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G.G.Tronics India Private Limited, Plot No : 10, 3rd Phase, 6th Main, Peenya Industrial Area, Bangalore – 560058, INDIA
Phone : +91-80-28372449, 28372450, 28372451 Fax : +91-80-28372387
Mail : info@ggtronics.com Website : www.ggtronics.com
This Document is confidential and may be privileged. Using it partially or wholly for
any purpose or copying or storage in any medium without written permission of
G.G.Tronics is strictly prohibited.
Thank you for your decision on choosing the SSDAC-G36 that adds
value in your venture for modernization of safety signaling system in Railways. It is
our privilege that the SSDAC-G36 will be integrated into the family of signaling
system for effortless management of block and station section proving. The 2 / 2
Microcontroller voting with CENELEC SIL-4 level safety validation makes the system
most safe and reliable under stringent working environment.
We ensure at the end of the day the customer is satisfied and look at other versions of
3DP-1S for point zones, 3D-2S for IBS and AS for Auto Section signaling solutions at
various section layouts.
We look forward to serving you with commissioning and technical support round the
clock for years to come.
We thank you once again for choosing our product for your signaling needs.
Yours Sincerely,
Shamantha K.S.,
Director,
G.G.Tronics India Private Limited,
Bangalore, India
1 Introduction 1
1.1 Overview ............................................................................................................. 1
1.2 Configurations of System .................................................................................... 1
1.3 Specifications ...................................................................................................... 2
1.4 System Design ..................................................................................................... 2
1.5 Physical Description ............................................................................................ 3
1.6 Construction Details ............................................................................................ 3
2 System Overview 4
2.1 SSDAC- 2DP1S system in brief .......................................................................... 4
2.2 Configuration of SSDAC- 2DP1S ....................................................................... 5
2.3 System working principle .................................................................................... 5
2.4 SSDAC- 2DP1S (2DP1S Configuration Setting) ................................................ 7
2.4.1 SSDAC- 2DP1S SF (Start Fed Configuration Setting) ....................................... 7
2.4.2 SSDAC- 2DP1S EF (End Fed Configuration Setting) ........................................ 8
3 System Wiring Details 11
3.1 Introduction: ...................................................................................................... 11
3.2 Transmitter Coil 1 Connection (MS-5): ............................................................ 11
3.3 Transmitter Coil 2 Connection (MS-4) ............................................................. 12
3.4 Receiver Coil 1 Connection (MS-17) ................................................................ 13
3.5 Receiver Coil 2 Connection (MS-16) ................................................................ 14
3.6 Modem-A Communication (FSK) Connection (MS-6) .................................... 15
3.7 Modem-B (COM2) Communication (FSK) Connection (MS-11) .................... 16
3.8 SM/Event Logger Connection (MS-15) ............................................................ 17
3.9 RESET- A (MS-12) ........................................................................................... 18
3.10 RESET- B (MS-13) ........................................................................................... 19
3.11 Vital Relay A (MS-2) ........................................................................................ 20
3.12 Vital Relay B (MS-3) ........................................................................................ 21
3.13 Preparatory Relay A (MS-7) ............................................................................. 22
3.14 Preparatory Relay B (MS-8).............................................................................. 23
3.15 Train Simulator (MS - 9) ................................................................................... 24
3.16 DC-DC Converter (MS - 14) ............................................................................. 25
3.17 LCD Display (MS - 10) ..................................................................................... 26
3.18 Relay Box .......................................................................................................... 27
3.19 System Level Connections ................................................................................ 30
4 Installation Procedure 32
4.1 Pre Requisites for Installing SSDAC Systems .................................................. 32
4.2 Unpacking the systems ...................................................................................... 33
4.3 Steps for Installation .......................................................................................... 34
4.3.1 Location of Axle Detectors ............................................................................... 35
4.3.2 Marking & Drilling holes on the Rail ............................................................... 36
4.3.3 Fixing of Axle Detectors (Transmitter and Receiver Coil) ............................... 37
4.3.4 Fixing of Rail Deflector .................................................................................... 37
4.4 Installation of Location Box (Full size) ............................................................ 38
4.4.1 Power Supply Arrangement .............................................................................. 38
Figure 2-1 Single Section Digital Axle Counter 2DP1S Configuration .......................... 5
Figure 2-2 SF of 2DP1S Configuration Setting ............................................................... 7
Figure 2-3 EF of 2DP1S Configuration Setting ............................................................... 8
Figure 3-1 System level Connection of 2DP1S Configuration ...................................... 31
Figure 3-2 MS Coupler connection diagram for 2DP1S Configuration ........................ 31
Figure 4-1 Reset Box ...................................................................................................... 42
G.G.Tronics gives warranty for this product for 12 months from date of purchase by the
user against manufacturing defects in material and workmanship. After expiry of this
period, the customer can still avail repair facility at extra cost. The warranty is subject
to the following conditions
2. The defective Card / Unit must be delivered at the user’s cost to service center
in G.G.Tronics.
3. The guarantee is not valid for the damages resulting from accidents,
mishandling, negligence, unauthorized repairs, tampering, loss of components /
accessories, exposure to extensive heat and temperature, damped due to rain or
any other chemical such as acid etc.
Serial Number :
Date of Dispatch :
Authorized Signature
G.G.Tronics India Private Limited for the last decade has harnessed the power of
intellectual signaling professionals to design and produce fail-safe and reliable products
for Railway Signaling Application. Our products meet the CENELEC standard with
SIL-4 Level. These include Block proving by Digital Axle Counter for 2DP 1Section,
3DP 1Section, 3DP 2Section and Auto Section, Train Actuated Warning Device with
Station Master Console, Fail Safety Flasher, Fail Safety Timer and DC-DC Converter
Card etc.
G.G.Tronics India Private Limited has highly motivated professionals and specialists
trained on the above technologies. We reiterate and extend our commitment for
modernization of signaling systems in Railways.
The fail safety feature is built into the system by means of 2 out of 2
architecture. Two computing elements are built in system to check the arrival and
clearance of the train in the track section. The equipment is of continuously self
checking type and is having separate indication to show track Clear / Occupied
conditions, Vital contacts given through Vital Relays. Any disturbance or failure
in the equipment, including power supply failure results in withdrawal of clear
indication and shows occupied status along with Vital Relay outputs. Any defect
occurring in the equipment will not result in a condition that will lead to an unsafe
situation. The SSDAC unit is independent and totally self-contained product.
Each unit of SSDAC contains the following hardware modules, which are
necessary for effective functioning of the system and to establish, fail safe
operation of 2 out of 2 voting. The system salient features are computation by
Dual CPUs, Failsafe AND Gate for both CPUs to cast their individual decisions to
drive vital safety relay. The units employ safety hardware and safety validated real
time software.
The hardware and software for all the configurations are same. The
different PCB modules for the units are listed below
Communication Module
Reset box
Axle Detectors
• Height: 266 mm (6 U)
• Depth: 320 mm
1. In SSDAC-2DP1S configuration, there will be two SSDAC units i.e. Start Fed –
SF and End Fed – EF Units.
2. These units will be interfaced through FSK Modem communication using separate
½ quad cables.
4. It will be connected with the station-reset and repeater relay signal using 6-core
signalling cable of 1.5 Sq mm.
6. It can be interfaced with intelligent station reset box through FSK communication
of 1200 bps using separate ½ quad cable.
7. More than 14,000 events stored in SM-CPU / Event Logger module of the system
will be downloaded through RS232 communication port available on the module.
STATION STATION
A B
MODEM COMMUNICATION
1/2 quad cable
END FED
START FED
APPROACH APPROACH
DETECTORS DETECTORS
UP DIRECTION DOWN
DIRECTION
21KHZ 25KHZ MAXIMUM 25 KM's,Up to -30db 21KHZ 25KHZ
TX1 TX2 TX1 TX2
1. Once the system is powered ON, it will boot and enter the reset state. A
dedicated unit called a reset box will be used to reset the SSDAC.
2. In this configuration two reset boxes will reset two SSDAC placed at each
station.
3. There will be two relays namely preparatory and vital relays provided in the
system, which remains in the de-energized state.
4. The system will wait for the stationmaster to actuate the SM Key and reset
button to enter the preparatory state.
5. The SM Key and reset button of both the units of the particular section will
be actuated and then system will enter preparatory state.
6. However, the stationmaster has to make sure that there are no trains in that
section only then he can actuate the reset button.
8. After counting all the wheels at both entry and exit points, the respective
preparatory relay A (EF) and preparatory relay B (SF) will get de-energized.
9. The system enters clear mode after In-count and Out-count of the pilot train
matches and vital relay A (EF) and vital relay B (SF) will get energized.
10. Whenever any train enters the section, on counting the first wheel system
shall enter occupied mode and the In-counts will be incremented till the last
wheel of the train.
11. When the train that has already entered the station, exits the station, Out-
count will start incrementing.
12. When both In-counts and Out-counts match, the section will enter the clear
mode and the vital relay A (EF) and vital relay B (SF) will get energized.
14. The System Status, Checksum & Version No, Counts and error code are
displayed in the Reset Box LCD display through FSK Communication using
½ Quad Cable.
The SSDAC- 2DP1S system consists of SF (Start Fed) and EF (End Fed)
Systems.
SSDAC - 2D SF Start Fed Configuration ( CPU Card Top View Component Side )
Up 12
LK LK
17 10 25 18
0
Next step is to set the address of the CPU in each of the units for
proper communication between the units. In order to identify the CPUs in each
Jumper Settings
Address
LK10 LK11 LK12 LK13 LK14 LK15 LK16 LK17
Assigned
LSB MSB
1 0 0 0 0 0 0 0 1
0 1 0 0 0 0 0 0 2
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 0 1 1 1 1 1 1 252
SSDAC - 2D EF End Fed Configuration ( CPU Card Top View Component Side )
Up 12
LK LK
17 10 25 18
0
Table 2-4 Jumper Settings for setting CPU address EF of 2DP1S Configuration
Jumper Settings
Address
LK10 LK11 LK12 LK13 LK14 LK15 LK16 LK17
Assigned
LSB MSB
1 1 0 0 0 0 0 0 3
0 0 1 0 0 0 0 0 4
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 1 1 1 1 1 1 1 254
Group Group
SSDAC Unit SF - Start Fed EF – End Fed
Local Address Local Address
SSDAC CPU-1 001 CPU-1 003
1-2 CPU-2 002 CPU-2 004
SSDAC CPU-1 005 CPU-1 007
3-4 CPU-2 006 CPU-2 008
SSDAC CPU-1 009 CPU-1 011
5-6 CPU-2 010 CPU-2 012
▼ ▼ ▼ ▼ ▼
▼ ▼ ▼ ▼ ▼
▼ ▼ ▼ ▼ ▼
SSDAC CPU-1 251 CPU-1 253
‘n’ CPU-2 252 CPU-2 254
Note: Any deviation from the above configuration, the SSDAC – 2DP1S system does
not boot and enters wrong configuration status with error message displayed.
A
C
A
C
The RX coil1 (21 KHz) axle detector receives the induced signals and
these are fed to PD1 for processing the information through MS Coupler 17 (5
pin, refer DRG: 3). From the MS Coupler pins, the signals are connected to a (6-
pin) Phoenix connector J15 on the Motherboard. These are finally connected to
PD1. The pin configuration of J15 (6-pin) connector is given in table below.
E
B
D C
The RX coil2 (25 KHz) axle detector receives the induced signals and
these are fed to PD2 for processing the information through MS Coupler 16 (5
pin, refer DRG: 3). From the MS Coupler pins, the signals are connected to a (6-
pin) Phoenix connector J17 on the Motherboard. These are finally connected to
PD2. The pin configuration of J17 6-pin connector is given in table below.
E
B
D C
MS coupler
Sl. (MS-16), refer Description Wiring Details Of RX2 Coil Axle
No DRG no: 3 Of Signal Detector
Pin Cable
23 / 0.2mm, 2 core
Blue shielded PVC cable with
blue sheath 15m
1 A RED RX2b 25 KHz
connected to the MS
coupler MS-16 of the
system
23 / 0.2mm, 2 core
White shielded PVC cable with
blue sheath 15m
2 B BLACK RX2a 25 KHz
connected to the MS
coupler MS-16 of the
system
Input to Trolley
3 C RED TP OUT + RED
protection
Input to Trolley
4 D BLACK TP OUT - BLACK
protection
5 E NC NC NC No Connection
The two CPU modules send the digital packet information to the COM1
module through the motherboard. The analog signal from modem module through
Euro Connector is available at (4-Pin) connector J21 on motherboard and then
connected to MS coupler 6 (3-Pin, refer DRG: 3) on the back plate. The COM1 is
Note: Modem A (COM1) is used in EF, CF and 3DP1S unit types of SSDAC
A
C
MS coupler
(MS-6), refer
Sl.No DRG no: 3 Description of Signal Cable to be used
Pin Cable
1 A RED A-MODEM-INOUT+ ½ Quad 0.9 mm
2 B BLACK A-MODEM-INOUT-
3 C NC NC No Connection
The two CPU modules send the digital packet information to the COM2
module through the motherboard. The analog signal from modem module through
Euro Connector is available at (4-Pin) connector J22 on motherboard and then
connected to MS coupler 11 (3-pin, refer DRG: 3) on the back plate. The COM2
is connected with remote SSDAC unit for communication by means of 2Wire,
0.9mm dia Quad cable. The pin configuration of (3-pin) MS Coupler 11 is given
in table below.
Note: Modem B (COM2) is used in SF, CF and 3DP1S unit types of SSDAC
A
C
MS coupler (MS-11),
Sl. No refer DRG no: 3 Description of Signal Cable to be used
Pin Cable
1 A RED B-MODEM-INOUT+
½ Quad 0.9 mm
2 B BLACK B-MODEM-INOUT-
3 C NC NC No Connection
The two CPU modules send the digital packet information to the
SM/Event Logger module through the motherboard. The analog signal from
modem module through Euro Connector is available at AMP connectors J24 (4-
Pin) and J25 (6-pin) respectively on motherboard and then connected to MS
coupler 15 (5-pin, refer DRG: 3) on the back plate. This module also consists of
EEPROM’s, which stores the events of SSDAC. Stored events can be down
loaded to PC/Laptop locally through RS-232 Port (Baud Rate-9600bps). This
module sends the system information through FSK of 1200 baud rate to reset box
by establishing the connection between the A&B of MS coupler 15 and T5&T6 of
reset box FSK connector. The pin configuration of (5-pin) MS coupler 15 is given
in table below.
E
B
D C
MS coupler
(MS-15), refer Description of
Sl. No DRG no: 3 Cable to be used
Signal
Pin Cable
SM-MODEM-
1. A RED
INOUT+ ½ Quad 0.9 mm up to
SM-MODEM- station
2. B BLACK
INOUT-
3. C RED RTC-BAT
2 Core coil cable
4. D BLACK DIG- GND
5 E NC NC No Connection
MS coupler
(MS-12), refer Description of
Sl. No DRG no: 3 Cable to be used
Signal
Pin Cable
1. A RED RESET1+ 1.5mm Signaling
cable or 1/2 Quad
2. B BLACK RESET1- 0.9mm (refer note)
3 C NC NC No Connection
A
C
MS coupler (MS-13),
refer DRG no: 3 Description of
Sl. No Cable to be used
Signal
Pin Cable
1. A RED RESET2+ 1.5mm Signaling
cable or 1/2 Quad
2. B BLACK RESET2 - 0.9mm(refer note)
3 C NC NC No Connection
Note:
A
F B
G
E C
D
MS coupler
MS coupler (MS-1) on
Sl. (MS-2), refer
Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
No
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED VR-A+ (+24V DC) C,D RED
3. F,E BLACK VR-A- (-24V DC) F,E BLACK
4. G BLUE RLYUV1-FB (-5V DC) G BLACK
A
F B
G
E C
D
MS coupler
MS coupler (MS-1) on
Sl. (MS-3), refer
Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
No
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED VR-B+ (+24V DC) C,D RED
3. F,E BLACK VR-B- (-24V DC) F,E BLACK
4. G BLUE RLYUV2-FB (-5V DC) G BLACK
A
F B
G
E C
D
MS coupler
MS coupler (MS-2) on
(MS-7), refer
Sl. No Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED PREP1+ (+24V DC) C,D RED
3. F,E BLACK PREP1 - (-24V DC) F,E BLACK
4. G BLUE PREP1-FB (-5V DC) G BLACK
A
F B
G
E C
D
MS coupler
MS coupler (MS-2) on Relay
Sl. (MS-8), refer
Description of Signal Box, refer DRG no: 5
No DRG no: 3
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED PREP2+ (+24V DC) C,D RED
3. F,E BLACK PREP2 - (-24V DC) F,E BLACK
4. G BLUE PREP2-FB (-5V DC) G BLACK
A
F B
G
E C
D
MS coupler
MS coupler (MS-2) on Train
(MS-9), refer Description of
Sl.No. Simulator Box, refer DRG no: 19
DRG no: 3 Signal
Pin Cable Pin Cable
2 Core Coil wire -
1. A RED WHEEL-M1 A
Red
2 Core Coil wire -
2. B BLACK WHEEL-S1 B
Black
2 Core Coil wire -
3 C GREEN WHEEL-SUP1 C
Red
2 Core Coil wire -
4 D RED WHEEL-M2 D
Black
2 Core Coil wire -
5 E BLACK WHEEL-S2 E
Red
2 Core Coil wire -
6 F GREEN WHEEL-SUP2 F
Black
2 Core Coil wire -
7 G BLACK DIG- GND G
Green
A
C
MS coupler (MS-14),
refer DRG no: 3 Connection from
Sl.No Power Supply
battery / IPS
Pin Cable
1. A RED + 24V DC
2. B BLACK - 24V DC 2 Core cable Coil Wire
3. C NC No Connection
The Vital relay and Preparatory relay are housed in the Relay box. The
relay coil and its contacts of vital and preparatory relays are terminated on to the
two separate MS coupler MS-1 and MS-2 (10-pin, refer DRG: 5) fixed at the back
of the Relay box. The wiring is as shown in table below. The Relay Drive output
from SSDAC is connected to Vital Relay through coupler MS-1 and preparatory
relay through MS-2.
H A
I B
G C
F J
D
E
MS coupler (MS-1),
refer DRG no: 5 Description of signal to vital
Sl.No. Connection to be made
relay
Pin Cable
1. A RED Coil R1 (VR +) (+24V DC)
2. B RED Coil R2 (VR -) (-24V DC)
3. C BLUE A1 (+5 VDC)
4. D BLUE A2 (VR – FB) (-5V DC) Direct connections should be
made between the coupler of
5. E BROWN C1 (+24V)
Relay Box (MS-1, refer DRG:
6. F BROWN C2 (+VPR) (+24V DC) 5) and coupler of SSDAC
7. G GREEN B3 (- 24V) (MS-2 / 3, refer DRG: 3)
8. H GREEN B4 (- VPR) (-24V DC)
9 I NC No Connection
10 J NC No Connection
RELAY TYPE: Q type 24V, 1000Ω
Ω 6F, 6B for Vital Relay
A B C D
1 (+5 VDC) (+24V) 1
2 (VR – FB) (-5V DC) (+VPR) (+24V DC) 2
3 (- 24V) 3
4 (- VPR) (-24V DC) 4
5 5
6 6
7 7
8 8
R1 (VR +) (+24V DC) (VR -) (-24V DC) R2
R3 R4
H A
I B
G C
F J
D
E
MS coupler (MS-2),
refer DRG no: 5 Description of signal to
Sl.No Connection to be made
Preparatory relay
Pin Cable
1. A RED Coil R1 (PR +) (+24V DC)
2. B RED Coil R2 (PR -) (-24V DC)
3. C BLUE A1 (+5 VDC)
4. D BLUE A2 (PR – FB) (-5 VDC) Direct connections should be
made between the coupler of
5. E BROWN C1 (+24V)
Relay Box (MS-2, refer DRG: 5)
6. F BROWN C2 (+PPR) (+24V DC) and coupler of SSDAC
7. G GREEN B3 (- 24V) (MS-7 / 8, refer DRG: 3)
8. H GREEN B4 (- PPR) (-24V DC)
9 I NC No Connection
10 J NC No Connection
RELAY TYPE: Q type 24V, 1000Ω
Ω 6F, 6B for Preparatory Relay
A B C D
1 (+5 VDC) (+24V) 1
2 (PR – FB) (-5V DC) (+PPR) (+24V DC) 2
3 (- 24V) 3
4 (- PPR) (-24V DC) 4
5 5
6 6
7 7
8 8
R1 (PR +) (+24V DC) (PR -) (-24V DC) R2
R3 R4
Railway Track
21 KHz 25 KHz
21 KHz 25KHz
RX RX
TX Axle Detectors TX Ax le Detectors
Relay Box
SPARE
SPARE
SPARE
FSK
RD1
RD2
COM2
Vital Relay B Relay Box
Communication
DC-DC Converter
DC-DC Converter
Prep Relay B Vital Relay A
PD1 PD2 PD1 PD2 Prep Relay A
SM SM
SPARE
COM1
CPU CPU CPU / CPU CPU CPU /
1 2 Event 1 2 Event
Logger Logger
24VDC
SSDAC SF
24VDC
SSDAC EF
SSDAC Status
SSDAC Status
in LC D Display RS 232/ FSK
in LC D Display
To SSDAC To SSDAC C ommunication
RS 232/ FSK
SF Unit C ommunication EF Unit
MS 1
MS 1
MS 3 MS 2
MS 4 MS 5 MS 4 MS 5
MS 1 MS 2 Vital Relay MS 1 Vital Relay MS 3
25 TX 21 TX 25 TX 21 TX
B A
STATIONB
STATION A
MS 8 MS 6 MS 7
MS 6 MS 7 Preparatory Preparatory MS 8
Modem A
Relay B Relay A
DB25
DB25
MS 9 MS 9
MS 11 MS 13 MS 12
MS 12 MS 11 MS 13
Modem B Reset B Reset A
MS 14 MS 15
MS 14 MS 15 24 I/P SM COM
MS 16 MS 17
24 I/P MS 16 MS 17
SM COM 25 RX 21 RX
25 RX 21 RX
MS 1 MS 2
MS 1 MS 2
VR PR
VR PR
Reset Reset
Box with QUAD Cable QUAD Cable QUAD Cable Box with
Error Error
Display Display
Quantity
The SSDAC units are supplied after RDSO inspection and are dispatched
in a kit form for easy installation and commissioning. The kit consists of
Display Box
Reset box
Filter Box
Fixing items
Installation Manual
• The equipments are packed in bubble sheet packing and provided with
Thermo Cole spaces for shock absorption and finally despatched in
corrugated cardboard cartons that are again covered with polythene
covers to make them moisture proof.
• The SSDAC unit consisting of, system, display module, relay box,
filter box and the fused tag blocks are to be housed in a full GRS
Location Box adjacent to the track.
• The Reset box / boxes are to be provided in the station master cabin.
• The wiring between all these units is to be carried out as per Railway
standards.
• Lay of power, signalling cables and cables coming from TX/RX coils.
• Painting and fixing of required planks and the fuse terminal block.
• Terminating the cables as per drawings DRG No: 15 & DRG No: 16
(2DP1S SF and EF Configuration) on the Fuse Terminal Block.
• Placing of the unit with all the PCB modules, display module and the
Relay box on the plank provided in the location box.
• All the shields and the screen wires shall also be connected to the
earth.
• Connect the wires coming from the system to the reset box as per
drawing DRG No: 20 and DRG No: 21
• Connect the power cables coming from the system to the source of
power supply of 24V DC at the station, keeping the FTB (DRG No: 15
& DRG No: 16) connector open.
• In main Lines, loop lines, yard area the Axle detectors can be fixed just
after the Starter Signal post of each line under monitoring of SSDAC.
• It should be ensured that the rail is not badly worn causing the wheel
flanges to graze over the fittings according to RDSO Specification
RDSO/SPN/177/2005 Clause No: 4.0.7.
• The design of the detector is suitable for 90R, 52Kg and 60Kg rails.
• For easy identification of the cables, the colors of the sheath of the
cables are made as Grey for 21 KHz and Blue for 25 KHz. For further
identification of TX and RX coils, both ends of the cables are provided
with colored sticky tapes as follows 21KHz TX-RED, 21KHz RX-
YELLOW, 25KHz TX- BLUE, 25KHz RX- BLACK
• The marking jig is to be fixed from bottom of the rail and tightened to
the rail with bolts.
• The marking for 3 holes with punch is to be made on the Web of rail
using marking jig refer DRG No: 23
• From bottom of the rail drill the holes at 68 mm for 52 KG, 84 mm for
60 KG and 57 mm for 90 R as per DRG No: 23
Important: The marking and drilling of holes on the web to the given
dimensions are very important for proper working of the system.
• The Axle detectors are to be fixed on web of the rail at the drilled holes
by means of M12 bolts & nuts with spring washers and check nuts.
(NOTE: the torque wrench, specified in the checklist, should be used
for tightening of nuts and bots.)
• M12 x 100mm – 3 Nos. bolts & nuts are used for fixing the axle
detectors. 2nd nut is with Nylon washer and is to be used on each bolt.
• Transmitter coil assembly (21 KHz & 25 KHz) should be fixed on the
outer side of rail. The transmitter assembly should sit properly on the
web of rail.
• Receiver coil assembly (21 KHz & 25 KHz) should be fixed on the
inner side of rail. The receiver assembly should be placed properly on
the web of rail.
• The TX coil cables of 21 KHz & 25 KHz are taken together in one
HDPE pipe to the location Box. Similarly both 21 KHz & 25 KHz RX
coil cables are taken together but separately from TX coil cables to the
location box.
• The location box foundation should be cast at rail level and as per
scheduled dimensions of Railways. (Standard practice in railways).
• One Shelf made out of teak wood should be provided in the location
box for keeping SSDAC Counting Unit & Relay Box.
The SSDAC system works off 24V DC supply. This has to be provided
by the respective station through power cables. The continuous current drain,
depends upon the configuration employed at that station and the requirement
of battery and charger are as indicated below
The power supply and its connections are indicated in DRG No: 20.
• The same battery can be used for supplying all the systems of a
particular configuration.
4.4.2 Batteries
Low Maintenance Battery Bank may be used for powering of the SSDAC.
The batteries are to be procured as per latest RDSO specification.
4.4.4 Cable
The connecting cable from Battery / IPS to SSDAC units at the site
should be as given below:
The Digital Axle Counter depends heavily on the axle detector coils that
are responsible for detecting the wheels of a train. The Axle detectors design,
mounting and connection to the system are very important for the proper operation
of the SSDAC. For wheel recognition, counting, ignoring the trolley wheels, etc.
the output from the coil is essential. In order to meet the above requirements, the
following procedure is adopted while installing the axle detector coils.
While installing care should be taken that, the TX coils are on the outer
side of the rail and RX coils are on the inner side and are mounted as per drawing
DRG No: 16, with surface ‘A’ of the RX coil at a depth of 55mm from the top
surface of the rail.
The leads of individual, TX and RX coils have to be taken from the track
to the system in separate HDPE pipes to avoid interference. Hence a set of 2 pipes
will be required for one pair of TX and RX coils.
These cables are to be terminated on to the FTB as per drawing DRG No:
15 (2DP1S Configuration) on the FTB.
The system along with the associated display box, filter box and the Relay
box are to install in location boxes of full GRS type. The chassis of the systems
with its motherboard and all PCB modules mounted in the position are supplied as
indicated modules after testing and passing by RDSO. All the modules are fixed
rigidly to the chassis for which not be loosened. The chassis is to be fixed rigidly
in the location box with the help of screws provided for the same. Similarly the
relay box and the display unit should also have to be fixed rigidly on the plank.
The front view of the system chassis is shown for the different configurations in
the drawings DRG No: 1 and DRG No: 2.The rear view of the system chassis is
shown for the different configurations in the figures DRG No: 3.
A universal rear plate has been designed with MS Couplers for easy
connection, with clear identification of their usage and purpose for different
configurations. The Couplers have been chosen with different pin numbers for
different functions. Also male and female couplers are used to make foolproof
Along with the chassis MS Couplers assemblies with cables with clear
marking are supplied for connection and wiring on the FTB.
2D-SF 1 1
2D-EF 1 1
4.4.9.1 Controls
• 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.
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.
A set of cables with MS Couplers with labelling is also sent with the
system. After the placement of the system in location box, cables from MS
Couplers and cables from the external equipments are to be terminated at the
FTB as per the DRG No: 15 (2DP1S SF Configuration) and DRG No: 16
(2DP1S EF Configuration). The power supply, communication and reset
cables are to be passed through the surge protectors as per the DRG No: 20.
The fused tag block assembly act as interface between the internal
wiring and the external wiring of both power and signals of the SSDAC. The
fused tag blocks are mounted on DIN rail along with surge protector and end
blocks. Each fused tag blocks are equipped with required number of fuses
depending up on the circuit to which it is wired to, as per the details in
drawings DRG No: 15 (2DP1S SF Configuration) and DRG No: 16 (2DP1S
EF Configuration). The surge protectors are rated for 24 V main supplies and
48 V for reset box. The wiring diagram takes for the proper routing of the
cables through the surge protectors. The metallic frame of the surge protector
should be connected to the main earth rigidly achieved proper earth protection.
After fixing the axle detector coils, system, relay box, reset box etc it is
essential that preliminary checks are to be made for the continuity of the
wiring, insulation, resistance between different wires and connecting terminals
in order to satisfy the correct terminations and avoiding unnecessary shorts.
The drawing DRG No: 15 (2DP1S SF Configuration) and DRG No: 16
(2DP1S EF Configuration) may be referred for this purposes
The various LED indications are tabulated below for power on, clear
and occupied mode conditions, when the system is healthy.
The above information corresponds to the different aspects of the system as follows
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n
EF
A d 4 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
Column 1
Line 4 Status/ Error messages
The above information corresponds to the different aspects of the system as follows
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0
EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2
S S D A C R e s e t B o x V 0 0 1
C o m m u n i c a t i n g w i t h
S S D A C
C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2
Since SSDAC system is in Powered UP condition and Reset Box is powered UP next,
it communicates with SSDAC and show the Checksum and S/W Version of SSDAC
and continue with the current status of SSDAC.
If Reset Box is powered UP first and then SSDAC system is Powered UP next, the
following display will be shown.
2DP-1S (2 DP 1 Section)
1. Power up condition:
C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2
W a i t i n g f o r R E S E T
W a i t i n g f o r R E S E T
C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2
W a i t i n g f o r R E S E T
R e s e t A p p l i e d
4. Preparatory condition:
0 0 0
0 0 0
W a i t f o r P i l o t T r a i n
W a i t f o r P i l o t T r a i n
0 0 2
0 0 0
P i l o t i n g i n P r o g r e s s
W a i t f o r P i l o t T r a i n
0 0 0
0 0 2
W a i t f o r P i l o t T r a i n
P i l o t i n g i n P r o g r e s s
5. Clear condition:
0 0 0
0 0 0
S e c t i o n C L E A R
S e c t i o n C L E A R
6. Occupied condition:
7. Error Condition:
0 4 0
0 4 2
D i r e c t - O U T C O U N T 4 5
S Y S T E M I N E R R O R
C h e c k s u m S / W V e r 0 0 2
0 4 2
R e s e t A p p l i e d
S Y S T E M I N E R R O R
40 0
C h e c k s u m S / W V e r 0 0 2
D i r e c t - O U T C O U N T 4 5
R e s e t A p p l i e d
10. Preparatory condition after Error and Reset applied at both the DP:
0 0 0
0 0 0
W a i t f o r P i l o t T r a i n
W a i t f o r P i l o t T r a i n
There are different types of errors. The errors listed below are handled by
software. Each error is identified with one error code. The analysis of all these errors
and the corrective measures to be taken are tabulated in table of below.
Error
Code on Corrective
Errors Analysis
display measure
of CPU
Error occurred due to
Place the PD1
missing of the Phase
module in the slot
01 PD1_BOARD_MISSING detector 1 module (PD1-
and reset the
21KHz) during run time
system
and boot time diagnosis.
Error occurred due to
Place the PD2
missing of the Phase
module in the slot
02 PD2_BOARD_MISSING detector 2 module (PD2-
and reset the
25KHz) during run time
system
and boot time diagnosis.
Error occurred due to Place the SM-CPU
missing of the SM-CPU module in the slot
03 SM_CPU_MISSING
module during run time and reset the
and boot time diagnosis. system
Error occurred due to Place the
missing of the Communication A
04 MODEM_MODULE_A_MISSING Communication A module in the slot
module during run time and reset the
and boot time diagnosis. system
Error occurred due to Place the
missing of the Communication B
05 MODEM_MODULE_B_MISSING Communication B module in the slot
module during run time and reset the
and boot time diagnosis system
Error occurred due to
Place the Relay
missing of the Relay
Drive A module in
06 RELAY_DRIVE_A_MISSING Drive A module during
the slot and reset
run time and boot time
the system
diagnosis
Error occurred due to
Place the Relay
missing of the Relay
Drive B module in
07 RELAY_DRIVE_B_MISSING Drive B module during
the slot and reset
run time and boot time
the system
diagnosis
PD2 module
1. Make the
supervisory is low for
connection
6 seconds
Properly
Cause 1: TX2/RX2
2. Replace
coils not connected
TX1/RX1
properly
34 PD2_SUP_LOW coil
Cause2: TX2/RX2
3. Replace
coil gone bad
CPU1/CPU2
Cause 3: CPU1/CPU2
4. Replace PD2
gone bad
module
Cause 4: PD2 module
gone bad
Error occurs when any 1. Make the
one sensor is connection
influenced two or more Properly
times. 2. Replace
35 PD1_PULSING Cause 1: Loose TX1/RX1
contacts of TX1/RX1 coil
connections 3. Replace PD2
Cause 2: PD2 module module
gone bad
Error occurs when any 1. Make the
one sensor is connection
influenced two or more Properly
times. 2. Replace
36 PD2_PULSING Cause 1: Loose TX2/RX2
contacts of TX1/RX1 coil
connections 3. Replace PD1
Cause 2: PD1 module module
gone bad
1. Make the
Error occurs when connection
double sensor is Properly
influence in the sequence 2. Replace
Cause 1: Loose TX1/RX1,
37 PD_STATE_MISSING
contacts of TX1/RX1, TX2/RX2
TX2/RX2 connections coil
Cause 2: PD1, PD2 3. Replace PD1,
module gone bad PD2 module
No/Improper feedback
from Vital Relay A relay
1. Make the
Cause 1: Loose
connection
contacts of Vital relay
Properly
connections
2. Replace
43 VITAL_RELAY_A_FAILURE Cause2: Relay Drive 1
Relay Driver
module gone bad
1 module
Cause 3: CPU1/CPU2
3. Replace
module gone bad
CPU1/CPU2
No/Improper feedback
from Vital Relay B relay 1. Make the
Cause 1: Loose connection
contacts of Vital relay Properly
connections 2. Replace
44 VITAL_RELAY_B_FAILURE
Cause2: Relay Drive 2 Relay Driver
module gone bad 2 module
Cause 3: CPU1/CPU2 3. Replace
module gone bad CPU1/CPU2
Without IN COUNT,
45 DIRECT_OUT_COUNT Reset the system
OUT COUNT registered
Power failure at Down Make the
stream CPU1
49 TRANSIENT_POWER_FAILURE_DS1 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Down Make the
50 stream CPU2
TRANSIENT_POWER_FAILURE_DS2 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Up Make the
stream CPU1
51 TRANSIENT_POWER_FAILURE_US1 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Up Make the
stream CPU2
52 TRANSIENT_POWER_FAILURE_US2 connection
Cause 1: Loose contacts
of power connections Properly
Reset Procedure
• Stationmaster A inserts and turns the SM key and press the reset button
simultaneously.
• Preparatory LED start blinking and LCD display’s “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.
• Now the pilot train is allowed in the section to balance the section. On
successful piloting of train with minimum of two axles and matching of In-
counts and Out-counts section gets balanced.
• SSDAC–2DP1S system cover the section goes through reset operation and
vital relays of SSDAC-SF and SSDAC–EF energize/pickups. Occupied
LEDs goes off and clear LEDs glow at both station A and station B.
SSDAC has various monitoring points. These different points are being
tabulated below.
EN2B O/P and GND (for SF, CF, 3DP1S units) 11.5V to 12.5V DC
CPU 2
EN2A O/P and GND (for EF, CF) 11.5V to 12.5V DC
Time Maintenance
Daily NIL
Weekly NIL
Check and record the readings of
Power supply module and PD
Monthly
module and check the TX / RX Coil
Voltages as per Table 8-1
Half yearly Replace if any parts broken
Note: 1 set of tool kit to be purchased separately for every 10 sets of SSDAC
systems
Sl.No DO’s
The interconnection drawings are to be followed for connecting the
1 Transmitter and Receiver Coils. Tx1 is 21 KHz, Tx2 is 25 KHz & Rx1
and RX2 coils are 21 KHz & 25 KHz, respectively.
Ensure that Receiver and Transmitter coil cables have been laid in
2
different pipes.
Ensure that both the TX coils & RX coils are having proper alignment
3
on Rail.
Ensure that packing of sleepers with ballast on both sides of Axle
4
detector is proper.
Check that metal sheaths of the outdoor cable are connected to earth at
5
both ends.
The recommended cables for wiring of the system at site should be
6
used.
7 The steady battery voltage 24 V should be maintained.
8 The cable connections should not be connected loosely.
The MS Coupler connectors of SSDAC System are checked and
9
maintained firmly.
Preparatory Resetting should be done only after ensuring that there is no
10
train in the Section.
It is recommended that heat resisting paint to be used on the apparatus
11 case so that the temperature inside apparatus case is maintained lower in
comparison to other normal paints.
Usage of Spokes Trolley wheel reduces the SSDAC system entering the
Error mode and increases the Availability. The straight movements or
14
passing of Motor Trolley or Push Trolley with solid mass wheel does
not effect the SSDAC system.
Sl.No DON’Ts
Don’t cut or join the Transmitter / Receiver cables supplied along with the coil.
1
It would result in change of input Receiver signal.
Don’t remove the modules from SSDAC System under Power ON condition.
2 Remove the modules if necessary after switching OFF the power to the SSDAC
System.
Local Address of the CPU – 1, CPU – 2 and Configuration settings of the
3
SSDAC System should not be changed at the field.
The Hardware of Communication module and Relay Drive module are similar
for all systems. However their position of mounting is different in different unit
4
types. These modules have to be equipped correctly after verifying the drawings
(DRG No: 1 & DRG No: 2), which indicates their positions.
When Section is in Occupied / Preparatory Mode, Motor Trolley wheel, Push
5 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.
The SSDAC System does not support Entry / Exit of Motor Trolley wheel
whether fixed to Motor Trolley or Push Trolley in Occupied Sections, Back to
6 Back movement within a period of 6 seconds, Shunting operations. The
SSDAC system may enter into Error mode if the Motor Trolley or Push Trolley
with solid mass wheel movement on the track is Wobbling.
0 General Information:
Observed
OK / Not
Sl. No. Item Required SF EF OK
UNIT UNIT
Relay used in Relay Q type, 24V, 1000 Ohm
1.1 (Printed Sticker of VR/PR either on front
Box VR & PR cover or inside bottom of the relay box)
Diode across each
Should be provided with BY127 /
1.2 relay coil in reverse
IN4007 / IN5408
bias.
1.3 Unused Quad pair To be terminated on terminals.
Dressing of Quad To be properly dressed with
1.4
pair insulated tape.
Spiral before No individual conductor to be
1.5
termination. made spiral
Observed
OK /Not
Sl. No. Item Required SF EF OK
UNIT UNIT
Wiring of TX / RX
Wired on approved ARA / PBT
2.1 coils & MS coupler
terminal strips
cables
Condition of worn Should be within vertical limit of
out of Rail worn out
2.2 60 Kg - 13 mm 159-172 mm
52 Kg - 8 mm 148-156 mm
90 R - 5 mm 138-143 mm
GGT Jig as per drawing no.DRG-
23 of Installation manual version
Marking of holes on 1.0 Revision 1 to be used as per
rail rail section.
2.3
(From bottom of the 60 Kg 84 mm
rail) 52 Kg 68 mm
90 R 57 mm
from the bottom of the rail.
Should be of 14mm dia Should be
Drilling of holes in
2.4 square (perpendicular), should not
the web of rail
be oblong.
Torque applied to
fix track device Jaicom make JPR65 or
2.5
using Torque Equivalent - 88 Nm.
wrench
2.6 Fixing of TX Outside the rail
2.7 Fixing of RX Inside the rail
Fixing of axle On the same rail as per drawing
2.8 detectors at entry & no. DRG-12 of installation manual
exit end Version 1.0,Revision 1
Laying of axle
2.9 In corrugated / HDPE pipe
detector cable
Screen of axle
2.10 Should be earthed
detector cable
Fixing of deflector As per drawing given to
2.11 Installation Manual Version 1.0
plates Revision 1 DRG-18
3. Outdoor (Quad Cable/PIJF twisted pairs telecom cable for Axle counter system
working in station area, As per RDSO letter no. STS/E/SSDAC/SPN/177
dated-28/30.08.2006)
3.1 Test format for testing of QUAD cable/PIJF twisted pair telecom cable
before commissioning of SSDAC in Station area
Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
Block section
3.2.1 a ≤ 12 Km.
length limit
Only Quad cable is to be
Communication
used between field units.
3.2.2 b Media
No Signaling Cable is to
Type of Cable
be used in totality/parts.
Proper pair of wires to be
3.2.3 c Use of pair used for connectivity.
Annex-1 may be referred
No wires to be paralleled
Duplication of
3.2.4 d for reducing conductor
Wires
resistance.
Insulation
Shall be greater than
3.2.5 e resistance of Quad
/equal to 10 M ohm.
cable
Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
3.2.2 QUAD/PIJF
Jelly filled telecom cable/
Quad cable to be used
Communication
between field units &
3.2.2.1 a Media
OFC Equipment room.
Type of Cable
Signaling Cable shall not
be used at all.
Proper pair of wires to be
3.2.2.2 b Use of pair used for connectivity.
Annex-1 may be referred
No wires to be paralleled
Duplication of
3.2.2.3 c for reducing conductor
Wires
resistance.
Insulation
Shall be greater than
3.2.2.4 d resistance of
/equal to 10 M ohm.
Quad cable
Not to exceed 56
ohm/Kms at 200 C for
Loop resistance quad cable &
3.2.2.5 e of designated * ohm/Kms for PIJF
pair telecom cable.
See Annexure -2 for
correction factor.
Earth of quad Shall be less than One
3.2.2.6 f
cable ohm
Cable Shall be filled up &
3.2.2.7 g
allocation table attached
Unused Quad To be terminated on
3.2.2.8 h
pair terminals.
Dressing of To be properly dressed
3.2.2.9 i
Quad pair with insulated tape.
Spiral before No individual conductor
3.2.2.10 j
termination. to be made spiral
3.3 Test format for testing of QUAD cable/PIJF twisted pair telecom cable in
between SSDAC Unit and Station before commissioning of SSDAC
Attenuation Loss: The output/Input impedance of signal generator/dB meter shall be 600
ohm.
Near End Crosstalk: Test tone of 150 KHz to be fed in the adjacent pair of the same quad &
NEXT to be measured at the same end on the other pair of the same
quad.
Far End Cross talk: Test tone of 150 KHz to be fed in the adjacent pair of the same quad &
FEXT to be measured at the far end on the other pair of the same quad.
Observed OK /Not
Sl. No Item Required
SF UNIT EF UNIT OK
4.1 a. Sl. No. of SSDAC Same serial number pairs.
units Example – 001 (SF UNIT),
001 (EF UNIT)
b. Details of Track Track circuit No.
circuit
4.2 Placement of Should be in proper position
Cards/modules
4.3 Firmness of Should be tightened with screw /clip
card/Modules provided
4.4 MS Couplers Installed and tightened properly
Observed
Sl. Remarks
Item Required SF EF
No OK / Not OK
UNIT UNIT
Shall be of Q type 24 V ,
5.1 PPR & VPR Relays
1000 ohms
5.2 Fuse ratings 2.0 Amps
a) Charger should be fit for
axle counter use.
5.3 b) There should not be any
Power supply for axle other load on the power
counter supply except axle counter.
c) Class B & C types surge
protection must be provided
on 230 V mains line.
Ripple of Input Power Less than 10 mV rms / 50 mV
5.4
Supply peak to peak.
Glitch in Input Power
5.5 Supply by putting No glitch should be there
ON/OFF the charger
Drive voltage of the VPR.
(This may be checked
5.6 >22V
across R1 & R2 of coil of
relay).
Drive voltage of the PPR.
(This may be checked
5.7 >22V
across R1 & R2 of coil of
relay).
Observed
Sl. Remarks
Item Required SF EF
No. OK / Not OK
UNIT UNIT
Wired as per drg no. DRG-
6.1Box Reset Box
Reset 18 OF Installation Manual
6.2 Reset Box Connected to earth
Earthing. properly.
6.3 a) Reset not possible when
Axle Counter section is
clear and healthy.
Reset function b) Reset not possible when
Axle counter section is in
Preparatory reset mode.
6.4 24 V D. C.
level at Reset 22V DC to 30 V DC
box input.
6.5 Level of reset
signal from 48 V ± 4 V DC
reset box.
6.6 Level of reset
signal at 38 V to 50V DC ± 2V DC
SSDAC unit
input.
7.0 COMMISSIONING
Remarks
SF EF
Sl.No. Type of Card Part No. Version OK / Not
UNIT UNIT
OK
1 Phase Detector Card 1 H001M01R1 00
2 Phase Detector Card 2 H001M02R1 00
3 CPU Card 1 of SF H001M09R1 00 * NA *
4 CPU Card 2 of SF H001M10R1 00 * NA *
5 CPU Card 1 of EF H001M11R1 00 * NA *
6 CPU Card 2 of EF H001M12R1 00 * NA *
7 SM CPU/Event Logger
H001M03R1 00
Card
8 Communication Card 1 H001M04R1 00 * NA *
9 Communication Card 2 H001M05R1 00 * NA *
10 Relay Driver Card 1 H001M07R1 00 * NA *
11 Relay Driver Card 2 H001M06R1 00 * NA *
12 DC-DC Converter Card H001M08R1 00
13 LCD Display Box H001M24R1 00
14 Relay Box with Q-type;
24 V ; 1000 Ohm relay- G36-RB2R00 00
6F/6B
15 Filter Box G36-RSFL00 00
16 Axle detectors
G36-T212500 00
(Web type TX Coils)
17 Axle detectors
G36-R212500
(Web type RX coils)
18 Reset Box G36-RSBX01 00
19 Surge Voltage Protection
G36-LTDU00 00
device
* NA *: Not applicable
White
(A)
X
X
(B)
Quad color
Table-1
Colour scheme of PE insulated Quads
Quad Colour
Quad No Pair A - Wire B -Wire Pair No. C- Wire D - Wire
No.
Orange 1 1A White Orange 1B Red Grey
Blue 2 2A White Blue 2B Red Grey
Brown 3 3A White Brown 3B Red Grey
Green 4 4A White Green 4B Red Grey
Yellow 5 5A White Yellow 5B Red Grey
Black 6 6A White Black 6B Red Grey
Designated pair of wire of the same quad (mentioned in Table -1) should be used.
Do not use one wire from one quad and another wire from some other quad.
If any wire of a pair of the quad is broken/Non functional, then use fresh pair of wire.
Temp. Corre. Temp. Corre. Temp Corre. Temp. Corre. Temp. Corre.
Deg C factor deg C Factor deg C factor deg C factor deg C Factor
1. 2. 1. 2. 1. 2. 1. 2. 1. 2
Observed Result( No
S.No. Type of Trolley wheel influence / Goes to error / Remarks
Counted / other)
4 spoke wheel
Wheel Dia with flange –
550 mm
1 Wheel base – 110 mm
Flange thickness – 9 mm
Wheel Flange – 20 mm
Spoke width –
6 spoke wheel
Wheel Dia with flange –
Wheel Width –
2
Flange width –
Flange depth –
Spoke width –
Solid Wheel with 6 holes
Wheel Dia with flange –
3 Wheel Width –
Flange width –
Flange depth –
8 spoke wheel
Wheel Dia with flange –
530 mm
4 Wheel base – 100 mm
Flange thickness – 15 mm
Wheel Flange – 15 mm
Spoke width – 63 mm
DC – DC Converter
Battery (24V)
Description
300mV 300mV
to 1.2V to 1.2V
Date
(AC) (AC)
4.75
to
5.25
V 17.75
-11.75 V
40 to 11.75
40 to V to
70 V RX 10 V V
Phase
(Limit)
70 V RX SIG 10 V to to 18.25
for
SIG & to 12 to
& GND 12 V -12.25 V
GND V 12.25
24.750 to Socket 10 V to 10 V to V 22V to
22-30 V 20.802 to Socket <1V <1V V
25.250 12 V 12 V 26V
21.302
KHz 750
KHz 750 to
to 1200
1200
MV
MV
DC – DC Converter
Battery (24V)
Description
300mV 300mV
to 1.2V to 1.2V
Date
(AC) (AC)
4.75
to
5.25
V 17.75
-11.75 V
40 to 11.75
40 to V to
70 V RX 10 V V
Phase
(Limit)
70 V RX SIG 10 V to to 18.25
for
SIG & to 12 to
& GND 12 V -12.25 V
GND V 12.25
24.750 to Socket 10 V to 10 V to V 22V to
22-30 V 20.802 to Socket <1V <1V V
25.250 12 V 12 V 26V
21.302
KHz 750
KHz 750 to
to 1200
1200
MV
MV
PPR
B2 B1
B24
1.5 Sq.mm Signaling cable PR
C2 C1
N24
COUNTER
Reset T3 PPR A2 A1
RESET CIRCUIT
Reset T 12 VPR A2 A1
PR
R2 R1
VPR +24V
Reset T 13 A4 A3
MS7 Second Pair
+24V -24V
VPR C2 C1
B24
OCCUPIED LED
POWER LED
PREP LED
CLEAR LED
VPR D2 D1
N24
VPR
B2 B1
B24
1.5 Sq.mm Signaling cable VR
C2 C1
N24
-24Vdc