Professional Documents
Culture Documents
Handbook on
MAINTENANCE
of
CAMTECH/S/PROJ/2012-13/HB-DAC (M)/1.0
February 2013
FOREWORD
Track circuits and Axle counters play a vital role in railway signalling as these
detect the presence of train vehicle on a given section of track. Digital Axle Counters;
the advanced version of conventional axle counters are progressively being installed
on Indian Railways due to their enhanced safety features and reliability.
CAMTECH is continuously making efforts in documentation and upgradation of
information on advanced maintenance practices. The current handbook consisting of
maintenance information on Digital Axle Counters of RDSO approved firms is a
further step in this direction.
The information given in this handbook will help signal personnel in maintaining
the above system.
CAMTECH Gwalior
Date: 11.03.2013
A.R.Tupe
Executive Director
PREFACE
Conventional track circuits and axle counters have their own limitations in
terms of its range of operation and reliability and require frequent maintenance. The
Micro-controller and software based Digital Axle Counters require less maintenance
and have added feature of diagnostics information through LEDs. Digital Axle
Counters, both Single section and Multi Section have applications in straight sections
and point zones of Station area as well as in proving of Block section.
This handbook has been prepared to help the field personnel in maintaining Digital
Axle Counters installed in their section for trouble-free performance. The handbook
has been divided into vendor specific sections; containing maintenance information on
the systems manufactured by different RDSO approved firms.
It is clarified that this handbook does not supersede any existing provisions laid
down in Signal Engineering Manual, Railway Board publications and RDSO
publications. This handbook is not statutory and instructions given in it are for the
purpose of guidance only.
We are sincerely thankful to Shri R. Meena, Sr.D.S.T.E./Agra/NC Rly., M/s
Eldyne Electrosystems Pvt. Ltd., Kolkata, M/s Central Electronics Ltd., Sahibabad,
M/s G.G.Tronics, Bangalore, M/s Siemens Ltd. Mumbai and field personnel who
helped us in preparation of the handbook.
Since technological upgradation and learning is a continuous process, you may feel
the need for some addition/modification in this handbook. If so, please give your
comments on email address dirsntcamtech@gmail.com or write to us at Indian
Railways Centre for Advanced Maintenance Technology, In front of Adityaz Hotel,
Maharajpur, Gwalior (M.P.) 474005.
CAMTECH Gwalior
Date: 08.03.2013
D.K.M.Yadav
Jt .Director (S&T)
Contents
Description
Pages
Foreword
Preface
iii
Contents
Correction Slip
ix
1-16
1-9
1-11
Section IV: Maintenance of DACF 710 A & DACF 710 P CEL Single Section
Digital Axle Counter
1-9
1-12
Annexure I Abbreviations
Annexure II References
Date of
issue
Remarks
DISCLAIMER
It is clarified that the information given in this handbook does not supersede any
existing provisions laid down in the Signal Engineering Manual, Railway Board and
RDSO publications. This document is not statuary and instructions given are for the
purpose of guidance only. If at any point contradiction is observed, then SEM,
Railway Board/RDSO guidelines may be referred or prevalent Zonal Railways
instructions may be followed.
---------------------------------------------------------------------------------------------------OUR OBJECTIVE
To upgrade Maintenance Technologies and Methodologies and achieve improvement in
Productivity and Performance of all Railway assets and manpower which inter-alia would
cover Reliability, Availability and Utilisation.
If you have any suggestion & any specific comments, please write to us:
Contact person:
Postal Address:
Phone
0751 - 2470185
Fax
0751 2470841
dirsntcamtech@gmail.com
Section I
Maintenance of
Eldyne AzLS
Single Section Digital Axle Counter
Go to Main Index
Contents
Section I: Maintenance of Az LS Eldyne Single Section Digital Axle
Counter
Sr. No.
Description
Page No.
1.1
Introduction
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Adjustment procedure
10
1.9
Reset Box
11
1.10
11
1.11
12
1.12
12
1.13
13
1.14
Log Sheet
16
Go to Main Index
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Section I
Maintenance of
Az LS
Eldyne Single Section Digital Axle Counter
1.1 Introduction
The AzLS system consists of at least two detection points Zp30CA-2, one at each end (entry
& exit) of the track section to be monitored. It consists of following parts:
(a) Outdoor Trackside system consisting of
(i) Rail contacts (SK30H) - It consists of two coil sets Sk1 and Sk2, both installed on the
same rail. The transmitter heads (Tx) are installed on the outside of the rail and receiver
heads (Rx) are installed on the inside of the rail directly opposite the respective Tx heads.
The two Tx coils are fed with different frequencies (approx. 30.6 kHz and 28 kHz). The
SK30H is fitted by three bolts to the web of the rail. The vertical position of the
respective mounting holes depends on the rail profile.
(ii) Track-Side Electronic Unit (EAK).
SK30H and EAK together form one detection point Zp30CA-2.
Each Tx/Rx head is equipped with fixed cables for connection to the electronic junction
box (EAK30H). (available in lengths 4m, 5.5m and 8m)
(b) Communication Link (A pair of star quad cable)
(c) Reset Relay (1000 ohm AC immunized Q series)
(d) Vital Relay (1000 Ohm AC immunized Q series 24 V 8F/8B)
1.2 Fixing of track devices after replacement of rail
Drill the mounting holes on the rail web in correct position as per following approximation
formula:
a = (0.409 * h), where a = height of the mounting hole, h = height of the rail
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Height of mounting hole for different rail profiles is given below:
Rail Profile
a [mm]
90 lbs
56 mm
52 Kg
63 mm
60 Kg
68 mm
The final three holes of diameter 13mm are drilled on the rail web with the help of drilling
jig. consisting of:
(i) Drilling template
(ii) Mounting device for the drilling machine
(iii)Templates for the standard rail profiles
(iv) Fastening device
(v) The drilling machine
Washer
M8 bolt
Nut
M12 bolt
Nylon Bush
Insulating Plate
Fig.1.2: Mounting of Rail Contacts
(Tx heads on the outside and Rx heads on the inside of the rail)
1
2
3a
3b
2
3a
3b
6a
5
6b
WAGO-terminal
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Terminal on Zp30CA-2(AzLS)
Sk1 / E1
Sk1 / E2
Sk1 / E3
Sk1 / S2
Sk1 / S1
Sk2 / S1
Sk2 / S2
Sk2 / E3
Sk2 / E2
Sk2 / E1
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
bl tr bk
bk tr
tr bk
bk tr bl
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
1.4 Adjustment of Rail contact Tx head with Dummy wheel and Tool Kit
The Tx head is adjusted such that the received rectified voltage produced when a wheel is
present has the same amplitude but the opposite polarity as the voltage produced with the
wheel absent.
A dummy wheel is required for the adjustment of the rail contact.
On main lines the dummy wheel is normally set to 40mm.
During adjustments the dummy wheel must be kept vertically at the centre of Rx
heads.(Fig.).
Dummy Wheel
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Selector switch position 5: Shows the value of reference voltage for SK1 (PEGUE1).
This can be adjusted by the potentiometer R1 on the Analog board.
Selector switch position 6: OFF
Selector switch position 7: Shows the rectified Rx voltage (MESSAB2) for SK2. For fine
adjustment the potentiometer R4 on the Analog board should be used.
Selector switch position 8: Shows the reference voltage for SK2 (PEGUE2). This can be
adjusted by the potentiometer R3 on the Analog board.
Selector switch position 9: OFF
R4 R3
R1 R2
Potentiometer
R1
R2
R3
R4
Function
Potentiometer for sk1 reference voltage PEGUE1
Potentiometer for sk1 voltage MESSAB1
Potentiometer for sk2 reference voltage PEGUE1
Potentiometer for sk2 voltage MESSAB2
Note:
Rotate R2 (or R4) clockwise to increase the Rectified Voltage MESSAB1 or MESSAB2.
Rotate R2 (or R4) anti-clockwise to decrease the Rectified Voltage MESSAB1 or
MESSAB2.
Rotate R1 (or R3) clockwise to increase the Reference Voltage PEGUE1 or PEGUE2.
Rotate R1 (or R3) anti-clockwise to decrease the Reference Voltage PEGUE1 or
PEGUE2.
Switches
Switch
S1
S2
S3
Function
Switch fixed by factory in position 1.May be put into position 2 for using
rail contact with longer cable length.
Switch fixed by factory in position 1.May be put into position 2 to raise
the transmitter power of the rail contact for better signal to noise ratio.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
11
10
Fig. 1.10 : Connector terminals of AzLS Track side Electronic Unit EAK for measurement
of voltage and frequency
Checking of Power supply voltage to EAK
Recommended power supply for EAK is 21.5 V DC to 28.8 V DC (for 24V version) and
54 120VDC (for 60 120V version). Measure the power supply voltage fed to the track
side electronic unit with the meter and the probe set directly to the power supply connector
terminals 2 (+) & 18 (-).
Section I Maintenance of AzLS Eldyne SSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Communication (data) between two EAK
Communication pair is connected to
Connector 5 and 21, if Digital Card is installed in outer slot
Connector 6 and 22, if Digital Card is installed in middle slot
Fig. 1.11 : Connector terminals of AzLS Track side Electronic Unit EAK for power supply
and communication (data) link
Vital Relay output
If Digital Card is installed in outer slot
Check at Connector 33 and 39, for on-board vital relay input
Check at Connector 34 and 40, for on-board vital relay output
If Digital Card is installed in middle slot
Check at Connector 36 and 42, for on-board vital relay input
Check at Connector 37 and 43, for on-board vital relay output
Voltage at relay should be more than 20 V.
MOVs AzLS
For Digital
Card installed
in middle slot
For Digital
Card installed
in outer slot
For Digital
Card of AzLM
installed in
outer slot
For
Analog
Card
February 2013
10
CAMTECH/S/PROJ/12-13/HB-DAC (M)
1.8 Adjustment procedure
Connect the test equipment to the diagnostic port of EAK as shown in fig.1.13
Steps to adjust the rectified voltage
MESSAB1
Put Selector Switch to position 4.
Measure the rectified voltage with and without dummy wheel.
Turn Potentiometer R2 on the Analog board to positive max.
The rectified voltage without dummy wheel must be set to positive maximum.
If there is a big difference between the positive value and the negative value, move the
Tx heads upward or downward along the serration and adjust to optimum position.
Taking the transmitter head upwards increases the negative voltage and decreases the
positive voltage and vice versa.
Adjust using Pot. R2 such that rectified voltage with and without dummy wheel are
absolute equal (equal but having opposite polarity). Tolerance <=30mV.
After getting the positive and negative voltages within the above specified tolerance limit
tighten the transmitter head properly with the torque wrench set at 25 Nm.
Fig.1.13: Connection of tool kit to diagnostic port of EAK for measurement of parameters
Trolley suppression
For Trolley suppression to be effective, the positive voltage (without dummy wheel) should
be greater than the negative voltage (with dummy wheel) by a value not less than 30 mV so
that the rectified Rx voltage does not go to negative with the specified trolley wheel. It is
recommended that the adjustment should be done using a spoke trolley wheel that is
normally used in the section.
Section I Maintenance of AzLS Eldyne SSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
11
MESSAB2
Repeat the above procedure for MESSAB2 (using Selector Switch position 7, and
Potentiometer R4 on the Analog board).
PEGUE1
Put Selector Switch to position 5
Measure voltage
Adjust using potentiometer R1 on analog board such that
MESSAB1(without dummy wheel) Tolerance +-2%
PEGUE1 =
PEGUE2
Repeat for PEGUE2 using Selector Switch position 8 and potentiometer R3 such that
PEGUE2 = MESSAB2 (without dummy wheel) Tolerance +-2%.
1.9 Reset Box
ERBS-02 is the reset box for Alcatels Single/Double Section Digital Axle Counter
ZP30CA-2 (AzLS). This provides the basic resetting pulse (24VDC) for reset relay, which is
used for a polarity reversal of power supply to the EAK (the track side electronic unit) for
approximately 3 seconds. The front panel of the terminal consists of:
1. Reset Key
2. Push Switch
3. Reset Counter
4. Power ON indication YELLOW LED
5. Preparatory Reset indication GREEN LED
6. Line Verification Indication YELLOW LED
7. Section Clear / Unoccupied indication GREEN LED
8. Section Closed / Occupied indication RED LED
Additionally a buzzer is provided to give audio indication that the 3 second reset pulse is on.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
12
Each reset is registered in the sealed reset COUNTER unit. The count increases by one after
each reset commanded by the operator.
1.11 Types of resetting for AzLS
AzLS V1.1 provides four types of reset:
1. Single point preparatory reset (for berthing section)
This reset does not clear the section immediately. It is sufficient that one of the detection
points of the relevant section receives a preparatory reset. After carrying out the preparatory
reset, a train must pass through the section on caution running conditions. Only then the
section will be cleared.
2. Two point co-operative preparatory reset (for block section)
The reset command is to be applied to both detection points within one hour. If this time
elapses, the reset command is rejected. The other conditions are same as given in clause 1
above.
3. Single point hard reset (for point zone)
It is sufficient that one of the detection points of the relevant section receives a hard reset. In
addition to this pressing and turning of verification switch is required. The hard reset clears
the section immediately.
4. Two point Co-operative hard reset
The two point hard reset is initiated through individual external relay circuits which reverse
the polarities of the supply voltages to at least two detection points of the section.
1.12 Check points for maintenance
Carry out visual inspection of trackside equipment i.e. EAK, rail contacts and integral
cables (connecting leads), earthing etc.
Check physically whether the rail contacts and cabling including earthing connections
are proper.
Ensure that Tx heads are clear of rail.
Ensure the proper size and tightness of deflectors and that these are fitted at least 250
mm away from rail contacts (Tx/Rx coils).
Ensure for proper fixing of Track side connection box (EAK) on the mushroom base
plate and all 4 nos. screws are tight.
Ensure that cable armours are properly earthed in location box.
Check for proper spacing (min. 350 mm) and packing of sleepers on which track
devices are fitted.
Check that the earthing connection of mushroom cover/apparatus case is intact and in
good condition, the earth lead wire and nut connecting earth wire etc. are not
corroded.
Check that cable pairs used are properly dressed and terminated in such a way that no
conductors remain exposed and check that no individual conductor are made spiral.
These should be twisted in pair to improve EMC.
February 2013
13
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Check that mushroom cover is properly fixed and there should be no possibility for
entry of rain water.
Check the input voltage at location box/EAK keeping the charger OFF for at least 15
min. Voltage at location box/EAK should not go below 21.5 V for 24 V EAK and 54
V for 60 V EAK.
Check ripple voltage of power supply at EAK, it should not exceed 10 mv peak to
peak.
Check rectified voltage (with dummy wheel) and reference voltages are within limit.
Check the cards are in proper position and both analog and digital cards are fitted
firmly in their corresponding slot.
Measure the earth resistance and paint its value on earth enclosures/nearest wall. If
required take suitable steps to improve the earth resistance. It should be less than 1
Ohm.
Always use 13mm high speed drill bit to drill holes on rail web.
Place foam packings between top of the Digital/Analog cards and dust cover to avoid
loosening due to vibrations. (As per practice in BPL division W.C.Rly.)
Tighten M8 bolts (on transmitter heads) with torque of 25Nm and M12 bolts (to fix rail
contact on rail web) with torque of 45Nm. Torque greater than specified value will break
the bolts and torque less than specified value will make the rail contact loosely fitted.
The rail contact integral cables must be free to loop near the Tx-Rx heads. Therefore the
protective hose must not be fitted up to the rail contact. Otherwise the rail contact integral
cables may get damaged by the rigid hose because of short bending radius.
Fig. 1.15.: (a) Correct installation (b) Incorrect installation with short bending radius
February 2013
14
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Never use any kind of hand spanner to fix the rail contact bolts. Use only torque
wrench.
Fig. 1.16.:
(a) Ordinary
hand
spanner
(b) Torque
wrench
To set the addresses of detection point computers, use ball-point pen never use pencil.
Fig. 1.17.: Sketch showing correct and incorrect ways of rail contact cable laying
The rail contact cable wires must be twisted in pairs to improve EMC.
To earth the rail contact cable screen, remove the cable insulation for a length of
maximum 45mm from the end of cable. Never remove insulation from any other part of
cable.
February 2013
15
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Twisted cable
WAGO
connectors
Cable screens
Earthing clips
Insulation
Armour of quad cable connecting DP to location and location to relay room should be
earthed at relay room only.
Ensure that twisted pairs of quad cable remain twisted right upto the terminals, no
coiling to be done.
Take all the measurements whenever the DP is adjusted.
February 2013
16
CAMTECH/S/PROJ/12-13/HB-DAC (M)
1.14 Log Sheet
This should be periodically updated and kept as future reference.
Station Name :
Log item AzLS
Tolerance range
Rail Profile
Switch S1 & S2 address for CPU1 Outer Slot
Switch S3 & S4 address for CPU2 Outer Slot
Switch S1 & S2 address for CPU1 Middle Slot
Switch S3 & S4 address for CPU2 Middle Slot
Selector
Input power supply
position
(terminal 2 & 18 of EAK)
in test unit
ETU001
1
a)Power supply Channel 1
2
b)Power supply Channel 2
4
c) MESSAB1
( Rx1 voltage w/o dummy wheel )
d) With dummy wheel set on 40
mm
5
e) Reference voltage PEGUE1
7
f) MESSAB2 (Rx2 voltage w/o
dummy wheel )
g) With dummy wheel set on 40
mm
8
h) Reference voltage PEGUE2
Terminal
Transmitter frequency SK1
SK1/S1 & Transmitter voltage SK1
SK1/S2
Terminal
Transmitter frequency SK2
SK2/S1 & Transmitter voltage SK2
SK2/S2
DP:
DP:
DP:
Bit 16.1
Bit 16 1
Bit 16.1
Bit 16.1
21.5 V to 28.8 VDC
2235 VDC
2235 VDC
+80..+1000mVDC
-80.-1000mVDC
Adjust (as per c)
+80..+1000mVDC
-80..-1000mVDC
Adjust as per (f)
30.0.. 31.25KHz
4085 VAC
27.4..28.6KHz
4085 VAC
Go to Chapter Index
February 2013
Section II
Maintenance of
Eldyne AzLM
Multi Section Digital Axle Counter
Contents
Section II: Maintenance of Az LM Eldyne Multi Section Digital Axle Counter
Sr. No.
Description
Page No.
2.1
Introduction
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
Adjustment procedure
2.11
Reset Box
2.12
Resetting procedure
2.13
2.14
2.15
Log Sheet
Go to Main index
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Section II
Maintenance of
Az LM
Eldyne Multi Section Digital Axle Counter
2.1 Introduction
The AzLM is a vital axle counter equipment for multiple track sections containing 2 out of 2
microcontrollers to count the axles, establish the track occupancy of a track section and to
provide this information to the block or the interlocking equipment. It consists of
Outdoor Trackside System
Double rail contact Sk30H mounted on rail consists of two coil sets Sk1 & Sk2 of
Transmitter (Tx) & Receiver (Rx) installed on the same rail. The two Tx coils are fed
with different frequencies (approx. 30.6 KHz and 28 KHz) which induce a voltage in
Rx coils.
Track side Electronic unit EAK30H contained in the trackside housing and connected
with SK30H via integral cables (available in lengths 4m, 5.5m and 8m). It consists of
Analog Card
Digital Card
Motherboard
Communication link between EAK and indoor equipment.
Indoor Equipment
Axle Counter Evaluator (ACE) installed at the station.
Reset Relay 1000 ohm AC immunized Q series
Vital Relay (QN1 8F-8B) connected externally to the Parallel Card
1 Terminal for line-cable
1
2
3a
3b
6a
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Terminal on
Zp30H(EAK)
Sk1 / E1
Sk1 / E2
Sk1 / E3
Sk1 / S2
Sk1 / S1
Sk2 / S1
Sk2 / S2
Sk2 / E3
Sk2 / E2
Sk2 / E1
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
The connections for Power Supply/Communication to the EAK are as under:
Connections
Superimposed Power (+) & Data Line
Superimposed Power (-) & Data Line
Terminals
3
13
Provide a shorting link between terminal 2 & 1 and 12 & 11 if the same pair of conductors is
used for superimposed data and power supply to the EAK. If separate power supply is used
for installation, the communication line has to be between terminals 3 & 13 and the 60V
power supply has to be connected to terminals 1 & 11.
2.4 Evaluator (ACE)
Axle Counter Central Evaluator is the decision making unit for multi section digital axle
counter. It has the following sub components.
CPU card
Power Supply Card
Serial Card
Parallel Card
2 3 4
1 Power supply
4
2 Computer
3 Covering plate
4 Serial I/O
5
5 Parallel I/O
5 3 3
Fig. 2.3.: Axle Counter Evaluator (ACE) front view
CPU Card. Two CPU Cards are required for 2 out of 2 system. Diagnostic interfaces and
alphanumeric display are available on CPU Card.
Power Supply Card. It works on 24VDC and generates 5VDC and 12VDC required for the
electronic circuitry. Two Power Supply Cards are required for 2 out of 2 system.
Section II Maintenance of AzLM Eldyne MSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Serial Card receives information from detection points through ISDN communication link
and provides this information to CPU Cards. One Serial Card can monitor maximum two
detection points.
Parallel Card is responsible for providing section information.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Fig 2.7: Interconnection between EAK, PDCU & Serial I/O Card
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
2.6 Test equipment (Tool Kit) ETU001
The Test equipment ETU001 is same as that for AzLS. (Please refer Section I Para 1.6).
2.7 Adjustment of Rail contact Tx head with Dummy wheel and Tool Kit
The procedure for adjustment of TX head is same as that for AzLS (Please refer Section I
Para 1.5).
2.8 Functions of Selector Switch in ETU 001
Functions of Selector switch in ETU 001 are same as given for AzLS (Please refer Section I
Para 1.7).
2.9 Parameters to be checked for adjustment of rail contact
Outputs of DC-DC Converters, Rx Voltages MESSAB1 & MESSAB2, Reference Voltages
PEAGUE1 & PEAGUE2 are checked in the same way as per the procedure given in Section
I Para 1.8. The other parameters can be checked as follows:
(i) Axle Counter Evaluator (ACE)
Power Supply Voltage range at ACE is 21.5 28.8VDC which can be measured at the
connectors U1 & U2 at the backplane of the ACE. Alternatively the input voltage to the
ACE can be measured at fuse terminals on CTB.
(ii) Power Data Coupling Unit
Check outgoing voltage for trackside connection box at terminal nos. 4 & 5 of PDCU
(iii) Checking Frequency of Tx heads
The frequency of the transmitter heads are to be measured by true RMS Multimeter only. For
this purpose additional probe set is provided with Tool Kit ETU001. These readings can be
taken at connector terminals S1 & S2 of both Sk1 & Sk2 inside EAK.
(iv) Checking of Power supply voltage to Trackside unit EAK
Recommended power supply for EAK is 54 120 VDC. Measure the power supply voltage
fed to the track side electronic unit with the meter and the probe set directly at the power
supply connector terminals 1 & 11 if separate pair of conductors is used for 60 V DC power
supply and at 3 & 13 if the communication line and 60 V DC power are superimposed in the
same pair of conductors.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
2.10 Adjustment procedure
Adjustment procedure is same as that for AzLS.(Please refer Section I Para 1.9)
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
2.15 Log Sheet
All the measurements should be recorded in the following format:
Outdoor Equipment: EAK
Date
Item
Selector position 1
a) Power supply
in test unit
Channel 1
2
b) Power supply
Channel 2
4
c) ( Rectified Rx1
voltage w/o
dummy
wheel ) MESSAB1
(d) With dummy wheel
set on 40 mm
5
(e) Reference voltage
PEGUE1
7
(f) ( Rectified Rx1
voltage w/o dummy
wheel ) MESSAB2
(g)With dummy wheel
set on 40 mm
Terminal
i) Input Power supply voltage
3 & 13 of EAK
Terminal
(j) Transmitter frequency SK1
SK1/S1
& (k) Transmitter voltage SK1
SK1/S2
Terminal
(l)Transmitter frequency SK2
SK2/S1
& m)Transmitter voltage SK2
SK2/S2
Indications
n) H1-1 Red/H1-2 Green
Analog
(o) H2-1 Red/H2-2 Green
board
(p) H3-1 Red/H3-2 Green
Indications
(q) H1-1 Green/H2-1 Green
Digital board
(r)H1-2 Green/H2-2 Green
(s) Signature
Permissible range
2235 VDC
Recorded value
2235 VDC
+80..+1000mV DC
-80..-1000mV DC
Adjust as per (c)
+80..+1000mV DC
-80.-1000mV DC
54 V to 72 V DC
30.0.. 31.25 KHz
4085 VAC
27.4..28.6 KHz
4085 V AC
Note
Note
Note
Note
Note
Date
Input Voltage
PDCU Voltage
ACE
Voltage
> 21.5
V DC
Input to
PDCU
>5V
DC
Ripple
Voltage <10
mV rms
Designation
& Signature
with initials
Remarks
Ripple Voltage
< 10 mV rms
February 2013
Section III
Maintenance
of
Siemens Az S 350 U
Multi Section Digital Axle Counter
CAMTECH/S/PROJ/2012-13/HB- DAC(M)
February 2013
Contents
Section III: Maintenance of Az S 350 U Siemens Multi Section Digital Axle
Counter
Sr. No.
Description
Page No.
3.1
Introduction
3.2
3.3
3.4
Power Supply
3.5
Reset options
3.6
3.7
3.8
10
3.9
10
3.10
Replacing Boards
11
Go to Main index
CAMTECH/S/PROJ/2012-13/HB-DAC (M)
Section III
Maintenance of
Az S 350 U
Siemens Multi Section Digital Axle Counter
3.1 Introduction
Az S 350 U consists of two main components:
Outdoor equipment
Indoor equipment
The outdoor equipment is the ZP 43 wheel detection equipment. The indoor equipment
consists of the evaluation computer. The ZP 43 wheel detection equipment is connected
to the indoor equipment via a two-core cable.
EU Evaluation Unit
CH1/2 Counting head
DEK 43 Double Wheel Detector
TCB Trackside connection box
Fig 3.1.: Basic configuration of Az S 350 U
February 2013
CAMTECH/S/PROJ/2012-13/HB-DAC (M)
Height X of the hole depends upon the rail profile and shall be as per table given below:
Table A
Rail profile
Height X
Height of new rail
Permissible wear & tear
60 Kg
85 mm
172 mm
13 mm
52 Kg
69 mm
156 mm
8 mm
90 lbs
56 mm
143 mm
5mm
1.
2.
3.
4.
5.
6.
7.
8.
9.
February 2013
CAMTECH/S/PROJ/2012-13/HB-DAC (M)
Fig. 3.5.:
Installation
of Double
Wheel
detector
Fig. 3.6.: Terminal Assignment with lightning protection module board in the
Trackside Connection Box
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Fig. 3.8: Front view of Az S 350 U evaluation computer (including slot numbers)
3.3.1Overview of boards
SIRIUS2 board
Serial computer interface universal board
The SIRIUS2 board enables communication between
the connected evaluation computers. This board is used
on one channel only. On the front panel, there is a 48pin connector for connection to all interface signals. An
optional front connector with two 9-pole sub-D sockets
is used for modem connection. A service PC can be
directly connected via a two-pole diagnostic socket.
Fig.3.9: (a) Front view of SIRIUS2 board
(b) front connectors with sockets
BLEA12 board
Block input / output board with 12 relay outputs
All inputs and outputs to and from the interlocking are
done via the BLEA12 block input /output board. It has
12 floating relay outputs and 12 floating opto-coupler
inputs. Inputs and outputs are made via a 48-pin
connector on the front panel of the board. The four
buttons (T1 to T4) on the front connector of the first pair
of BLEA12 boards permit connection of the auxiliary
axle count reset button (AzGrH).
Fig. 3.10: (a) Front view of BLEA12
board (b) Front connector with buttons
February 2013
CAMTECH/S/PROJ/2012-13/HB-DAC (M)
STEU board
Control and diagnostic board
The STEU board buffers the signals transmitted by the counting heads. There is one
STEU board per channel. The LEDs on this board display the following:
Normal display: display of the operating states of the four track vacancy detection
sections (during operation; operating state display)
Statistics display (diagnostics): display of operating states for a certain counting
head or track vacancy detection section (switchover / selection via AzGrH button)
Display after emergency shutdown: display of operating states in case of emergency
shutdown
VESBA board
Amplifier, trigger and band-pass filter board
Each directly connected counting head requires one VESBA board. It provides electrical
isolation between indoor and outdoor equipment (counting head). The VESBA board
splits the signal frequencies f1 and f2 into two independent channels and filters,
amplifies, rectifies and evaluates (trigger) the data transmitted from the counting head.
VAU board
Processing & Monitoring board
The VAU processing and monitoring board, a CPU board, constitutes the
failsafe microcomputer system (SIMIS C computer core). It provides
monitoring and comparator functions for synchronous dual-channel
microcomputer operation.
Table B
Indication
VGL(Yellow LED)
SPW (Red LED)
PAB (Red LED)
ANL (Red LED)
Red button
Description
Comparator
Voltage Controller
Program-controlled shutdown
Start-up
System reset
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Fig.3.12: Front
view of SVK2150
board
February 2013
CAMTECH/S/PROJ/2012-13/HB-DAC (M)
Counting heads of the TVDS have been traversed within the last six seconds.
The last test of switching capability (internal software test SOPP) of the data
channels on the VAU board has not been successful.
The axle last recorded by the evaluation computer in a track vacancy detection
section is an axle counted in.
3.6 Adjusting ZP 43 V Wheel Detection Equipment
3.6.1Tools and Test Equipment required for adjustment
Open-end, ring or box spanner, width across flats 13
Screwdriver 0.6 x 2.8 as per DIN 7437
Screwdriver 0.6 x 3.5 as per DIN 7437
Test equipment: Probe adapter board and multi-meter (Fluke-189 or equivalent)
with measuring ranges.
3.6.2 Probe Adapter Board
The probe adapter board SCN S25552-B43-D1 can be used during commissioning and
maintenance for testing and adjusting work on the ZP 43 V WDE. Adjusting work
(voltage and frequency measurements) can be performed using a commercially available
multi-meter. Measuring sockets arranged in pairs are provided on the front panel (Refer
Fig. 3.13 on page 8). The multi-meter is connected to these measuring sockets.
3.6.3 Multimeter Requirements
The multi-meter (Fluke-189 or equivalent) must meet the following requirements:
DC measuring range: 300 mV to 100 V
AC measuring range: 40 mV to 100 V
Frequency measuring range: 2.5 kHz to 45 kHz
3.6.4 Procedure for measurement/adjustment
Remove all stray metal parts (e.g. tools) in the vicinity of the double wheel detector.
Plug the test adapter board into the connector provided on the backplane.
Set the required AC/DC range on the multi-meter.
Connect the probes of multi-meter to the relevant measuring sockets provided on the
front panel of test adapter board.
Take the measurements and adjust the parameters if required as follows:
(a)Checking Wheel Detection Equipment Supply Voltage U60
The voltage at the measuring sockets U60 must be between 30 V DC and 72 V DC.
(b)Checking Wheel Detection Equipment Voltage U24
The voltage at the measuring sockets U24 must be between 21.3 V DC and 22.4 V
DC. This is the internal, stabilized supply voltage of the wheel detection equipment.
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All parts of the wheel detection equipment may be carrying an interference voltage.
Therefore, always connect the measuring leads for connecting the probe adapter board
and the measuring equipment to the measuring equipment first and then insert them
into the measuring sockets of the probe adapter board.
Do not touch any metal parts of the measuring leads if they are connected to the wheel
detection equipment.
Hold the boards only by the long sides (guide edges), front panel, locking or
designation plate holder.
Keep the boards in their original protective packaging until they are installed in the
wheel detection equipment.
Do not touch circuit board terminals, conductors, components or plug connectors.
In all adjustment work, the double wheel detector must be in the uninfluenced state
(no wheels or other metal objects in the vicinity).
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10
Sr.
Parameter
No.
1
Signal F1
2
Signal F2
Acceptable Range
Observed Values
CH1 CH2 CH3 CH4 CH5 CH6
2.9 to 3.1 V DC
2.9 to 3.1 V DC
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11
Switching OFF
The evaluation computer may only be switched off in consultation with the SM/
authorised person.
For switching OFF a computer for corrective maintenance or long-term shutdown
purposes:
In case of long-term computer shutdown, the supply voltage must be switched off, do
not exceed the admissible out-of-service period of. 5.5 months (only if supply voltage
is switched off immediately after channel failure).
If these times are exceeded, special safety measures must be performed. The
evaluation computer may only be put into operation again by Siemens specialist staff.
3.10 Replacing Boards
Only remove or insert boards and front connectors when the computer is in the deenergized state. Removing and inserting boards in the energized state may damage or
destroy boards or computer.
Removing Boards
To remove boards, proceed as follows:
Loosen the knurled screws at the upper
and lower locking bars of the mounting
frame (if present).
Remove both locking bars.
Loosen front connectors (if present).
If the board is supplied with a handle, pull
at the handle to remove the board. Remove
boards without a handle using the
extraction tool. Pull out the board
completely.
Fig. 3.16 : Extraction tool for boards
Inserting Boards
To insert boards, proceed as follows:
Slightly press up the upper locking bar and insert the board into the mounting frame
according to the location diagram.
Plug in front connectors (if present) previously prepared and tighten them.
Tighten the knurled screws of the locking bars.
The VAU board must always be replaced in pairs
Go to Chapter index
February 2013
Section IV
Maintenance of
CEL
DACF 710 A & DACF 710 P
Single Section Digital Axle Counter
CAMTECH/S/PROJ/2012-13/HB- DAC(M)
February 2013
Contents
Section IV: Maintenance of DACF 710 A & DACF 710 P CEL Single Section
Digital Axle Counter
Sr. No.
Description
Page No.
4.1
Introduction
4.2
Components of DACF
4.3
4.4
4.5
4.6
4.7
4.8
Maintenance
4.9
Resetting procedure
4.10
10
4.11
11
Go to Main index
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Section IV
Maintenance of
DACF 710 A & DACF 710 P
CEL Single Section Digital Axle Counter
4.1 Introduction
The system comprises of trackside counting units, installed at both ends near the
detection points on the track. No separate evaluator is required. Two versions available
(i) DACF 710 P (Phase reversal type)
The DACF 710 P is not affected by the push trolleys having 4 spoke and 8 spoke wheels;
and rail dolly. Trolley suppression track circuit is not required. It counts the following
push trolleys: (a) Push trolley with perforated wheel; (b) Dip lorry and (c) Motor trolley.
(ii) DACF 710 A (Amplitude Modulation type) The SSDAC remains unaffected with all
types of insulated push trolleys but goes into disturbed state (ERROR condition) for non
insulated trolleys. Trolley suppression track circuit is required.
4.2 Components of DACF
The CEL DACF system consists of following units
Axle detectors
Transmitter (TX) coils 2Nos. fed with 21 kHz and 23 kHz carrier signals
Receiver (RX) coils 2 Nos. to receive the transmitter signal
The Rx signal is phase modulated with each train wheel passing over the detection point.
Trackside electronic unit (SSDAC)
The SSDAC unit comprises total 8 cards namely:
Card No.1 & 2 - Signal Conditioning Card
Card No.3 & 4 - Micro controller logic blocks (2 Micro controllers)
Card No. 5 - Event Logger Card
Card No. 6 - Modem Card
Card No. 7 - Relay Driver Card
Card No. 8 - Power Supply Module (DC-DC converter)
4.3 Vital relay box
The VR box consists of dual relay i.e VR & PR relay of Q
style, 24V and 1000 ohm. It is provided in the trackside
location box along with SSDAC unit.
Fig. 4.1: Vital Relay Box
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
4.4
i.
ii.
iii.
iv.
v.
vi.
vii.
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
Colour
GREEN
2.
LD OK
GREEN
3.
PULSE OK
GREEN
4.
TP CON
GREEN
MLB Cards
Sr. No. LED
1.
8 LED BLOCK
2.
CLEAR
3.
OCCUPIED
Modem Card
Sr. No. LED
1.
Tx
2.
RX
3.
MODEM
4.
CD
DC-DC Converter
Sr. No. LED
1.
+5V
2.
+12V
3.
+24V
4.
+15V ISO
Colour
All RED
GREEN
RED
Colour
GREEN
GREEN
GREEN
GREEN
Relay Driver
Sr. No. LED
1.
MLB 1 CLEAR
2.
MLB 1 CLOCK
3.
MLB 2 CLEAR
4.
MLB 2 CLOCK
5.
RELAY DRIVE
Information
ON when TX coil & Oscillator are working normally.
OFF when these becomes faulty.
ON when signal from RX coils are normal and above
certain level, OFF when fault in RX coil or disconnection
ON when signal from RX coil normal and pulse level in
Card OK. OFF when RX coil faulty, wrongly connected
or disconnected
Permanently OFF as trolley suppression track circuit is
not required in phase reversal type system.
Information
Normally OFF, ON when error appears
ON for clear condition
ON for occupied condition
Information
Transmitting the signal when LED is flashing.
Receiving the signal when LED is flashing
Normally OFF, Glows and again goes low when system is reset.
Carrier is detected when LED is flashing
Colour
GREEN
GREEN
GREEN
GREEN
GREEN
Colour
RED
RED
RED
RED
Information
ON when section clear, OFF when section occupied
LED flashes when section is clear.
ON when section clear, OFF when section occupied
LED flashes when section is clear
ON when section clear, OFF when section occupied.
Information
ON when +5V supply available
ON when +12V supply available
ON when +24V supply available
ON when +15V ISO supply available
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
LED
RUN
LOG
3.
DNLD
Colour Information
GREEN Blinks continuously indicating normal working of Event Logger Card
GREEN Blinks whenever data is being logged into the flash memory (approx.
after every 2 minutes)
GREEN ON when data is being downloaded from the flash memory of the
card, OFF when download is complete.
4.8 Maintenance
4.8.1 Recording of Signal levels
For maintenance of Single Section Digital Axle Counter various parameters are to be
checked periodically. The various signal input and output levels and its limits which are
to be recorded and adjusted to correct levels wherever necessary are given in following
tables:
24 V DC Supply (Battery)
Measure the DC 24 V input to the system with charger ON, charger OFF condition with
all the units connected (i.e. on load) or using dummy load.
S.No.
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
Receiver Coil Output
Measure the RX coil signal output with and without dummy wheel.
Fig 4.7: Adjustment of Receiver coil with the help of dummy wheel
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
For Phase Reversal type Digital Axle Counter
S.No. Parameter
Limit mV rms
1.
RX Coil 1 (21 KHz)
275 - 600
2.
RX Coil 2 (23 KHz)
275 - 600
Measured Value
Card
1.
SCC
1
2.
SCC
2
Parameter
Clear mode
Occupied mode
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
S.
Parameter
No.
1.
2.
3.
4.
4.75 to 5.25 V
11.50 to 12.50 V
23.50 to 24.50 V
14.50 to 15.50 V
5V
12 V
24 V
15 v ISO
Measured
output
(DC Volts)
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February 2013
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February 2013
10
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Note:
Reset command to Micro-controllers will not be generated if system is in
clear/preparatory/occupied state. System can be resetted if it is in error state or out
counts were registered after occupied state.
Resetting operation by both stations is required and is necessary in BPAC use.
4.10 Tools and Spares
The following tool kit and spares are required for installation and maintenance:
Tool Kit
1.
Portable data analyzer for downloading event logger data for analysis and
report
generation.
(Specification
ref:
RDSO
letter
No.
STS/E/AC/DIGITAL/CEL dated 19.12.2006.
2.
Pure sine wave Digital Multimeter make Fluke model 187/Rishabh
model 285/ Kusum Meco model 859CF or equivalent.
3.
Train simulator, Model TS 267P CEL make
4.
Extender card (Card No.557)
5.
Dummy wheel
6.
Ring spanner 17-19, 24-26
7.
Open end spanner 17-19, 24-26
8.
Socket spanner with handle
9.
Torque wrench (Jaicom JPR65 or equivalent, 88NM)
10. Screw driver No. 902
11. Screw driver No. 935
12. Marking jig for drilling
13. Dummy load to check power supply (resistive)
1 No.
1 No.
1 No.
1 No.
1 No.
1 No. each
1 No. each
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
Recommended Spares
The following spares are to be recommended to be kept for 5 Nos. of working Single
Section Digital Axle Counter in a particular section.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
2 Nos
2 Nos
1 No
1 No.
2 Nos.
1 No.
1 No.
1 No.
1 Set
1 Set
1 Set
1 No.
1 No.
1 No.
February 2013
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11
Ensure that Receiver and Transmitter coil cables have been laid in different
pipes.
Ensure that both the TX coils & Rx coils are having proper alignment on Rail.
Ensure that packing of sleepers with ballast on both sides of Axle detector is
proper.
Check that metal sheaths of the outdoor cable are connected to earth at both
ends
The recommended cables for wiring of the system at site should be used.
The M.S Circular connectors of SSDAC are checked and maintained firmly.
The SSDAC & Reset box is provided with sealing arrangement. They should
be sealed at site.
Resetting should be done only after ensuring that there is no train in the
section
Don'ts
Dont install the Axle detectors near the rail joint (should be more than 6
sleepers away).
Dont install the Axle detectors where the rail is badly worn out.
Dont cut or join the Transmitter / Receiver cables supplied along with the
coil. It would result in change of frequency of signal.
Dont use any other outdoor cable other than the recommended cables.
Avoid installing the Axle detectors on curve of rail / too much slope of rail to
the possible extent.
Dont remove the cards from SSDAC units under power ON condition of
system.
Remove card if necessary after Switching OFF the power to the unit.
Go to Chapter index
February 2013
Section V
Maintenance
of
SSDAC-G36
G.G.Tronics Single Section Digital Axle Counter
Contents
Section V: Maintenance of G36 GG Tronics Single Section Digital Axle
Counter
Sr. No.
Description
Page No.
5.1
Introduction
5.2
5.3
Configurations
5.4
Relay Box
5.5
Reset Box
5.6
5.7
5.8
Protective devices
5.9
Maintenance
5.10
Resetting procedure
5.11
5.12
Precautions
10
5.13
10
5.14
12
Go to Main index
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Section V
Maintenance of
SSDAC-G36
G.G.Tronics Single Section Digital Axle Counter
5.1 Introduction
SSDAC G36 manufactured by M/s G.G.Tronics India Pvt. Ltd., is a microcontroller
based system with 2 out of 2 architecture suited for proving station and block section.
5.2 Modules of G36 SSDAC
The hardware and software for all the configurations are same. The main modules for
SSDAC-G36 are listed below:
SSDAC unit
Reset box
Axle Detectors (Tx & Rx coils factory tuned to 21 KHz & 25 KHz with
associated cables of 15 Mtrs.each)
5.3 Configurations
SSDAC-G36 units can be installed to work in the following configurations:
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CAMTECH/S/PROJ/12-13/HB-DAC (M)
LCD alphanumeric display with 4 lines & 20 characters per line is fixed on SF/EF units
for providing live display of different status, wheel counts and error messages in plain
English for guiding the installation and maintenance staff.
Note:
(i). CPU1 & CPU2 have unique addresses.
(ii). Communication and relay drive modules are equipped in different positions in SF/EF
units for unique port addressing.
Station
DP-SF
DP-SF
Station
Block Section
Station Section
DP-EF
Station
DP-EF
Fig.5.1:2DP1S system layout plans for block section and station section
(ii) SSDAC- 3DP1S System
In SSDAC 3DP1S configuration, there will be three SSDAC units i.e. Unit A, Unit B and
Unit C can be interfaced using FSK Modem communication. All the other features are
similar to that of 2DP1S system.
DP-B
Fig.3.2: 3DP1S system layout
plan for point zone
DP-A
DP-C
Block Section
Section A
Station
Section B
DP-SF
DP-CF
DP-EF
Fig. 5.3: 3DP2S system layout plan for two consecutive sections in a straight line
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
5.4 Relay Box
Relay boxes are provided depending upon the configuration as given below:
Sr. No.
1.
Configuration
2DP1S version
2.
3.
3DP1S version
3DP2S version
Units
SF
EF
-SF
EF
CF
Vital relay
1
1
1
1
1
2
Preparatory Relay
1
1
-1
1
2
Fig. 5.4.:
Reset box
front view
This has
SM Key
a facility of locking to prevent unauthorized operations. For executing a reset command,
this key has to be kept pressed after unlocking it.
Reset Push Button This switch is meant for sending the reset command to the system.
For sending the reset command, both the SM Key and the reset push button are to be held
pressed simultaneously and momentarily.
Line Verification Box
Line verification Box is supplied only for case where hard reset has to be adopted instead
of a preparatory reset.
Indications
One 10 mm Green and Red LED are provided for indicating status of block section.
One 5 mm green LED for indicating the status of preparatory reset. Flashing- when local
reset is applied. Steady - when reset is applied at the other end also & the system is
waiting for pilot train. OFF when the section becomes clear.
One 5 mm Yellow LED for indicating the line verification status. Normally OFF; glows
only when line verification key is operated for executing direct reset.
One 5 m Yellow LED for indicating power ON condition.
Section V - Maintenance of G-36 G.G. Tronics SSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Counter
One 6 digit non-resettable counter is provided which increments after each resetting
operation.
Display
One LCD display with 4 lines & 40 characters gives display of events, System Status,
Checksum and Version No, Counts and error code.
The reset box is connected to the system with one pair of quad cable for FSK
communication and 12 core signal cable for transfer of reset commands and reception of
the signals from the system.
The reset box required may be one per unit or two per unit depending upon the
configurations. Process of resetting required for a particular configuration also differs.
For example a single stationmaster or two separate stationmasters can do reset.
T16
T15
T14
T13
T12
T11
FSK DETAIL
T1
Spare
T2
Spare
T3
Spare
T4
Spare
T5
SM Modem FSK
T6
SM Modem FSK
T10
T9
T8
T7
LV FC 1B
LV FC 2A
LV FC 2B
Vital Relay FC2
Vital Relay BC2
+RESET
-RESET
Spare
T6
T9
T10
T11
T12
T13
T14
T15
T16
T5
T4
T3
T2
T1
RESET DETAIL
T1
+24V
T2
GND
T3
Prep Relay FC1
T4
Spare
T5
Vital Relay FC1
T6
Spare
T7
Spare
T8
LV FC 1A
T6
T5
T4
T3
T2
T1
SIGNALLING CABLE
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
2DP1S version
3DP1S version
3DP2S version
Continuous
current drain
< 2 Amp.
< 3 Amp.
< 3 Amp.
Battery capacity
Charger capacity
5 Amp. 2 Nos.
5 Amp. 1 No.
5 Amp. 3 Nos.
FTB Point
1,2
5,6,7,8
11,12,13,14
15 to 22
23,24,25,26
Rating
6.3 Amps
6.3 Amps
6.3 Amps
2 Amps
2 Amps
Quantity
2 Nos. on + limbs
4 Nos.
4 Nos.
8 Nos.
4 Nos.
27,28
35,36,43,44
51 to 58
2 Amps
2 Amps
2 Amps
2 Nos.
4 Nos.
8 Nos.
Quantity
1 No.
1 No.
1 No.
1 No.
5.9 Maintenance
Adjustments required in the field
The adjustment has to be done after measuring the voltages at monitoring points provided on
different modules, tabulated in the Table C.
Output voltages of DC-DC Converter
Measure the input voltage of 24 V DC between GND and the corresponding input monitoring
point; this should be within 22 V and 26 V DC.
With the same GND measure the other voltages.
Section V - Maintenance of G-36 G.G. Tronics SSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Adjust +5V precisely to 5V with the help of potentiometer provided for the purpose on the
front plate of DC-DC Converter.
Similarly adjust +18V fed to the PD card.
Measured values
range
4.75V to 5.25 V
17.75V to 18.25 V
11.75V to 12.25 V
11.75V to 12.25 V
22V to 26V
11.5V to 12.5V DC
11.5V to 12.5V DC
11.5V to 12.5V DC
11.5V to 12.5V DC
>20V DC
>20V DC
Expected values
Without wheel
With wheel
900 mV to 1.2 V AC < 350 mV AC
4V to 5V DC
3 V to 3.9 V DC
4.5V to 5V DC
3 mV to 5 mV DC
4.5V to 5V DC
3 mV to 5 mV DC
10V to 12V DC
0.1 or 0.2 V (Min.)
4V to 5V DC
--
3 V to 3.9 V DC
< 2 V in both PD
cards
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
(ii) For measuring AC voltages of Tx/Rx coils and at Phase Detector terminals, it is
essential that a true RMS voltmeter with Digital Multi-meter of 100 kHz bandwidth
like Fluke model 187 or higher and their equivalents of other manufacturers is used
for getting proper readings.
(iii) Presence of train wheel condition is to be created with the help of dummy wheel.
Maintenance schedule specified by manufacturer
Schedule
Maintenance
Daily
NIL
Weekly
NIL
Monthly
Check and record the readings of Power
Supply module and PD module and check
the Tx/Rx coil voltages as per the log sheet
Half yearly
Replace if any parts broken
5.10 Resetting Procedure
The procedure for reset for the different configurations is described in the following
paragraphs.
The reset box is wired to SSDAC system through a repeater relay named as VPR. The
repeater relay in the relay room repeats the status of the vital relay of the SSDAC system.
For all SSDAC system configurations the same reset circuit can be used.
(i) Reset procedure for 2DP1S system
The SSDAC-2DP1S system allows reset from stationmaster whenever system is powered
on or system/section enter error mode or unbalanced with occupied LED glowing, but no
hardware failures. SSDAC-SF and SSDAC-EF need reset from station A and station B.
Under this condition, reset is possible only if preparatory and vital relay are in deenergize/drop state. The following procedure is adopted for resetting a 2DP1S system:
Stationmaster A inserts and turns the SM key and press the reset button
simultaneously.
Preparatory LED start blinking and LCD displays Reset Applied in the position of
remote DP status indicating that reset is pressed.
Stationmaster B inserts and turns the SM key and presses the reset button
simultaneously.
After SSDAC-SF and SSDAC-EF communication is successful both the systems
enter the preparatory mode with preparatory LED glowing in the reset box at station
A and station B and the counter gets incremented by 1.
The LCD displays Wait For Pilot Train in both Local and remote DP status
position.
Now the pilot train is allowed in the section to balance the section. On successful
piloting of train with minimum of two axles as Incounts and Out-counts, section gets
balanced.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
The section goes through reset operation and vital relays of SSDAC-SF and SSDAC
EF energize/pickup. Occupied LEDs goes off and clear LEDs glow at both station A
and station B.
Reset procedure is now completed and SSDAC-2DP1S section is ready for train
movements.
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Station B stationmaster insert and turns the SM key and presses the reset button
simultaneously of reset box in station B for section B.
After, communication of reset status between EF and CF unit of section B is
successful. Preparatory LED of section B at Station A and at station B glows steadily
indicating that section B is in preparatory mode and ready for piloting. The rest
procedure is same as for Section A.
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
Recommended Spares
The following spares are to be procured separately for 5 nos. of Single Section Digital
Axle Counter working in field.
Sr. Spares
Part no.
Quantity
No.
1.
Phase detector modules 1 (PD1 )
H001M01R1
2
2.
Phase detector modules 2 (PD2 )
H001M02R1
2
3.
CPU1 Module of SF
H001M09R1
1
4.
CPU2 Module of SF
H001M10R1
1
5.
CPU1 Module of EF
H001M11R1
1
6.
CPU2 Module of EF
H001M12R1
1
7.
Communication module 1
H001M04R1
1
8.
Communication module 2
H001M05R1
1
9.
Relay drive module 1
H001M07R1
1
10. Relay drive module 2
H001M06R1
1
11. Event logger/SM-CPU module
H001M03R1
2
Section V - Maintenance of G-36 G.G. Tronics SSDAC
February 2013
10
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Sr.
No.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Spares
Part no.
Quantity
H001M08R1
G36 T212500
G36 R212500
--G36 RSBX01
H001M21R1
2
2
2
1
2
2
1
H001M21R1
G36 RB2R00
5.12 Precautions
Maintain 24 V DC supply between 22V & 26V DC at the terminals of the system
always.
Use 120 AH battery with axle counter type charger to take care of severe interruption
of 230 V mains supply.
Ensure good earthing with an earth resistance of 1 to 2 ohms by providing parallel or
special earth.
The entry of cables at the location box is to be filled with sand and sealed with
Bitumen compound without any gaps for preventing the entry of rats.
To avoid damage of web mounted detector coils due to track repair work or tie
tamping machine, ensure that only careful manual activity is performed on the portion
where the detectors are mounted.
Suitable warning board may be erected on either side of the detector coil not
infringing with the schedule of dimensions with the approval of competent authority.
For push trolleys, avoid solid wheels. Instead use spoked wheel.
After power ON, check that amber LEDs on PD cards do not glow under no wheel
condition. If they glow, interchange Rx wire connections of the module (21/25 KHz)
to put off the LEDs. Amber LEDs shall glow undr wheel presence.
5.13 Dos & Donts
Dos
Always follow interconnection drawings for connecting the Transmitter and Reciever
Coils.(Tx1-21 KHz, Tx2-25KHz, Rx1-21 KHz, Rx2-25 KHz).
Ensure that Receiver and Transmitter coil cables have been laid in different pipes.
Ensure that both the Tx coils and Rx coils are having proper alignment on rail.
Ensure that packing of sleepers with ballast on both sides of axle detector is proper.
Check that metal sheaths of the outdoor cable are connected to earth at both ends.
Use only the recommended cables for wiring of the system at site.
Maintain steady battery voltage of 24 V DC
Check MS coupler connectors of SSDAC system and maintain firmly.
Section V - Maintenance of G-36 G.G. Tronics SSDAC
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
11
Preparatory Resetting should be done only after ensuring that there is no train in the
section.
It is recommended that heat resisting paint to be used on the apparatus case so that the
temperature inside apparatus case is maintained lower in comparison to normal
paints.
Place Caution Board near the SSDAC Axle Detectors to avoid damage to the coils
from packing machines.
Provide Deflector plates near the SSDAC Axle Detectors to avoid damage to the coils
from hanging parts of trains.
Use spoked wheels for push trolleys in place of solid wheels to avoid error in SSDAC
system.
Donts
Do not connect the cable connections loosely.
Dont cut or join the Transmitter/Receiver cables supplied along with the coil. It
would result in change of input Receiver signal.
Dont remove the modules from SSDAC system under Power ON condition. Remove
the modules if necessary after switching OFF the power to the SSDAC system.
Local address of CPU-1, CPU-2 and configuration settings of the SSDAC system
should not be changed at the field.
When section is in Occupied/Preparatory mode, Motor trolley wheel, Push trolley
with solid mass wheel and Material trolley wheel must not be allowed to Enter/Exit
the section to avoid SSDAC system going to Error condition.
February 2013
12
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Date
Battery
FTB
1&2
2230V
AC Volts
TX1
V rms
/freq
TX2
V
rms
/freq
RX1
V
rms
/freq
RX2
V
rms
/freq
FTB
52 &
53
40-70
V
20.802
to
21.302
kHz
FTB
56 &
57
4070 V
24.7
50 to
25.2
50
kHz
FTB
54&
55
300
mV
to
1.2
V
FTB
58&
59
300
mV
to
1.2
V
Phase Detector 1
Phase Detector 2
RX
Sig
&
GND
AC
Volts
RX
Sig
&
GND
AC
volts
SUP
level
&
GND
DC
volts
RX PH-SIG &
GND socket DC
volts
Normal
Dummy
Wheel
10 to
12 V
<1v
SUP
level
&
GND
DC
volts
RX PH-SIG &
GND socket DC
volts
5V
+12
V
-12
V
+18V
Dummy
wheel
PD1
PD2
10 to
12 V
<1v
10
to
12
V
10
to
12
V
4.75
to
5.25
V
Go to chapter index
Normal
With push
trolley on
Axle
Detector
(4 spokes)
RX PH
SIG &
GND
socket
February 2013
11.75
to
12.25
V
11.75
to
12.25
V
17.75
to
18.25
V
24V
22
to
26
V
CAMTECH/S/PROJ/12-13/HB-DAC (M)
ANNEXURE I
ABBREVIATIONS
Section I :Az LS Eldyne SSDAC
AC
Alternating Current
AzLM
Thales Multi Section Digital Axle Counter
AzLS
Thales Single Section Digital Axle Counter
DC
Direct Current
DIP
Dual in line Packeged
DP
Detection Point
EAK
Tack side Electronic Unit
ETU001
Test equipment (Tool Kit)
Hz
Hertz
LED
Light Emitting Diode
MESSAB1
Rx voltage for SK1
MESSAB2
Rx voltage for SK2
PCB
Printed circuit Board
PEGUE1
Reference voltage for SK1
PEGUE2
Reference voltage for SK2
RMS
Root Mean Square
Rx
Reciever
Sk1, Sk2
Tx /Rx coil sets
SK30H
Rail contacts
Tx
Transmitter
Zp30CA-2.
Detection points
Section II: Az LM
AC
ACE
AzLM
AzLS
DC
DIP
DP
EAK
ETU001
Hz
ISDN
LED
MESSAB1
MESSAB2
PCB
PEGUE1
PEGUE2
RMS
Rx
Sk1, Sk2
SK30H
Tx
Zp30CA-2.
Eldyne MSDAC
Alternating Current
Axle Counter Evaluator
Thales Multi Section Digital Axle Counter
Thales Single Section Digital Axle Counter
Direct Current
Dual in line Packeged
Detection Point
Tack side Electronic Unit
Test equipment (Tool Kit)
Hertz
Integrated Services Digital Network
Light Emitting Diode
Rx voltage for SK1
Rx voltage for SK2
Printed circuit Board
Reference voltage for SK1
Reference voltage for SK2
Root Mean Square
Reciever
Tx /Rx coil sets
Rail contacts
Transmitter
Detection points
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
Carrier Detection
CEL
DACF 710 A
DACF 710 P
dB
DC
DIP
DNLD
LCD
LD
LED
LV
MLB
Level Detector
Light Emitting Diode
Last Vehicle
Micro Controller Logic Block
PR
PPR
RDSO
Rx
SCC
SM
SSDAC
TP
Trolley Protection
Tx
Transmitter
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC (M)
VR
Vital Relay
Ampere Hour
Centre Fed
Central Processing Unit
Vital Relay for Centre Fed
Direct Current
Two detection points Single section
Three detection points Single section
Three-detection points for two consecutive sections in a straight line
End Fed
Vital Relay for End Fed
Frequency Shift Keying
Fused Terminal Blocks
Ground
Hertz
Kilo Hertz
Liquid Crystal Diode
Lightning Detector Unit
Light Emitting Diode
Mild Steel
Phase Detector
Repeater relay for Preparatory Relay
Preparatory Relay
Style Q AC immunized relay
Research Design & Standards Organisation
Receiver
Start Fed
Vital Relay for Start Fed
Station master
Single Section Digital Axle Counter
Transmitter
Repeater relay for Vital Relay
Vital Relay
February 2013
CAMTECH/S/PROJ/12-13/HB-DAC
ANNEXURE II
REFERENCES
Installation Manuals - Single section Digital Axle Counter DACF -710 A &
DACF 710 P M/s Central Electronics Ltd.
Go to main Index
February 2013