Digital Axle Counter

Presented by
CHANDRU.S
SSE/SIG/SA
RDSO SPECCIFICATION
RDSO SPECIFICATION SPN/177/2003

CENELAC SIL 4 STANDARDS.

LATEST APPROVEDAXLE COUNTER AS PER RDSO/SPN/177/2005

 TYPES

UNIVERSALAXLE COUNTER
DIGITAL AXLE COUNTER
HIGH AVAILABLITY SINGLE SECTION DIGITAL A/C
BLOCK PROVING SYSTEM
MULTISECTION SECTION DIGITAL A/C
 ADVANTAGES OF AXLE COUNTER

MONITORS VERY LONG TRACK SECTIONS.(12KM)

LAST VEHICLE CHECK IS DONE AUTOMATICALLY.

NO EFFECT DUE TO BALLAST RESISTANCE.

 ERROR FREE OPERATION OVER LARGE TEMPERATURE
RANGE.

TRAIN DETECTION ON RUSTED, SANDED & WATER LOGGED

RAILS.

IMMUNE TO TRACTION RETURN CURRENTS

 TRACKSIDE ELECTONICS COUNTING EQUIPMENT

WEB TYPE AXLE DETECTORS

COMPATIBLE WITH 90R, 52 Kg AND 60 Kg RAIL PROFILE

DETECTION OF ALL WHEELS WITH NORMAL FLANGE AND

DIAMETER > 400 mm
 STATION TO STATION BLOCK

STATION STATION
A B
BLOCK SECTION

TYPICAL 10 - 20 KM
AS
4 4 4 4

VITAL RELAY 2 VITAL RELAY BLOCK/

BLOCK/
INTERLOCKING SSDAC-1 SSDAC-2 INTERLOCKING
EQUIPMENT
EQUIPMENT POWER POWER
 SSDAC DESIGN
FAIL SAFE FEATURES
AC SIGNAL PROCESSING

CLOCK SIGNAL GENERATION

IT USE 2 OUT OF 2 DECISION BY MICROCONTROLLER

(8051 ARCH)
 SSDAC DESIGN

OPTO ISOLATED OUTPUT FOR VITAL RELAY

VITAL RELAY READ BACK

CHECKING OF HEALTH SIGNALS IN SYSTEM & WITHDRAWING

VITAL RELAY DRIVE, IF FAULTY
 SSDAC DESIGN
REAL TIME PROCESSING OF EVENTS

INTERRUPTS NOT USED

POINTERS NOT USED

CYCLE TIME LESS THAN 100 MICROSECONDS

DIAGNOSTIC FEATURES INCLUDED

PACKET TIME OF 800 msecs.

 SSDAC Components

Electronic Counting Unit Vital Relay Box

Surge Voltage Protection Device Reset Box

 SSDAC Component
HIGH FREQUENCY (21 KHz & 23 KHz) Tx & Rx SIGNALS
MICROCONTROLLER BASED DESIGN WITH 2 OUT OF 2 DECISION
V.21 MODEM
OPTO ISOLATED RELAY DRIVE
EVENT LOGGER
ALL THE ABOVE IMPLEMENTED IN THE FOLLOWING CARDS
SCC CARDS (CARD 1 & 2)
MLB CARDS (CARD 3 & 4)
EVENT LOGGER CARD (CARD 5)
MODEM CARD (CARD 6)
RELAY DRIVER CARD (CARD 7)
DC-DC CONVERTER CARD (CARD 8)
SSDAC Block Diagram

PULSE 1
TX1 MODEM To 2nd unit of
SCC1 MLB1 V . 21 SSDAC
RX1

AXLE
DETECTORS RELAY READ BACK
(21KHz)

TX2 MLB2 RELAY DRIVE VITAL RELAY

SCC2 PULSE 2 (24V) (Q TYPE, 24V
RX2 1000 OHM)

AXLE
DETECTORS
(23KHz) DC-DC
CONVERTOR
LEGEND
SCC 1 & 2 : SIGNAL CONDITIONER CARD
MLB 1 & 2 : MICROCONTROLLER LOGIC BLOCK BATTERY
TX1, TX2 : TRANSMITTER COILS
24V
RX1, RX2 : RECEIVER COILS
 SSDAC WORKING
GENERATION OF CARRIER SIGNAL FOR Tx COILS

DEMODULATION OF SIGNAL FROM Rx COILS

GENERATION OF VALID PULSES

VERIFY THE DIRECTION OF TRAIN AND CONVERT THE PULSES

INTO COUNTS
 EXCHANGE THE COUNTS BETWEEN TWO SSDAC UNITS.

EVALUATION OF COUNTS FOR ARRIVING A DECISION FOR VITAL

RELAY OUTPUT

ERROR CHECKING AND DISPLAY

 SSDAC Input & Output
INPUTS
:
HIGH FREQUENCY AXLE DETECTORS.
V.21 MODEM
RESET COMMAND OF 48 V
OUTPUT:
DRIVE FOR VITAL RELAY (Q TYPE, 24V, 1000 OHM)

DRIVE FOR PREP RELAY (Q TYPE, 24V, 1000 OHM)

RS232 OUTPUT FOR MONITORING

EVENT LOGGER CARD (FLASH MEMORY)

POWER SUPPLY:

24V DC BATTERY / IPS

 SSDAC Applications
AXLE COUNTERS ARE USED IN LEIU OF TRACK CIRCUITS FOR
VERIFYING THE TRACK FREE / OCCUPIED CONDITION OF:
BERTHING TRACK (STATION)
YARD
BLOCK SECTION
INTERMEDIATE BLOCK SIGNALLING
AUTO SECTION
TRAIN ACTUATED WARNING AT LC GATES
 SSDAC MODEL DACF-710P
Phase reversal type Axle detectors. Track circuit is not required for
trolley suppression.
i) The system is not affected by
a) 4 spoke trolley; b) 8 spoke trolley; and c) rail dolly.
ii) The system counts :
a) Push trolley with perforated wheel; b) Dip lorry and c) Motor
trolley.
When train passes 170 to180 out of phase occurs

Resetting of axle counter only after registration of 1st out count.

VR Box (VR-721) supplied along with this system is of Dual Relay

Both VR & PR Q type, 24V, 1000 are used along with the system.
PHASE DETECTION(710P)
 SSDAC MODEL DACF-710A
a) Amplitude Modulation type Axle detectors are used. The track circuit
relay connection into the system is required for trolley suppression.
b) The SSDAC remains unaffected with all types of insulated push
trolleys.
c) The SSDAC goes into disturbed state (ERROR condition) for non
insulated trolleys.
When train passes amplitude varies by 10% to 15%
Resetting voltage in the system is by means of 48V DC.

Resetting of axle counter only after registration of 1st out count.

VR Box (VR-721) supplied along with this system is of Dual Relay.

Both VR & PR Q type, 24V, 1000 .

Surge Voltage Protection device SV-121 has been provided with

additional protection module for modem line for reset box.
AMPLITUDE DETECTION
 SSDAC Applications Block
CAN BE USED ALONG WITH SGE BLOCK INSTRUMENTS ON D/L
CAN BE USED ALONG WITH CELs MULTIPLEXER ON D/L & S/L
RDSO Drg. No. S 32012 & S 32016
CAN BE USED ALONG WITH UFSBI ON WEBFIL / DELTRON ON D/L
VITAL RELAYS OF DAC CAN BE INTERFACED WITH OTHER TYPES
OF BLOCK OPERATING INSTRUMENTS ON S/L AS WELL AS ON D/L
SSDAC - INSTALLATION
 INSTALLATION OF SSDAC
Installation of Axle Detectors
Installation of Electronic Counting unit
Installation of Reset Box
Installation of Surge Voltage Protection Device
Earthing Arrangement
Power Supply Arrangement
 INSTALLATION AXLE DETECTORS
Selection of Rail
Fixing of Marking Jig
Punching of holes using marking jig
Drilling of holes using 14mm Drill
Installation of TX & RX coils
Fixing of Deflector Plates
SELECTION OF RAIL
FIXING OF MARKING JIG
Fixing of marking Jig as shown

Mark using punching guide as

per rail size.
 DRILLING OF HOLES

3 holes of 14mm are

drilled
FIXING OF AXLE DETECTORS TORQUE
WRENCH TOOL
Torque Wrench
Model JPR65 will
be supplied as a
toolkit item
FITTING OF AXLE DETECTORS

TX1 RX1

TX2 RX2
FIXING OF DEFLECTOR PLATES

Deflector plates
on both sides to
be fitted
INSTALLATION OF COUNTING UNIT

Electronic Counting unit Vital Relay Box

SETTING UP OF LOCATION BOX
INSTALLATION DETAILS
INSTALLATION OF LOCATION HALF
LOCATION BOX

Vital Relay Box

Electronic Counting
unit
RESET BOX
Alphanumeric 20 x 2 row LCD Display for
Axle Counts of Local and Remote unit

Error Code in Numeric format

Section Status

Last 10 Errors with date and time

Provision of downloading of data from reset

box
 INSTALLATION Surge Voltage
Protection Device
Four modules provided for all the input lines of SSDAC, i.e. Power
supply (24V), Reset (48V) & both the modem lines (i.e. SSDAC to
SSDAC and SSDAC to reset box)

Added protection is given for input 24V power line.

 EARTHING
All the screen of cables should be properly earth

Always verify the physical state of these modules for any

damage due to lightening

In case of any damage kindly replace these modules with

respective part Nos only.
 INSTALLATION EARTHING
ARRANEMENT
Use of Electrode consisting of
Galvanised Iron pipe not less 38mm
in diameter & 2.5mts in length
Use of Earth resistance
improvement material for better
absorption & retaining moisture
contained in soil.
Use of Earth wire leads consists of
stranded copper wire of 29 sq. mm
(19 strand wires of 1.4 mm
diameter) or ACSR of size 64 sq.
mm (19 strands of 2.11 mm
diameter)
Limits of Earth Resistance
1 ohms for apparatus case
(SSDAC & VR Box)
1 ohms for reset box connected
to Earth near SMs Room
 POWER SUPPLY ARRANGEMENT

It consists of
24V, 40 AH Battery and 24V, 5A Battery charger or
24V, 5A output from one of the modules of IPS.
2 core, 25 sq. mm Power cable for connection from
battery to SSDAC unit.
 PRECOMMISSIONING CHECKLIST
Pre commissioning checklist needs to be filled & signed by railways & firm
should be sent to firm & RDSO. Main points includes
Use of 1000 ohms relays at location
Use of Diodes at location for PR & repeater relays
Condition of rail
Drilling of holes in straight line
Loss in quad cable at 1KHz should be <20db
Insulation of quad cable >10Mohms
Use of Axle counter type Battery charger
Proper Earth as specified in manual
Effect of trolley movement should be recorded at time of commissioning
Training
 SSDAC Communication
COMMUNICATION BETWEEN TWO SSDAC UNITS IS IN THE FORM
OF DATA PACKETS
DATA PACKETS CONSISTS OF
COUNT CHANGE INFORMATION
COUNT UPDATE INFORMATION
RESET INFORMATION, IF ANY
ERROR INFORMATION, IF ANY
TRANSMISSION ON CABLE OR VOICE CHANNELS ON OFC OR
RADIO BY MEANS OF V.21 MODEM (FULL DUPLEX)
 SSDAC Monitoring
CARD WISE DISPLAY OF ERRORS BY MEANS OF LEDs
FUNCTION WISE LEDs IN EACH CARD
RS 232 PORT FOR ONLINE MONITORING
EVENT LOGGER CARD WITH SOFTWARE FOR LOGGED DATA
ANALYSIS
ONLINE DISPLAY OF SECTION STATUS, COUNTS DISPLAY &
ERROR CODE WITH ERROR DIESCRIPTION ON 20 X 2
ALPHANUMERIC LCD DISPLAY
TOOLKIT PORTABLE DATA ANALYZER
Portable data
Analyzer tool with
data analysis
software
Serial cable

48
Down Loading Data from SSDAC
Equipment
 SSDAC
RDSO/SPN/177/2005
(710A/P) is latest & fully compatible with
RDSO/SPN/177/2003
(700AP)
 RECOMMENDED TOOLKIT
(1 set of tool kit to be purchased separately for every
10 sets of SSDAC systems)
1 Portable data analyzer for downloading event logger
data for analysis and report generation.
2 Pure sine wave Digital multimeter make Fluke model
187/ Rishabh model 28S / Kusum Meco model 859CF
or Equivalent
3 Train simulator, Model TS 267P CEL make
4 Extender card (Card No. 557)
5 Dummy wheel (as per Drg No. L007750A3, D14)
6 Ring spanner 17-19,24-26
7 Open end spanner 17-19, 24-26
8 Socket spanner with handle
 TOOLKIT MULTIMETER & TRAIN
SIMULATOR
DIGITAL MULTIMETER
TRAIN SIMULATOR FOR
PHASE & AMPLITUDE

52
 TOOLKIT SPANNERS & DUMMY
WHEEL
Ring spanner 17-19,24-
26
Open end spanner 17-
19, 24-26
Socket spanner with
handle
Screw Driver No. 902
Screw Driver No. 935
Dummy Wheel

53
SINGLE SECTION DIGITAL AXLE COUNTER

IMPROVEMENTS CARRIED OUT IN SSDAC

)
(AS PER RDSO/SPN/177/2005
 MODIFICATIONS IN SSDAC 710A/P IN
COMPARISION WITH
SSDAC 700AP

NEW MODEM CARD

TRANSMISSION GAIN INCREASED TO 0dB
AGC CIRCUIT HAS BEEN ADDED.
RESET COMMAND IS ACTIVE ONLY FOR 200msec TO 10 secs.

NEW MLB CARD

PROVISION FOR RESET INTERLOCKING.
NEW SOFTWARE VERSION S006.

MOTHERBOARD CARD
LAYOUT CHANGE FOR RESET INTERLOCKING.
 RESET BOX
NEW RESET BOX (RB 259A) INCLUDES
LCD DISPLAY FOR CRC AND SOFTWARE VERSION
SECTION STATUS
COUNTS DISPLAY OF LOCAL AND REMOTE UNIT
ERROR DISPLAY OF LOCAL AND REMOTE UNIT
FLASHING PREPARATORY LED ON ACTUATION OF RESET IN LOCAL
UNIT AND BECOMES STEADY ON ACHIEVEING OF PREPARATORY
RESET STATE.
HARDWARE COMPATIBILITY
NEW RESET BOX IS NOT COMPATIBLE TO OLD RESET BOX

SVPD
ADDITIONAL MODULE FOR RESET BOX HAS BEEN ADDED.s
 SOFTWARE VERSION S006
COUNTING OF MOTOR TROLEY WHEEL HAS BEEN ENABLED.

IMPROVED SYSTEM AVAILABILITY BY USE OF FAULT TOLERANT

VALIDATION OF DATA PACKETS

DATA PACKET LENGTH REDUCED FROM 1.8 SECS TO 0.8 SECS

RESULTING INTO STATUS UPDATION AFTER EVERY 0.8 SECS

SYSTEM MORE TOLERANT TO TRANSIENT / NOISE ON

COMMUNICATION MEDIA.
S. Paramet S005 S006
No er
.
1. Checksu 16 Bytes 24 Bytes
m
2. Motor Gives error Section
trolley 44/45 becomes
following clear after
train passing motor
trolley after
 Local DP 00005 00 Occupied
Remote DP 00003 00 Occupied
Axle Error Status
Counts Code
Pulse generation on
movement of train wheel
21 KHz
LCD Status of Reset Box

23 KHz

Local DP 00004 44 Independent pulse Forward

Remote DP 00003 80 Remote error
Pulse generation on Axle Error Status
movement of motor trolley wheel Counts Code
21 KHz

23 KHz LCD Status of Reset Box

MAINTAINENCE OF SSDAC
 MAINTAINENCE OF SSDAC (CONTD )

MEASURE THE Tx COIL (21 KHz & 23 KHz) AND Rx

COIL (21 KHz & 23 KHz) SIGNAL LEVELS. THEY
SHOULD BE WITHIN LIMITS
MEASURE THE OUTPUT SIGNALS OF CARDS AT THE
TEST POINTS PROVIDED ON CARDS
CHECK AND MEASURE THE INPUT POWER SUPPLY TO
SSDAC
RESET BOX SHOULD BE INSPECTED FOR ITS PROPER FUNCTIONING
ALL CABLE CONNECTIONS ON THE CT BOARD OF APPARATUS AT
LOCATION BOXEX SHOULD BE CHECKED
 ALL EARTH CONNECTIONS SHOULD BE EXAMINED
MONTHLY FOR CONNECTIONS AND SOLDERED
JOINTS TO BE IN PROPER CONDITION
ARMOR OF QUAD CABLE SHOULD BE PROPERLY
EARTH
RESISTANCE OF EVERY EARTH SHOULD BE
MEASURED ON YEARLY BASIS.
INSTALLATIONS NEAR SSP & FEEDER POINTS MAY BE
PROPERLY EARTHED
 RECOMMENDED SPARES
The following spares are to be procured
separately for 5 nos. of Single Section Digital
Axle Counter working in field
1 SCC 1&2 cards (Card 1 & 2) 2 Nos
2 MLB 1&2 cards (Card 3 & 4) 2 Nos
3 Modem card (Card 6) 1 No
4 Relay driver (Card 7) 1 No
5 Event Logger Card (Card 5) 2 Nos
6 DC-DC converter (Card 8) 1 No
7 Axle detectors (AD711) 21 KHz/23KHz (TX coil) 1 No
8 Axle detectors (AD711) 21 KHz/ 23 KHz (Rx coil) 1 No
SELF DIAGONASTIC

DISPLAY ERROR CODE

TROUBLE SHOOTING OF SSDAC
FAMILIARITY WITH ERROR CODES

FRONT VIEW VALUE GIVEN TO LEDs

1 2 1 2
LSB LSB
3 4 4 8

10 20
5 6
MSB MSB
40 80
7 8
CLASSIFICATION OF ERROR CODES

COMMUNICATION RELATED ERRORS

COUNT RELATED ERRORS
RELAY READ BACK RELATED ERRORS
MISCELLANIOUS ERRORS
RESET BOX RELATED ERRORS
ERROR NO 30 LINK ERROR

The link error is detected when the link between the two SSDAC
units is open or loss of carrier detect or
CD.
This is displayed as error No. 30.

ACTION REQUIRED

Error No. 30 is displayed when link is open.

Check the communication link between the units.

Check the remote unit is at ON.
Check the quad cable.
Check the power supply ripple of charger.
Check the battery condition.
ERROR NO 41 CRC ERROR

The Cyclic Redundancy Error is displayed when data of the packets gets corrupted.
Due to this the CRC of the packet does not matches.

ERROR NO 42 EOB ERROR

The END OF BLOCK error is displayed when data of the packets gets corrupted. Due to
this the End of packet is not
detected. 41 42

ACTION REQUIRED

IF OFC

Check of the proper channel used.

Check for the trans signal, level at 0db.
Check for the receiver signal, shall not be > -15db.
 MODEM CARD PARAMETERS
1 >= -6 db
1650 Hz > 400
mv
Trans
2 >= -6 db
980 Hz > 400 mv

3 >= -30 db
980 Hz > 15 mv

Receive
4 >= 30 db
1650 Hz > 15 mv

CHECK FOR THE DIP SWITCH

IF NOT REPLACE MODEM CARD
 COUNT RELATED ERRORS
Sequence error (31)
Count unequal error (39)
Count miss match (35)
Self count miss match (32)
Shunt error (36)
Internal shunt error (37)
Non overlap pulse error (44)
Exit miss match error (48)
 SEQUENCE ERROR (31)

When sequence of pulse is in correct.

ACTION REQUIRED

Check the arrangement of detectors.(0-170-340mm)

Proper height of the detectors (88mm from the top
).
Replace rail detectors.
 COUNT UNEQUAL ERROR (39)

When Count of pulse is in correct.

ACTION REQUIRED

Check the voltage at SCC (2-2.5v)

Coil resistance TX- 01 Ohm/ RX- 02 to 03 Ohms
TP > 33 Mtrs.
Check the reverse biased diodes in VPR, PPR and TPR.
 COUNT MISS MATCH ERROR (35)

when entry and exit count miss matches.

ACTION REQUIRED

Check the arrangement of detectors.(0-170-340mm)

Proper height of the detectors (88mm from the top ).
Check the voltage at SCC (2-2.5v)
Replace ML with new version (V.21)
 SELF COUNT MISS MATCH (32)

When MLB 1&2 cards count differs.

ACTION REQUIRED

Check for the S/W version V.21 (S006)

Replace the MLB card.
 SHUNT ERROR (36)

Train moves over the external detector with out proper

movement over internal detector.

INETRANL SHUNT ERROR (38)

When internal detectors are influenced twice

ACTION REQUIRED

Apply reset as per SWR

Pilot train will clear the section
 SUPERVISORY ERROR (37)

Signal level of any axle detectors becomes low.

ACTION REQUIRED

Check voltage and frequency of TX and RX

Check SCC 1&2.
Check MLB card.
 NON OVERLAP PULSE ERROR (44)

When A&B pulses or C&D pulses are not overlapping.

ACTION REQUIRED

Check for worn out rails/ bent rails.

Check by motor trolley /perforated push trolley/ dip lorry etc.
Check MLB card for S/W version V.21 (S006)
 TROUBLESHOOTING OF SSDAC
(CONTD )

IN CASE OF LIGHTNING, THE SVPD DEVICES SHOULD

BE CHECKED FOR PROPER WORKING
POWER LINE & RESET LINE SURGE MODULES ARE
INDICATIVE TYPE SURGE DEVICES.
MODEM LINE DEVICES ARE NON INDICATIVE TYPE
THE DAMAGED MODULE(S), IF FOUND SHOULD BE
REPLACED WITH FRESH MODULE(S) OF SIMILAR
TYPE. CONTACT CEL FOR PART NOS
 RESET BOX ERROR

No display
corrupted display.

ACTION REQUIRED

Check modem
Apply reset to display.
Replace reset box.
 DOS & DONT
DOS

The inter connection drawings are to be followed for connecting the Transmitter & Receiver coils

Tx1 is 21 KHz, Tx2 is 23 KHz & Rx1 and Rx2 coils are 21 KHz & 23 KHz, respectively.
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.(88mm from top of rail)
Ensure that packing of sleepers with ballast on both sides of Axle detector is proper.(400mm)
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 steady Battery voltage 24V should be maintained.
The cable connections should not be connected loosely.
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
 DONT
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.(<8mmfor 52kg
and13mm 60kg )
Dont cut or join the Transmitter / Receiver cables supplied along with the coil. It
would result in change of frequency of signal.
Dont lay the TX and RX coil cables in the same pipe.
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.
THANKYOU