unit must be replaced and returned to Safetran under the Return Material Authorization process.”

iii Document No.: SIG-00-02-03 Version: F

• Changed the second paragraph to read: “Some faults are informational faults and will not cause a SHUTDOWN; however, they are still entered into the summary log. Some faults may be correctable by user action. Table 7-1 lists those faults and the action to take.”

Page 7-5, Table 7-1

• Replaced all occurences of “If error persists, unit requires servicing” with “If error persists, replace unit and return it to Safetran under the Return Material Authorization process.”

• Added Shutdown Error Code 394 that states “1E2 03/08/07 16:27:47.2 Processor communication error, Unable to communicate with slave processor” in the Sample Summary Log Messages Column, “394” in the Shutdown Error Code Column, and “Replace unit and return it to Safetran under the Return Material Authorization process” in the Corrective Action Column

Page 7-6, paragraph 7.4

• Changed paragraph number 7.2 to 7.4

Page 7-7, paragraph 7.5 Inserted new paragraph 7.5 that states: ‘Troubleshooting Maintenance Call (MC) Light Problems Several operations in the SSCC system will turn-off the MAINT CALL (MC) light. This procedure assumes:

• The warning devices are not activated and SSCC unit is healthy.

• No track is out-of-service (A track OOS turns off the MC light)

• MC operation is being placed in service for the first time and wiring must be checked.

• MCF files that effect the Maintenance Call (MC) Lights When the parameters listed in 7-2 are energized via the Menus, the MC lights will not illuminate.

Before beginning Troubleshooting procedures, ensure that the parameters depicted in 7-2 are not the cause of the MC Light being out.

• Verify the status of the listed parameters prior to performing normal troubleshooting procedures for the listed MCF’s.”

Page 7-7, Table 7-2

• Inserted Table 7-2

Table 7-2: MCF / MC Light-Out Cross Reference Chart

MCF

SSCC

Unhealthy Low Battery, if Low Battery Detection enabled Track taken out of service

BASIC X X

BASICPLS X X X

3TRK1WRP X X X

2TRK2WRP X X X

2TRKDSTK X X X

SUPISL X X X

3TRK2TRN X X X

2TRK2TRN X X X

DAXPRMPT X X X

iv

Page 7-8, paragraph 7.5.2 Inserted paragraph 7.5.2 that states: “Troubleshooting Procedures for Maintenance Call (MC) Light Problems.

The following procedure checks the most common items first. If the MAINT CALL light does not turn on after a step, proceed to the next step.

1. Observe MAINT CALL LED on Connector J2

• If LED 1 is on, go to step 2.

• If LED 1 is off, go to step 3.

2. Determine that the MC light functions by testing the lamp circuit as follows:

a. Measure DC voltage between B (+ meter lead) and MAINT CALL (MC) out (- meter lead) on the green connector J2.

If voltage is within 0.5 volts of B, then the lamp or lamp circuit is open and must be repaired.

If voltage is less than 1.0 volts, go to next step.

b. Measure between N (- meter lead) and MC (+ meter lead) on the green connector.

If voltage is within 0.5 volts of B, then the lamp circuit is okay, but the MC output is off.

If LED 1 is on, replace SSCC If LED 1 is off, go to the next step

3. If the SSCC health light is flashing rapidly or off, determine cause or replace SSCC.

4. Battery voltage may be low:

• If Low Battery is set to Enabled in Configuration Menu, verify that the voltage on the battery connector is more than the Low Battery Level shown.

If, after following the steps above, the MC lamp stays off, call Safetran Technical Support for further assistance at (800) 793-7233.”

Page 8-1, paragraph 8-2, Note

• Changed Note to read “SSCC MEF software revision 9V546.A06.H or above requires SEAR II

MEF software revision 9V645.A01.G or above to establish communications.”

Page A-1, Appendix A

• Deleted the former Appendix A, titled “Using a Conventional Meter.” The former Appendix B, titled “SSCC IIIA MCF Release History” is renumbered to Appendix A

History Card, Sheet 2 of 2

• Changed title of History Card to reflect new usage, renaming the title to “SSCC Generic History

Card”

• Deleted former table “Multimeter Reading Variance From Actual Lamp Voltage” and inserted new table from the updated Paragraph 6.4 continuing with the same table title

02-7-2006:

• Changed footers to reflect ‘Rev E.1’ changes v

Page 4-19, paragraph 4.2.2.6

• Added note below paragraph title “…Disable DETECT LAMP NEUTRAL WIRE…”

Page 4-37, Figure 4-11

• Added note next to Default YES…, “…Set to NO…”

Page 4-39, Figure 4-13

• Added note next to Default = YES, “…Set to NO…”

Page 4-41, Figure 4-15

• Added note next to Default = YES, “…Set to NO…”

Page 4-43, Figure 4-17

• Added note next to Default = YES, “…Set to NO…”

Page 4-45, Figure 4-19

• Added note next to Default = YES, “…Set to NO…”

Page 4-47, Figure 4-21

• Added note next to Default = YES, “…Set to NO…”

Page 4-49, Figure 4-23

• Added note next to Default = YES, “…Set to NO…”

Page 4-51, Figure 4-25

• Added note next to Default = YES, “…Set to NO…”

Page 4-53, Figure 4-27

• Added note next to Default = YES, “…Set to NO…”

Page 6-2, paragraph 6.3

• Added sentence to first subparagraph, “…Safetran’s FLX-4000 LED…”

Page 6-2, paragraph 6.3

• Added wording to second subparagraph, “…on volt meters…”, “…measurement…”

Page 6-2, paragraph 6.3

• Reworded third subparagraph to read, “…This distorted AC waveform condition…”

Page 7-1, paragraph 7.2

• Added note, “…The power supplies in many LED signals…” vi

10-6-2005:

Paragraph numbering style changes throughout.

Page 1-2 , paragraph 1.2.1.1 Added features as indicated in bold below:

• Programmable gate control delay (40-Ampere unit includes second GC, inverted GC, pre-emption relay drive, or advance warning sign beacon relay drive)

• Configurable application and test timers

Page 1-11, Table 1-2 for connector J2, pin 7 Added text in bold below:

This output is referenced to negative battery.

Page 1-12, paragraph 1.3.2.1 Removed reference to running DT software on Pocket PC (not currently supported).

Page 1-13, paragraph 1.3.2.1 Added WARNING following first paragraph at top of page.

Page 1-19, paragraph 1.4.1.5 Downgraded WARNING to CAUTION.

Page 1-21, paragraph 1.4.1.8 Added following bullet to Non-vital I/O 1 – (Flash Sync) specification:

• This I/O is referenced to controller’s negative battery

Page 1-25,

• Added paragraphs 1.5.3 and 1.5.4

Page 2-11, 2.2.4 SSCC III PLUS DC Power Connections

• Changed WARNING to the following CAUTION

CAUTION

DO NOT CONNECT POWER TO THE SSCC UNTIL

AFTER COMPLYING WITH PARAGRAPH 2.3. FAILURE

TO INITIALLY “POWER UP” IN THE PROPER

SEQUENCE MAY PREVENT SHORT-CIRCUIT

PROTECTION FROM DETECTING WIRING ERRORS

AND DAMAGE THE UNIT

Page 2-12, 2-13

• Made WARNING from last sentence of last paragraph in 2.2.4.

vii

• Inserted paragraph 2.2.5 (Non-Vital I/O 1 (Flash Sync) Connection), figure 2-7 and associated notes.

Page 2-13, 2-14

• Inserted paragraph 2.2.6 (Traffic Signal Preempt Relay Connections) and figure 2-8.

Page 2-16, 2.2.7.1 Rules For Using Echelon® LAN

• Downgraded WARNING to CAUTION.

Page 2-16, 2-17, 2.3 POWER UP AND INITIALIZATION

• Removed two WARNINGS and a CAUTION, inserted the following WARNING:

WARNING

OBSERVE CORRECT POLARITY WHEN

CONNECTING BATTERY TO THE SSCC IV B AND N

CONTACTS ON FRONT-PANEL CONNECTOR J2.

REVERSED POLARITY WILL RESULT IN

CONTROLLER DAMAGE

• Revised first sentence and added five steps for a startup procedure.

• Added text to end of final NOTE (“The warning devices will remain activated until the proper inputs are energized for MCF selected”)

Page 2-18, 2.3.1 Failure During Power Up and Initialization

• Added “PEDESTRIANS,” to second paragraph of WARNING.

Page 3-1, 3.1 GENERAL

• Added to second paragraph: “. . . GCP and DAX inputs, PSO track circuits, wrap circuits, or traffic signal pre-emption relay check contact. An LED indicator is associated with each input.

When the input is activated the LED is illuminated, and when the input is deactivated the LED is dark. The Two Track Directional Stick MCF (2TRKDSTK) uses a flashing LED to indicate that the directional stick is bypassing an input in the XR circuit.”

• Added to second paragraph: “. . . or active beacon on highway-railroad advance warning signs.”

Page 3-2, Table 3-1

• Following text added to all MCF descriptions except BASIC and DAXPRMT MCFs: “In addition, this MCF supports active beacons on highway-railroad advance warning signs.”

viii

• Added to 2TRKDSTK MCF: “In addition, this MCF supports active beacons on highway-railroad advance warning signs, and an optional test switch input for activating warning devices and releasing the directional stick.”

Page 3-3

• Added following NOTE:

NOTE

Active Beacons are one or more flashing yellow signal heads on a Highway-Railroad Advance Warning Sign mast that are used to provide supplemental emphasis to the advance warning sign while the highway-railroad grade crossing warning devices are activated.

Active beacons may be installed by the highway agency when curves or hills restrict preview of a highway-railroad grade warning system.

A BEACON DELAY TIMER may be used to keep the beacon activated a period of time after the warning devices deactivate. The purpose of the delay time is to provide time for traffic stopped at the crossing to resume speed before the active beacon is turned off. The delay time is determined by engineering study.

Page 3-6, 3.2.2.1 BASICPLS MCF Description

• Added the following text; “. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing activation, or for traffic pre-emption relay health check. Refer to paragraph 3.3 for using 2GC Output / Input #7 (2GC/I7).”

Page 3-6, 3.2.2.2 BASICPLS MCF Operation

• Last sentence, changed input 7 to input 4.

Page 3-8, 3.2.3.1 3TRK1WRP MCF Description

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing

Page 3-9, 3.2.3.3 3TRK1WRP MCF Physical Inputs

• Added following Note for inputs 3 and 5 in Table 3-4: “Disable in Program menu if not used”

Page 3-10, 3.2.4.1 2TRK2WRP MCF Description

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing ix

Page 3-11, 3.2.4.3 2TRK2WRP MCF Physical Inputs

• Added following Note for input 5 in Table 3-5: “Disable in Program menu if not used”

Page 3-12, 3.2.5.1 2TRKDSTK MCF Description

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing

Page 3-14, 3.2.5.3 2TRKDSTK MCF Physical Inputs

• Added following Note for input 5 in Table 3-6: “Disable in Program menu if not used”

• Modified text and added note as follows: “Inputs for a 2TRKDSTK MCF may be from any discrete track circuit, or combination of track circuits, representing each approach circuit and island circuit, such as audio track circuits, DC or AC track circuits, or Style C track circuits. The corresponding input LED flashes when the directional stick is ‘picked’ to bypass that input.”

NOTE

While a flashing input LED indicates that the directional stick is “picked” bypassing that input, it does not indicate that the input is deenergized. When the input LED is flashing and the entering approach and island input LEDs are lit, the directional stick is “stuck” indicating the input is de-energized.

Page 3-15

• Added “3.2.5.6 Test Switch Mode” text plus WARNING, CAUTION and NOTE.

Page 3-16, 3.2.6.1 SUPISL MCF Description

• Strike “(such as a wheel counter system)” from second sentence.

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing

Page 3-17, 3.2.6.3 SUPISL MCF Physical Inputs

• Added following Note for input 5 in Table 3-7: “Disable in Program menu if not used”

Page 3-17

• Added “3.2.6.5 Supplemental Island Timer” text.

Page 3-18, 3.2.7.1 3TRK2TRN MCF Description x

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing

Page 3-19, 3.2.7.3 3TRK2TRN MCF Physical Inputs

• Added following Note for inputs 3 and 5 in Table 3-8: “Disable in Program menu if not used”

Page 3-20, 3.2.8.1 2TRK2TRN MCF Description

• Added the following text; “,. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign. Input #7 is a configurable input that can be used for crossing

Page 3-21, 3.2.8.3 2TRK2TRN MCF Physical Inputs

• Added following Note for input 5 in Table 3-9: “Disable in Program menu if not used”.

Page 3-22, 3.2.9.1 DAXPRMT MCF Description

• Added the following note:

NOTE

If LOS timer functionality is required, it should be a function of the train detection equipment providing input to the crossing controller.

Page 3-22, 3.2.9.2 DAXPRMT MCF Operation

• Added the following note:

Effective with version ‘F’ of this MCF, the Advance Pre-empt Timer must complete before the Minimum Activation Timer begins. This results in forcing the complete cycling of Advance Pre-empt and Minimum Activation times, even in the event of a false train detection.

Page 3-24, 3.2.9.3 DAXPRMT MCF Physical Inputs

• Added following Note for inputs 3 and 5 in Table 3-10: “Disable in Program menu if not used”.

Page 3-24, 3.3 USING 2GC OUTPUT / INPUT #7 MODE (2GC/I7)

• Added to second sentence of note: “. . . or Beacon, where 2GC controls an active beacon on a highway-railroad advance warning sign.”

xi

Pages 3-25 through 3-27

• Added paragraphs 3.3.1 through 3.3.6.

Page 4-4, 4.2.1.3 Program Gate Delay Timers

• Reword first note.

Page 4-5, Table 4-1. SSCC IV Displays for Enabling Inputs (by MCF)

• Input number changes in third and fourth columns.

Page 4-5

• Added note at bottom of page.

Page 4-6, 4.2.1.6 Program 2GC/I7 MODE (40-Amp Unit Only)

• Added “and BEACON” to end of second sentence in second paragraph.

Page 4-6, Table 4-2

• Added Beacon information.

Page 4-6

• Added WARNING at bottom of page.

• Added “and Beacon” to second sentence of note below new WARNING.

Page 4-7, 4.2.1.7 Program Advance Pre-emption Time (40-Amp Unit Only)

• First paragraph following note, changed range high limit to 99 seconds.

Page 4-8, 4.2.1.8 Program Minimum Activation Time

• Added note.

• First paragraph following note, changed range high limit to 99 seconds.

Page 4-8, 4-9

• Inserted the following new material:

4.2.1.9 Program Beacon Delay Time

4.2.1.10 Program Island Delay Enable

Page 4-9, 4.2.1.11 Program Stick Release Time (2TRKDSTK MCF Only)

• First paragraph, first sentence, added “for each track”.

• First paragraph, second sentence, changed range high limit to 120 minutes.

• Added WARNING.

Page 4-10

• Inserted “4.2.1.13 Program Input 7 (40-Amp Unit Only)(2TRKDSTK MCF only)”

• Inserted “4.2.1.14 Program Test Switch (2TRKDSTK MCF only)”

Page 4-19, 4.2.2.5 Configure Aux. I/O

• Added paragraph below figure 4-2.

xii

Page 5-5, Table 5-1

• Added “In addition, this MCF supports active beacons on highway-railroad advance warning signs.” To various MCF descriptions

Page 5-5

• Added note to step 14, added “or Beacon” to step 15.

• Insert new steps 19-20.

Page 5-5

• Insert new steps 27-30.

Page 5-10

• Inserted WARNING at top of page before step 32.

Page 5-17, 5.2.2 Using the SERVICE Menu

• Modified paragraph to “Using the Out of Service Menu” and added explanatory text.

Page 6-10, 6.6.1 SSCC IV Crossing Operational Check List & Tests

• Added/modified Check / Test steps.

Page 7-2, Figure 7-1

• Added note to flow diagram.

Page 8-1, 8.2 LAN

• Added information on ATCS addressing.

Page 9-1, 9.1 SOFTWARE UPGRADE

• Added WARNING

Page B-2, Appendix B

• Minor wording change to WARNING.

xiii

This page intentionally left blank xiv

TABLE OF CONTENTS

Section Title Page

SECTION 1 INTRODUCTION........................................................................................ 1-1

1.1 GENERAL ........................................................................................................................................1-1

1.2 EQUIPMENT OVERVIEW ............................................................................................................1-1

1.2.1 Solid State Crossing Controller III PLUS (SSCC III PLUS) ...................................1-1

1.2.1.1 SSCC III PLUS FEATURES ..........................................................................................1-2

1.2.2 Lighting Surge Panels...................................................................................................1-4

1.3 SYSTEM FUNCTIONAL DESCRIPTION ....................................................................................1-8

1.3.1 SSCC III PLUS Controls and Indicators....................................................................1-9

1.3.2 I/O Interface.................................................................................................................1-11

1.3.2.1 RS-232 DIAGNOSTIC PORT J5.................................................................................1-12

1.3.2.2 LAN..........................................................................................................................1-13

1.3.3 Standard Sequence of Operation ..........................................................................1-14

1.3.4 Crossing Operation in the Event of an SSCC III PLUS Failure ........................1-15

1.3.5 Open Lamp Neutral Wire Detection .....................................................................1-15

1.3.6 Use of Independent Pairs of Lamp Outputs .......................................................1-16

1.3.7 Cross Wiring Lamp Output Pairs ............................................................................1-16

1.3.8 Use of Multiple Controllers .....................................................................................1-16

1.4 SPECIFICATIONS.........................................................................................................................1-17

1.4.1 SSCC III PLUS Specifications ....................................................................................1-17

1.4.1.1 SSCC III PLUS MECHANICAL SPECIFICATIONS .......................................................1-17

1.4.1.2 SSCC III PLUS ENVIRONMENTAL SPECIFICATIONS.................................................1-17

1.4.1.3 SSCC III PLUS SITE POWER REQUIREMENTS ..........................................................1-17

1.4.1.4 SSCC III PLUS POWER REQUIREMENTS ..................................................................1-18

1.4.1.5 ECHELON® LAN INTERFACE .....................................................................................1-19

1.4.1.6 SSCC III PLUS OPERATING SPECIFICATIONS ..........................................................1-19

1.4.1.7 SSCC III PLUS TEST, SETUP AND PROGRAM MODES.............................................1-21

1.4.1.8 SSCC III PLUS INTERFACES .....................................................................................1-21

1.4.2 Lighting Surge Panel (A91170-1, A91170-2, A91181-1, A91181-2) Specifications ...............................................................................................................1-22

1.4.2.1 LIGHTING SURGE PANEL MECHANICAL SPECIFICATIONS.........................................1-22

1.4.2.2 LIGHTING SURGE PANEL I/O INTERFACE..................................................................1-23

1.5 ORDERING INFORMATION.....................................................................................................1-24

1.5.1 SSCC III PLUS 40-Ampere Unit, A91190...............................................................1-24

1.5.2 SSCC III PLUS 20-Ampere Unit, A91195...............................................................1-24

1.5.3 Lighting Surge Panels.................................................................................................1-25

1.5.4 Mating Connectors.....................................................................................................1-25 xv SIG-00-02-03 Version: F

SECTION 2 INSTALLATION .......................................................................................... 2-1

2.1 GENERAL ........................................................................................................................................2-1

2.2 PHYSICAL INSTALLATION .........................................................................................................2-1

2.2.1 Mounting The SSCC III PLUS System.......................................................................2-1

2.2.2 Wiring Harness...............................................................................................................2-5

2.2.2.1 MATING CONNECTORS ..............................................................................................2-5

2.2.2.2 WIRE SIZE AND TYPE..................................................................................................2-5

2.2.2.3 WIRE PREPARATION ...................................................................................................2-6

2.2.2.4 WIRE INSERTION.........................................................................................................2-7

2.2.2.5 STRAIN RELIEF.............................................................................................................2-7

2.2.2.6 MAXIMUM LAMP CABLE LENGTHS ............................................................................2-7

2.2.2.7 CONNECTING UNDERGROUND WIRING TO LIGHTING/SURGE PANELS ....................2-9

2.2.3 Lighting/Surge Panels ................................................................................................2-10

2.2.4 SSCC III PLUS DC Power Connections...................................................................2-11

2.2.5 Non-Vital I/O 1 (Flash Sync) Connection ............................................................2-12

2.2.6 Traffic Signal Preempt Relay Connections ..........................................................2-13

2.2.7 Non-vital ATCS Communication Connections ...................................................2-15

2.2.7.1 RULES FOR USING ECHELON® LAN.........................................................................2-15

2.3 POWER UP AND INITIALIZATION .........................................................................................2-16

2.3.1 Failure During Power Up and Initialization .........................................................2-18

SECTION 3 SSCC III PLUS MODULE CONFIGURATION FILES (MCF)................. 3-1

3.1 GENERAL ........................................................................................................................................3-1

3.2 MCF DESCRIPTIONS....................................................................................................................3-2

3.2.1 BASIC MCF......................................................................................................................3-3

3.2.1.1 BASIC MCF DESCRIPTION ........................................................................................3-3

3.2.1.2 BASIC MCF OPERATION...........................................................................................3-4

3.2.1.3 BASIC MCF PHYSICAL INPUTS..................................................................................3-5

3.2.1.4 OPTIONAL LOSS-OF-SHUNT TIMER...........................................................................3-5

3.2.2 BASICPLS MCF ...............................................................................................................3-6

3.2.2.1 BASICPLS MCF DESCRIPTION..................................................................................3-6

3.2.2.2 BASICPLS MCF OPERATION ....................................................................................3-6

3.2.2.3 BASICPLS MCF PHYSICAL INPUTS ...........................................................................3-7

3.2.2.4 OPTIONAL LOSS-OF-SHUNT TIMER...........................................................................3-7

3.2.3 3TRK1WRP MCF ............................................................................................................3-8

3.2.3.1 3TRK1WRP MCF DESCRIPTION...............................................................................3-8

3.2.3.2 3TRK1WRP MCF OPERATION .................................................................................3-8 xvi

3.2.3.3 3TRK1WRP MCF PHYSICAL INPUTS ........................................................................3-9

3.2.3.4 OPTIONAL LOSS-OF-SHUNT TIMER...........................................................................3-9

3.2.4 2TRK2WRP MCF ..........................................................................................................3-10

3.2.4.1 2TRK2WRP MCF DESCRIPTION.............................................................................3-10

3.2.4.2 2TRK2WRP MCF OPERATION ...............................................................................3-10

3.2.4.3 2TRK2WRP MCF PHYSICAL INPUTS ......................................................................3-11

3.2.4.4 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-11

3.2.5 2TRKDSTK MCF ...........................................................................................................3-12

3.2.5.1 2TRKDSTK MCF DESCRIPTION..............................................................................3-12

3.2.5.2 2TRKDSTK MCF OPERATION ................................................................................3-12

3.2.5.3 2TRKDSTK MCF PHYSICAL INPUTS .......................................................................3-14

3.2.5.4 STICK CANCELLATION TIMER ...................................................................................3-14

3.2.5.5 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-15

3.2.5.6 TEST SWITCH MODE.................................................................................................3-15

3.2.6 SUPISL MCF ..................................................................................................................3-16

3.2.6.1 SUPISL MCF DESCRIPTION.....................................................................................3-16

3.2.6.2 SUPISL MCF OPERATION .......................................................................................3-16

3.2.6.3 SUPISL MCF PHYSICAL INPUTS ..............................................................................3-17

3.2.6.4 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-17

3.2.6.5 SUPPLEMENTAL ISLAND TIMER.................................................................................3-17

3.2.7 3TRK2TRN MCF ...........................................................................................................3-18

3.2.7.1 3TRK2TRN MCF DESCRIPTION..............................................................................3-18

3.2.7.2 3TRK2TRN MCF OPERATION................................................................................3-18

3.2.7.3 3TRK2TRN MCF PHYSICAL INPUTS.......................................................................3-19

3.2.7.4 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-19

3.2.8 2TRK2TRN MCF ...........................................................................................................3-20

3.2.8.1 2TRK2TRN MCF DESCRIPTION..............................................................................3-20

3.2.8.2 2TRK2TRN MCF OPERATION................................................................................3-20

3.2.8.3 2TRK2TRN MCF PHYSICAL INPUTS.......................................................................3-21

3.2.8.4 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-21

3.2.9 DAXPRMT MCF............................................................................................................3-22

3.2.9.1 DAXPRMT MCF DESCRIPTION ..............................................................................3-22

3.2.9.2 DAXPRMT MCF OPERATION.................................................................................3-22

3.2.9.3 DAXPRMT MCF PHYSICAL INPUTS........................................................................3-24

3.2.9.4 OPTIONAL LOSS-OF-SHUNT TIMER.........................................................................3-24

3.3 USING 2GC OUTPUT/INPUT #7 MODE (2GC/I7) .............................................................3-24

3.3.1 2GC Normal Operation (Both 20 Amp and 40 Amp Models) .......................3-25

3.3.2 2GC Inverted Operation (40 Amp Models Only) ..............................................3-25

3.3.3 2GC Traffic Signal Simultaneous Preemption Relay Drive (40 Amp Models xvii

Only) ...............................................................................................................................3-25

3.3.4 2GC Traffic Signal Advance Preemption Relay Drive (40 Amp Models Only)3-2

3.3.5 2GC Active Beacon Relay Drive for Advance Warning Signs (40 Amp Models

Only) ...............................................................................................................................3-26

3.3.6 Input 7 in the Preemption Modes .........................................................................3-27

SECTION 4 DISPLAYS & MENU DESCRIPTIONS...................................................... 4-1

4.1 GENERAL ........................................................................................................................................4-1

4.2 MAIN MENU .................................................................................................................................4-1

4.2.1 PROGRAM Menu...........................................................................................................4-2

4.2.1.1 PROGRAM LAMP FLASH RATE ....................................................................................4-3

4.2.1.2 PROGRAM GATES USED (NOT AVAILABLE FOR BASIC MCF) ...................................4-3

4.2.1.3 PROGRAM GATE DELAY TIMERS.................................................................................4-3

4.2.1.4 PROGRAM GATE RISING BELL OFF .............................................................................4-4

4.2.1.5 PROGRAM ENABLED INPUTS ......................................................................................4-4

4.2.1.6 PROGRAM 2GC/I7 MODE (40-AMP UNIT ONLY) (NOT AVAILABLE FOR BASIC OR

DAXPRMT)...............................................................................................................4-6

4.2.1.7 PROGRAM ADVANCE PRE-EMPTION TIME (40-AMP UNIT ONLY) (NOT AVAILABLE FOR

BASIC) .......................................................................................................................4-7

4.2.1.8 PROGRAM MINIMUM ACTIVATION TIME ..................................................................4-7

4.2.1.9 PROGRAM BEACON DELAY TIME (40-AMP UNIT ONLY)(N/A FOR BASIC AND

DAXPRMT MCFS)....................................................................................................4-8

4.2.1.10 PROGRAM ISLAND DELAY TIME (40-AMP UNIT ONLY) (2TRKDSTK MCF ONLY)..4-9

4.2.1.11 PROGRAM STICK RELEASE TIME (2TRKDSTK MCF ONLY) ......................................4-9

4.2.1.12 PROGRAM SUPPLEMENTAL ISLAND TIME (SUPISL MCF ONLY)...............................4-9

4.2.1.13 PROGRAM INPUT 7 (40-AMP UNIT ONLY)(2TRKDSTK MCF ONLY)...................4-10

4.2.1.14 PROGRAM TEST SWITCH (40-AMP UNIT ONLY)(2TRKDSTK MCF ONLY) ..........4-10

4.2.1.15 PROGRAM ENABLED OUTPUTS (40-AMP UNIT ONLY)...........................................4-11

4.2.1.16 PROGRAM TIME........................................................................................................4-11

4.2.1.17 PROGRAM DATE .......................................................................................................4-11

4.2.1.18 PROGRAM DAYLIGHT SAVING ..................................................................................4-12

4.2.1.19 PROGRAM PASSWORD .............................................................................................4-12

4.2.1.20 PROGRAM SET TO DEFAULT .....................................................................................4-13

4.2.1.21 EXIT PROGRAM MODE .............................................................................................4-14

4.2.2 CONFIGURE Menu......................................................................................................4-14

4.2.2.1 CONFIGURE LOSS-OF-SHUNT TIMERS FOR EACH INPUT ........................................4-15

4.2.2.2 CONFIGURE MCF .....................................................................................................4-16

4.2.2.3 CONFIGURE ATCS ADDRESS....................................................................................4-17

4.2.2.4 CONFIGURE LOW BATTERY.......................................................................................4-18 xviii

4.2.2.5 CONFIGURE AUX. I/O ..............................................................................................4-18

4.2.2.6 CONFIGURE DETECT LAMP NEUTRAL WIRE .............................................................4-19

4.2.2.7 CONFIGURE SET TO DEFAULT ..................................................................................4-19

4.2.2.8 EXIT CONFIGURE MODE ...........................................................................................4-20

4.2.3 SETUP LAMP VOLTAGES Menu...............................................................................4-20

4.2.3.1 SELECTING THE PROPER VOLTMETER FOR SETTING LAMP VOLTAGE .......................4-22

4.2.3.2 SETUP OUTPUT 1 L1 (OUTPUT A) ...........................................................................4-22

4.2.3.3 SETUP OUTPUT 1 L2 (OUTPUT A) ...........................................................................4-23

4.2.3.4 SETUP OUTPUT 2 L1 (OUTPUT B, 40-AMP UNITS ONLY)......................................4-23

4.2.3.5 SETUP OUTPUT 2 L2 (OUTPUT B, 40-AMP UNITS ONLY)......................................4-23

4.2.3.6 EXIT SETUP MODE ....................................................................................................4-23

4.2.4 TEST CONFIGURE Menu............................................................................................4-24

4.2.4.1 TEST CONFIGURE LAMP TEST CANCEL TIMER..........................................................4-24

4.2.4.2 TEST CONFIGURE LAMP TEST DELAY TIMER ............................................................4-25

4.2.4.3 TEST CONFIGURE LAMP TEST ON TIMER .................................................................4-26

4.2.4.4 TEST CONFIGURE SET TO DEFAULT..........................................................................4-26

4.2.4.5 EXIT TEST CONFIGURE MODE ..................................................................................4-27

4.2.5 TEST Menu....................................................................................................................4-27

4.2.5.1 TEST LAMPS STEADY.................................................................................................4-29

4.2.5.2 TEST FLASH LAMPS...................................................................................................4-29

4.2.5.3 TEST TIMED LAMPS ..................................................................................................4-29

4.2.5.4 TEST TIMED LAMPS REPEAT .....................................................................................4-30

4.2.5.5 TEST ACTIVATE CROSSING .......................................................................................4-30

4.2.5.6 EXIT TEST MODE ......................................................................................................4-30

4.2.6 QUERY Menu................................................................................................................4-31

4.2.6.1 QUERY SOFTWARE VERSIONS...................................................................................4-31

4.2.6.2 QUERY CONFIGURATION VERSIONS.........................................................................4-33

4.2.7 SERVICE Menu .............................................................................................................4-34

SECTION 5 APPLICATION PROGRAMMING ............................................................ 5-1

5.1 GENERAL ........................................................................................................................................5-1

5.2 PROGRAMMING THE SSCC III PLUS .......................................................................................5-2

5.2.1 Order of Steps to Program the SSCC III PLUS......................................................5-2

5.2.1.1 VERIFY/SELECT THE DESIRED MCF ............................................................................5-3

5.2.1.2 USING THE PROGRAM MENU..................................................................................5-6

5.2.1.3 USING THE CONFIGURE MENU.............................................................................5-13

5.2.1.4 USING THE TEST CONFIGURE MENU...................................................................5-16

5.2.2 Using the Out of SERVICE Menu (Not available in the BASIC MCF) ...........5-17 xix

SECTION 6 LAMP VOLTAGE ADJUSTMENT & TESTING........................................ 6-1

6.1 GENERAL ........................................................................................................................................6-1

6.2 LAMP VOLTAGE DRIVE ..............................................................................................................6-1

6.3 USE OF LED TYPE LAMPS ..........................................................................................................6-2

6.4 METER READING CONVERSION EXAMPLES.........................................................................6-2

6.4.1 Lamp Voltage Measurement Example 1 ................................................................6-3

6.4.2 Lamp Voltage Measurement Example 2 ................................................................6-3

6.5 LAMP VOLTAGE ADJUSTMENT PROCEDURE.......................................................................6-3

6.5.1 Adjustment of FAR Gate Flasher Lamps (Output A) ..........................................6-6

6.5.1.1 1L1 ADJUSTMENT (FAR GATE) .................................................................................6-6

6.5.1.2 1L2 ADJUSTMENT (FAR GATE) .................................................................................6-7

6.5.2 Adjustment of FAR Gate Flasher Lamps (Output B, 40-Amp unit only).......6-7

6.5.2.1 2L1 ADJUSTMENT (FAR GATE) .................................................................................6-7

6.5.2.2 2L2 ADJUSTMENT (FAR GATE) .................................................................................6-8

6.5.3 Adjustment of NEAR Gate Flasher Lamps (Output A) .......................................6-9

6.5.4 Adjustment of NEAR Gate Flasher Lamps (Output B, 40-Amp unit only) .6-10

6.6 FLASHING LIGHT SIGNAL ALIGNMENT ...............................................................................6-11

6.7 SYSTEM VERIFICATION TESTS................................................................................................6-12

6.7.1 SSCC III PLUS Crossing Operational Check List & Tests...................................6-12

SECTION 7 - TROUBLESHOOTING............................................................................. 7-1

7.1 GENERAL ........................................................................................................................................7-1

7.2 TROUBLESHOOTING SSCC III PLUS ERRORS .......................................................................7-1

7.3 SSCC ERROR CODES ...................................................................................................................7-5

7.4 LAMP NEUTRAL WIRE OPEN ....................................................................................................7-6

7.5 TROUBLESHOOTING MAINTENANCE CALL (MC) LIGHT PROBLEMS ...........................7-7

7.5.1 MCF files that effect the Maintenance Call (MC) Lights ...................................7-7

7.5.2 Troubleshooting Procedure for Maintenance Call (MC) Light Problems.....7-7

SECTION 8 EXTERNAL COMMUNICATON............................................................... 8-1

8.1 GENERAL ........................................................................................................................................8-1

8.2 LAN..................................................................................................................................................8-1

8.3 RS-232 DIAGNOSTIC PORT J5 ..................................................................................................8-2

8.3.1 SSCC III PLUS Serial Port To PC ................................................................................8-2

8.3.2 SSCC III PLUS Serial Port To SEA/R..........................................................................8-4 xx

SECTION 9 SOFTWARE VERIFICATION & UPGRADE............................................. 9-1

9.1 GENERAL ........................................................................................................................................9-1

9.2 SOFTWARE UPGRADE ................................................................................................................9-1

9.3 SOFTWARE VERIFICATION........................................................................................................9-1

9.3.1 Query Menu ...................................................................................................................9-2

9.3.1.1 QUERY SOFTWARE VERSIONS.....................................................................................9-2

9.3.1.2 QUERY CONFIGURATION VERSIONS...........................................................................9-3

9.3.1.3 EXIT QUERY MODE .....................................................................................................9-3

SECTION 10 APPLICATION DRAWINGS .................................................................10-1

10.1 GENERAL ......................................................................................................................................10-1

APPENDIX A SSCC III PLUS MCF RELEASE HISTORY .............................................A-1

LIST OF FIGURES

Number Title Page

Figure 1-1. SSCC III PLUS 40-Ampere Unit, A91190......................................................................................1-3 Figure 1-2. SSCC III PLUS 20-Ampere Unit, A91195......................................................................................1-3 Figure 1-3. Isolated Gate Control Lighting Surge Panel, A91181-1 (for 20-Amp or 40-Amp unit).1-6 Figure 1-4. Isolated Gate Control Lighting Surge Panel, A91181-2 (for 40-Amp unit only) .............1-6 Figure 1-5. Common Return Lighting Surge Panel, A91170-1 (for 20-Amp or 40-Amp unit)..........1-6 Figure 1-6. Common Return Lighting Surge Panel, A91170-2 (for 40-Amp unit only) ......................1-7 Figure 1-7. Typical Isolated Gate Control.........................................................................................................1-7 Figure 1-8. Typical Common Return Gate Control........................................................................................1-8 Figure 1-9. Crossing Controller Basic Architecture .......................................................................................1-9 Figure 2-1. SSCC III PLUS Mounting Dimensions For 19-Inch Rack (Typical for A91990, A91195)2-2 Figure 2-2. SSCC III PLUS Mounting Dimensions For 23-Inch Rack (Typical for A91990, A91195)2-3 Figure 2-3. SSCC III PLUS Surge Panel Mounting Dimensions (Typical for -1 And -2 Versions)......2-4 Figure 2-4. Typical Crossing Profile....................................................................................................................2-8 Figure 2-5. Typical Lamp And Bell Cables........................................................................................................2-9 Figure 2-6. Insulated Testing Link (shown in open position) .................................................................. 2-10 Figure 2-7. Flash sync control and reference............................................................................................... 2-13 Figure 2-8. Traffic Signal Preemption Relay Connections ........................................................................ 2-14 xxi

Figure 2-9. LAN Bus Wiring ............................................................................................................................... 2-16 Figure 2-10. Power Up Screen.......................................................................................................................... 2-17 Figure 2-11. Software Version Message......................................................................................................... 2-17 Figure 2-12. Initialization Screen ..................................................................................................................... 2-17 Figure 2-13. Typical Idle Screen....................................................................................................................... 2-17 Figure 3-1. Typical XR Inputs for BASIC MCF.......................................................