1.

INTRODUCTION

High Availability Single Section Digital Axle Counter (HA-SSDAC) is train detection
equipment used in Railways for monitoring a defined track section to provide occupancy/clear
status. The system detects the presence of a train in a specified track section. It is a safety
critical system for ensuring utmost safety tothe passengers, goods and saving of national
property. This system prevents allowing of a train in an already occupied track section by
giving Track Occupied status to further control systems. The HASSDAC is developed with
the aim to enhance the availability of Digital Axle Counters. It consists of dual processing
units and auto resetting feature hence redundancy is provided at every level.

To ensure safety and improve efficiency in train operation, any signaling system
requires continuous availability. The HASSDAC has been designed to increase the availability
of the existing Single Section Digital Axle Counter (SSDAC).

 HASSDAC conforms to RDSO specification No. RDSO/SPN/177/2013 Ver. 3.0

 In GG-Tronics HA-SSDAC-G36R system, one SSDAC system is mounted on one rail

which communicates via quad cable, and another SSDAC system is mounted on another
rail which communicates via separate pair of Quad cable / OFC voice channel or Direct
fiber (Direct fiber interface can be provided by GG-Tronics).

 Wheel Detectors are mounted apart one axle gap on either side of rail to avoid axle rocking.

 Separate power supply arrangement is provided to avoid common mode failure.

 Vital Relays of both SSDAC systems are in parallel to avoid block failure. The safety is
taken care by at least one SSDAC system.

 Manual Reset is required only when both SSDAC systems fail, which is a remote
occurrence

 Cable redundancy for both Signal and Power is provided to reduce failures during cable
faults.

 HA SSDAC-G36R is a fail-safe micro controller based system with 2 x 2 out of 2

architecture suited for proving Block Section and Entry/Exit of station.

 HA SSDAC-G36R can be used for several applications like 2DP1S Block section, IBS and
Auto signaling with high availability.

 Here high availability is achieved through the dual axle counter system. If any one of the
systems fails, another one takes care, thus availability is achieved through redundancy.

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 2. MODULES OF HA-SSDAC SYSTEM

Axle Detectors (Phase Reversal type)

 An Axle Detector consists of 2 Transmitter (TX) and 2 Receiver (Rx) coils.
 One pair of TX & Rx coil works on 21 KHz frequency and other on 25 KHz.
 The HA-SSDAC-G36R system consists of:
 Transmitter (TX) coils – 4 Nos. (2 Normal & 2 Redundant) fed with 21 kHz and 25
kHzcarrier signals.
 Receiver (RX) coils – 4 Nos. (2 Normal & 2 Redundant) to receive the
transmittersignal.
 The Rx signal is phase modulated with each train wheel passing over the detection point.
 The Tx & Rx coils are factory tuned at 21Khz & 25Khz and are supplied with 15 meter
cableswhich are to be run in individual HDPE pipes up to the location box.
 They have to be web mounted on the rail with Tx on the outer side and Rx on the inner side
where the wheel flange passes over the coils.
 The pilot holes in the jig are to be used to ensure proper height of the coils on 52Kg, 60Kg &
90-R rails by fixing the jig on the bottom of the rail.
 Coils are to be fixed with antitheft bolts & nuts provided by the manufacturer.

Figure 1: Web mounted Axle detectors (TX ,RX

Coils)

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Figure 2: HA-SSDAC G36R unit with Dual Electronics system

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a) Phase Detector Card [PD card]
(i) Each card generates the carrier signals, which is transmitted, to its transmitter coil mounted
on each detection point.
 PD card (21 KHz) to TX Coil A.
 PD card (25 KHz) to TX Coil B.
(ii) Demodulation and Pulse generation
Each card demodulates its receiver signal from Rx coil A
& B to generate pulses corresponding to wheels passing
over the detection point. These pulses are then validated
and fed to Central Processing Unit Cards.
 Rx Coil A to PD1 (21 KHz).
 Rx Coil B to PD2 (25 KHz).
The PD Cards (PD) generate high frequency (21 KHz, &
25KHz) carrier signals, which are transmitted to the two
independent TX coils of axle detectors. The two independent Rx coils receive these signals,
which are at a phase difference up to 180° with respect to reference signal of TX coils.
 The SSDAC system with phase reversal type track devices does not require short
length DC track circuits (3 Rail Length.) and its TPR relay connections for trolley
suppression.

The PD Cards (PD) generate high frequency (21 KHz, & 25 KHz) carrier signals, which are
transmitted to the two independent TX coils of axle detectors. The two independent Rx coils
receive these signals, which are at a phase difference up to 180° with respect to reference
signal of TX coils.
The SSDAC system with phase reversal type track devices does not require short length DC
track circuits (3 Rail Length.) and its TPR relay connections for trolley suppression.

PD1

Phase Detector 1 card is 21KHz wheel detector card responsible to get connected to 21 KHz
wheel sensor in the field. This card generates Transmitter voltage to Tx coil and senses back
receiver signal. It compares the Transmitter and Received signal phase and amplitude to
generate wheel pulses and supervisory voltages. Whenever wheel passes the wheel sensor the
Phase change in terms of wheel pulses of Wheel 1 is generated by this card to process further
by CPU cards for wheel counting. This card also generates Supervisory signal to CPU card for
checking health of the wheel sensor and PD1 card working.

PD2

Phase Detector 2 card is 25 KHz wheel detector card responsible to get connected to 25 KHz
wheel sensor in the field. This card generates Transmitter voltage to Tx coil and senses back

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receiver signal. It compares the Transmitter and Received signal phase and amplitude to
generate wheel pulses and supervisory voltages. Whenever wheel passes the wheel sensor the
Phase change in terms of wheel pulses of Wheel 2 is generated by this card to process further
by CPU cards for wheel counting. This card also generates Supervisory signal to CPU card for
checking health of the wheel sensor and PD2 card working.

(b) Central Processing Unit [CPU card]

The Central Processing Unit are the heart of the unit. Two identical cards have been
implemented to give 2-out-of-2 decision. These cards perform the functions related to
counting of pulses, count validation, communication through Modem with 2nd Unit of
SSDAC and decision making to give output. The input pulses are given to both the Central
Processing Unit Blocks. Both the Central Processing Units continuously monitor each other’s
health and wheel counts. If the results are not matching then the system goes into Error state.
The results of count check and health between 2 Central Processing cards are always matched
to arrive at a clear decision by the system.
Vital relay read back feature is included in the Central Processing Unit to read back the vital
relay in occupied as well as in the clear state and checks as per the decision given from the
card.

CPU1 and CPU2

CPU 1 & 2 cards are the Central Processing Cards

which are responsible for address setting,
configuration setting, Reset philosophy setting and
wheel counting. These cards also take care of
Diagnostics features of the total safety of the system.
These cards generate CPU EN 1 & 2 signals to Vital
Relay Drive RD1 and RD2 cards for driving the VR
relays indicating section status. These cards also
signal RD card to pick up and drop PR relay for
Preparatory mode indication. The complete safety
feature of the SSDAC system in 2oo2 architecture is handled by these CPU cards.

(c) Relay Driver module

The card module checks and generates the vital relay drive output to finally clear/occupied
status of the corresponding track section. The output is used to drive fail-safe vital relay.
The Relay Driver card (RD) is the output card for driving Vital Relay for Single Section
Digital Axle Counter (SSDAC). The card is of extended Euro size card terminated with 64 pin
standard Euro Connector. The card directly plugs into the motherboard of SSDAC. One RD
module is used in each SSDAC counting unit. The Relay Driver card receives the enable
of clear and

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clock signals from Central Processing Units and drives
the vital relay to energized condition (Pick up) when
section is clear. If a train occupies the section, the vital
relay is dropped. The command signals and vital relay
Pick up is indicated on the card.

RD1 and RD2

RD1/ RD2 cards are Responsible for driving PR and VR
relays by taking instructions from CPU cards. The VR
relays are driven by vital safety 2oo2 and fail safe AND
gate circuit to achieve highest degree of safety. This
card also gives feedback to CPU cards about VR and PR
relay working status.

(d). Communication Module

FSK Modem is V.23, used for communication between two units of SSDAC. The digital
packets generated by processor cards are sent to remote unit on a pair of cable. Serial I/O
Multiplexer is used to select the micro controller card that will communicate with the modem
on the remote unit.

The Salient features of the card include: -

(i). FSK Half Duplex modem chip

(ii). V.23 mode of operation ( 2 wire )

(iii). 1200 Baud rate

(iv). Multiplexes the two serial ports

(v). Originator (Entry unit) and Answerer (Exit unit) for V23

selected.(vi). Automatic gain controls provided in receive path.

COM1 and COM2

COM1/COM2 cards are responsible for communicating through FSK protocol communication
between Entry and Exit ( SF & EF ) systems on quad cable or voice channel of OFC
system. The communication software running in CPU cards ensures the integrity of the data
packets for proper safety working of the SSDAC system.

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(e) Event Logger module
Event Logger card is designed to capture and store important
data (events) from local SSDAC unit. The stored data can be
downloaded from the event logger card for the purpose of
analyzing the events occurring during the operations of the
SSDAC.

SM-CPU/Event Logger Module

SM-CPU/Event Logger Module’s responsibility is to record and
store all Events and allow downloading through the computer.
This card also has Station Master Reset Box interface via FSK
communication to give all the data required to be displayed like
Configuration, wheel counts, System status at the Reset Box
display kept in station room.

(f). DC-DC Converter card

The Card receives 24V battery input and generates 5V,
+12V and -12V, 18V and 24V output with common ground
for all circuit requirements.
The main features of the board are: -
i. Low Ripple
ii. Wide input line regulation
iii. Very good load regulation
iv. Input/output protected for short circuit.

(g). Reset Box with Display

Reset Box which is kept in Station Room is used for Resetting HA - SSDAC System while it
is required to normalize and display all Error and Working status to the user. Intelligent and
interactive Reset Boxes are supplied for each of the SF/EF units & are located in the stations
connected with the block section to be proved. There will be one reset box in each station for
single line, and two boxes corresponding to up line & down line for double line working.

The following controls & displays are provided for operation & maintenance :

 The SM Key & the Reset Push Button are provided for resetting of the system.

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 One green & one red LED of 10mm size are provided for indicating status of block
section.
 5mm green LED for indicating the status of preparatory reset is provided. It will flash
when local reset is applied. Become steady when reset is applied at the other end
also & the system is waiting for pilot train.
 This LED is put OFF when the section becomes clear.
 One 5 mm yellow LED is provided for indicating the line verification status. It will be
normally OFF & glows when line verification key is operated for executing direct reset.
 One 5mm yellow LED is provided for indicating power ON condition.
 One 6 digit non resettable counter is provided which increments after each reset.
 One LCD display with 4 lines & 20 characters gives live display of events, wheel
counts& error messages.
 The Reset Box is connected to the system with, one pair of quad cable for FSK
Communication.

Figure 3 : Dual Display Interactive Reset Box at Station with Automatic Reset Facility

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 Figure 4 : Reset Box rear view

Reset Box features

 Rear Side of reset box having DIP switch settings for address.
 Two DIP switches are available for two different display.
 If the address matches only the display of reset box will show the Status of the
system.
 In reset box HA SSDAC having individual system status LED’s and Common
sectionLED’s.
 In Rear Side HA SSDAC reset box Event downloader connector is available.
 Through the DB9 connector we can download the events of the systems.
 Last 3 error history will be scrolling in LCD display.
 Communication error packet list will be available in LCD display.

Voltage Window Card

Voltage Window card is responsible for accepting Reset Voltage applied to the system to be
Within working acceptable range of 48 volts +/- 5 volts.

Fused tag block assembly

Fused tag block (FTB) assembly with 6.3A fuses for power supply & 2A fuses for signals for
terminating both internal & external cables is provided. This tag block houses 4 no.s of
lightening discharge units connected across external connections as indicated below.

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  In the path of 24V DC input supply. (24V rating)
 Quad cable connection between units. (24V rating)
 Quad cable connection between reset box & units. (24V rating)
 Input reset voltage supply. (48V rating)

Relay Box
The relay box houses the vital relay (VR) & the preparatory relay (PR) of Q-type 1000 ohm
coils. Their outputs are connected to VPR & PPR relays in the relay room through the FTB,
for extending signals under different conditions of the system. Feedback from the contacts of
these relays is also taken to the system for processing.

Display Module
A display module placed above the SF/EF units provides plain English messages on the status
of the system and also wheel counts through a 4 line 20 characters alphanumeric display.

Other accessories
 Surge Voltage protection devices
 Filter unit

3. SALIENT FEATURES
 RDSO/SPN/177/2012 Ver. 3.0
 Meets CENELEC SIL-4 Safety Level Standards, as per this standards mature and
ruggedwith inherent fail-safety, highest reliability, availability and maintainability.
 Employs Phase reversal technique.
 Works between train speeds of up to 250 Kmph. Can work on 90-R, 52Kg & 60Kg
rails,with proper drilling on the rails.
 Works with 24V DC power supply with variation of +20% & -30%.
 Wrong operations totally avoided with hardware polarization & unique addressing of
units up to 255 combinations
 Protected with Fuses & lightening surge protectors.
 Event logger stores more than 14000 events for future analysis.
 Water logging on track does not affect the functioning of the system.
 Can work from -10°c to +70°c.
 Can be employed in both RE & Non-RE areas without any modification.
 2 Independent safety electronics in a single card frame for high availability.
 2 separate output Vital Relays for paralleling to achieve highest availability.
 Configurable as common wheel sensing detectors for both axle counting electronics.

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 4. PRINCIPLE OF WHEEL DETECTION

 Phase detection employed.

 Signals fed at 21Khz and 25Khz to Tx coils – at 40V to 70V.
 Phase of signal output of Rx compared with Tx.
 AT PD Module/Card :
 Under No wheel condition Tx and Rx will be IN-PHASE.
 Under wheel condition Tx and Rx signals will be 180° OUT-OF-PHASE.
 Under these conditions pulses are fed to CPU at 5V and 0V.
 Wheels above 550mm diameter only are detected.

Figure 5 : Solid wheel and spoke wheel of push trolley

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 Figure 6 : Wheel Detection - Train Wheel – Count

Figure 7 : Wheel Detection - Trolley Wheel - No Count

Figure 8 : Wheel Detection - Dip Lorry - No Count

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 5. INSTALLATION GUIDE LINES

An installation manual, data logger manual and pre-commissioning Check list are
supplied along with each unit for guidance.
The HA SSDAC units are placed in full GRS location boxes along with Relay box &
display unit.
A fused Tag block along with surge arrestors mounted on DIN rail is also fixed in
thelocation box.
A detailed standard schematic of interconnection between the external cables &
internal cables is provided.
The Quad cable between two units and between reset box and unit are to be
terminated.
A signal cable is to be connected between the reset box & the unit.
A power cable of 25 sq. mm (Aluminium) to be terminated.
In HA SSDAC dual system two set of coils are available. Both coils to be fixed
onopposite rails.
Distance between two coils should be 2 meters in diagonally.
Tx & Rx coils to be fixed on the rails by drilling 14 mm dia holes with the help of
thejig provided for fixing the distance of the holes from bottom on different rails.
These coils are fixed to the rails through tamper proof bolts.
Tx & Rx coils are supplied with 15m cables. Each pair has to be taken up to
thesystem independently through HDPE pipes.
Earthing should be provided with ≤1ohms resistance.
The cables to be meggered and continuity checked before powering the system.
The system is fully tested and adjusted for correct operation in the factory before
dispatch.
Only potentials at PD card are to be adjusted after installation.
RDSO have issued a pre commissioning check list which has to be complied in
allrespects before commissioning the system.

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 Figure 9 : Installation of Axle Detectors

Cabling requirement

Type of cable Description

Quad Cable Between location to station / relay room (1 Pair* - System
communication via OFC and 1 Pair - communication (system
toRESET BOX).
Quad Cable Between location to location (1 pair - System communication
FSK)
OFC Channel Between 2 stations for systems communication via OFC.

Signal Cable From relay room to Location-

8 Core for repeating Relays (VPR1, PPR1,VPR2 and
PPR2)2 Core for Reset Voltage from reset box to Axle
counter Location
From Relay Room to Reset Box:
14 Core signal cable for relay status and reset voltage to
system.
Power Cable 2 Core 25 Sq mm Al. From Station to
Location-For System input voltage (24VDC)
If Signal cable used to power up the system 6C for B24 and
6Cfor N24.

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Figure 10 : HASSDAC G36R Cable Plan
(Proposed)

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 6. EARTHING
Following is the checklist of earthing of HASSDAC at Location box and station:

Sr. No. Item Maintenance Free Conventional Earth

Earth (< 2 Ω ) (<2Ω)
1 SPDs Yes No
2 Quad Cable Yes No
3 Signal Cable Yes No
4 Power Cable Yes No
5 Location Box Yes No
6 Chassis No Yes
7 Relay Box No Yes
8 Filter Box No Yes
9 Reset Box No Yes
Note: - Chassis, Relay box, Filter box and Reset box should be connected to Conventional
Earth separately or made Floating Earth (Open).

7. RESET CRITERIA
For Single line working one reset box is provided at the station associated with SF or
EF unit of that track
In double line section each station will have two reset boxes corresponding to thetwo
units of the SF/EF for UP/Down lines.
The reset potential has to be within the range of 36 to 52V.
The system accepts reset under the following conditions:
 Initial power ON.
 When power fails & restores back when I/P voltage to the system fluctuates
beyond limits.
 The reset is applied to both the field units.
 When there is an in count at the entry & at least one out count at the exit
indicating the train has touched the end of block section.
The system will not accept reset under the following conditions:
 When the section is clear.
 When the system is waiting for pilot train.
 When there is an in count but no out count is registered. (Occupied state)
 When reset is given only from one station (not co-operative)
 When the system is in permanent error status.

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  When reset is applied at one end & the other end does not reset within 5
minutes.
 Removal of any of the PCB modules or fuses.
 Disconnection / damage of axle detector of coils.

8. RESET PROCEDURE
Two type of reset arrangements are available in HA SSDAC System:
Auto Reset
Manual Reset

Manual Reset is required only when both SSDAC system fails which is a remote
occurrence
Auto reset will be done if any one of the system fails.
Individual reset counters are available for Manual reset and Auto reset.

Auto Reset
Auto reset will be done when any one the system fails and another one is showing
Clear.
For Auto resetting and indication purpose relay contacts of VPR1,VPR2,PPR1
andPPR2 are given to reset box.
The reset box having intelligence for reading all relay inputs and take a decision to
reset the sections.
Through the relay contacts reset box will monitoring the section status . If anyone
system fails reset box will energies the auto reset.
The reset pulse time is 5 seconds.
After five seconds the failed section comes to preparatory mode.

Auto reset conditions

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 When the Auto reset condition is available, the Micro controller will start the inbuilt
timer for 10 sec. After the time period Micro controller will drive the Auto reset
miniature relay. The generated reset will applying to the system for 5 sec.
After one auto reset the counter of auto reset will be increased by one.
After one auto reset if failed system isn’t in preparatory mode the next auto reset will
be done only after another one section clear.(i.e. Another one train has to pass the
section.)

Manual Reset
The Manual reset should be done when, both system showing error.
The manual reset procedure is common as SSDAC system.
Press the reset button and turn and press the SM-KEY simultaneously.
The reset voltage will applied for both systems.
After successful reset both systems will shown the section is in preparatory mode.

9. CONFIGURATION SETTING IN CPU MODULES

(LINKS 18 TO 25)
SSDAC-G36-2DP-1S version system consists of a start fed unit (SF) & end fed unit
(EF) which are located at either end of a block section. With the common hardware &
software of both the units, the configuration of SF/EF have to be assigned uniquely.
This can be achieved through jumper settings on links 18 to 25 provided in the CPU
cards.
Figures below indicate the jumpers as seen from top view of component side. The
physical & logical setting for SF is shown below. This setting has to be carried out on
both CPU1 & CPU2 cards.

Figure 11 : 2DP-1S Configuration Setting of SF (Links 18 to 25 - Physical & Logical setting)

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LK25 LK24 LK23 LK22 LK21 LK20 LK19 LK18
0 0 0 0 0 0 0 1

2DP-1S Configuration Setting of SF (Links 18 to 25 - Physical & Logical setting)

LK25 LK24 LK23 LK22 LK21 LK20 LK19 LK18

0 0 0 0 0 0 1 0

Figure 12 : 2DP-1S Configuration Setting of EF (Links 18 to 25 - Physical & Logical setting)

10. ADDRESS SETTING IN CPU MODULES (LINKS 10

TO 17 )
In each of the SF & EF units, unique address has to be set for CPU1 & [Link] this
purpose jumpers 10 to 17 are to be used. Addresses of 1, 2 up to 252 are assigned to
the CPU’s of SF. For the processors of EF addresses of 3 & 4 up to 254 are assigned.
The table below indicates the local addresses assigned to the CPU’s.
Logical setting of the jumper LK10 to LK17 for SF & EF are indicated below.

Figure 13 : CPU addressing of SF

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 Figure 14 : CPU addressing of EF

The table below indicates the summary of addressing scheme of SF & EF units.

SSDAC UNIT SF-START FED GROUP EF-END FED GROUP

LOCAL LOCAL
ADDRESS ADDRESS
SSDAC 1-2 CPU-1 001 CPU-1 003
CPU-2 002 CPU-2 004
SSDAC 3-4 CPU-1 005 CPU-1 007
CPU-2 006 CPU-2 008
SSDAC 5-6 CPU-1 009 CPU-1 011
CPU-2 010 CPU-2 012
▼ ▼ ▼ ▼ ▼

▼ ▼ ▼ ▼ ▼

▼ ▼ ▼ ▼ ▼

SSDAC CPU-1 251 CPU-1 253

‘n’ CPU-2 252 CPU-2 254

For setting the configuration & address, berg sticks are provided with links. These links
have to be set as per the above details.

Note: Under any deviation from the above settings of configuration, & addressing scheme, the
SSDAC – 2DP-1S system does not boot and enters into wrong configuration status &
error message 59, “Invalid Configuration” is displayed.

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11. EVENT LOGGING THROUGH SM-CPU OR EVENT
LOGGER CARD

SM-CPU or Event Logger Card:

 Monitors the SSDAC system and logs vital events during normal and error
operation with date and time stamp.
 As many as 95 different events are recorded.
 Optional display connected to Event Logger Card displays the communication
errors happening in Real-time which aids in assessing the health of
communication channel.

Event logged during normal operation

 Communication status ok.
 Vital and Preparatory Relay pickup / drop.
 Reset operations.

Event logged during error operation

 Communication link fail.
 System down due to failure of any card.
 Vital and Preparatory Relay error status.
+5 VDC variations.
 Error.

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 run time and boot reset the system
time.
08 PEER_CPU_MISSI Missing of the any one Place the CPU module
NG of the CPU module missing in the slot and
during run time and reset the system
boot time.
09 COMM_LU1_TO_ EF CPU1 could not 1. Check MS Coupler
US1_FAILURE transmit to remote SF 6,make proper
( US- CPU1Due to connection.
Upstream) communication 2. Check CPU1 &
problem COMM1 replace
iffound bad
10 COMM_LU1_TO_ EF CPU1 could not 1. Check MS Coupler
US2_FAILURE transmit to remote 6,make proper
unit SF CPU2. Due connection.
tocommunication 2. Check CPU1 &
problem COMM1 replace
if
found bad
11 COMM_LU1_TO_ SF CPU1 could not 1. Check MS
DS1_FAILURE transmit to remote Coupler11, make
(DS-Downstream) unit EF CPU2. Due proper connection.
tocommunication 2. Check CPU1 &
problem COMM2 replace
iffound bad
12 COMM_LU1_TO_ SF CPU1 could not 1. Check MS
DS2_FAILURE transmit to remote Coupler11, make
unit EF CPU2. Due proper connection.
tocommunication 2. Check CPU1 &
problem COMM2 replace
iffound bad
13 COMM_US1_TO_ EF CPU1 could not 1. Check MS Coupler
LU1_FAILURE receive from remote 6,make proper
unit SF CPU1. Due connection.
tocommunication 2. Check CPU1 &
problem COMM1 replace
iffound bad
14 COMM_US2_TO_ EF CPU1 could not 1. Check MS Coupler
LU1_FAILURE receive from remote 6,make proper
unit SF CPU2. Due connection.
tocommunication 2. Check CPU1 &
problem COMM1 replace if

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 found bad

15 COMM_DS1_TO_ SF CPU1 could not 1. Check MS

LU1_FAILURE receive from remote Coupler11, make
unit EF CPU2. Due proper connection.
tocommunication 2. Check CPU1 &
problem COMM2 replace
iffound bad.
16 COMM_DS2_TO_ SF CPU1 could not 1. Check MS
LU1_FAILURE receive from remote Coupler11, make
unit EF CPU2. Due proper connection.
tocommunication 2. Check CPU1 &
problem COMM2 replace
iffound bad
17 COMM_LU2_TO_ EF CPU2 could not 1. Check MS Coupler
US1_FAILURE transmit to remote SF 6,make proper
CPU1 connection.
Due to communication 2. Check CPU1 &
problem COMM1 replace
if
found bad.
18 COMM_LU2_TO_ EF CPU2 could not 1. Check MS Coupler
US2_FAILURE transmit to remote 6,make proper
unit SF CPU2. Due connection.
tocommunication 2. Check CPU1 &
problem COMM1 replace
iffound bad.
19 COMM_LU2_TO_ SF CPU2 could not 1. Check MS
DS1_FAILURE transmit to remote Coupler11, make
unit EF CPU1. Due proper connection.
tocommunication 2. Check CPU2 &
problem COMM2 replace
if
found bad
20 COMM_LU2_TO_ SF CPU2 could not 1. Check MS
DS2_FAILURE transmit to remote Coupler11, make
unit EF CPU2. Due proper connection.
tocommunication 2. Check CPU2 &
problem. COMM2 replace
iffound bad.
21 COMM_US1_TO_ EF CPU1 could not 1. Check MS Coupler
LU2_FAILURE receive from remote 6,make proper
SF CPU2 connection.

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22 PD1_SUP_LOW PD1 module 1. Make the
supervisory is low connection Properly
for3 seconds 2. Replace TX1/RX1
Cause 1: TX1/RX1 coil
coilsnot connected 3. Replace CPU1/CPU2
properly 4. Replace PD1 module
Cause 2: TX1/RX1
coilgone bad
Cause 3:
CPU1/CPU2gone
bad
Cause 4: PD1 module
gone bad
23 PD2_SUP_LOW PD2 module 1. Make the
supervisory is low connection Properly
for3 seconds 2. Replace TX1/RX1
Cause 1: TX2/RX2 coil
coilsnot connected 3. Replace CPU1/CPU2
properly 4. Replace PD2 module
Cause2: TX2/RX2
coilgone bad
Cause 3:
CPU1/CPU2gone
bad
Cause 4: PD2 module
gone bad.
24 PD1_PULSING Error occurs when any 1. Make the
one sensor is connection Properly
influenced two or 2. Replace TX1/RX1
more times. coil
Cause 1: Loose 3. Replace
contacts of PD1module.
TX1/RX1
connections
Cause 2: PD1 module
gone bad.
25 PD2_PULSING Error occurs when any 1. Make the
one sensor is connection Properly
influenced two or 2. Replace TX2/RX2
more times. coil
Cause 1: Loose 3. Replace
contacts of PD2module.
TX2/RX2
connections
Cause 2: PD2 module

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 gone bad.

26 PD_STATE_MISSI Error occurs when 1. Make the

NG both sensors are connection Properly
influenced in 2. Replace
sequence TX1/RX1,
Cause 1: Loose TX2/RX2 coil
contacts of 3. Replace PD1,
TX1/RX1,TX2/RX2 PD2module.
connectionsCause 2: 4. Check rail drilling
PD1, PD2 measurements
module gone bad properly & rectify the
Cause 3: Rx phase in driller.
dummy wheel setting
in PD1 & PD2
modulenot set
properly with dummy
wheel.
Cause 4: If Rx coil is
mounted down than
prescribed in the manua
27 PD_SUP_PULSA If supervisory 1. Make the
TING signals pulsates more connection Properly
than 4times 2. Replace
Cause 1: TX1/RX1 or TX1/RX1,
TX2/RX2 coils not TX2/RX2 coil
connected properly 3. Replace CPU1/CPU2
Cause2: TX1/RX1, 4. Replace PD1,
TX2/RX2 coil gone PD2module
badCause 3:
CPU1/CPU2 gone bad
Cause 4: PD1, PD2
module gone bad.

28 PD_STATE_FAIL Error occurs when any 1. Make the

wheel counting state connection Properly
sequence is missing 2. Replace
Cause 1: TX1/RX1 or TX1/RX1,
TX2/RX2 coils not TX2/RX2 coil
connected properly 3. Replace CPU1/CPU2
Cause2: TX1/RX1, 4. Replace PD1,
TX2/RX2 coil gone PD2module
badCause 3:
CPU1/CPU2
gone bad

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 Cause 4: PD1, PD2
module gone bad
29 PD_NOT_SENSING Error occurs when 1. Make the
both the PD modules connection Properly
do not sense the wheel 2. Replace
for more than 3times TX1/RX1,
Cause 1: TX1/RX1 or TX2/RX2 coil
TX2/RX2 coils not 3. Replace PD1,
connected properly PD2module
Cause2: TX1/RX1,
TX2/RX2 coil gone
badCause 3: PD1,
PD2
module gone bad.

30 PREPARATORY_ No/Improper feedback 1. Make the

REL from Preparatory A connection Properly
AY_A_FAILURE relay 2. Replace Relay
Cause 1: Loose Driver1 module
contacts of 3. Replace
Preparatory relay CPU1/CPU2module.
connections
Cause2: Relay Drive
1module
gone bad
Cause 3:
CPU1/CPU2module
gone bad.
31 PREPARATORY_ No/Improper feedback 1. Make the
REL from Preparatory B connection Properly
AY_B_FAILURE relay 2. Replace Relay
Cause1: Loose Driver2 module
contacts of 3. Replace CPU1/CPU2
Preparatory relay
connections
Cause2: Relay Drive
2module gone bad
Cause 3:
CPU1/CPU2
module gone bad.
32 VITAL_RELAY_A No/Improper feedback 1. Make the
_FAILURE from Vital Relay A connection Properly
relay 2. Replace Relay Driver
Cause1: Loose 1 module

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 contacts of Vital relay 3. Replace CPU1/CPU2
connections
Cause2: Relay Drive
1module gone bad
Cause 3:
CPU1/CPU2
module gone bad.
33 VITAL_RELAY_B No/Improper feedback 1. Make the
_FAILURE from Vital Relay B connection Properly
relay 2. Replace Relay
Cause1: Loose Driver2 module
contacts of Vital relay 3. Replace CPU1/CPU2
connections
Cause2: Relay Drive
2module gone bad
Cause 3:
CPU1/CPU2
module gone bad
34 DIRECT_OUT_CO OUT COUNT Reset the system after
UNT registered Without IN the train has passed
COUNT, the exit DP.
35 TRANSIENT_POW Power failure at Make the connection
ER Downstream Properly
_FAILURE_DS1 CPU1Cause 1:
Loose contacts of
power
connections
36 TRANSIENT_POW Power failure at Make the connection
ER Downstream Properly
_FAILURE_DS2 CPU2Cause 1:
Loose contacts of
power
connections
37 TRANSIENT_POW Power failure at Make the connection
ER Upstream CPU1 Properly
_FAILURE_US1 Cause 1: Loose
contacts of power
Connections.
38 TRANSIENT_POW Power failure at Make the connection
ER Upstream CPU2 Properly
_FAILURE_US2 Cause 1: Loose
contacts of power
connections
39 INVALID_NETWO When CPU address [Link] the address
RK iswrongly set settings as per
_ADDRESS
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 instruction manual.
2. reset the system
40 INCORRECT_CO This is a Boot Up 1. Replace both CPU1
DE_CRC error. When CRC of &CPU2 card in both
the code mismatches the units
with the 2. Inform the Company
stored CRC
41 INVALID_CONFI When unit type and Change the address
GURATION address of CPU are and configuration
wrongly set. settings as per the
requirement and reset
the system.
42 INVALID_COUNTS Train with 10,000 Reset the system
wheels.
43 RAM_TEST_FAILE This is a Boot up 1. Replace both CPU1
D errorwhen RAM (In- &CPU2 card in both
built memory of the units
Micro 2. Inform the Company
controller) has failed

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 12. PRECAUTIONS TO BE TAKEN FOR TROUBLE
FREE OPERATION
Power Supply-24DC:

Use Axle Counter type , ripple free Charger

Use 120 AH battery with adequate life
Use 25 sq mm AL cable for feeding power to the system
Provide Class ‘B’ Surge Protector at source of 24 V DC in station
Avoid tapping of different loads to the power source of Axle Counter

Quad Cable:
Loss should be less than 30 dB between SF and EF(1.2 db/km)
Every joint adds loss to the cable, minimize joints and take care for making good
permanent joints.
Insulation resistance to be more than 10 M ohms at 500 V DC between conductors,
between pairs and between wire and an armour.
Loop resistance to be within 56 ohms/km.
Maintain continuity of armor between SF and EF & earth at both ends.

Parallel circuits

It has come to notice that usage, termination and wiring of quad cable is far from
satisfactory for trouble-free working of digital axle counters. Basic issue pertains to
electromagnetic interference from parallel circuits in the cable and [Link]
guidelines are recommended to enhance performance of DAC systems.
Long parallel circuits shall be avoided in the same quad. Requirement is that parallel
circuit shall be as far spaced as possible. So, one long and one short circuit can be
accommodated in same quad but not both long circuits.
DAC circuits in BPAC of up and down lines in double line sections shall be in separate
quads and kept one/two quads away from each other as far as possible to avoid mutual
interference due to long parallel circuits.
DAC circuits in location shall not bunched along with parallel relay/power circuits.
Relay circuits are known to generate switching transients that can couple enough
energy in parallel circuits nearby and interference with low power circuit’s data
circuits.
Any other parallel wiring (relay circuits/power circuits/earthling wires etc.) shall cross
DAC circuits at perpendicular and any parallel portion shall be kept at minimum
150mm lateral distance away from the wiring for DAC circuits.

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 Relay circuits shall preferably be not taken in the same cable as DAC circuits. In
unavoidable circumstances relay circuits shall be in furthest quad (spatially) from the
one containing DAC circuits.

Twisting of cable pair

Twisted pairs are required to avoid mutual interference between low level ac signals.
Even short lengths of non-twisting (few inches) can couple enough differential mode
electromagnetic signals to interfere with low voltage DAC communication signals.
Quad cable twisting shall be ensured during termination so that minimum one twist
per inch is maintained till the last inch into terminations.
Any wiring from quad cable terminations to equipment shall be done by using twisted
singles of indoor signaling cable (1mm square) or any other approved indoor twisted
pair cable.
Signaling cable or any other untwisted pair cable shall never be used in DAC
communication circuits to avoid intermittent type of failure.

Earthing

Earth resistance to be less than 1 ohms.

If not archived by single earth provide multiple earth and parallel then.

TX and RX coils

Fix coils by marking holes on different rails with the help of jig provided.
Drill 14 mm holes horizontally.

Figure 15 : Drilling of holes with the help of jig

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Prevention of damage to Axle Detectors

Axle Detectors are vulnerable for damage due to Tamping machine.

Provide warning boards for caution.
Provide deflectors to avoid damage to coils by hanging items on train.
Run cables from coils though HDPE pipes to avoid damage to coils and cables
bymiscreants and rodents.
Pack the space for cable entry in location box with sand and seal the top surface with
bitumen compound /cement plaster.

Figure 16 : Caution Board

Trolley Movement
Push trolleys with solid wheels drive the system to error mode due to wobbling of the
wheels
Use spoked trolley wheels
Mount TX/RX coils on outer rails of the curves
Provide trolley protection circuit.

Wiring & Terminations

Preferably quad cable shall be terminated in cage clamp type terminals that provide
solid 360 degree surface connection and sufficient pressure on the wire to make a good
electrical contact.
Cables shall be terminated at the bottom portion of location and equipment and their
wiring done at higher levels inside location. This will help in keeping wiring of
different types segregated from each other. All earth wires and surge protection
devices also shall be kept at the lower levels for the same reasons.
Wiring and cabling shall not be bent abruptly and shall be given sufficient bending
radius to ensure that conductors inside the cabling/wiring are not damaged due to
bending. Wiring shall be properly supported by channels toughing and other means
to ensure that connections are not under pressure due to wire hang.
Wiring and cabling shall not be supported at any sharp edged object to ensure that
conductors are not damaged during their installation/maintenance.

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 13. MAINTENANCE

Maintenance schedule as recommended by OEM

The system needs very little maintenance in terms of power supply, quad cable
condition, and earthing, proper voltages from RX coils to PD cards.
The table below gives the maintenance schedule.

Periodicity Maintenance
Weekly • Check for the proper voltage at the battery source for the unit
Fortnightly • Check and record the readings of
• Power supply module
• PD module
• Check the coil Voltages
Half yearly/ Yearly • Replace defective parts if any
Every 10 Years • Power Supply/DC-DC Converter modules
• must be replaced

Monitoring points of HA SSDAC

• Voltage Readings at different monitoring points is shown below.

Module Monitoring point Expected values

DC-DC Converter +5VDC and GND 4.75to5.25V DC
+18VDC and GND 17.75to18.25VDC
+12VDC and GND 11.75to12.25VDC
-12VDC and GND 11.75to12.25VDC
+24VDC and GND 22V to 26V DC
CPU 1 EN1B O/P and GND 11.5Vto12.5VDC
(for SF, CF, 3DP1S units) 11.5V to 12.5V DC
EN1A O/P and
GND(for EF, CF)
CPU 2 EN2B O/P and GND 11.5V to 12.5V DC
(for SF, CF, 3DP1S units) 11.5V to 12.5V DC
EN2A O/P and
GND(for EF, CF)
RELAY DRIVE 1 (for VITAL RLY A O/P (+) > 20V DC
EF, CF) VITAL RLY A O/P (-)
RELAY DRIVE 2 (for VITAL RLY B O/P (+) > 20V DC
SF, CF, 3D units) VITAL RLY B O/P (-)

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Module Monitoring point Expected values
Without wheel With wheel
PHASE DETECTOR RX-SIG and GND 900 mV to 1.2 V AC <
350mV
(PD1 and PD2 ) SUP-OUT and GND AC
WHEEL-M-OUT and GND 4V to 5V DC 3V to 3.9V DC
WHEEL-S-OUT and GND 4.5V to 5V DC < 100mv
RX-PH-SIG and GND 4.5V to 5V DC < 100mv
SUP-ADJ and GND 10 V to 12V DC < 500mv
4V to 5V DC 3V to 3.9V DC

14. ADVANCED APPLICATIONS OF HA SSDAC-G36R

 Block proving single / double line
 Intermediate Block Signaling IBS
 Automatic Block Signaling ABS

Intermediate Block Signaling – IBS

 The line between two stations may where required be divided into two sectionknown
as “Intermediate Block Section".
 In order to increase the traffic over the lengthy block sections between the stations.
 In order to reduce human intervention in operating the train movement

Automatic Block Signaling – ABS

 The line between two stations may where required be divided into a series of section
known as "Automatic Block Signaling Section".
 Space interval between the trains are secured automatically by using track circuits or
axle counters.
 In order to increase the traffic over the lengthy block sections between the stations.
 In order to reduce human intervention in operating the train movement.
 Entry into each block signaling section is protected by a color light Multiple Aspect
Stop Signal.
 Track Circuits or Axle Counters to controls the aspects of the Signal.
 By using HA SSDAC we can avoid external auto reset circuits for auto section.
 In build reset box auto reset circuit will help us to achieve it.

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Communication

 In HA SSDAC one unit having two modems. Which is giving voice channel output V.23?
 To avail the high availability and avoid common mode error through the
communication one channel in Quad cable another one channel in OFC.

15. COMMUNICATION INTERFACE

(i) Communication between SF – DP and EF – DP through Quad cable
 The physical communication between SF – DP and EF – DP is very vital for proper
 working of the system. The Quad cable termination has to be done with care after
making
 Quad cable jointing near location boxes.
 The selection of proper pair, loop resistance, dB loss, IR value between cable pair, IR
value between cable pair with other pairs, IR value between cable pair and Armor /
shield, cross talk are very important parameters to be taken care and it should be within
the limits and suitable for Data communication as prescribed in the RDSO
recommended pre commissioning check list.
 The SSDAC system uses two-wire CCITT standard V.23 half duplex communication
protocol at 1200 bits/second.
 The maximum transmission distance depends on the dB loss of the Quad cable
selected pair and should be less than 30 dB at 2000 Hz.
 As a reference a good quality communication cable will have dB loss of 1.0 to 1.3 dB /
Km and maximum loop resistance of 56ohm/KM with capacitance of 45nF/Km.
 The IR value shall be measured with Megger with 500 Volts range and should be more
than 10 Meg Ohm.
 The cross talk values should be more than 55 dB for both NEXT and FEXT.
 If the distance of the Block is more than 12 Km’s the termination Resistors of type
Carbon
 Film 600 Ohms Half Watts should be terminated at both the ends of Quad cable pair
used
 for matching the Impedance of the Quad cable as per CCITT recommendations.
 For better reliability the Right pair identified as below of star quad cable should be
used with
 proper pair terminations. The Quad cable used should not be loaded with anotherpair.

- 34 -
 Figure 17 : Quad cable 0.9 mm
Quad 1 : 1st Pair > Blue – White 2nd Pair > Red –
GreyQuad 2 : 5th Pair > Brown – White 6th Pair > Red -
GreyQuad 3 : 3rd Pair > Green – White 4th Pair > Red –
GreyQuad 4 : 7th Pair > Orange – White 8th Pair > Red –
Grey

(ii) Communication between SF – DP and EF – DP through OFC

 The physical communication between SF – DP and EF – DP when it is connected
through OFC, the termination should be done on any one of voice channel designated
for signaling and safety purpose.
 The OFC system Transmit and Receive gain of that particular channel should not be
kept with any amplification gain factors. These parameters should be checked and
confirmed with the responsible Telecom Staff of the section. The connection between
DP location box to nearest OFC room should be wired with Quad cable only and all
the tests as per Section 3.0 should be followed.
 Caution should be taken by the division that OFC systems should not be switched off
without informing the concern signaling staff during OFC maintenance as switching
off of the OFC system will fail the system and Block section. This needs Resetting the
Axle Counter / section after switching on the OFC system.
 24 VDC Power Supply Arrangements
 The SSDAC system is Microprocessor based Electronics Equipment and needs a stable
 power supply for its operation. Since the SSDAC system is Fail Safe system any
problem in system, power supply or communication link, the system goes to Error
mode.
 For the proper operation of the SSDAC system 120 AH Batteries and Axle Counter
suitable Battery Chargers needs to be provided in the station. The output 24 VDC
power from Battery should be connected to both SF – DP and EF – DP at respective
[Link] power supply for Reset Box at respective stations also should be powered
with the same 24 VDC power supply.

- 35 -
 At the input of the Battery Charger 220 VAC Surge Protection devices needs to be
provided. At the output of the Battery 24 VDC Surge Protection device needs to be
connected to protect the systems from lightning and high voltages.
 The 24 VDC power to Reset Box should be taken directly from Battery output (before
Surge Protection device) with 2 Amps Slow blow or HRC fuse there by protecting
Reset Box from any high voltages entering from power cables. The output of the
Surge Protection device should be sent to individual location box to power the DP’s
through 6 Amps slow blow or HRC fuse.
The Battery charging and discharge test should be conducted to assess the condition of
Batteries by switching off the charger for 15 minutes with SSDAC systems switched
on and check for Battery voltages between 22 – 30 VDC before commissioning the
SSDAC systems.

16. DO’S AND DON'TS

Sr. No DO’s

1 The interconnection drawings are to be followed for connecting the Transmitter

and Receiver Coils. Tx1 is 21 K Hz, Tx2 is 25 KHz & Rx1 and RX2 coils
are 21 KHz & 25 KHz, respectively
2 Ensure that Receiver and Transmitter coil cables are laid in different pipes.
3 Ensure that both the TX coils & RX coils are having proper alignment on Rail.
4 Ensure that packing of sleepers with ballast on both sides of Axle detector is
proper
5 Check that metal sheaths of the outdoor cable are connected to earth at both
ends
6 The recommended cables for wiring of the system at site should be used
7 The steady battery voltage 24 V should be maintained.

8 The cable connections should not be loose.

9 The M.S Coupler connectors of SSDAC are checked and maintained firmly.

10 Preparatory Reset should be done only after ensuring that there is no train.

11 It is recommended that heat resisting paint to be used on the apparatus case so

that the temperature inside apparatus case is maintained lower in comparison to
other normal paints.

- 36 -
 Sr. No DON’Ts
1 Don’t cut or join the Transmitter/Receiver cables supplied along with the coil.
It would result in change of levels of signals.
2 Don’t remove the modules from SSDAC Units under POWER ON condition
ofsystem.
Remove module if necessary after switching OFF the power to the Unit.
3 Local Address of the CPU-1 and CPU – 2 and configuration settings of
thesystem
should not be changed at the field.
4 The hardware of Communication module and Relay Drive module are similar
for all systems. However their positions of mounting are different in different
unit types. These modules have to be equipped correctly after verifying the
drawings as mentioned in the installation manual (DRG-1 to DRG-4) which
indicates their positions
5 Caution Board has to be placed near the SSDAC Axle detectors to avoid
damage to the Coils from packing machines

17. BACKUP SPARES (Recommended 1 set for 5 systems)

[Link] SSDAC Spares Quantity

1 Phase Detector modules1&2 (PD1 and PD2) 2
2 CPU1 and CPU2 Modules 2
3 Communication Modules 2
4 Relay drive Module 1
5 Event Logger/SM-CPU Module 1
6 DC-DC converter Module 1
7 Axle detectors 21 KHz/25KHz (TX coil) 2
8 Axle detectors 21 KHz/ 25 KHz (RX coil) 2
9 Hardware for mounting axle detectors 1
10 MS circular connectors (6 No.) 1
11 Reset box RB 1
12 SSDAC unit (housing with mother board, without 1
modules)
13 Relay Box 1

- 37 -
 18. RECOMMENDED TOOLS
Sr. Tools Quantity
No
1 PC/Laptop for downloading event logger data for 1
analysis and report generation
2 Pure sine wave Digital Multimeter (Fluke make 187 1
or Rishab make 18S or similar
3 Train simulator 1
4 Extender module 1
5 Dummy wheel 1
6 Ring spanner 17-19,24-26 1
7 Open end spanner 17-19, 24-26 1
8 Socket spanner with handle 1
9 Torque wrench 1
10 Screw Driver No. 902 1
11 Screw Driver No. 935 1
12 Marking jig for drilling 1

19. MAINTENANCE LOG SHEET FOR HA-SSDAC

(System 1 Channel 1)

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