Trouble Shooting Manual - Stationary ACDs

RAKSHA KAVACH™ Konkan Railway Corporation Ltd
RAKSHA KAVACH
TROUBLESHOOTING
AND
MAINTENANCE MANUAL
STATIONARY ACDs
Konkan Railway Corporation Limited

(A Government of India Undertaking)
Belapur Bhavan, Plot No. 6, Sector 11, P.O Box No. 9,
CBD Belapur, Navi Mumbai – 400 614
Stationary Troubleshooting & Maintenance Manual Version 1.1 Dt.5th February, 2008 Page 1 of 45
TROUBLESHOOTING AND
MAINTENANCE MANUAL
STATIONARY ACDs
Version 1.1, Date: 5th February, 2008
Copyrights
No part of any content or document may be reproduced in any form or
incorporated into any information retrieval system, electronic or mechanical
without prior written consent from Konkan Railway Corporation Limited.
Copyright  2004 by Konkan Railway Corporation Ltd. All rights reserved.
Disclaimer
Every effort has been made to ensure that the information presented herein is
accurate and complete. This manual has also been reviewed for accuracy.
Conversely, different versions of this product have different features and
capabilities, and this manual reflects only one of those versions.
Information presented in this document is subjected to change without notice.
Reference document:
Functional Requirement Specification (FRS) of Anti Collision Device (ACD) RDSO
/ SPN / 182 / 2004 Version 1.0 with amendment 3 and upto 5th deviations
approved by Railway Board.
Intended Users
This manual is intended for use by the Installation, Troubleshooting and
Maintenance personnel looking after Stationary ACDs of the RAKSHA KAVACHTM
TABLE OF CONTENTS
1 ABBREVIATIONS AND DEFINITIONS .........................................................................................................5
3 INTRODUCTION TO STATION ACD...........................................................................................................14
4 STATION ACD TROUBLESHOOTING AND MAINTENANCE ...............................................................15
4.1 STATION ACD INTERFACING WIRING DIAGRAM.........................................................................................15
4.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF STATION ACD...........................16
4.3 PREVENTIVE MAINTENANCE FOR STATION ACD ..........................................................................20
4.4 MANDATORY SPARES FOR STATION ACD .......................................................................................20
5 INTRODUCTION TO MANNED LC GATE ACD........................................................................................22
6 MANNED LC GATE ACD TROUBLESHOOTING AND MAINTENANCE ............................................23
6.1 MANNED LC GATE ACD INTERFACING WIRING DIAGRAM ........................................................................23
6.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF MLCG ACD ................................24
6.3 PREVENTIVE MAINTENANCE FOR MLCG ACD................................................................................30
6.4 MANDATORY SPARES FOR MANNED LC GATE ACD......................................................................30
7 INTRODUCTION TO UNMANNED LC ACD ..............................................................................................32
8 UN-MANNED LC ACD TROUBLESHOOTING AND MAINTENANCE .................................................33
8.1 UN-MANNED LC ACD INTERFACING WIRING DIAGRAM............................................................................33
8.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF UMLC ACD ................................34
8.3 PREVENTIVE MAINTENANCE FOR UNMANNED LC ACD ..............................................................39
8.4 MANDATORY SPARES FOR UNMANNED LC ACD ...........................................................................39
9 INTRODUCTION TO ACD REPEATER.......................................................................................................41
10 ACD REPEATER TROUBLESHOOTING AND MAINTENANCE ...........................................................42
10.1 ACD REPEATER INTERFACING WIRING DIAGRAM ......................................................................................42
10.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF ACD REPEATER........................43
10.3 PREVENTIVE MAINTENANCE FOR REPEATER ACD .......................................................................45
10.4 MANDATORY SPARES FOR REPEATER ACD ....................................................................................45
LIST OF FLOWCHARTS
FIGURE 1: STATION ACD INTERFACING W IRING DIAGRAM .........................................................................................15
FIGURE 2: FLOWCHART FOR STATION ACD & ACD-M PROBLEMS TROUBLESHOOTING ...........................................18
FIGURE 3: FLOWCHART FOR INPUTS (CONTROL PUSH BUTTONS OF SM CONSOLE) TROUBLESHOOTING................19
FIGURE 4: MANNED LC GATE ACD INTERFACING W IRING DIAGRAM .........................................................................23
FIGURE 5: FLOWCHART FOR BOTH FLASHER AND HOOTER UNIT TROUBLESHOOTING...............................................26
FIGURE 6: FLOWCHART FOR COMMUNICATION PROBLEM TROUBLESHOOTING..........................................................27
FIGURE 7: FLOWCHART FOR SINGLE FLASHER UNIT TROUBLESHOOTING ..................................................................28
FIGURE 8: FLOWCHART FOR GATE SENSING PROBLEM TROUBLESHOOTING .............................................................29
FIGURE 9: UN-MANNED LC ACD INTERFACING W IRING DIAGRAM .............................................................................33
FIGURE 10: FLOWCHART FOR COMMUNICATION PROBLEM TROUBLESHOOTING........................................................36
FIGURE 11: FLOWCHART FOR BOTH FLASHER AND HOOTER UNIT TROUBLESHOOTING. ...........................................37
FIGURE 12: FLOWCHART FOR SINGLE FLASHER UNIT TROUBLESHOOTING ................................................................38
FIGURE 13: ACD REPEATER INTERFACING W IRING DIAGRAM ....................................................................................42
FIGURE 14: FLOWCHART FOR COMMUNICATION TROUBLESHOOTING.........................................................................44
1 Abbreviations and Definitions

1.1 Abbreviations
Abbreviation Description
ABU Autom atic Brak ing U nit
ACD Anti Coll is io n Devic e

ACD-M ACD – Mai ntena nce
CCU Charge Co ntr ol Unit

DPXZ Dead Point Crossing Zone
DTU Data Term inal Uni t
DMU Diesel Multiple Uni t
EB Em ergenc y Brak e
EMU Elec tric Mul tipl e Un it
ESD Electro Static Discharge
FSS Firs t Sto p S ign al
GPS Global Pos itioning Sys tem

IBL Intelligent Braking Logic
ICS In ter-Coc k Switch or Toggle S witc h
I&C Installation and Commissioning
LC Level Cros sing
LCD Liquid Crys ta l Dis pl ay
LED Light Em itti ng Diode
LF Loc o Forem an
LSS Las t S top Signa l

MLCG Manned Level Cross ing Ga te
ME MU Ma inline Elec tr ic Mul tip le Unit
MSOT Maxim um Speed Over Turn O ut
NB Norm al Brak e
RDSO Res earc h, Design , and Stan dards Orga ni zation
REP Repea ter

RIU Remote Input Unit
RM Radio Mod em
Abbreviation Description
SLR Self Generating Luggage Cum Guard Van

SM Station Master
SOS Save our Souls (Emergency)

STN Station
TID Track Identification Digit

TID-FS Track Identification Digit - Fai l Saf e
TID-GR Track Identification Digit - Group
TID-SR Track Identification Digit - Speed Res tric tio n
UMLC Un-Mann ed Le vel Cr os s ing
VFD Vacuum Flores c ent Dis pla y
1.2 Definitions
Automatic Braking Unit (ABU): It is a Sub-System of Loco ACD used for
automatic application of Normal/Emergency Brakes.
ACD: Anti-Collision Device is a micro processor based control system with built-in
wireless data communication; when implemented, it acts as a non-vital safety
shield over the existing signal based train protection systems. Depending on the
application location, there are different ACDs, viz Loco ACDs, Guard ACDs for
passenger trains, Guard ACDs for Goods trains, Station ACD, LC ACD, ACD
Repeater, TID Assigning ACD and Loco Shed ACD.
ACD Guard Van: It is a Guard Van provided with a functional Guard ACD.
ACD Locomotive: It is a ‘light’ Locomotive fitted with Loco ACD or self propelled
vehicles (defined as ‘Train’ in G & SR of IR) fitted with Loco ACD.
ACD Network: It is a network of different types of ACD units, namely Loco ACD,
Guard ACD, Station ACD, Level Crossing Gate ACD, Loco shed ACD, TID
assigning ACD and Repeater ACD. Each ACD is an intelligent microprocessor
based system, which uses a GPS receiver ( for Loco and Guard ACDs ), data
radio modem for communication with other ACD units and interfaces with track
circuits and point status inputs, speedometer, self-propelled vehicles and other
external devices, on need basis
ACD Repeater: It is a unit installed at locations identified as Inter-ACD
communication shadow zones along with Radio antenna, Interconnecting cables,
Power supply modules, Batteries and other accessories.
ACD Territory: It is a section of Railway system in which ACD Network has been
installed and commissioned.
ACD Train: It is a train fitted with Loco ACD and Guard ACD or a DMU EMU/
MEMU having Loco ACDs at either ends or any DMU with locomotive in the
middle.
‘Cancel’ Push Button: It is a push button used on Driver’s console for
cancellation of ‘Side-Collision’ and/or ‘Train Parting’/‘Jumbling’ condition as well
as ‘SOS’ condition (which was generated by Driver through pressing of twin SOS
buttons provided on the Console). It is also used for SOS cancellation generated
by self in case of Guard ACD and Station ACD.
Dead Points & Crossing Zone (DPXZ): It is an identified ‘points and crossing
zone’ at the station where the Deviation Count Theory is not applicable due to
complex track layout or due to existence of GPS shadow zone.
Deviation Count Theory: It is a technique by which both loco and guard ACDs
automatically deduce using input from GPS receiver the change in their Track IDs
when they negotiate a point zone already pre-fed as data in the deviation count
table of that station. Accuracy & efficacy on Points on a curve, Ladder points,
Diamonds & Slips to be spelt out clearly by supplier.
DZ Station: It is a station having one or more DPXZ (s).
Emergency Brake: Emergency Brake is the brake applied by the ACD system
wherein brake pipe pressure in locomotive & its formation is reduced from 5.0
Kg/cm2 to 0 Kg/cm2 to control speed of train to desired limit.
Gate Sensing Switch: It is an electrical interface provided at the Manned LC
Gate to detect ‘open’ / ‘closed’ status of the Gate.
GPS: Global Positioning System (GPS) is a satellite-based system using which a
GPS Receiver can determine its exact location on earth. It comprises of a
constellation of 27 Earth-orbiting Satellites (24 in operation and three as backup).
The orbits are arranged so that at anytime, anywhere on Earth, at least four
satellites are visible in the sky.
GPS Receiver: GPS Receiver receives signals from the GPS satellites, calculates
its location on earth in terms of latitudes and longitudes and provides these data
to any host CPU through a serial port at predefined regular intervals (say, once in
a second). This operation is based on a mathematical principle called trilateration.
In addition to the location data, it also provides speed, course angle of travel and
timestamp.
GPS Shadow Zone It is a track section in which the GPS Receiver does not give
output or does not give accurate and coherent output. Extent of shadow zone to
be delineated by the supplier
Goods Guard ACD: It is a portable ACD self-contained with GPS antenna, radio
antenna and battery that can be used in Guard Vans of goods trains.
IBL (Intelligent Braking Logic): It is a logic by which Loco ACD applies Normal
Brake / Emergency Brake, based on the self-calculated braking distance so as to
reduce the speed to the designed level for achieving various functionalities of
ACD Network.
ICS (Inter Cock Switch): It is a switch to disable the Loco ACD of a trailing /
banking Loco(s) in multiple / double heading / banking operations to put them in
Passive Mode. In case of DMU / EMU / MEMU, the ICS puts the Loco ACD in
Guard mode.
Jumbling: When the inter-distance between the Loco ACD and its Guard ACD
decreases by more than 100m with respect to the pre-calculated train length by
Guard ACD (when it gets attached initially to its Loco ACD), it is considered as
train jumbling.
LC ACD: It is an ACD installed at Manned or Un-Manned Level Crossings along
with radio antenna, interconnecting cables, batteries and other accessories.
Loco ACD: It is an ACD installed in a locomotive or self-propelled rail vehicle
along with Automatic Braking Unit, Driver’s consoles, Radio and GPS antenna,
Speedometer interface and interconnecting cables.
Loco Shed ACD: It is an ACD installed at Loco shed along with Radio antenna,
interconnecting cables and other accessories.
Low-comm (Low Range of Communication): When the Station ACD detects
first packet from approaching Loco / Guard ACD from a distance less than the
predefined distance, the Loco ACD / Guard ACD is termed to have low range of
communication.
Manned LC Gate ACD: It is an ACD installed at Manned Level Crossing Gate
along with radio Antenna, other accessories including interfacing with devices that
provide open/close position of the LC Gate, interconnecting cables and Power
Supply Modules and batteries.
NB NOT OK IN ABU:“NB NOT OK IN ABU” is the signal the ACD generates,
when application of the Normal Brake fails to cause reduction in speed within time
span of 20 seconds, because of defects associated with either the ACD system or
the brake power of the train.
No-Comm: When there is no communication from Station ACD to the Loco ACD
or the Route status from Station ACD is not available the situation is called No
communication or “NO COMM”
Normal Brake: Normal Brake is the brake applied by the ACD system, wherein
brake pipe pressure in locomotive & its formation is dropped from 5.0 Kg/cm2 to
4.2 Kg/cm2 to control speed of train to desired limit.
Parting: When the inter-distance between the Loco ACD and its Guard ACD
increases by more than 100m with respect to the pre-calculated train length by
Guard ACD (when it gets initially attached to its Loco ACD), it is considered as
train parting.
Passive Mode: It is a mode assumed by Loco ACD when its locomotive is not a
leading loco. In this mode, it ceases to perform any functionality except detecting
the change in its TID.
Point Zone: It is a portion of track covering a turnout / point & crossing, including
25m-track portion in rear of either side of the end of that turnout / point & crossing
area.
Portable: It refers to a Guard ACD, which is portable as it is required to be fixed
and removed at train originating / terminating / intermediate stations.
Side Collision: When any train stops in block section it generates Side Collision
condition due to which Side Collision LED indication glows on the driver’s console
and prompts the Driver to press CANCEL button if everything is OK.
Silent Mode: It is a mode assumed by Loco ACD / Guard ACD in Station Area
when its speed is less than 3Km/h. In silent mode, the Loco ACD / Guard ACD
remains in reception state only and comes out of this mode when it perceives
collision like dangerous situation.
Sleep Mode: It is a mode assumed by Loco ACD / Guard ACD outside the ACD
territory. In this mode, they carry TID-NU and the user interface of Loco ACD /
Guard ACD shall not be active.
Sleep Zone: It is a track section of Railway system that is located outside the
ACD territory. ACD system does not provide any protection in sleep zone.
SM Console: it is a console intended for station master with Audio and Visual
Indications and push buttons.
Station ACD: It is an ACD installed in Station area along with the SM’s console,
radio antenna and other accessories including need based interfacing with
Signaling circuits and interconnecting cables.
Station Area: It is a railway section falling between either farthermost First Stop
Signal / Last Stop Signals located on both sides of the station; or outermost facing
points, if there are no stop signals at that station.
Station ID: It is a two or three character ID assigned to a Station, which may or
may not have automatic signaling, between two consecutive stations for uniquely
identifying the same
Radio Shadow Zone: It is a track section in which inter-ACD radio
communication within a distance of 3000m of a radial range is not available for a
continuous stretch of more than 200m.
Radio Communication: It is an interchange of data packets amongst various
ACDs within a pre-defined time interval, using radio waves in a simplex / half-
duplex mode at a nominated spot frequency in UHF range
TID Assigning ACD: It is an ACD used to assign TID to the passing Loco ACDs
by deriving inputs from track circuits in the TID Assigning zone. It is generally
located at stations bordering the ACD territory, prior to entering into the ACD
territory.
TID-GR: It is a TID assigned to a Group of tracks in big yards, (normally beyond
the second loop from the main lines) where train movements above the shunting
speeds are not permitted.
TID-NU: It is a neutral TID assumed by Loco ACD and Guard ACD in sleep zone.
Guard ACD also assumes initially TID-NU when it is switched ‘ON’ inside the ACD
territory and subsequently acquires the correct TID from the Loco ACD, after
attachment.
TID-SR: It is a TID assigned to an entire station yard for stations having big yards,
where train movements above the shunting speeds are not permitted.
TID-LS: It is a TID assigned to Loco ACDs of those locomotives, which enter the
Loco shed. The Loco ACD shall not apply brakes if it is carrying TID-LS. Also, it
shall not apply brakes when it is carrying TID other than TID-LS and receives a
data packet from other Loco ACD or Guard ACD, which is carrying TID-LS. All
user interfaces shall remain active for self-test of Loco ACD.
TID-S: It is a TID assigned to Loco ACD and/or Guard ACD of a rolling stock that
enter inside the siding area. All user interfaces shall remain active for self-test of
Loco ACD carrying TID-S.
TID-FS: It is a status of TID assumed by Loco ACD / Guard ACD, when it is not in
a position to identify the track on which it is located.
Track ID (TID): It is a two-digit decimal number (value between ’00’ and ‘63’) that
uniquely identifies the track on which a Loco ACD or Guard ACD is located inside
the ACD territory. It is a virtual number used in the data files of different ACDs.
Train Ahead: This is indicated on the Driver’s Console of the rear train, when it
applies the brake for the following scenario: When one train is following another
train in same direction, on the same track in the Block section.
Train Approaching: This is indicated on the Driver’s Console of the train, when it
applies the brake for the following scenario: When one train is approaching
another train in the opposite direction, on the same track in the Block section
Un-Manned LC ACD: It is an ACD installed at Un-Manned Level Crossing along
with radio Antenna, interconnecting cables and Power Supply Modules and
batteries.
2 Introduction to RAKSHA KAVACH


RAKSHA-KAVACH (ACD System) is a “non-vital” network of anti-collision

devices which prevent collisions between trains and between trains and Road
vehicles in Indian Railways, or minimize the damage caused by collisions.
The ACD system includes a variety of ACDs such as on-board (mobile) ACDs
present in Locomotives and Guard vans and track-side (stationary) ACDs such as
Station ACDs, Manned Level Crossing Gate ACDs, Un-Manned LC ACDs, TID
Assigning ACDs, Loco Shed ACDs and ACD Repeaters.
All ACD Units within the ACD system communicate with each other via radio when
they are within a radius of up to 3000m. Onboard ACD units use inputs from
Global Positioning System (GPS) for determination of train location, speed, course
angle of travel and time.
If two ACD units are within a predefined distance and deemed to be at a risk of
collision, the ACD system activates automatic braking operation to prevent
collisions. ACD system provides audiovisual warning to the road users at level
crossings when train is approaching. In non interlocked manned LC Gates, when
approaching Loco ACD detects ‘Gate Open’ condition, the speed of the train / loco
is regulated.
The ACD system performs the following functions:
• Prevention of Head-on Collisions between ACD trains/ACD locomotives in
block section.
• Prevention of Rear-end Collisions between ACD trains/ACD locomotives in
block section.
• Prevention of Side Collision between ACD trains/ ACD locomotives in block
sections in both directions.
• Prevention of collision in station area.
• Prevention of Collision due to fouling of lines having different TID’s in station
area.
• Detection of Train Parting / Jumbling.
• Station approach warning to the drivers.
• Speed Limit imposition
• Approach warning for Road Users at level crossings equipped with ACD.
• SOS functions.
• Event logging.
STATION ACD
TROUBLESHOOTING AND
MAINTENANCE
3 INTRODUCTION TO STATION ACD

Station ACD is part of the network of ACDs called RAKSHA KAVACH which act
as a safety shield to prevent or minimize collisions between trains and between
trains and road vehicles in Indian railways.
Station ACD is installed in stations. The ACD receives information via broadcasts
by Loco ACD and Guard ACD that pass through the station.
In emergency situations, the Station Master can generate a Manual SOS from the
Station ACD and stop all ACD-fitted trains within a radius of 3000m.
In station area, the Station ACD monitors the movement of Loco ACDs and Guard
ACDs. Information such as Main Line Occupation, Route set to main line or not
and TID assignment (in stations with dead point zones) is sent to the Loco ACDs
and Guard ACDs.
4 STATION ACD TROUBLESHOOTING AND MAINTENANCE

4.1 Station ACD Interfacing Wiring Diagram
GP ANTENNA
FROM AC POWER SOCKET

(240V,50Hz)
24V/8A BATTERY RM
CHARGER CUM INPUT
POWER SUPPLY
F
STATION F
BATTERY
(24V/40AH) B
I ACD B
I
SM
CONSOLE
- -
10 12
RELAY ROOM
OF STATION
Figure 1: Station ACD Interfacing Wiring Diagram
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 15 of 45
4.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF STATION ACD

The following table and subsequent flowcharts describe the troubleshooting and maintenance procedures for problems
observed in Station ACD.
SL. PROBLEM OBSERVED

CHECK POINTS
NO. IN THE FIELD REMARKS
a) Check 24V LED, if not glowing check 5A fuse.
b) Check the connection between the charger and the ACD. If OK, check voltage at
Check the
the load terminals of charger. If there is no voltage, check fuse and AC power
Station ACD not cause for fuse
1. availability to the charger. If both are OK, replace charger.
functioning open and
c) If 24V LED is glowing and 15V LED is not glowing, change the Station ACD.
rectify it.
d) If 15V LED is glowing, check whether TX LED is also glowing. If TX LED is not
glowing, change Station ACD.
a) Follow a & c procedures of problem 1.

b) If TX LED is blinking and the SM console is in ACD-M mode, then the FIB-10
card has failed. The above problem can be confirmed by observing the
ACD-M Problem
2. STATION ACD’s LCD which displays: “TRK CKT: 5 FAIL”. This indicates that
(SM-CONSOLE)
track number 5 failed in FIB-10 CARD or failure of physical connections between
ACD and tag block. Change the corresponding FIB-10 card or the Station ACD.
c) Check physical connections between SM-console and Station ACD.
a) Check the switches (SOS, MESSAGE and CANCEL) on the SM-console by
Control Push Buttons of pressing each of them.
3
SM console. I. Press both SOS switches at the same time. SOS message will be displayed,
the SOS lamp glows (i.e. SOS LED) and the buzzer is heard for 10 sec.
SL. PROBLEM OBSERVED

CHECK POINTS
NO. IN THE FIELD REMARKS
II. Press “cancel” button twice, then SOS message will not be displayed on the
STATION ACD.
III. Press “message” button If the station receives any messages, they will be
displayed on the SM console. Receipt of messages is indicated when the
yellow LED glows.
b) If any of the above buttons do not work, it indicates failure of physical
connections, or problem in the SM console, or failure of FIB-12 card. If physical
connections are OK and SM console is problem-free, then change the FIB-12
card or Station ACD.
c) Even if one control push button fails to work, change the SM console.
STATION ACD
FUNCTIONING
NOT OK
CHECK NOT OK
CHECK NOT OK OK CHECK CHECK
PHYSICAL CONNECTIONS REPLACE
24V LED VOLTAGE AT LOAD CHARGER
BETWEEN CHARGER FUSE
GLOWING TERMINALS FUSE
& ACD
OK
OK
OK NOT OK
FIX LOOSE CHECK REPLACE

CONNECTIONS AC POWER CHARGER
OK
NOT OK
NOT OK
CHECK NOT OK
CHECK REPLACE
15V LED
5A FUSE FUSE
GLOWING MAKE AC POWER
AVAILABLE
OK
CHECK REPLACE
Tx LED ACD
BLINKING OK
OK
NOT OK
CHECK
NOT OK
SM CONSOLE IN YES PHYSICAL CONNECTIONS FIX
ACD-M MODE BETWEEN ACD & CONNECTIONS
TAG BLOCK
NO
RESTART
ACD
NO ACD-OK YES
REPLACE
LED ACD - OK
ACD
GLOWING
Figure 2: Flowchart for Station ACD & ACD-M Problems Troubleshooting
Figure 3: Flowchart for Inputs (Control Push Buttons of SM Console)

Troubleshooting
4.3 PREVENTIVE MAINTENANCE FOR STATION ACD

The following preventive maintenance measures have to be strictly
adhered for proper functioning of the Station ACD.
• Check battery voltage regularly
• Observe physical health of the unit at regular intervals
• Apply anti-corrosive liquid on battery terminals regularly
4.4 MANDATORY SPARES FOR STATION ACD

The following items are to be maintained as mandatory spares to be kept
at nodal points to ensure smooth functioning of the Station ACD.
S. NO. ITEMS NO. OF UNITS
1. Station ACD 10% of the Total ACDs in use
2. SM’s Console 10% of the Total nos in use
3. 5 A Fuse 10% of the Total nos in use
4. 24V Charger 10% of the Total nos in use
MANNED LC GATE ACD

TROUBLESHOOTING AND
MAINTENANCE
5 INTRODUCTION TO MANNED LC GATE ACD

MLCG ACD is part of the “non-vital” network of ACDs called RAKSHA
KAVACH which acts as a safety shield to prevent or minimize collisions
between trains and between trains and road vehicles in Indian railways.
MLCG ACD is installed at manned level crossing gates. If the gate is open
or damaged, MLCG ACD warns the approaching trains which regulate
their speeds to minimize collisions at level crossing gates. It is also
supported by a Hooter and Flasher to provide an Audio-Visual Warning to
road users at Level crossings.
6 MANNED LC GATE ACD TROUBLESHOOTING AND MAINTENANCE

6.1 Manned LC Gate ACD Interfacing Wiring Diagram
GP ANTENNA
FROM SOALR PANEL

(16V,166W)
+ -
S LOAD INPUT
RM
P CCU
V
BATT
MLCG
ACD
FROM
GATE SENSING BOOM SWITCH
SIGN.IN
RELAY UNIT
FLASHER - 1 FLASHER - 2
BATTERY
(16V/200AH)
GATE STATUS
INDICATION
BOX
HOOTER & HOOTER &
FLASHER FLASHER
UNIT - 1 UNIT - 2
Figure 4: Manned LC Gate ACD Interfacing Wiring Diagram
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February Page 23 of 45
6.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF MLCG ACD

observed in Manned LC Gate ACD.
PROBLEM OBSERVED IN
SL.NO. CHECK POINTS REMARKS
THE FIELD
a) Check if 16V LED is glowing. If not OK, check physical wiring between CCU,
Manned LC Gate ACD input (16V input), and battery (16V). Fix loose Check the cause
Manned LC Gate ACD not
1 connections. for fuse open and
functioning
b) Check ON/OFF switch. Check the 8A fuse in CCU. If blown, replace fuse. rectify it.
c) If problem persists, change ACD.
a) Check if 16V & 5V LEDs are glowing. If not, follow the procedures given for
problem 1.
2 Communication Problem b) Check physical connections between RM port and GP antenna. Fix loose
connections.
a) Check 5A in ACD and 8A fuse in CCU. If blown, replace fuse.
b) Check if 16V LED is glowing. If not, follow the procedures given for problem
Both Flasher and Hooter not 1.
3
working c) Check physical connections between Flasher units (1&2) to ACD. If not
working, replace the unit
d) If the unit is still not working, change the ACD
a) Check physical connections. Fix loose connections. If OK, change Hooter
4 Hooter not working.
unit.
a) Check physical connections. Fix loose connections. If OK, change flasher
5 Flasher not working.
unit.
PROBLEM OBSERVED IN
SL.NO. CHECK POINTS REMARKS
THE FIELD
a) Check physical connection between ACD and gate switch relay unit.
b) Check 6A fuse in CCU. If blown, replace it.
c) Check physical connections between switches boom A & boom B. Also check
6 Gate open/close sensing
connections between gate switching relay unit/CCU and ACD. If physical
problem.
connections are not OK, fix them.
d) If problem persists, change the gate switch relay unit. If not OK, change ACD
In switched on condition, ACD- a) Check 8A fuse. If blown replace it.
7
M LED glowing continuously b) If problem persists change the ACD
a) Check if 16V and 5V LEDs are glowing. If not, follow the procedures given for
Train is approaching towards problem 1.
8 gate, and both flasher & Hooter b) Check TX and RX LED’s. If they do not blink while the LOCO is at the gate
not working. there is a communication problem.
c) If problem persists, change ACD
Loco is passing the particular
a) Follow the procedures given for problem 6.
gate at low speed (25Kmph),
9 b) Check if TX and RX LED’s are blinking when the Loco is near the gate. If not
even when the level crossing
blinking, change the ACD.
gate is closed.
FLASHER & HOOTER

PROBLEM
NOT OK
CHECK
CHECK REPLACE OK
WORKING OF FLASHER
5A FUSE 5A FUSE
& HOOTER
OK NOT OK
NOT OK NOT OK
CHECK OK
OK CHECK CHECK REPLACE
WORKING OF FLASHER
16V LED 8A FUSE FUSE
& HOOTER
OK
NOT OK
CHECK NOT OK OK
CHECK
PHYSICAL CONNECTIONS FIX
WORKING OF FLASHER
BETWEEN CCU,ACD & CONNECTIONS
& HOOTER
BATTERY
OK
NOT OK
CHECK NOT OK
5V LED
OK
REPLACE FLASHER
& HOOTER UNITS
REPLACE
ACD
CHECK
NOT OK
WIRING OF FLASHER &
HOOTER
OK
FLASHER & HOOTER

WORKING
Figure 5: Flowchart for both Flasher and Hooter Unit Troubleshooting.
COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
GLOWING OF BLINKING OF Tx
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
CHECK PHYSICAL CHECK OK
FIX
WIRING BETWEEN CCU, BLINKING OF Tx
CONNECTIONS
ACD & BATTERY & Rx LED
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK
CHECK NOT OK CHECK OK

FIX
CONNECTIONS FROM RM BLINKING OF Tx
CONNECTIONS
PORT TO ANTENNA & Rx LED
OK
NOT OK
REPLACE
ACD
NOTE : CHECK COMMUNICATION (BLINKING OF Tx & Rx LEDs)

WITH ANOTHER WORKING ACD
Figure 6: Flowchart for Communication Problem Troubleshooting.
SINGLE FLASHER
UNIT PROBLEM
NOT OK
CHECK
PHYSICAL CONNECTION FIX
BETWEEN FLASHER CONNECTIONS
UNIT & ACD
OK
CHECK
NO
FLASHER UNIT
WORKING
REPLACE
FLASHER UNIT
YES
OK
CHECK
FLASHER
FLASHER UNIT
UNIT OK
WORKING
NOT OK
REPLACE
ACD
Figure 7: Flowchart for Single Flasher Unit Troubleshooting
GATE OPEN / CLOSE

SENSING PROBLEM
CHECK
NOT OK CHECK OK
GATE OPEN / CLOSE
BETWEEN ACD & GATE CONNECTIONS
SENSING
SWITCH UNIT
NOT OK
OK
CHECK PHYSICAL
CONNECTIONS BETWEEN NOT OK CHECK OK
FIX
BOOM A & BOOM B GATE GATE OPEN / CLOSE
CONNECTIONS
SWITCH RELAY UNIT INDICATOR
& CCU
OK
NOT OK
CHANGE GATE
SWITCH RELAY UNIT
CHECK OK
GATE OPEN / CLOSE
GATE OPEN / CLOSE
SENSING OK
SENSING
NOT OK
REPLACE
ACD
Figure 8: Flowchart for Gate Sensing Problem Troubleshooting
6.3 PREVENTIVE MAINTENANCE FOR MLCG ACD

adhered for proper functioning of the Manned LC Gate ACD.
• Whenever “Battery Low” indication is reported, charge the battery
using Portable Charger and DG Set.
6.4 MANDATORY SPARES FOR MANNED LC GATE ACD

at nodal points to ensure smooth functioning of the Manned LC Gate ACD.
1. Manned LC Gate ACD 10% of the Total ACDs in use
2 5A Fuse 10% of the Total nos in use
3. 8A Fuse 10% of the Total nos in use
4 Hooter 10% of the Total nos in use
5. Flasher 10% of the Total nos in use
7. Gate Switch Relay Unit 10% of the Total nos in use
8. Charge Control Unit 16 V 10% of the Total nos in use
UNMANNED LC ACD
TROUBLESHOOTING AND
MAINTENANCE
7 INTRODUCTION TO UNMANNED LC ACD

UMLC ACD is part of the network of ACDs called RAKSHA KAVACH
which provides a safety shield to prevent or minimize collisions between
trains, and between trains and road vehicles in Indian railways.
UMLC ACD is installed at unmanned level crossings along with a Hooter
and Flasher to provide Audio-Visual Warning to road users about
approaching trains.
8 UN-MANNED LC ACD TROUBLESHOOTING AND MAINTENANCE

8.1 Un-Manned LC ACD Interfacing Wiring Diagram
GP ANTENNA
FROM SOALR PANEL

(16V,166W)
+ -
S LOAD INPUT
RM
P CCU
V
BATT
UMLC
ACD
FLASHER - 1 FLASHER - 2
BATTERY
(16V/200AH)
HOOTER & HOOTER & GP ANTENNA

FLASHER FLASHER
UNIT - 1 UNIT - 2
Figure 9: Un-Manned LC ACD Interfacing Wiring Diagram
8.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF UMLC ACD

observed in Unmanned LC ACD.
PROBLEM OBSERVED IN
SL. NO. CHECK POINTS REMARKS
THE FIELD
a) Check physical wiring between CCU, Un-Manned ACD input
(16V input), and battery (16V). Fix loose connections. Check the cause
Unmanned LC ACD not
1. b) Check ON/OFF switch. Check the 8A fuse in CCU. If blown, for fuse open and
functioning
replace fuse. rectify it.
a) Check if 16V & 5V LEDs are glowing. If not, follow the
procedures given for problem 1.
2. Communication Problem b) Check physical connections between RM port and GP
antenna. Fix loose connections.
a) Check 5A and 8A fuse in CCU. If blown, replace fuse.
b) Check if 16V LED is glowing. If not, follow the procedures
Both Flasher and Hooter not given for problem 1.
3.
working. c) Check physical connections between flasher units (1&2) to
ACD. If not working, replace the unit.
d) If the unit is still not working, change the ACD.
4. Hooter not working. a) Check physical connections. Change Hooter unit.
5. Flasher not working. a) Check physical connections. Change flasher unit.
PROBLEM OBSERVED IN
THE FIELD
a) Check if 16V and 5V LEDs are glowing. If not, follow the
Train is approaching towards procedures given for problem 1.
6. gate, and both flashers & b) Check TX and RX LED’s. If they do not blink while the LOCO
sirens not working. is at the gate there is a communication problem.
c) If problem persists, change ACD
COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
FIX
CONNECTIONS
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK

FIX
CONNECTIONS
OK
NOT OK
REPLACE
ACD

Figure 10: Flowchart for Communication Problem Troubleshooting.
FLASHER & HOOTER

PROBLEM
NOT OK
CHECK
CHECK REPLACE OK
WORKING OF FLASHER
5A FUSE 5A FUSE
& HOOTER
OK NOT OK
NOT OK NOT OK
CHECK OK
OK CHECK CHECK REPLACE
WORKING OF FLASHER
16V LED 8A FUSE FUSE
& HOOTER
OK
NOT OK
CHECK NOT OK OK
CHECK
WORKING OF FLASHER
BETWEEN CCU,ACD & CONNECTIONS
& HOOTER
BATTERY
OK
NOT OK
CHECK NOT OK
5V LED
OK
REPLACE FLASHER
& HOOTER UNITS
REPLACE
ACD
CHECK
NOT OK
WIRING OF FLASHER &
HOOTER
OK
FLASHER & HOOTER

WORKING
Figure 11: Flowchart for both Flasher and Hooter Unit Troubleshooting.
SINGLE FLASHER
UNIT PROBLEM
CHECK NOT OK
PHYSICAL
FIX
CONNECTIONS BETWEEN
FLASHER UNIT CONNECTIONS
& ACD
OK
CHECK
NO
FLASHER UNIT
WORKING
REPLACE
FLASHER UNIT
YES
OK
CHECK
FLASHER
FLASHER UNIT
UNIT OK
WORKING
NOT OK
REPLACE
ACD
Figure 12: Flowchart for Single Flasher Unit Troubleshooting
8.3 PREVENTIVE MAINTENANCE FOR UNMANNED LC ACD

adhered for proper functioning of the Unmanned LC ACD.
8.4 MANDATORY SPARES FOR UNMANNED LC ACD

at nodal points to ensure smooth functioning of the Unmanned LC ACD.

1. Unmanned LC ACD 10% of the Total ACDs in use
2 5A Fuse 10% of the Total nos in use
4 Hooter 10% of the Total nos in use
5. Flasher 10% of the Total nos in use
6. Charge Control Unit 16V 10% of the Total nos in use
ACD REPEATER
TROUBLESHOOTING AND
MAINTENANCE
9 INTRODUCTION TO ACD REPEATER

ACD REPEATER is part of the network of ACDs called RAKSHA
KAVACH which provides a safety shield to prevent or minimize collisions
between trains, and between trains and road vehicles in Indian railways.
ACD REPEATER is installed at locations identified as inter-ACD
communication shadow zones where radio communication is weak and
packets received from Loco ACD/Guard ACD are stored and forwarded to
other ACDs.
10 ACD REPEATER TROUBLESHOOTING AND MAINTENANCE

10.1 ACD Repeater Interfacing Wiring Diagram
GP ANTENNA
FROM SOALR PANEL

(16V,166W)
+ -
S LOAD INPUT
RM
P CCU
V
BATT
ACD
REPEATER
BATTERY
(16V/100AH)
Figure 13: ACD Repeater Interfacing Wiring Diagram
10.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF ACD REPEATER

The following table and subsequent flowcharts describe the troubleshooting and maintenance procedures for problems observed
in ACD Repeater.
PROBLEM OBSERVED
IN FIELD
a) Check 16V & 5V LEDs. If not glowing, check physical wiring between
CCU, ACD Repeater input (16V input), and battery (16V). Fix loose
Check the cause
ACD Repeater not connections.
1. for fuse open and
functioning b) Check ON/OFF switch. Check 5A & 8A fuse in CCU. If any fuse is
rectify it.
blown, replace fuse.
c) If problem persists, replace ACD Repeater.
a) Check if 16V & 5V LEDs are glowing. If not, follow the procedures
given for problem 1.
2. Communication Problem
b) Check physical connections between RM port and GP antenna. Fix
loose connections.
COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
FIX
CONNECTIONS
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK

FIX
CONNECTIONS
OK
NOT OK
REPLACE
ACD

Figure 14: Flowchart for Communication Troubleshooting.
th
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5 February, 2008 Page 44 of 45
10.3 PREVENTIVE MAINTENANCE FOR REPEATER ACD
adhered for proper functioning of the Repeater ACD.
10.4 MANDATORY SPARES FOR REPEATER ACD

at nodal points to ensure smooth functioning of the Repeater ACD.

1. Repeater ACD 10% of the Total ACDs in use
4. Charge Control Unit 16V 10% of the Total nos in use
`
th
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5 February, 2008 Page 45 of 45

Trouble Shooting Manual - Stationary ACDs

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RAKSHA KAVACH™ Konkan Railway Corporation Ltd

Konkan Railway Corporation Limited

1 Abbreviations and Definitions

ACD Anti Coll is io n Devic e

CCU Charge Co ntr ol Unit

GPS Global Pos itioning Sys tem

LSS Las t S top Signa l

REP Repea ter

SLR Self Generating Luggage Cum Guard Van

SOS Save our Souls (Emergency)

TID Track Identification Digit

2 Introduction to RAKSHA KAVACH

RAKSHA-KAVACH (ACD System) is a “non-vital” network of anti-collision

3 INTRODUCTION TO STATION ACD

4 STATION ACD TROUBLESHOOTING AND MAINTENANCE

FROM AC POWER SOCKET

Figure 1: Station ACD Interfacing Wiring Diagram

4.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF STATION ACD

SL. PROBLEM OBSERVED

a) Follow a & c procedures of problem 1.

SL. PROBLEM OBSERVED

FIX LOOSE CHECK REPLACE

Figure 2: Flowchart for Station ACD & ACD-M Problems Troubleshooting

Figure 3: Flowchart for Inputs (Control Push Buttons of SM Console)

4.3 PREVENTIVE MAINTENANCE FOR STATION ACD

4.4 MANDATORY SPARES FOR STATION ACD

MANNED LC GATE ACD

5 INTRODUCTION TO MANNED LC GATE ACD

6 MANNED LC GATE ACD TROUBLESHOOTING AND MAINTENANCE

FROM SOALR PANEL

Figure 4: Manned LC Gate ACD Interfacing Wiring Diagram

6.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF MLCG ACD

FLASHER & HOOTER

FLASHER & HOOTER

Figure 5: Flowchart for both Flasher and Hooter Unit Troubleshooting.

CHECK NOT OK CHECK OK

NOTE : CHECK COMMUNICATION (BLINKING OF Tx & Rx LEDs)

Figure 6: Flowchart for Communication Problem Troubleshooting.

Figure 7: Flowchart for Single Flasher Unit Troubleshooting

GATE OPEN / CLOSE

Figure 8: Flowchart for Gate Sensing Problem Troubleshooting

6.3 PREVENTIVE MAINTENANCE FOR MLCG ACD

6.4 MANDATORY SPARES FOR MANNED LC GATE ACD

7 INTRODUCTION TO UNMANNED LC ACD

8 UN-MANNED LC ACD TROUBLESHOOTING AND MAINTENANCE

FROM SOALR PANEL

HOOTER & HOOTER & GP ANTENNA

Figure 9: Un-Manned LC ACD Interfacing Wiring Diagram

8.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF UMLC ACD

CHECK NOT OK CHECK OK

NOTE : CHECK COMMUNICATION (BLINKING OF Tx & Rx LEDs)

Figure 10: Flowchart for Communication Problem Troubleshooting.

FLASHER & HOOTER

FLASHER & HOOTER

Figure 12: Flowchart for Single Flasher Unit Troubleshooting

8.3 PREVENTIVE MAINTENANCE FOR UNMANNED LC ACD

8.4 MANDATORY SPARES FOR UNMANNED LC ACD

S. NO. ITEMS NO. OF UNITS

9 INTRODUCTION TO ACD REPEATER

10 ACD REPEATER TROUBLESHOOTING AND MAINTENANCE

FROM SOALR PANEL

Figure 13: ACD Repeater Interfacing Wiring Diagram

10.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF ACD REPEATER