02 Systemdescription ACM200 A6Z00034296029

System Description
Clearguard ACM 200

Axle Counting System
A6Z00034296029/- System Description

2013-06-05 Clearguard ACM 200 Axle Counting System
Siemens AG, 2013 All rights reserved Page 1 of 35
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Contents
1 Information for the user.................................................................................................... 4
Overview ............................................................................................................................. 4
About this document ........................................................................................................... 4
Contact to Siemens............................................................................................................. 5
2 System overview ............................................................................................................... 6

System overview ................................................................................................................. 6
2.1 Efficiency criteria .............................................................................................................. 7
Axle counting systems: proven and fail-safe ...................................................................... 7
High-reliability, fail-safe computer system .......................................................................... 7
Highly cost-effective track vacancy detection ..................................................................... 8
Flexibility for all customer requirements.............................................................................. 8
Reduced maintenance requirements .................................................................................. 9
2.2 System features ................................................................................................................ 9
Flexible protection of track vacancy detection sections...................................................... 9
Variable combinations for all requirements....................................................................... 10
Procedure-protected interconnection of ACMs ................................................................. 11
Connection to most diverse interlockings ......................................................................... 12
Individual adaptation to existing installation sites ............................................................. 12
Flexible configuration ........................................................................................................ 13
Clear diagnostics............................................................................................................... 16
Variable power supply for all requirements....................................................................... 18
High availability and high train speeds by multiple-axle counting method........................ 18
3 Structure and functions.................................................................................................. 19

3.1 Overview of track vacancy detection system .............................................................. 19
Overview ........................................................................................................................... 19
3.2 Mode of operation of ACM 200 ...................................................................................... 20
Mode of operation ............................................................................................................. 20
3.3 Outdoor equipment: structure and functions .............................................................. 22
Wheel detection equipment for ACM 200 ......................................................................... 22
3.4 Indoor equipment: structure and functions ................................................................. 24
Axle counter module ......................................................................................................... 24
ACM front panel ................................................................................................................ 25
Hardware overview ........................................................................................................... 27
3.5 Cable distributor and cabling ........................................................................................ 29
Cable distributor and cabling ............................................................................................ 29
4 Technical data ................................................................................................................. 30

Technical data................................................................................................................... 30
5 Standards......................................................................................................................... 33
Conformity with European directives and standards ........................................................ 33
6 Indices .............................................................................................................................. 34
List of abbreviations .......................................................................................................... 34
List of figures ..................................................................................................................... 35
List of tables ...................................................................................................................... 35

Information for the user
1 Information for the user
Overview
Contents of this section

This section contains general information about the contents of this document.
About this document
Scope
This document applies to the Clearguard ACM 200 axle counting system in equipment
revision level 1.
Purpose
This System Description describes the features and functions of the Clearguard ACM 200
axle counting system. The Clearguard ACM 200 axle counting system is a track vacancy
detection system which supplies reliable information about the state of track vacancy
detection sections (clear / occupied). This System Description presents the design of the
axle counting system comprising indoor equipment and outdoor equipment.
The features and functions are described application-independently.
The Clearguard ACM 200 axle counting system is part of the Clearguard track vacancy
detection system product line from Siemens. The axle counting system can be combined
with the following electronic wheel detection equipment (also referred to as counting
heads (CH)): Clearguard ZP 43 E, Clearguard ZP 43 V, or Clearguard ZP D 43.
The Clearguard ACM 200 axle counting system is referred to below simply as ACM 200.
The wheel detection equipment variants are referred to below as ZP 43.
Target group
This document is directed at technically qualified railway staff.
Documentation is part of equipment described

This document is part of the equipment described. It must be kept for the entire lifetime of
the equipment. Make this document available to the staff responsible for the activities
described. Insert any amendments subsequently received from Siemens into the
document.

Information for the user
Supplementary documents
The following documents are also important as supplementary documents:
Title Document number

Standard Design Document A6Z00034296050
Clearguard ACM 200 Axle Counting System
Operating and Service Manual A6Z08110055889
Clearguard ZP 43 E
Clearguard ZP 43 E, German Rail Network
(available in German only)
Clearguard ZP 43 V
Clearguard ZP D 43
EC Declaration of Conformity A6Z00033123935
Clearguard ACM 200, C1112005
Table 1 Supplementary documents
Suggestions
Contact us if you have any suggestions on how we can improve this document. In this
way, you will benefit all users of this document. We would appreciate receiving your ideas
and requests.
Contact to Siemens
Address
Siemens AG
P.O. Box 33 27
38023 Braunschweig, Germany
Tel.: ++49 531 226 0
E-mail: rail-automation.mobility@siemens.com

System overview
2 System overview
System overview
Figure 1 ACM 200 axle counting system
Further member of Clearguard product family: ACM 200

ACM 200 is a further axle counting system in the Clearguard track vacancy detection
system product family from Siemens. ACM 200 is an automatic axle counting system with
modular design. The state-of-the-art axle counting system provides reliable information
about clear and occupied track vacancy detection sections and thus makes an important
contribution to trouble-free railway operations. ACM 200 can be combined with ZP 43
wheel detection equipment. The system has been designed for a wide range of
applications.
Fields of application of ACM 200

Mainline and regional railways
Metros and trams
Freight lines and depots
Main and secondary lines, station areas, and point areas
Single- and multiple-track lines
Lines with and without a block system
All types of traction
All common types of car
Track sections of any length
Train speeds of up to 400 km/h

System overview
2.1 Efficiency criteria
Axle counting systems: proven and fail-safe
Fail-safe system
ACM 200 protects track vacancy detection sections according to the proven and fail-safe
Simis principle. Axle counting evaluation computers using the Simis principle have been
distinguished for many years by their use of proven technology.
Maximum safety
ACM 200 has been developed according to the safety requirements stipulated by the
European CENELEC standards for railway applications.
Recognized and independent assessors have confirmed that ACM 200 meets the highest
safety integrity level, SIL 4, in accordance with the CENELEC standards EN 50126,
EN 50128 and EN 50129.
As regards safety, ACM 200 complies with the Technical Principles for the Approval of
Safety-related Systems for Signaling of the Federal German Railways Office (EBA) and is
EBA-approved.
High-reliability, fail-safe computer system
Simis principle fail-safe and highly reliable

The axle counter module (ACM) in ACM 200 is distinguished by a high level of reliability
of the hardware used.
The ACM includes a computer unit which is designed in accordance with the Simis
principle. This computer unit consists of two independent microcomputers of identical
design which are identically programmed and work synchronously with each other.
The process data is read into each channel in parallel and processed synchronously. The
statuses of the process step sequences and the test and output data generated during
the process steps are checked for correspondence.
Regularly executed test routines continuously check the individual computer channels
independent of the process status to ensure that they function correctly.
Working principle of 2-out-of-2 configuration

The fail-safe and highly reliable ACM, which works on the Simis principle, has a
redundantly designed hardware core with a 2-out-of-2 configuration. With this
configuration, two identically designed microcomputers work in a synchronous mode.
The Simis computer, consisting of two microcomputers, gives ACM 200 a high-availability
working principle.

System overview
Highly cost-effective track vacancy detection
One single module type for cost-effective application

ACM 200 is distinguished by a high level of cost-effectiveness.
The modular architecture is based on a standardized platform with one module type
being used for all applications, the ACM. The compact ACM has a sturdy metal housing
for harsh industrial use, and is quick to install. The universal use of one single module
type permits cost-effective and long-term hardware procurement, and reduces the costs
of keeping spare parts and possible sources of faults.
Switches are used for the purpose of connecting a number of ACMs to a commercially
available Ethernet network.
Low-cost installation on mounting rail

The ACM is installed on a mounting rail. The latch fixing on the rear of the ACM permits
rapid installation by latching into place. This optimized form of installation shortens the
commissioning times and reduces on-site installation costs.
Flexibility for all customer requirements
Modular architecture for most diverse customer requirements

The axle counting system comprises one or more ACMs. The modular architecture of
ACM 200 permits the system to be individually configured to satisfy the most diverse
customer requirements. The number of ACMs can be adjusted to the relevant topology
depending on the function. Hence, ACM 200 offers the ideal solution for all demanding
central and local track vacancy detection applications.
Individual operating concepts can be realized cost-effectively. The concept of ACM 200
permits easy extension and modification, thereby ensuring investment security for years
to come. Hardware replacement and extension or configuration updates can be carried
out in a very short space of time. Short out-of-service periods can be used for this
purpose, without interrupting rail operations.
Floating relay interface

ACM 200 has a floating relay interface for connection to any type of interlocking or
subsystem, permitting its flexible adaptation to different operating conditions. Existing
systems can thus be updated or extended at low cost with the highly cost-effective
ACM 200.

System overview
2.2 System features
Reduced maintenance requirements
High-reliability, maintenance-free hardware

The highly reliable hardware component, the ACM, ensures that maintenance
requirements are kept low. Usage of the maintenance-free ACM means reduced life-cycle
costs. As only one module type is used to realize all track vacancy detection applications,
the costs of keeping spare parts are minimized.
Maintenance without interrupting normal operations

An ACM can be replaced with the power on. The configured data of the ACM can be
transferred to a spare ACM simply by removing and then reinserting a programmable
connector (ID plug). System components must no longer be switched off and operations
no longer be interrupted.
LEDs on the ACM permit easy on-site diagnostics.
With the integrated and password-protected web site which is accessed via a standard
PC, rapid and easy diagnostics are possible. Maintenance costs are reduced, and
operational disruptions cleared up significantly faster.
2.2 System features
Flexible protection of track vacancy detection sections
Fail-safe clear and occupied indications

The key feature of ACM 200 consists in monitoring individual track vacancy detection
sections (TVDS) and evaluating the signals transmitted by wheel detection equipment in
order to issue a fail-safe clear or occupied indication. This status information is
transmitted via the floating relay interface of the ACM to any interlockings or subsystems.
Usage of floating relay interface for additional functions

If one of the two relay interfaces of the ACM is not being used for the output of clear /
occupied indications, it can be used for the output of safety-related information (SRI). The
information is input via the optocoupler inputs of a partner ACM.
Protection of track vacancy detection sections with ZP 43

ACM 200 is combined with ZP 43 wheel detection equipment. The ZP 43 generates an
electromagnetic field around the rail (wheel detection according to the transmitter /
receiver principle). Any change in the electromagnetic field is detected by the ZP 43 and
passed on to ACM 200. The ZP 43 has proven itself over many years and is immune to
the influence of magnetic rail brakes and eddy-current brakes. The ZP 43 is a state-of-
the-art product for many fields of application.

System overview
2.2 System features
Control distance
The control distance between ACM 200 and connected ZP 43 wheel detection equipment
is up to 21 km. The relevant conditions and constraints must be observed.
Variable combinations for all requirements
Connection of two ZP 43 to one ACM

Two ZP 43 can be connected to an ACM directly and the ACM can monitor two track
vacancy detection sections. In the lower part of the ACM front panel, there is an Ethernet
interface for the connection of additional ACMs, diagnostics and loading of configuration
data.
Variable axle counting system by combining ACMs
Figure 2 Combination of a number of ACMs to form an axle counting system
The Ethernet interface of an ACM allows further ACMs to be connected to build up a

network of ACMs.
A maximum of four further partner ACMs can be connected to each ACM. Modules of
ACM 200 or the Clearguard ACM 100 axle counting system can be partner ACMs. Using
this 1-plus-4 combination, a total of ten ZP 43, also combined with WSD wheel detectors,
can be connected.
For the purpose of exchanging wheel signal data, the ACMs are connected to each other
via a switch.
The 1-plus-4 combination implements the following:
One ACM monitors the wheel signal data from the two directly connected ZP 43.
The four partner ACMs monitor the wheel signal data from the eight remote ZP 43
or WSD wheel detectors which are connected.

System overview
2.2 System features
Extension of axle counting system by further 1-plus-4 combinations

Each ACM can be connected to up to four further partner ACMs (in accordance with the
principle of the maximum 1-plus-4 combination). Axle counting systems of any size can
be formed by this cascade arrangement. This variable interconnection of the ACMs
permits an axle counting system which is specific to the customers requirements to be
implemented at low cost.
Procedure-protected interconnection of ACMs
Procedure-protected ACM interconnection

For secure transmission of the clear / occupied indications and fail-safe status information,
Siemens single-channel secure cyclic data transmission procedure, SLC (safety layer
cyclic), is used. All ACMs interconnected via the Ethernet interface exchange their status
information by means of SLC.
ACM interconnection for long track vacancy detection sections

Due to local conditions, track vacancy detection sections may be limited by ZP 43 which
are not in the vicinity of the ACM 200 axle counting system. These remote ZP 43 must
be connected to ACMs which are positioned locally. The wheel signal data is
transmitted using SLC. Open transmission systems can be used for remote data
transmission between interconnected ACMs. In this way, track vacancy detection
sections of any desired length can be monitored using ACM 200.
Data transmission via open transmission systems

Data can be exchanged between the interconnected ACMs via an open transmission
system. Secure transmission of the data is realized by SLC. For the transmission of
status information when the distances are larger, modems are used. The modems are
interconnected via copper wires in the case of electrical networks, or via fiber-optic cables
(FOC) when using optical networks.
Data transmission via public telephone networks

If the axle counting data is to be transmitted via public telephone networks, additional
measures against unauthorized access must be taken. These measures are described in
EN 50159.

System overview
2.2 System features
Connection to most diverse interlockings
Connection to new and existing interlockings

The floating relay interface permits transmission of the data about clear and occupied
track vacancy detection sections to a wide range of interlocking systems of any type.
ACM 200 can be connected to new and existing electronic and relay interlockings.
This relay interface permits flexible use under a wide range of operating conditions. In
addition to the clear and occupied indications, ACM 200 can optionally transmit operator-
specific safety-related information (SRI) via the relay interface.
Individual adaptation to existing installation sites
Calibration of ACM
Due to application-specific conditions (e.g. different control distances, cable properties),
the ACM must be adapted to existing on-site situations. The ACM can be automatically
calibrated by pressing the CAL button on its front panel. No further checking is required.
Commissioning costs are reduced and downtimes are considerably minimized thanks to
simplified maintenance.
Variable direction reversal of wheel detection equipment

When the wheel detection equipment is installed on site, the mounting location (to the left
or right of the track) may have to be changed as compared to the configured location. For
flexible adaptation to the prevailing track conditions, the evaluation direction can be
individually switched over for each connected set of wheel detection equipment by
pressing the DIR1 and DIR2 buttons on the ACM front panel. Any necessary
modifications during normal operations (e.g. constructional changes or extensions) can
thus also be implemented fast and cost-effectively.

System overview
2.2 System features
Flexible configuration
Figure 3 Integrated web site (configuration view)
Integrated web site for configuration purposes

An integrated web site is available for ACM 200 for configuration purposes. With a
standard PC connected, the web site can be called up using a web browser.
The integrated web site provides rapid access to the ACMs which are in the axle counting
systems network. An ACM can be selected by inputting its specific IP address. The
configuration data is protected against modification by means of a password. The
configuration data for the selected ACM can be set using checkboxes, buttons and text
boxes on the state-of-the-art graphical user interface. The integrated web site is available
in two languages.
Configuration using checkboxes, buttons and pull-down menus

Preset configuration data (default data) can be simply modified to suit customer-specific
requirements using checkboxes, buttons and pull-down menus.

System overview
2.2 System features
The following can be configured for the ACM:

two track vacancy detection sections (TVDS1 and TVDS2)
two directly connected (own) sets of wheel detection equipment (DS1.1 to DS2.2)
four partner ACMs (partner ACMs 1 to 4)
assignment of the wheel detection equipment to the ACMs track vacancy detection
sections
definition of the counting direction of the wheel detection equipment for the track
vacancy detection sections
two items of safety-related information (SRI)
definition of the relay output of the track vacancy detection sections (single- or dual-
channel) or output of safety-related information (SRI)
definition of a single- or dual-channel axle count reset (reset possible from different
places)
types of axle count reset (AZG with / without RR, VAZG with / without RR, AZGH)
oscillation behavior
"pulse detected" indication output
Configuration using text boxes

A large number of additional items of configuration data can be edited via text boxes.
The following can be configured for the ACM (examples):
names for the track vacancy detection sections and wheel detection equipment
communication parameters for the ACM and partner ACMs
Flexible configuration of axle count reset types

For ACM 200, the type of axle count reset can be customized using the integrated web
site. The following can be configured for each track vacancy detection section:
immediate axle count reset (AZG) with or without reset restriction (RR)
preparatory axle count reset (VAZG) with or without reset restriction (RR)
immediate axle count reset (AZG) and preparatory axle count reset (VAZG) in
parallel in one track vacancy detection section
Configuration of immediate axle count reset

With immediate axle count reset (AZG), the respective track vacancy detection section is
indicated as clear immediately after the axle count reset operation has been executed.
The immediate axle count reset (AZG) operation is rejected if a reset restriction is present
(when a reset restriction (RR) is configured). A reset restriction is activated if, for example,
the last axle counted by ACM 200 in the respective section was an axle counted in. A
reset restriction can be canceled by checking the track vacancy detection section
(proceed-on-order run or visual inspection) or executing an auxiliary axle count reset
(AZGH) operation. Subsequently, the track vacancy detection section can be reset by an
axle count reset (AZG) operation.

System overview
2.2 System features
Configuration of preparatory axle count reset

With preparatory axle count reset (VAZG), the track vacancy detection section in question
remains occupied for a certain time after the relevant axle count reset operation has been
executed.
The track vacancy detection section is not indicated as clear until after a proceed-on-
order run with the axles counted in matching those counted out.
The requirements for a proceed-on-order run must be stipulated in the relevant railway
operators regulations.
Configuration of parallel immediate and preparatory axle count reset

Both types of axle count reset (AZG and VAZG) can be configured in parallel for each
track vacancy detection section. Thus, the immediate axle count reset (AZG) can be
implemented as a secondary axle count reset procedure.
Flexible configuration of oscillation behavior

ACM 200 can also be used for track vacancy detection on lines where trains come to a
halt. Any oscillation of an axle over a ZP 43 is recognized by ACM 200 and does not
result in counting errors. This behavior can be flexibly configured for each track vacancy
detection section via the integrated web site.
"Pulse detected" indication output

The output of a "pulse detected" indication permits the ZP 43 to be flexibly used for non-
fail-safe switching functions, for example for throwing points or controlling gates. Thanks
to this configuration option, additional systems for auxiliary services are not required on
the track.
Saving and loading of configuration data

The configuration data specified using the integrated web site is saved in a readable file
on the hard disk of a standard PC, or loaded immediately onto the configuring connector
(ID plug) of the ACM. A consistency check is carried out on the configuration data. In the
event of a deviation, an error message is displayed.

System overview
2.2 System features
Clear diagnostics
Figure 4 Integrated web site (diagnostic view)
Diagnostics using LEDs on ACM

On-site diagnostics is performed using the LEDs on the front of the ACM. The current
status of the ACM can be easily diagnosed by reference to the different coloring of the
LEDs.
On-site diagnostics using integrated web site

For additional on-site diagnostics, a standard PC with a common web browser can be
connected via the Ethernet interface. The integrated web site enables the current status
data to be requested via its graphical user interface. The clear display permits optimal
support for all maintenance tasks.
Remote diagnostics using integrated web site

The integrated web site enables remote diagnostics by dialing into a network (internet,
intranet) from any location at any time of day. After a connection has been established to
ACM 200 and the IP address of the desired ACM has been input, diagnostics can be
performed. The graphical user interface clearly shows status and diagnostic data for the
selected ACM by means of a graphic panel and by list displays.
Usage of graphic panel for diagnostics

The status information for an ACM is displayed in color on a graphic panel. This provides
a rapid overview of the most important items of status information. The following

System overview
2.2 System features
automatically cyclically updated information and fault indications are displayed on the
graphic panel:
clear or occupied for the two track vacancy detection sections (TVDS1 and
TVDS2) of the ACM
number of counted axles
statuses of the wheel detection equipment (DS1 and DS2)
statuses of the LEDs of the ACM
reset of the ACM possible by a mouse click (if configured)
In the event of a fault, the graphic frame and text for the element affected are shown in
red. This makes a rapid overview of the information possible.
Usage of list displays for diagnostics

Apart from the graphic panel, an overview of numerous items of status information can
additionally be called up in the form of data lists. A list consists of data fields with axle
counting-specific and diagnostic information. After a data field has been selected, a text
field appears below the list display with further information and instructions on how to
proceed for troubleshooting purposes. If desired, it is possible to display only the fault
data. This diagnostic data is shown in red.
Logging and re-display of status information

The lists displayed using the integrated web site can be logged at definable intervals. The
log files can be saved on the hard disk of a connected PC. For later diagnostic purposes,
the available log files can be read into the web site again and displayed on it. There is
graphical support for making an event-specific selection (made simply on a timebar
display) from the log files which have been read in.

System overview
2.2 System features
Variable power supply for all requirements
Variable connection options of ACM 200

The power supply for ACM 200 permits variable adaptation to available supply networks.
If a mains supply at 24 V DC is not available for the ACMs power supply, different power
supply modules are available for optimal adaptation.
ACM 200 has reversible protection against overvoltage at 24 V DC mains voltage. In the
event of an overvoltage, ACM 200 is switched off. To restart it, the power supply must be
briefly disconnected. ACM 200 features reverse polarity protection.
High availability and high train speeds by multiple-axle counting method
Multiple-axle counting method for fault-tolerant evaluation

The multiple-axle counting method (MACM) evaluates batches of several axles at a time
as a function of the train speed. The evaluation of several axles results in improved
interference suppression, and thus increases system availability. Train speeds of up to
400 km/h can be processed with this method.

Structure and functions
3.1 Overview of track vacancy detection system
3 Structure and functions
3.1 Overview of track vacancy detection system
Overview
Safety in rail operations calls for systems which work smoothly together. One of the most
important pieces of equipment, the track vacancy detection system, prevents successive
moves, protects entries and exits, and reliably indicates to other systems clear and
occupied track vacancy detection sections.
Axle counting systems are used to indicate whether tracks are clear or occupied.
Track vacancy detection using axle counting systems

In axle counting systems, there are wheel detection components (counting heads) at the
beginning and end of each track vacancy detection section (TVDS) to be monitored. To
determine whether there is a vehicle in a track vacancy detection section, the system
compares the number of axles entering it with the number leaving it.
Figure 5 Schematic representation of an axle counting system

3.2 Mode of operation of ACM 200
Mode of operation
ACM 200 is used for the automatic monitoring of open-line and station tracks. Clear and
occupied indications are transmitted to the interlocking or to subsystems for track
sections and points.
ACM 200 has the following structure (example):
Figure 6 System structure of ACM 200
ACM 200 consists of two parts:

outdoor equipment
indoor equipment
Outdoor equipment
The outdoor equipment consists of ZP 43 wheel detection equipment which detects
passing wheels. The pulses are transmitted via a two-core trackside cable to the
ACM 200 axle counting system installed in the interlocking building.

Indoor equipment
The indoor equipment consists of a combination of partner ACMs. Partner ACMs of
ACM 200 and ACM 100 can be combined to form a network.
ACM 200 has the following functions:
evaluation of the signal pulses transmitted by the ZP 43
comparison of the number of axles counted into a track vacancy detection section
with the number of axles counted out
monitoring of the track vacancy detection sections and output of the clear and
occupied indications to the interlocking
optional transmission of wheel detection and / or safety-related information (SRI) via
an ACM-ACM Ethernet connection
ACM 200 has a 2-out-of-2 computer configuration, based on the fail-safe Simis principle.
The process data (passage of a wheel) is detected by the ZP 43, processed and
transmitted to the assigned ACM. The ACM processes and evaluates the wheel detection
signals and indicates the results to the interlocking.
In addition to the output of clear and occupied indications, it is possible, for each track
vacancy detection section, to output a reset restriction (RR) and a reset acknowledgment
(RA) on a single channel.
The dual-channel immediate (AZG) or preparatory (VAZG) axle count reset is realized as
an input from the interlocking. The reset restriction can be canceled from the interlocking
using an optional dual-channel auxiliary axle count reset (AZGH) operation. This is also
possible directly on the ACM.
Connection of ACM 200 to interlocking

ACM 200 is connected to any type of relay or electronic interlocking via the floating relay
interface. The outputs to the interlocking circuits are transmitted via a parallel relay
interface with floating relay contacts. The inputs are made through optocoupler inputs. In
addition to the dual-channel clear / occupied indications, safety-related information (SRI)
can optionally be output.
ACM interconnection for remote ZP 43

For connection of a remote ZP 43, the local ACM is linked to the ACM in the
interlocking via modems. Data is transmitted via an Ethernet interface.

3.3 Outdoor equipment: structure and functions
Wheel detection equipment for ACM 200
ACM 200 combinable with different types of wheel detection equipment
Figure 7 Wheel detection equipment (e.g. ZP D 43)
The outdoor equipment of ACM 200 consists of ZP 43 wheel detection equipment. The
following wheel detection equipment variants from the Clearguard product family can
continue to be used to keep the migration costs low:
ZP 43 E
ZP 43 V
With ACM 200, it is also possible to replace existing ZP 43 E / V by the successor product,
ZP D 43.
Features of combinable wheel detection equipment variants

Overview of wheel detection equipment variants:
Feature ZP 43 E / V ZP D 43
Area of application Mainline services Mainline services
Mass transit
Private and industrial
railways
Components DEK 43 double wheel DEK 43 double wheel
detector, trackside detector, trackside
connection box with connection box with
aluminum cover (ZP 43 E) aluminum base plate and
or plastic cover (ZP 43 V) plastic or aluminum cover
Wheel detection Wheel detection by an Wheel detection by an
(flangeless wheels) electromagnetic field electromagnetic field
around the rail around the rail with
improved EMC immunity
Interface- and function-
compatible

Feature ZP 43 E / V ZP D 43
Wheel dimensions Detection of all wheels Detection of all wheels
whose dimensions conform whose dimensions conform
or largely conform to the to the EBO
EBO Adaptation to non-EBO-
compliant wheels by a
coding plug in the wheel
detection equipment
Immunity Immune to eddy-current Immune to eddy-current
brakes brakes
Mounting Mounting over the sleeper Mounting over the sleeper
possible on request possible
Commissioning Manual calibration Semi-automatic calibration
Table 2 Overview of combinable wheel detection equipment variants
Reliable detection for trouble-free rail operations

The ZP 43 supplies reliable wheel detection signals for trouble-free rail operations. All
wheel detection equipment variants are distinguished by the following main features:
high mechanical stability
compatible with most common rail profiles up to the maximum permissible level of
wear
no mechanical adjustment necessary
reliable operation with very short wheel detection times at traversal speeds of up to
400 km/h at a wheel diameter of 830 mm
immune to traction return currents, current step changes in the catenary supply,
magnetic or electromagnetic interference, interference from signaling equipment
operating in the audio-frequency or medium-frequency range and the effects of
magnetic rail brakes
fault-free operation at ambient temperatures from -40 C to +80 C, in icy, snowy
and humid conditions and even with brief flooding
detection of all wheels whose dimensions conform to the EBO
integration of overvoltage protection components possible
Components of wheel detection equipment

The ZP 43 are installed at the limits of a track vacancy detection section. A set of wheel
detection equipment consists of the DEK 43 double wheel detector and a trackside
connection box (TCB). The trackside connection box accommodates the electronics for
evaluation of the wheel pulses.
The DEK 43 double wheel detector consists of a transmitter section and a receiver
section. The transmitter section is installed on the outer side of the rail and the receiver
section on the gage side of the rail. The DEK 43 double wheel detector is connected to
the trackside connection box by means of two connecting cables permanently attached to
the detector. The cables are optionally 5 m, 10 m or 15 m long. The DEK 43 double
wheel detector is bolted to the rail web.

3.4 Indoor equipment: structure and functions
Mode of operation of wheel detection equipment

The ZP 43 operates according to the principle of electromagnetic wheel detection at a
generator frequency of 43 kHz. A wheel entering the effective range of the double wheel
detector changes the field strength and lines of force of the alternating electromagnetic
field, thus producing signal pulses. These pulses are used to generate axle counts and,
from their offset, to determine the direction of travel. ACM 200 is informed about a
detected wheel by a change in the AC frequency of the respective detector subsystem.
Application variants
The ZP 43 can be used for the following application variants:
standard usage
double usage
external supply
ACM 200 supports these modes.
Axle counter module
Compact design
The main component of the axle counting system is the axle counter module (ACM). The
entire electronics, including the interfaces and control and display elements, is integrated
into the ACM. This eliminates time-consuming wiring for connecting functional units.
The housing is made of high-grade steel. Installation outside a switchgear cabinet is
possible. On its rear, the housing has a latch fixing for rapid installation on a mounting rail.
All interfaces on underside of ACM

The electrical connections are located on the underside of the ACM. The majority of all
connections are realized through one compact process connector.
The following interfaces are combined on the process connector:
two fail-safe (dual-channel) relay outputs: the clear and occupied indications are
transmitted via floating relay contacts. For the relay output, either an equivalent or a
non-equivalent connection can be used. The outputs can optionally be used to
output safety-related information (SRI).
four fail-safe (dual-channel) optocoupler inputs: for dual-channel evaluation of the
immediate (AZG), preparatory (VAZG) and auxiliary (AZGH) axle count reset. The
inputs can optionally be used to read in safety-related information (SRI).
five single-channel relay outputs for reset restriction (RR), reset acknowledgment
(RA) and operational readiness of the ACM (module is OK)
two interfaces for ZP 43
power supply connection (e.g. system power supply)

The Ethernet interface for connection to other ACMs is located in the lower part of the
ACM. A standard PC can also be connected here for configuration and diagnostic
purposes.
Installation on mounting rail

The ACM is installed by latching onto a 122 mm mounting rail. A large number of ACMs
can be rapidly mounted next to each other on the mounting rail in a space-saving way.
The mounting rail can also be mounted on a wall. A number of mounting rails can also be
combined in racks or cabinets.
ACM front panel
Control and display elements on front panel

The integral control and display unit on the ACM front panel permits direct input to the
ACM (reset button, cancelation of the reset restriction, calibration, and direction reversal).
There are 13 LEDs on the front panel, which show either a steady or flashing green,
yellow or red light. These LEDs give a rapid overview of the operating statuses.

Element Meaning
A ID plug Configuring connector
with lettering field
B RST button Reset button (resets the
ACM)
1 OK LED ACM is OK
2, TVDS1 LED Status of track vacancy
3 TVDS2 LED detection section: clear /
occupied / faulty
or
Status of SRI: active /
inactive
4, DS1.1 LED Status of wheel detection
5, DS1.2 LED equipment (per detector
6, subsystem and channel):
DS2.1 LED
7 no passing wheel /
DS2.2 LED
passing wheel / faulty
8 RR1 LED Reset restriction 1 (RR /
button fault)
9 RR2 LED Reset restriction 2 (RR /
button fault)
10 COM LED Status of communications
11, Button Button for AZGH
12 RST-RR1, RST- (cancelation of the RR)
RR2
13 LED, CAL button Calibration of wheel
detection equipment
14, LED, DIR1, DIR2 Direction reversal
15 buttons
16 SIM1, SIM2 In preparation
sockets
17 Fuse Power supply of wheel
F1 0.2 A, F2 0.2 A detection equipment
18 Siemens code Field for the identification

number number of the module
19 RJ45 socket Ethernet interface
Figure 8 ACM front panel: control and display elements

ID plug for configuration data

A programmable configuring connector (ID plug, identity plug) is located in the upper front
section of the ACM. The ID plug has a non-volatile memory. The configuration data
specific to each ACM is loaded onto the ID plug via the integrated web site. The
associated track vacancy detection section can be written on the front of the ID plug.
When an ACM is exchanged, the data configured on the ID plug can be transferred to the
spare ACM. To do this, the ID plug is simply removed from the old ACM and inserted into
the spare ACM. The spare ACM is then immediately ready for use again with the same
device configuration, with no configuration effort.
Hardware overview
ACM axle counter module
Figure 9 ACM axle counter module
Application
Fail-safe track vacancy detection with a floating relay interface
Connection of two ZP 43 possible
For the processing of status information of two track vacancy detection sections

Features
Housing made of high-grade steel
9-pin interface on the front panel for a polarized ID plug with a lettering field
Control and display elements on the front panel:
6 buttons
13 multi-color LEDs
2 simulation sockets
2 fuses for power supply to the wheel detection equipment
Industrial Ethernet interface for connection of a CAT5 network cable
On the underside:
- 96-pin male connector, type C
(DIN 41612 / IEC 60603-2) for a compact process connector
- 4-pin female connector for the 24 V DC power supply connector
Installation by latching onto a 122 mm mounting rail
Dimensions (w x h x d): 65 x 175 x 240 mm
Weight: 1600 g
Industrial Ethernet switch (optional)
Figure 10 Switch (example)
Application
For interfacing of ACMs to form an Industrial Ethernet network
For connection of a standard PC for configuration and diagnostic purposes

3.5 Cable distributor and cabling
Features
Installation on:
35 mm mounting rail
122 mm mounting rail
walls
Interfaces:
8 RJ45 sockets for connection of ACMs and a standard PC
4-pin terminal block for power supply connection
2-pin terminal block for indication contact connection
Indication of the operating states by LEDs
Supply voltage:
2 x 24 V DC (18 V to 32 V)
Dimensions (w x h x d): 60 x 125 x 124 mm
Weight: 780 g
3.5 Cable distributor and cabling
Cable distributor and cabling
Installation interface between indoor and outdoor equipment

The cable distributor is the installation interface between the indoor and outdoor
components. This is where the cables for the outdoor components are connected. From
here, further connecting cables lead to the indoor components. A cable termination rack
or cabinet can be used as a cable distributor.
The connecting cables between ACM 200 and the cable termination rack or cabinet must
be shielded.
Star-quad or paired signaling cables are used in the outdoor equipment.
Earthing and protective measures

When the ACMs are being installed, all conductive housing parts (see SELV circuit,
EN 60950) must be earthed for reasons of operator safety. The conductive parts also
include the mounting rail. The ACM housing is earthed via the power supply connector.
It is recommended that the cables connected to the outdoor equipment are protected
against overvoltage by a lightning protection module and a block varistor.

Technical data
4 Technical data
Technical data
Types of traction: All electric and non-electric types

Wheels:
Material Steel or cast iron
Diameter 300 mm
Width 115 mm
Wheelbase 600 mm
Traversal speed Wheel diameter Minimum Maximum speed
(mm) wheelbase (km/h)
Sum total of both
wheel diameters
(mm)
300 600 220
335 670 250
600 1200 350
830 to 1250 1660 to 2500 400
Track:
Sleepers Wood, concrete, steel, ballastless track
Ballast resistance No effect
Rail profiles R 65, R 75, S 41,S 45, S 49, S 54, S 64, UIC 60 (others on request)
Protective device Deflector (optional)
Ambient
temperature
ranges:
ACM -40 C to +70 C
ZP 43 -40 C to +80 C
Connectable
ZP 43:
ZP 43 Connection via a two-core cable
Cable type Star-quad or paired signaling cable
Maximum control Examples of cable at Standard With additional
distance 45 C measures
A-2Y (St)YbY3x4x0.9S 7.1 km 14 km
(1B 0.3)

Technical data
A-2Y (St)YbY5x4x1.4S 6.5 km 21 km

(1B 0.3)
The maximum signaling cable length must be calculated on a system-
specific basis. The following values must not be exceeded:
continuous interference voltage Vint = 250 Vrms 16 to 50 Hz
transient interference voltage Vcatenary contact = 1500 Vrms (0.1 s)
The attenuation per unit length of the cable must not exceed 20.1 dB
at the operating frequencies of 3.5 kHz and 6.5 kHz. Max. 23.57 dB
are permissible with external supply.
Overall loop The ohmic resistance of the cable must not exceed a maximum overall
resistance loop resistance of 412 with supply via ACM 200.
Cable capacitance The cable capacitance (core to core) of an electrically continuous
cable must not be greater than 325 nF.
Rail mounting Rail web, rail base
Height adjustment Readjustment depending on the degree of rail wear
Traversal cycle ZP 43 E / V = 30 days
ZP D 43 = once a year
Diagnostics Local diagnostics via LEDindications and an integrated web site,
remote diagnostics possible
Axle counting
system:
Counting capacity 32,767 axles per track vacancy detection section
Permanently 20 axles per second and ZP 43
Number of max. 2 sets of ZP 43 wheel detection equipment
connectable sets of
wheel detection
equipment per
ACM
Number of max. 2 track vacancy detection sections
detectable
TVDSper ACM
Interconnection of Total of 10 sets of wheel detection equipment:
ACMs to form 1- 2 ZP 43, directly connected to ACM
plus-4 combination
8 sets of wheel detection equipment connected to partner ACMs,
enables max.
ZP 43 or WSD wheel detectors
connection of
wheel detection
equipment / wheel
detectors
Output information 2 fail-safe clear / occupied indications (equivalent or non-equivalent)
(via floating relay Reset restriction (RR), single-channel output
contacts per ACM)
Reset acknowledgment (RA), single-channel output
ACM is OK, single-channel output
Optional: safety-related information (SRI)
System start-up < 30 s (fully operational)
Modular system: Modules are installed by latching onto a mounting rail: mounting of
mounting rail possible on a wall, in racks and in cabinets

Technical data
Power Maximum: 12 W + 5 W per set of wheel detection equipment

consumption: Typically: 10 W + 4 W per set of wheel detection equipment
Supply voltage 21.6 V to 31.2 V DC,
(ACM): residual ripple max. 100 mVrms
Outputs (relays): Switching voltage
10 V to 72 V DC
10 V to 150 V AC
Switching current
2 mA to 250 mA DC
2 mA to 1 A AC
Inputs: Signal voltage
21.6 V to 72 V DC
Input current range
Actively: 3.5 mA to 8 mA
Passively: < 200 uA
MTBF: 25 C 40 C
ACM 31 years 24 years
ZP 43 E / V 180 years
ZP D 43 133 years
ID plug 4230 years 2640 years
Hazard rate: SIL 4 as per EN 50129 with respect to the hazards listed below
-1
The following hazard is controlled with a hazard rate of < 6.1 E-10 h :
the indication that there is no train in a section (clear) although there
is at least part of a train in the section, or the status transition
indications clear occupied clear (corresponds to a passing
train) although the relevant track vacancy detection section has not
been traversed
The indicated hazard rate applies when using the ZP D 43 with a
traversal cycle of once a year and when using the ZP 43 E / V with a
traversal cycle of 30 days.
Note: if the ZP 43 E / V is used with a traversal cycle of once a year,
the hazard rate is 2.1 E-9 /h per TVDS.
-1
The following hazard is controlled with a hazard rate of < 2 E-10 h
per TVDSoutput relay:
untimely dual-channel activation of the TVDSoutput relay (contacts not
in the release state) for the output of binary safety-related information
(SRI)
Note: when quantifying this hazard, it has been assumed on a
plausibility basis that the binary information to be transmitted changes
its state at least once a year.
Table 3 Technical data

Standards
5 Standards
Conformity with European directives and standards
The ACM 200 axle counting system described in this document complies, in the variant
developed by us, with the regulations of the applicable European directives and
standards. Details can be found in the EC Declaration of Conformity.

Indices
6 Indices
List of abbreviations
Abbreviation Meaning
ACM axle counter module
ACM 200 axle counting system
AZG (Achszhlgrundstellung) axle count reset operation
AZGH (Achszhlgrundstellungshilfsbedienung) auxiliary axle count reset
operation
CH counting head
COM communication
DEK (doppelter elektronischer Kontakt) double electronic contact
EBA German Federal Railways Office
EBO German Railway Building and Operation Regulations
FOC fiber-optic cable
LED light-emitting diode
MACM multiple-axle counting method
RA reset acknowledgment
RR reset restriction
SELV safety extra low voltage
SIL safety integrity level
Simis Siemens fail-safe microcomputer system
SLC safety layer cyclic
SRI safety-relevant information
TCB trackside connection box
TVDS track vacancy detection section
TVDS track vacancy detection section
VAZG (vorbereitende Achszhlgrundstellung) preparatory axle count reset
operation
ZP 43 E electronic wheel detection equipment, 43 kHz with aluminum
housing
ZP 43 V electronic wheel detection equipment, 43 kHz with plastic housing
ZP D 43 electronic wheel detection equipment, 43 kHz, digital signal
processing, analog interface

Indices
List of figures
Figure 1 ACM 200 axle counting system .......................................................................................... 6

Figure 2 Combination of a number of ACMs to form an axle counting system............................... 10
Figure 3 Integrated web site (configuration view) ........................................................................... 13
Figure 4 Integrated web site (diagnostic view)................................................................................ 16
Figure 5 Schematic representation of an axle counting system ..................................................... 19
Figure 6 System structure of ACM 200 ........................................................................................... 20
Figure 7 Wheel detection equipment (e.g. ZP D 43)....................................................................... 22
Figure 8 ACM front panel: control and display elements ................................................................ 26
Figure 9 ACM axle counter module................................................................................................. 27
Figure 10 Switch (example)............................................................................................................... 28
List of tables
Table 1 Supplementary documents ................................................................................................. 5

Table 2 Overview of combinable wheel detection equipment variants .......................................... 23
Table 3 Technical data................................................................................................................... 32


02 Systemdescription ACM200 A6Z00034296029

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02 Systemdescription ACM200 A6Z00034296029

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System Description

Clearguard ACM 200

A6Z00034296029/- System Description

A6Z00034296029/- System Description

2 System overview ............................................................................................................... 6

3 Structure and functions.................................................................................................. 19

4 Technical data ................................................................................................................. 30

A6Z00034296029/- System Description

1 Information for the user

Contents of this section

About this document

Documentation is part of equipment described

A6Z00034296029/- System Description

Title Document number

Table 1 Supplementary documents

A6Z00034296029/- System Description

Figure 1 ACM 200 axle counting system

Further member of Clearguard product family: ACM 200

Fields of application of ACM 200

A6Z00034296029/- System Description

2.1 Efficiency criteria

Axle counting systems: proven and fail-safe

High-reliability, fail-safe computer system

Simis principle fail-safe and highly reliable

Working principle of 2-out-of-2 configuration

A6Z00034296029/- System Description

Highly cost-effective track vacancy detection

One single module type for cost-effective application

Low-cost installation on mounting rail

Flexibility for all customer requirements

Modular architecture for most diverse customer requirements

Floating relay interface

A6Z00034296029/- System Description

Reduced maintenance requirements

High-reliability, maintenance-free hardware

Maintenance without interrupting normal operations

2.2 System features

Flexible protection of track vacancy detection sections

Fail-safe clear and occupied indications

Usage of floating relay interface for additional functions

Protection of track vacancy detection sections with ZP 43

A6Z00034296029/- System Description

Variable combinations for all requirements

Connection of two ZP 43 to one ACM

Variable axle counting system by combining ACMs

Figure 2 Combination of a number of ACMs to form an axle counting system

The Ethernet interface of an ACM allows further ACMs to be connected to build up a

A6Z00034296029/- System Description

Extension of axle counting system by further 1-plus-4 combinations

Procedure-protected interconnection of ACMs

Procedure-protected ACM interconnection

ACM interconnection for long track vacancy detection sections

Data transmission via open transmission systems

Data transmission via public telephone networks

A6Z00034296029/- System Description

Connection to most diverse interlockings

Connection to new and existing interlockings

Individual adaptation to existing installation sites

Variable direction reversal of wheel detection equipment

A6Z00034296029/- System Description

Figure 3 Integrated web site (configuration view)

Integrated web site for configuration purposes

Configuration using checkboxes, buttons and pull-down menus

A6Z00034296029/- System Description