Presentation On CEL SSDAC PDF

PRESENTATION
ON
CEL SSDAC
FAILURES
By
Shri M.K.RAO,
PS-2
Comparison of different systems
As per Railway Board figures for sept,09
In Hours
Make Nos MTBF MTTR
CEL 1847 1025 10.31
Alcatel 1588 1954 6.84
Siemens 191 2002 0.75
Gg tronics 74 1635 0.92
Advantages of Axle Counters
• Monitors very long track sections
• Last vehicle check is done automatically
• No effect due to ballast resistance
• Error free operation over large temperature range
• Train detection on rusted, sanded & water logged rails
• Immune to traction return currents
Axle Counters (CEL)
History Of Development
Sno Type Year Application
1 Single Entry/Exit 1977 Single Section
2 Multi Entry/Exit 1985 Single Section/Point Zones
3 Universal Axle Counter 1994 -do-
4 Digital Axle Counter 2003 Single Section
5. Digital Axle Counter 2012 Multi Section Under Trial
3
Comparison of SSDAC with UAC
S.No Description Universal Axle Counter Single Section Digital
Axle Counter
1. Equipment Outdoor & Indoor All outdoor
2. Axle Detectors Rail Clamp type Web Type
3. Hardware TTL IC’s 2 out of 2 Microcontrollers
4. Software - Nil - Yes
5. Communication Analogue v.21 Modem packets, FSK
6. 4 Quad Cable 2 Quad ½ Quad
7. OFC - Nil - Can be used
8. Out put Relays At 1 station of block At both stations of block
9. Reset 24V, Preparatory & 48V, Preparatory & Pilot
Pilot Train Train
10. Standards Custom built as per CENELEC SIL – 4 as per
IRS S-82/45 RDSO/SPN/177/2003
Single Section Digital Axle Counter at IRISET 10

PET CABLE (1/2 QUAD) FOR SSDAC
Stn. 'B' Stn. 'A'
0.9 mm O AXC CABLE 'B' Stn. RESET BOX 'A' Stn. RESET BOX
0.9 mm O AXC CABLE

SMS RESET PREP CLEAR OCC COUNTER SMS RESET PREP CLEAR OCC COUNTER
KEY BUTTON RESET KEY BUTTON RESET
4 QUAD
4 QUAD
EXIT Type V R BOX V R BOX ENTRY Type
SSDAC CLEAR CLEAR SSDAC

UNIT VR VR UNIT
1B OCC OCC 1A
4 4 BLOCK / BLOCK / 4 4
INTERLOCKING INTERLOCKING
EQUIPMENT EQUIPMENT
RH Rail RH Rail
Rx - II Rx - I Rx - II Rx - I
LH Rail LH Rail
HOME
Tx-II Tx-I Tx-II Tx-I
ADV. STATER
S S D A C PROVIDED IN BLOCK SECTION -- DIAGRAM

IRISET model 700 AP
8
SSDAC works in Pairs-IRISET model
9
CEL models
Amplitude Modulation type
– 700 A(Block Lab), 710 A
Amplitude & Phase Modulation Type-
700 AP (At TD lab-IRISET), 710 AP,
Phase Modulation Type-
701 P, 710 P (new one in TD lab)
10
Salient Features of SSDAC DACF-710P
Trackside electronic counting equipment
Web type axle detectors
Compatible with 90R,52kg & 60kg rail profiles
Detection of all wheels with normal flange and
Diameter > 400 mm
Track Clear/Occupied (Vital Relay output) at both
stations
Micro Controller based design with 2 out of 2
decision at each SSDAC Unit.
Decision based on 4 out of 4 logic for complete
section
Salient Features of SSDAC DACF-710P
Normal Operation under water logging condition
on rails.
Continuous monitoring of counts and health of
SSDAC units
Error display by means of LED’s and error
description on Reset box.
Easy to install, commission and maintain.
Compatible to work on Voice channels of OFC and
Radio
Functions
Generation of carrier signal for TX coils

Demodulation of signal from RX coils
Generation of valid pulses
Verify the direction of train and convert the pulses
into counts
Exchange the counts between two SSDAC units
Compare the counts for arriving a decision for vital
relay output
Error checking and display
Communication
• Communication between two SSDAC units is in

the form of data packets
• Data packet consists of
– Count change information
– Count update information
– Reset information if any
– Error information if any
• Transmission on Cable, OFC, Radio by means of
V.21 Modem (full duplex)
Hardware
– High frequency (21 & 23 KHz) signals
– Micro controller based design with 2 out of 2
decision
– V.21 Modem
– Opto isolated relay drive
Software
– ‘C’ language used

– Real time processing of events
– Interrupts not used
– Pointers not used
– Cycle time is approximately 100 micro
seconds
– Diagnostic features included
SSDAC – SOFTWARE FEATURES ,
TOOLS
8051 Based Architecture
8 Bit Micro Controller
ATMEL AT89S8252 Micro controller
2 out of 2 Decision
Uses C subset language
KEIL Vision Development System
Universal Programmer
16
89S8252 MICROCONTROLLER
2KB Program Memory-
256 bytes RAM
8KB Flash memory- Program Storage
32 Programmable I/O lines
Wide Operating Voltage range of 4V-6V
Parallel Ports
8 LED block display
Contd.
17
89S8252 – More Features
Full Duplex Serial Port
Programmable Watch Dog Timer
Fully Static operation up to 24MHz
(Upgraded to 40MHz)
Operating Temperature of –40°C - +85°C
18
Fail Safety Features
AC signal processing
Clock signal generation & its use
2 out of 2 decision using micro controllers
Opto isolated drive for vital relay
Vital relay read back
Checking of health signals in system & withdrawing
vital relay drive, if faulty
CABLE REQUIREMENT - SUMMARIZE
Power Cable 25 Sq. mm, 2 Core Aluminium

Quad Pair 0.9 mm (4 Quad)
2 pair for Double Line
1 pair for Single Line
Signalling Cable (1.5 Sq. mm)
12 Conductors for Double Line
6 Conductors for Single Line

Installation Details – Cable Requirement
Station A Station B
2 Core ½ quad 2 Core

Al to 6 Core 1.5sqmm 6 Core 1.5sqmm ½ quad Al
Power Reset Copper for Copper for to Power
cable box Repeater relays Repeater relays Reset cable
and Reset and Reset box
ENTRY Maximum 20 Kms EXIT

END Modem Communication ½ Quad Cable END
Evaluator Evaluator
21 KHz 23 KHz 21 KHz 23 KHz

Tx-1 Tx-2 Tx-1 Tx-2
Rx-1 Rx-2 Rx-1 Rx-2

21 KHz 23 KHz 21 KHz 23 KHz
Schematic Block Diagram
PULSE 1
TX1 MODEM To 2nd unit
SCC1 MLB1 V . 21 of SSDAC
RX1
AXLE
DETECTORS RELAY READ BACK
(21KHz)
TX2 RELAY VITAL RELAY

SCC2 MLB2 (Q TYPE, 24V
PULSE 2 DRIVE (24V)
RX2 1000 OHM)
AXLE
DETECTORS
(23KHz) DC-DC
CONVERTOR
LEGEND
SCC 1 & 2 : SIGNAL CONDITIONER CARD
MLB 1 & 2 : MICROCONTROLLER LOGIC BLOCK BATTERY
TX1, TX2 : TRANSMITTER COILS
RX1, RX2 : RECEIVER COILS
24V
V.21 is an ITU-T recommendation for full-duplex communication between
two analogue dial-up modems using audio frequency-shift keying
modulation at 300 baud to carry digital data at 300 bit/s. It is a variant of the
original Bell 103 modulation format.
V.22 is an ITU-T recommendation for full-duplex communication between

two analogue dial-up modems using PSK modulation at 600 baud to carry
data at 1200 or 600 bit/s. It is a variant of the Bell 212A modulation format.
V.22bis is an ITU-T recommendation extending V.22 with a faster rate

using QAM modulation at 600 baud to carry digital data at 2400 or 1200
bit/s. The 1200 bit/s mode is compatible with V.22.
V.23 is an ITU-T recommendation for half-duplex communication between

two analogue dial-up modems using FSK modulation at up to 600 or 1200
baud to carry digital data at up to 600 or 1200 bit/s respectively. An
optional 75 baud reverse channel carries 75 bit/s.
Axle Detectors (AD-711)
Axle detectors:-
Each detection point comprises of 1 pair of transmitter coils
and 1 pair of receiver coils. These are web mounted type.
Receiver coils are always mounted on the inner side &
transmitter coils are mounted on the outer side
Two different frequencies(21 KHz & 23 KHz) are used
i)To avoid mutual interference.
ii)To achieve higher noise immunity against traction current.
As far as possible both the detection points (Entry and Exit
end DPs) should be fixed on same rail i.e either on left hand
rail or right hand side rail
Installation of Axle detectors:
1. Three holes of 14 mm dia. are made with inter-separation
distance of 170 mm at 86 mm from top for 90R rail & at
88 mm for 52kg/60kg rail. Always prefer to use the
Marking Zig provided by the CEL.
2. In case of DACF-710A amplitude modulation installation,
trolley protection track circuit shall be more than:-
5 rail length for single line and axle detectors are to be
fixed at the centre.
3 rail lengths for double line and axle detectors are to
be fixed at 33 m away from block joint in the direction
of train movement.
3. Ensure the distance between two axle detectors of two
SSDAC systems is at least greater than 2 m to avoid
mutual interference.
4. Ensure that axle detectors are fixed in clear spacing of
400mm between the two sleepers.
5. Ensure that distance between location box and axle
detectors is less than 10 Metres
6. Ensure that these TX and RX cables are taken directly to
the location box without forming any loop.
7. Ensure that these cables are laid in HDPE(high density
polyethylene) pipes of minimum diameter 40 mm for the
safety of cables.
8. Ensure that HDPE pipes are laid at depth of not less than
1m from the bottom of the rail.
9. Ensure that TX coil cable and RX coil cable are laid
separately in different HDPE pipes which are separated
by minimum 400 mm.
10. Put both TX coil cables in one pipe and RX coil cables in
another pipe.
11. Deflectors are to be installed to protect the axle detectors
from hanging parts. Ensure that deflectors are connected
at a minimum distance of 30 cm to 40 cm from axle
detectors.
Wheel Detection Principle
SSDAC – Wheel sensing technique
Amplitude Modulation type
The passing train wheel influences the Rx coil signal & changes
its amplitude (dip)
22
Wheel Detection Principle
Transmitter coil
Input and
Reference Signal
Receiver Coil Output

(Normally 180 out of
phase under No wheel)
Wheel between
Tx and Rx coil
Under Wheel
Between t1 and t2
Once again Phase
shifted and now IN Phase shifted by 180 and
PHASE with Decreased Amplitude
Tx / Reference Signal t0 Time t1 t2

Wheel Detection Principle Wheel between
Tx and Rx coil

Under Wheel
2.2V
Rectified
1.7 V
Voltage
Schmitt trigger
corresponding Threshold
to the Phase
0.7 V
Shift 0V
5V
SCC Card Output

0V
Equivalent Digital data 1 1 1 1 0 0 1 1 1 1
t0 Time t1 t2
Wheel Detection Principle (Trolley Wheel)

Under Trolley Wheel
Trolley Wheel between

Tx and Rx coil
Rectified 2.2V
Voltage 1.7 V
corresponding Schmitt trigger
to the Phase threshold
Shift
0.7 V
0V
SCC Card Output 5 V

Equivalent Digital data 1 1 1 1 1 1 1 1 1 1
0V
t0 Time t1 t2
Differentiation of wheels
Train Trolley Wheel - Count
The wheel with Diameter
more than 400mm
1 1 1 0 0 1 1 1 SCC-1
1 1 1 1 0 0 1 1 SCC-2
Overlap
Motor Trolley Wheel - No Count

The wheel with Diameter
less than 400mm
1 1 1 0 0 1 1 1 SCC-1
1 1 1 1 1 1 0 0 SCC-2
No Overlap
Differentiation of wheels
Wheel Detection - Dip Lorry - No Count
The Dip Lorry wheel with Diameter less

than 400mm and lesser wheel flange
1 1 1 1 1 1 1 1 SCC-1
1 1 1 1 1 1 1 1 SCC-2
No Pulse and No Detection
SSDAC- counting
24
Address Setting
Every evaluator was assigned with a two digit hexadecimal Address

Address setting provision is available on the mother board
For setting the address open the back cover of the evaluator.
Set the Hexa decimal address of the evaluator by 8-way DIP switch. (Each Hexadecimal
number is comprised of 4 binary bits, hence 2 hexadecimal digits will have 8 binary
bits)
Address Setting
Default Factory address setting is 02 for Entry end evaluator

and 03 for Exit end evaluator
There are 8 DIP switches, one switch for each bit 8 7 6 5 4 3 2 1
The position of switches ON ON ON ON ON ON OFF ON
The corresponding weight of each bit 0 0 0 0 0 0 1 0

(‘0’ If switch is ON and ‘1’ if Switch is OFF)
Equivalent Hexa Decimal code 0 2
Hence the Hexa Decimal Address is 02
Entry-Exit Address Settings
29
Address Setting
There are total 15 pairs was designed and their Switch settings were as shown below
Address-Dip Switch Setting
32
Dip Switch Setting –Closer Look
33
MODE Address Setting
Why Address Setting ? Entry
Exit
02
03
Pair 1
(Factory Selected)
Entry 04
Exit 05
Pair 2
The communication between the evaluators Entry 06
Pair3
will take place within the pair only. Exit
Entry
07
08
Exit 09
Pair4
Entry 0A
Pair5
That means the Evaluator set with an address Exit 0B
Entry 0C
of Entry Mode (02) will communicate with the Exit 0D
Pair 6
Entry 0E
evaluator with an address of Exit Mode(03) Exit 0F
Pair 7
Entry 10
only and vice versa. ------PAIR-1. Exit 11
Pair 8
Entry 12
Exit 13
Pair 9
The Evaluator set with an address of Entry Entry
Exit
14
15
Pair10
Mode (02) will not communicate with any Entry 16
Pair11
Exit 17
other Evaluator of different pairs even though Entry 18
Pair12
Exit 19
it was set with an address of Exit Mode(05, 07, Entry 1A
Pair 13
Exit 1B
09, 0B……etc.,). Entry 1C
Exit 1D
Pair 14
Entry 1E
Exit 1F
Pair 15
Why Address Setting ?
02 03 02 03
Entry Exit Entry Exit
UP
Station A Station B Station C
Down
Exit Entry Exit Entry

03 02 03 02
(All the Entry and Exit units were assigned same address from one pair)
Case 1:The data packet generated by Up Exit end of station B to clear
the section may be received by Dn Entry end of Station B due to cable
fault (since 02 and 03 are one pair)
02 03 02 03
UP
Down

03 02 03 02
(All the Entry and Exit units were assigned same address from one pair)
Case 2: The data packet generated by Up Exit end of station B to clear
the section may be received by Up Entry end of Station B due to cable
fault (since 02 and 03 are one pair)
02 03 06 07
UP
Down

05 04 09 08
(All the Entry and Exit units were assigned different address from different pairs)
the section will be rejected by Dn Entry end of Station B in case of
cable fault (since 03 and 04 are belongs to different pairs)
02 03 06 07
UP
Down

05 04 09 08
(All the Entry and Exit units were assigned different address from different pairs)
the section will be rejected by Up Entry end of Station B in case of
cable fault (since 03 and 06 are belongs to different pairs)
Modem Card Setting
Set the DIP switches SW2 and

SW3 corresponding to the
ENTRY or EXIT end evaluator
as per the table given on the
shield cover of the Modem card
Different Cards of the
Evaluator and their
Functions
SSDAC
High frequency (21 & 23 KHz) TX & Rx signals
Micro controller based design with 2 out of 2 decision
V.21 Modem
Opto isolated relay drive
Event Logger
All the above implemented in the following cards:
1. SCC cards (card 1 & 2) 2. MLB cards (card 3 & 4)
3. Event Logger card (card 5) 4. Modem card (card 6)
5. Relay driver card (card 7)
6. DC-DC converter card (card 8)

SSDAC – INPUT/OUTPUT
Input: i) High frequency axle detector
ii) V.21 Modem
iii) Reset command of 48V dc.
Output: i) Drive for vital relay (Q type, 24V, 1000 )

ii) Drive for prep. Relay (Q type, 24V, 1000 )
iii) RS232 Monitor port
iv) Event Logger card (Flash Memory)
Power supply: i) 24V DC Battery- IPS

SSDAC- Application
Axle counters are used in lieu of track circuits for verifying the track
free /occupied condition of :
Berthing track (Station)
Yard
Block Section
Intermediate Block Signalling
Auto Section
Train actuated warning at LC gates

SSDAC Evaluator
It has eight Cards

SSDAC- SCC CARD
Carrier Signal Generation

Demodulation and Pulse generation.
Process the Analog signals
Convert in Digital form
Sends the pulses to MLB card
9TH May 2007 Single Section Digital Axle Counter at IRISET 2007 33
SCC-1 Card Function
It gives a continuous rectified output of
The Signal Conditioning Card -1 (SCC-1) 2.2V as long as there is no wheel and
generates 21KHz high frequency carrier signal phase shift between Received and
(It is also reference Signal) and transmits to Tx
coil,
transmitted signal is 180 out of phase.
This voltage reduces as the phase shift
reduces from 180 to 0 finally it gives
0V when the phase of received and
Tx transmitted signals are in phase.
Rx
1 1 1 0 0 1 1 1
Receives the induced signals from Rx coil The SCC card compares the phase of the
and process the same received signal with that of reference signal
(Transmitted signal) and generates the wheel
pulse corresponding to the phase shift.
SCC-1 Card Indications
TP Con: This LED continues to glow if Trolley Suppression circuit is
connected and working properly.
OSC OK: This LED indicate the normal working of the Tx coils and the
Oscillator. In case Tx coil is short, the OSC indication will not
glow, during the train movement this LED continues to glow
LD OK: LEVEL DETECTOR(LD) indicates that the signal from Rx coil is

normal and above a certain level. This indication will be OFF in
case
a. Fault in Rx Coil
b. Rx Coil Cable is disconnected
PULSE OK: This LED indicates the normal signal from Rx coil and pulse
level in card is OK. This indication will be OFF in case
a. Fault in Rx Coil.
b. Rx Coil Cable is connected in reverse polarity.
c. Rx Coil Cable is disconnected.
SCC-2 Card Function
It gives a continuous rectified output of
The Signal Conditioning Card -1 (SCC-1) 2.2V as long as there is no wheel and
generates 23KHz high frequency carrier signal phase shift between Received and
(It is also reference Signal) and transmits to Tx
coil,
transmitted signal is 180 out of phase.
This voltage reduces as the phase shift
reduces from 180 to 0 finally it gives
0V when the phase of received and
Tx transmitted signals are in phase.
Rx
1 1 1 1 0 0 1 1
Receives the induced signals from Rx coil The SCC card compares the phase of the
and process the same received signal with that of reference signal
(Transmitted signal) and generates the wheel
pulse corresponding to the phase shift.
SCC-2 Card Indications
TP Con: This LED continues to glow if Trolley Suppression circuit is
connected and working properly.
OSC OK: This LED indicate the normal working of the Tx coils and the
Oscillator. In case Tx coil is short, the OSC indication will not
glow, during the train movement this LED continues to glow
LD OK: LEVEL DETECTOR(LD) indicates that the signal from Rx coil is

normal and above a certain level. This indication will be OFF in
case
a. Fault in Rx Coil
b. Rx Coil Cable is disconnected
PULSE OK: This LED indicates the normal signal from Rx coil and pulse
level in card is OK. This indication will be OFF in case
a. Fault in Rx Coil.
b. Rx Coil Cable is connected in reverse polarity.
c. Rx Coil Cable is disconnected.
SSDAC – MLB CARD
MLB performs following functions

Pulse counting
Wheel Detection
Train Direction checking
Design based on 8051 architecture
10k byte program memory
Compatible on chip serial port
Parallel ports for address/mode input & vital
relay output
Extensive LED display for section status
Micro controller Logic Block Cards(MLB-1 & MLB-2)
The Micro controller Logic Block Card is the heart of the system.
They Process the data with the help of Software.
The MLBs are programmed to perform the following functions.
1. Monitor and receive pulse signals.
2. Output Pulse signals to other MLB.
3. Detect the passing wheels and its direction.
4. Count the wheels passing at the axle detectors
5. Supervise the axle detectors.
6. Code message packets for transmission to remote SSDAC.
7. Decode message packets received from the remote SSDAC.
8. Determine the number of axles in the section.
9. Control and supervise the status of Vital relay.
There are two Micro controller Logic Block Cards in this system, and
both are provided with similar hardware and software. Both the
MLBs are performing exactly the same functions.
Both the MLBs are receiving the pulses and supervisory signals from
both Signal Conditioning Cards (SCC1 and SCC2) simultaneously.
Each MLB validate the pulse signals received from SCC cards and
implement the wheel detection, train direction checking and wheel
counting functions.
Each MLB, after detecting pulses, keeps sending a copy of it to the
other MLB.
Each MLB receives the remote wheel count and system status.
Each MLB keeps track of three different counts viz
i. Primary Count Its own Wheel Count
ii. Secondary count Wheel Count of 2nd MLB
iii. Remote Count Count received from other end Evaluator.
In SSDAC unit the first MLB card sends the primary count as well as
the secondary count to the remote SSDAC on regular basis of every
800 milliseconds.
Now by evaluating the data of Primary count, Secondary count and
Remote count the MLB will give final decision whether the section
is occupied or clear.
Micro Controller Logic Block Card Indications
These 8 LEDs denotes a 2-digit

Hexadecimal error code
(Decoding of error codes was dealt
in detail separately)
Red LED glows if the MLB decision is

Section OCCUPIED or System ERROR
Green LED glows if the MLB decision

is Section CLEAR
SSDAC – EVENT LOGGER CARD
Following signals are recorded in 2MB

flash memory
Pulse signals.
Supervisory signals.
Card removal information
Serial packets from
MLB1 (Local unit)
MLB2 (local unit)
Remote unit (communication failure
and composite information from MLB1
& MLB2.
Inbuilt Real Time Clock
Event Logger Card
Event logger card is designed to capture and store important data

of local and remote units.
The stored data can be downloaded from the event logger card
and can be analyzed with the help of ‘CEL Data analyzer
software’.
Event logger card has a 2MB FLASH memory to store packets.
The data is initially stored in the buffer and subsequently

transferred to FLASH memory every two minutes.
Normally 4096 pages of the data can be stored in flash
memory in FIFO basis.
Event Logger Card
The cell to be replaced

periodically
RS232 port to connect to

Data analyser to download
the data
SSDAC – MODEM CARD
Modem performs
Multiplexes two serial channels
Selects one of two channels for
transmission
Converts signal conversion from digital
to analog
Widely accepted CCITT V.21 industry
standard
uses FSK modem chip
DIP switch settings for Gain
adjustment
Resetting Circuit
Generation of command for 48V
Modem Card
• Modem performs
– Multiplexes two serial channels of MLB-1 and
MLB-2.
– Selects one of two channels for transmission
– Converts signal conversion from digital to analog
and vice versa.
• Widely accepted CCITT V.21 industry standard
• 7510 FSK modem chip
• Resetting Circuit
– Generation of command for 48V
– Voltage reset window
– Reset Timing Window
• Additional Voltage Monitoring circuit
Modem Card Indications
Tx (Green LED) : Transmitting the Signal to
remote unit when LED is flashing.
Rx (Green LED) : Receiving the Signal from

remote unit when LED is flashing.
MODE (Green LED) : Normally remains OFF.

When System is made OFF and ON, LED
glows and again goes OFF when system
enters self test after successful reset. In error
condition when reset is applied MODE LED
glows and immediately goes off.
CD (Green LED) : Carrier Detector, LED glows
If link is present and carrier is available
between two Units.
Modem Card (6)-Function
Connects to MLB1 & 2 . Selects one of them
V.21 full Duplex Modem- Originator, Answerer types-
factory setting
300 baud rate Data Transmission.
Has Reset Ckt to generate pulses for MLB card.
Indications- Green ( Carrier ), TX, RX
Refresh rate : Approx. 1.8 sec.
Latest Ones have 0.8 secs
50
SSDAC-Packet Details
54
SSDAC – RELAY DRIVER CARD
Dual Clock checking circuits

Opto isolated circuit
Vital relay drive output
Preparatory reset (PR) relay drive
output.
Relay Driver Card
It receives the commands from MLB1 and MLB2 and
drives the external relays VR (Vital Relay) and PR
(Preparatory Relay)
Relay Driver Card Indications
It glows when MLB 1 sent the decision of Section Clear
and it will be OFF when MLB1 sent the decision of Section
Occupied or Disturbed.
It flashes as long as MLB 1 sending the clock pulses to

Relay Driver card.
It glows when MLB 2 sent the decision of Section Clear

and it will be OFF when MLB2 sent the decision of Section
Occupied or Disturbed.
It flashes as long as MLB2 sending the clock pulses to

Relay Driver card.
This LED glows when section is clear and when Relay

driver card gives an output to VR to pick up, otherwise
OFF.
SSDAC-Relay Status
58
SSDAC – DC-DC CONVERTER
CARD
Generates 5V, 12V , 24V & 15V ISO DC
voltages
Low Ripple
Wide input line regulation
Very good load regulation
Input/output protected for short circuit.
Immune to EMI/RFI Interference.
DC-DC Converter
It takes an input of 24V DC and generates
different voltages required for various
circuits of the system.
It also generates an Isolated +15V with

separate ground to drive external relays VR
and PR.
The Green LED Indications provided against

each DC voltages goes off in case of the
voltage goes out of range.
Reset Box
20X2 LCD Display for

displaying error codes
along with
Description
SM’s Key
Indications
List of 10 recent error codes are stored in
Counter error log entry. This error log can be viewed
without the use of PC, by pressing the reset
Push Button button for 10 seconds last 10 errors will be
displayed with time and date one by one
Reset Box Settings
Jumper J1 shall be removed and
J2 shall be connected for LV Proving
Mother
Board
ECN1
Card-2
ECN2
Card-1
Reset Switch For

DP1 LCD Refresh
9 Pin D-SUB for 1,2,3,4 all OFF For Entry Side
Down loading data 1-ON, 2,3,4-OFF For Exit Side
Reset Box
Card-1 which was plugged in ECN2 is interface card.

This Interface card is used to provide interface with the SSDAC
unit on a pair of quad cable.
The data packets generated by SSDAC unit will also transmits
to the reset box.
These data packets are processed in the reset box and the
information of axle counts and error codes with description
will be displayed.
This card has onboard flash memory which stores the serial
packets.
These data packets can be downloaded from the flash and
can be analysed.
Reset Box
Card-2 which was plugged in ECN1 is Reset card, it controls the

following activities.
SM’s Key actuator and Reset button for resetting.

Flashing and steady state of Preparatory LED indication.
Counter for recording number of resets.
24V to 48V DC-DC converter which generates 48V DC required
for resetting of SSDAC unit.
S M 'S R O O M / C A B IN R E LA Y R O O M S S D A C LO C A T IO N (SIT E)
VR
R2 R1 3
T E R M IN A LS IN B 24
RE SET B OX PP R VP R S IG N AL LIN G C2 C1
3 TO 5 S E C . 5 C A B LE (1 .5sq .m m )
N2 4 T IM E R C K T .
5TS1 B 24 VR
2N 5416 A2 A1 4 N24
B1 B2
VR P R E P (2 4V )
(F RO M R2 R1 5
5 (F R O M S S D A C U N IT - M S 3 of P IN ' A ' )
D C -D C C O N V E R TE R ) PP R S IG N AL LIN G D3 D4
B 48 IN C A B LE (1 .5sq .m m )
VR
6
3 B 48 O U T N24
6
PPR1 drops after PPR drop. Picks up with
R1 1 4 8
PP R1
PPR pickup and with a delay to 3 to 5sec.
P rep.R es et R elay
R2 11
16 13 9
N O T E:-
+12 1 ) V R ( V IT A L R E L A Y ) IS H N K 1 /Q N 1 2 4V , 10 00 O hm s, 6 F / 6 B R E L A Y A N D
CIR CU IT S UP P L IE D IN V IT A L RE LA Y B O X .
2) P P R (P R E P A R A T O R Y R E S E T R E L A Y ) & V P R (V IT A L R E P E A T E R R E L A Y )
A R E T O B E W IR E D A T S IT E W IT H Q N A 1 ,25 0 O hm s, 8F / 8B RE L A Y S .
(F RO M B 12 0 0 0 0 0 0
D C -D C C O N V E R TE R ) C O U N TE R 3 ) P P R 1 IS 1 2V , 9 60 O hm s O /E /N M A K E M IN IA T UR E RE LA Y A N D
D8 D7 S U P P LIE D IN R E S E T B O X . P IC K S U P A F T E R R E S E T & N O R M A L .
N 24
B24 6 V PR
8TS 1 4 ) 4 8V & 1 2V D C A RE G E NE R AT E D INT E RN AL LY IN RE S E T
A5 A6 B O X F R O M 24 V B A T T E R Y .
V PR
7
9TS1 B 24
B2 B1
D2 D1
POW ER P REP. O CC . C LE A R P R E P (24 V )

RESET 5
(FR O M C O U P LE R - M S 3 of P IN 'A ' )
N 24
B 48 O UT NO 1 P PR VP R
NO 2 NO 1 NO 2
(FR O M 3
S M 's K E Y RES ET
P P R 1 -B C O N T A C T ) D6 D5 D6 D5 48 V D C A V A ILA B LE
B U T TO N
W HE N RES ET
SSDAC
VR
PPR V PR
A P P LIE D U N IT
NO 3 NO 4 NO 3 NO 4
N4 8
S M 's K E Y RESET
BUTTON A6 A5 A6 A5
S S D A C P R E P A R A T O R Y R E S E T C IR C U IT
48V will be extended to SSDAC through PPR1 back contact.

Reset Circuit
SM’s Room Relay Room SSDAC Site
N24 3 to 5 sec PPR

V
V
Timer Circuit B24
PPR1 drops after PPR drop. Picks up with
PPR pickup and with a delay to 3 to 5sec. PR B24
v
v
R1 PPR
PR
PPR1 v
N24
R2
+12V B24
Regulator
V
24 to 12V DC
N24
DC-DC converter RESET BOX
24 to 48V DC
48V 24V
O/P I/P
Line Verification button at Site
J1
PPR1
V
Push
Button SM’s Key
VPR
V PPR
V To
48V DC SSDAC
Unit
V V
48V will be extended to SSDAC through PPR1 back contact.

Measurement of Signal Levels
Card Parameter Limits Units
DC Input 19.2V – 28.8V V DC
Oscillator Output 30V – 40V rms Volts rms
Oscillator Frequency 20.8 – 21.2KHz K Hz
Oscillator Output 30V – 40V rms Volts rms
Oscillator Frequency 22.8 – 23.2KHz K Hz
Rx Coil-1(21KHz) 275 – 600mV rms V rms
Rx Coil-1(23KHz) 275 – 600mV rms V rms
5V 4.75V – 5.25V V DC
DC-DC 12V 11.5V – 12.5V V DC
Converter 24V 23.5V – 24.5V V DC
15V ISO 14.5V – 15.5V V DC
Modem Modem Voltage > 400 mV (-6dB) V DC
VR Voltage (Clear) > 20V DC V DC
Terminations
VR Voltage(Occupied) < 2 V DC V DC
Without Wheel 2.0 – 2.5V DC V DC
SCC-1
With wheel < 0.7 V V DC
Without Wheel 2.0 – 2.5V DC V DC
SCC-2
With wheel < 0.7 V V DC
Precautions for trouble free operation
POWER SUPPLY 24 VDC
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
Precautions for trouble free operation
Quad Cable
Ensure the Insulation resistance of Quad cable Shall be

greater than or equal to 10 M ohm.
Ensure the attenuation loss measured at 2 KHz Shall not

be greater than 20.0 dB for full length of the cable used.
Ensure Separate Earth of quad cable.
Maintain the Earth resistance shall be less than 1 ohm.
Length of quad cable <12 km.

Quad Cable
To prevent electromagnetic interference from parallel circuits in

the cable and location, the following guidelines are
recommended to enhance performance of Digital Axle Counter
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.
Digital Axle Counter 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.
Quad Cable
Digital Axle Counter 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 circuits (data circuits).
Any other parallel wiring (relay circuits or power circuits or

earthling wires etc) shall cross Digital Axle Counter circuits at
perpendicular and any parallel portion shall be kept at
minimum 150mm lateral distance away from the wiring for
Digital Axle Counter circuits.
Relay circuits shall preferably be not taken in the same cable

as Digital Axle Counter circuits. In unavoidable circumstances
relay circuits shall be in furthest quad (spatially) from the one
containing Digital Axle Counter circuits.
Quad Cable Twisting of Cable Pairs:
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.
Quad Cable Continuity and Earthing of cable armor & screen at
intermediate terminations/Joints:
Screening of quad cable of effective when induced current can flow in

the screen thereby canceling/reducing the induction for the cable
conductors. For adequate induced current to flow in screen, it is
necessary that good earth connections are provided for screen & armor
at all the cable terminations and joints.
Quad cable screen & armor shall be made continuous at the
intermediate terminations/joints by soldering and connecting both ends
of cable screens & amours at the locations.
Connections to screen shall preferably be made by metallic clamps
soldered to screen to ensure good surface connection for electrical
continuity.
Combined earthing for both ends of armor and screen at intermediate
locations shall be ensured to be in good condition and having values as
low as possible but never more than 5 .
Earthing connection shall be kept short and as straight as possible
because any loop or turns can create inductive elements that impede
quick discharge of transients and surges to ground.
Protective Measures
Earthing: Earthing will play major role in communication based
electronic equipment.
The maximum values of earth resistance specified for earthing of
SSDAC and its accessories is < 1
The apparatus case to be connected to earth(the chassis of SSDAC
& vital relay box should be properly connected to apparatus case.
Metallic sheath and armouring of all the underground main cables
are to be earthed.
a) A. In RE area, the metallic sheath and armouring of main
telecom cables are earthed at both ends.
b) In RE area, the armouring of jelly filled cable shall be earthed at
both ends
The earthing shall be provided at every location box where cables
are terminated.
Earth already available for other equipment may be used for
earthing of reset box near SM’s room/Cabin etc.,
Precautions to be taken during earthing:
i. The earth electrodes shall be free from paint, enamel or grease.
ii. Under ordinary condition of soil, G.I or M.S electrode is used.
iii. In areas where corrosion is likely to be excessive, it is preferable to
use either copper or copper clad electrode.
iv. The length of electrode should be of minimum 2.5m length.
v. When a rocky area is encountered at a depth of less than 2m, the
electrode may be burried inclined with the inclination being
limited to 30 from vertical.
vi. The diameter of earth electrode is such that it can easily withstand
the strain of driving in rocky areas.
vii. The earth lead is should be of adequate size to offer negligible
resistance.
viii.In case the earth lead wire is burried underground, it should be
protected from corrosion by an application of suitable anti
corrosive paint or bitumen or varnish.
ix. Where the earthing arrangement for other equipment is required
in railways, the distance between earthing electrodes shall not be
less than 2m.
x. The earth leads for separate earthing should be electrically
insulated from each other throughout and also from metallic
structures in contact with the different earthing arrangements.
xi. The minimum clearance of equipment earths provided by the
electrical department(RE) of the railways or of the other
administration should be 20m away from SSDAC Axle counter
earth.
xii. In places where the soil is extensively corrosive, the soil may be
chemically examined before deciding the material of the earth
electrode.
xiii.The earth wire should be soldered to the screen/armouring and
securely connected to the earth electrode.
Protective Measures
Surge Protection:
All input lines to the SSDAC to be routed through
Surge Voltage Protection Device(SVPD)
1. 24V power supply.
2. 48V RESET supply.
3. Modem connection.
4. Reset box LCD display information.
SPD is installed at the location box.
SPD is also installed at the input of Reset Box.
Surge Voltage Protection Devices(SVPD):
Note: It is recommended to use as shorter wire as possible for

connections and earthing to these devices for better protection. In
case of lightning do replace these modules in case of its damage due
to lightning with fresh modules.
Reset Box Indications
v
v
v
v
v
N24
Error Decoding
Each LEDs denotes one Bit
8 Bits together forms a 2-Digit Hexadecimal Number
Top 4 LEDs together forms

LSB
of Hexadecimal Number
Bottom 4 LEDs together forms

MSB
of Hexadecimal Number
MSB LSB
Error Decoding
The Respective Positions of LEDs in the Hexa Decimal Number
1 2
3 4
5 6
7 8
8 LEDs Denotes 8 Digits
8 7 6 5 4 3 2 1 Position of each digit
MSB LSB
Error Decoding (1st Method) Binary Bits Hex
Code
0 0 0 0 0
Put ‘1’ at the respective places where LEDs are glowing otherwise put ‘0’
0 0 0 1 1
11 21 0 0 1 0 2
0 0 1 1 3
13 41 0 1 0 0 4
0 1 0 1 5
15 16
0 1 1 0 6
0 1 1 1 7
170 8
1 0 0 0 8
1 0 0 1 9
8 Bit Binary Code
1 0 1 0 A
Check with given Table

1 0 1 1 B
1 1 0 0 C
1 1 0 1 D
1 1 1 0 E
Hence the error Code is 7F
1 1 1 1 F
Error Decoding Binary Bits Hex
Code
0 0 0 0 0
Put ‘1’ at the respective places where LEDs are glowing otherwise put ‘0’
0 0 0 1 1
1 2 0 0 1 0 2
0 0 1 1 3
13 4 0 1 0 0 4
0 1 0 1 5
15 16
0 1 1 0 6
0 1 1 1 7
170 8
1 0 0 0 8
1 0 0 1 9
8 Bit Binary Code 0 1 1 1 1 1 1 1
1 0 1 0 A
Check with given Table

1 0 1 1 B
1 1 0 0 C
7 F 1 1 0 1 D
1 1 1 0 E
Hence the error Code is 7F
1 1 1 1 F
Error Decoding (2nd Method) Decimal Hexa
Decimal
The Weights of LEDs are as fallow 1 1

Substitute the weight of the LED in their respective positions if glowing, otherwise
put ‘0’ in their respective positions
2 2
Glowing 3 3
1 2 Glowing 4 4
Glowing
5 5
4 8 Glowing
6 6
Glowing
7 7
1 2 Glowing
Glowing 8 8
4 8 Not Glowing 9 9
10 A
+ 0 + + + + + 11 B
4 2 1 8 4 2 1
12 C
Equivalent Decimal Number 7 15
13 D
Equivalent Hexa Decimal Number 7 F
14 E
Hence the error Code is 7F 15 F
CLASSIFICATION OF ERROR CODES
DIAGNOSTICS CHECK ERROR

COUNT RELATED ERRORS
ERROR RELATED TO WRONG TRAIN MOVEMENT
VITAL RELAY RELATED ERRORS
HARDWARE SYNCHRONISATION RELATED ERRORS
POWER INTERRUPTION & COMMUNICATION RELATED
ERRORS
POWER RELATED & COMMUNICATION ERRORS
DIAGNOSTIC CHECK ERROR
ROM TEST (0X11)

RAM TEST (0X12)
SERIAL PORT CHECK (0X13)
CARD TEST ERROR (0X14)
ROM INLINE TEST (0X21)
RAM INLINE TEST (0X22)
CARD INLINE TEST(0X24)
COUNT RELATED ERROR
INOUT ERROR (0X33)

OUT B4 IN ERROR (0X34)
NEGATIVE COUNT ERROR (0X35)
SHUNT ERROR (0X36)
ERRORS DUE TO WRONG WHEEL
MOVEMENT
INTERNAL SHUNT ERROR (0X38)
WHEEL SHUNT ERROR (0X43)
INDEPENDENT PULSES ERROR(0X44)
SENSOR ALIGNMENT ERROR (0X45)
VITAL RELAY RELATED ERRORS
RELAY DIAG OPEN ERROR (0X50)

RELAY DIAG OCC ERROR (0X51)
RELAY UNOCC ERROR (0X52)
RELAY OCC ERROR (0X53)
HARDWARE SYNCHRONISATION
RELATED ERRORS
CARD TEST ERROR (0X14)
CARD TEST INLINE (0X24)
SEQUANCE ERROR (0X31)
SELF COUNT MISMATCH ERROR(0X32)
COUNT UNEQUAL ERROR (0X39)
TRACING ERROR (0X60)
SECONDARY CPU ERROR(0X61)
SECONDARY CPU FAIL(0X62)
CONFIGURATION ERROR DURING SELF TEST (0X70)
J CONFIG ERROR (0X71)
U CONFIG ERROR(0X72)
CONFIGURATION ERROR DURING NORMAL WORKING (0X73)
R CONFIG ERROR(0X74)
POWER RELATED & COMMUNICATION
ERRORS
WATCH DOG RESET ( 0X 66)
REMOTE RESET ERROR(0X7F)
SELF RESET ERROR(0X3F)
COMMUNICATION ERROR(0X40)
CRC FAIL ERROR(0X41)
EOB ERROR (0X42)
LINK ERROR(0X30)
REMOTE ERROR (0X80)
TROLLEY SUPPRESSION
No separate Track circuit is required for trolley
suppression for Phase Modulation Type
The system may go to ERROR condition for -

Motor trolley, Push trolley with perforated wheel, Dip
lorry)
115
SURGE VOLTAGE & LIGHTNING PROTECTION
Transient surge voltages arise as a result of Lightning
discharge, switching operations in electrical systems
and electrostatic discharge. These surge voltages often
destroy the electronic equipment to a large extent.
For effectively protecting the system from surge

voltages, all the input lines of SSDAC to be routed
through surge voltage protection devices.
Each surge voltage protection device consists of two

parts, namely, Base and Plug Trab.
116
SURGE VOLTAGE & LIGHTNING PROTECTION
The Plug Trab, a detachable device, connections are

not to be interchanged with one another. It can be
replaced with SPARE unit in case of blown device,
which is indicated by means of LED for 24 V.
Effectiveness of Plug Trab depends on Earth connection

of less than 1 ohms and connections should be firm and
proper to the SSDAC unit, VR box, etc.
The Surge Voltage protection device SV-120 is to be

installed at each location along with every SSDAC unit.
117
SPD At Location Box
118
SSDAC – DO’S & DON’T
USE OF SAME QUAD PAIR. AVOID USING DIFFERENT PAIR
OR MULTIPAIR OF QUAD CABLE
EARTHING OF CABLE SHIELDS, UNITS AS RECOMMENDED
IN SSDAC MANUAL.
USE OF TOOLKIT SUPPLIED BY CEL ONLY
USE OF 1000 OHM RELAY FOR PPR, PR & VPR
USE OF REVERSE BIAS DIODES
MAINTAIN MIN DISTANCE FOR TP
INSTALL EVENT LOGGER CARD
INSTALL SURGE VOLTAGE AND PROTECTION DEVICE
119
SSDAC - DO’S and DON’TS
DO’S
a) The inter connection drawings are to be followed .
Tx1 is 21 KHz, Tx2 is 23 KHz & Rx1 and Rx2 coils
are 21 KHz & 23 KHz, respectively.
b) Ensure that Receiver and Transmitter coil cables
have been laid in different pipes. Their Spacing > 400
mm
c) Adjacent Det Points should have a min Spacing of 2m
d) Ensure that both the TX coils & Rx coils are having
proper alignment on Rail.
120
DO’S (Contd..)
d) Ensure that packing of sleepers with ballast on both
sides of Axle detector is proper.
e) Check that metal sheaths of the outdoor cable are

connected to earth at both ends.
f) Recommended cables for wiring of the system at site

should be used.
g) Steady Battery voltage 24V should be maintained.
121
DO’S (Contd..)
h) Cable connections should not be connected loosely.
i) M.S.Circular connectors of SSDAC are checked and

maintained firmly.
j) SSDAC & Reset box is provided with sealing

arrangement. They should be sealed at site.
k) Resetting should be done only after ensuring that there is

no train in the section.
122
DON’TS
a) Don’t install the Axle detectors near the rail Joint

(should be more than 6 sleepers away).
b) Don’t install the Axle detectors where the rail is

badly worn out.
c) Don’t cut or Join the Transmitter / Receiver cables

supplied along with the coil. It would result in
change of frequency of signal.
123
DON’TS (Contd..)
d) Don’t lay the TX and RX coil cables in the same

pipe.
e) Don’t use any other outdoor cable other than the

recommended cables.
f) Avoid installing the Axle detectors on curve of rail /

too much slope of rail to the possible extent.
124
DON’TS (Contd..)
g) Don’t remove the cards from SSDAC units under

power ON condition of system. Remove card if
necessary after Switching OFF the power to the
unit.
125
SSDAC-Maintenance
OSC out put:
Voltage: 30-40 V rms
Freq: 21/23 KHZ+/- 0.2 khz
RX out put :
Amplitude Type : 750-1200 mv
Phase Type : 275- 600 mv.
S.C.C Card – At Red-Black Socket
2-2.5 V DC with out wheel
<0.7 V DC with Wheel
>1.7 V DC with Push Trolley
Cable :
Loss < 30 Db for entire length at 2 KHZ
126
SSDAC- Trouble Shooting
Communication – Link, CRC, EOB
Count Related
Relay related
Reset related
Misc
127
SSDAC - TOOLKIT
PORTABLE DATA ANALYSER

DIGITAL MULTIMETER
TRAIN SIMULATOR
MARKING JIG
TORQUE WRENCH
OTHER TOOLS
TOOLKIT – PORTABLE DATA
ANALYZER
Portable data Analyzer tool
with data analysis software
Serial cable
USB to Serial Converter
SSDAC-TOOLKIT
DIGITAL MULTIMETER
TRAIN SIMULATOR FOR
PHASE & AMPLITUDE
TOOLKIT – MARKING JIG & TORQUE
WRENCH
Use only marking jig

provided along with
toolkit
SSDAC - TOOLKIT
Ring spanner 17-19,24-26

Open end spanner 17-19,
24-26
Socket spanner with handle
Screw Driver No. 902
Screw Driver No. 935
Dummy Wheel
SSDAC – DO’S & DON’T
USE OF SAME QUAD PAIR. AVOID USING DIFFERENT PAIR

OR MULTIPAIR OF QUAD CABLE
EARTHING OF CABLE SHIELDS, UNITS AS RECOMMENDED
IN SSDAC MANUAL.
USE OF TOOLKIT SUPPLIED BY CEL ONLY
USE OF 1000 OHM RELAY FOR PPR, PR & VPR
USE OF REVERSE BIAS DIODES
MAINTAIN MIN DISTANCE FOR TP
INSTALL EVENT LOGGER CARD
INSTALL SURGE VOLTAGE AND PROTECTION DEVICE
SSDAC IN 2007
CONFIRMING TO RDSO/SPN/177/2005
SYSTEM ALREADY OFFERED TO RDSO FOR TYPE
APPROVAL
UPDATED SOFTWARE S006
NEW RESET BOX RB259
NEW MODEM CARD
SOFTWARE VERSION S006
Implementation of motor trolley logic approved by

RDSO for counting of motor trolley wheels.
Increase fault tolerance in software
Software S006 already under trials at 10 different
sites in Railways.
Software version S006 with motor trolley is presently
under validation.
SSDAC – NEW MODEM CARD
High Modem Transmit Gain

High Signal to Noise Ratio
SSDAC- NEW RESET BOX
PRESENTATION
ON
CEL SSDAC
FAILURES
By
Shri M.K.RAO,
PS-2
Common Problems that happen in CEL make SSDAC
1. Reset is not working.
2. DC-DC converter card failing frequently
3. POTs in SCC1 and SCC2 Card are failing.
4. DIP switches in modem card are failing frequently.
5. Reset due to induced voltage
6. Entering into permanent failure mode.
7. Malfunctioning due to temperature.
8. Absence of Surge arrestor module (in earlier models)
9. 4/6 Quad cable parameters are not good.
Possible reasons for not working of Reset.
1. DC-DC converter of Reset card failing.
2. Failure of LM317 regulator of modem card
3. Failure of OEN switches.
4. Program corruption in 20 pin IC 89C2051.
1. DC-DC converter of Reset card failing.
2. Failure of LM317 regulator of modem card
3. Failure of OEN switches of modem card.
4. Program corruption in 20 pin IC 89C2051.
Universal programmer kit will be used to load the program
again.
To overcome the above problem length of parallelism is
reduced and also reset window is increased to 2sec – 10sec
(earlier window is from 0 sec to 10 sec)
2. DC-DC converter card is failing frequently
The voltage regulators of +5V, +12V, +24V and ISOLATION
regulators are getting burnt/damaged.
3. POTs in SCC1 and SCC2 Card are failing.
Preset pots get damaged.
4. DIP switches in modem card failing frequently.
Entry and exit switches (SW1,SW3) are getting their contacts
Permanently opened. As a result communication error is
occurring.
SMD ICs used in this card are frequently getting faulty and
these are not readily available in the market.
6. Entering into permanent failure mode.
If Tx and Rx coils are screened for more than 3 sec the
equipment enters into failure mode and for less than 3sec,
there will be no failure mode.
7. Malfunctioning due to temperature.
To avoid the effect of dust and temperature wooden planks
are provided inside the location box. As a result there is
almost 6 – 8 degrees temperature difference. Other method is
to paint the location box interior with coolant paints.
8. Absence of Surge arrestor module (in earlier models)
Surge voltages in modem lines are causing these failures. Later on
firm had provided surge arrestor and filter circuits in modem
card.
9. 4/6 Quad cable parameters are not good.

Quad cable with meggered insulated resistance of less
than 10 mega ohms and unbalance in both the conductors
in the pair is making SSDAC to fail very badly.
Quad cable with meggered insulated resistance of more
than 10 mega ohms and unbalance in both the conductors in
the pair is making SSDAC to work perfectly.
• Modifications by RDSO
• New Software S-005.
• 1000 ohms relays for PR, VPR & PPR.
• 600 : 470 ohms Transformers.
• Surge Voltage Protection Devices.
• Event Logger Cards.
.
• S-005 Software installed July / Aug 2005
• Event Logger cards & SVPD Provided

after procuring from the firms.
• 1000 ohms / 24 volts Relays provided with

available stocks.
RELIABILITY
DEPENDS ON
• Design of the Equipment
• Installation
• Maintenance
• Design change – Software 004 TO 005
• Installation – Change of Instructions from time to
time.
• 1000 ohms relays instead of QNA1 208 Ohms.
• 1120 : 470 Transformers then 600 : 470
Transformers, later no transformers.
.
• Change in Drilling Jig for Track detectors.

First : Reference from Bottom of rail.
Now : Reference from Top of the rail.
Initially recommended the common earth
and equipment.
Now separate earth for equipment and
cable.
.
• Initially only one set of address – Factory Set
• This may cause error during cable
conductor short or cross talk in a double
line.
• Now 15 set addresses (programmable)
• In this, replacing has to be done only with
identical addresses.
• Initially no gain set in modem.
• Now two range of gain settings.
.
• Improvements as told by RDSO:

• Software “ S-006
Avoiding failures due to motor trolley.
Reducing “packet length” to reduce
link error / Communication error.
High gain modem with AGC
Improved S/N ratio.
To reduce transmission error.
Improved SM’s reset box:
Display wheel count / error codes.
RECOMMENDED TOOLKIT
(1 set of tool kit to be purchased separately for every 10 sets of SSDAC systems)
1 Portable data analyzer for downloading event logger data for analysis and report
generation.
2 Pure sine wave Digital multimeter make Fluke model 187/ Rishabh model 28S /
Kusum Meco model 859CF or Equivalent
3 Train simulator, Model TS 267P CEL make
4 Extender card (Card No. 557)
5 Dummy wheel (as per Drg No. L007750A3, D14)
6 Ring spanner 17-19,24-26
7 Open end spanner 17-19, 24-26
8 Socket spanner with handle
9 Torque wrench (Jaicom JPR65 or equivalent, 88NM)
10 Screw Driver No. 902, 935
11 Marking jig for drilling (Drg No. F008300, on D29& D29A)

RECOMMENDED SPARES
The following spares are to be procured separately for 5 nos. of Single
Section Digital Axle Counter working in field
1 SCC 1&2 cards (Card 1 & 2) 2 Nos
2 MLB 1&2 cards (Card 3 & 4) 2 Nos
3 Modem card (Card 6) 1 No
4 Relay driver (Card 7) 1 No
5 Event Logger Card (Card 5) 2 Nos
6 DC-DC converter (Card 8) 1 No
7 Axle detectors (AD711) 21 KHz/23KHz (TX coil) 1 No
8 Axle detectors (AD711) 21 KHz/ 23 KHz (Rx coil) 1 No
9 Reset box RB-259 1 No
10 Vital Relay Box with Relay 24V, 1000 ohm, Q type 1 No
11 Surge voltage protection device box (SV-121) 1 No

Following measures are suggested to be checked/ observed at axle
counter installations for improved reliability.
1. While terminating Quad cable it shall be ensured that minimum one twist per inch for
the terminated pair is maintained till the last inch into connection. This ensures that
wires do not pickup energy from each other due to mutual capacitance between wires
of the same pair.
2. Circuits in quad cable shall be allocated in such way that long parallel circuits are far
apart within the cable. Long parallel circuits in close proximity affect each other. Both
BPAC circuits in double line shall never be in same quad to avoid them interfering
with each other.
3. No phantom circuit shall be used in the quad used for axle counter communication.
4. Successive axle counters in continuous block working shall have different address
settings such that no repetition of address pair is made before 4th block section.
5. No detection point within 30m of neutral section & substation. It has been identified
in UK that near these installations, there is an earth potential rise that can affect
communication circuits.
6. Traction continuity bond on both side of DP for at least 50meters shall be ensured to
keep earth potential rise at the place of DP to minimum for reasons discussed above.
7. SSDAC works upto cable loss of 30dB at 2 khz but preferably it shall be kept below
25db at 2khz to keep some margin for cable deterioration over time.
8. Wiring segregation (Min 150mm) between clean & unclean wiring to ensure that
transients and other spurious energy picked up by unclean circuits does not affect the
internal clean circuits. Clean wiring is one that is completely internal to Location. All
circuits going out of location are unclean.
9. Any crossing between these clean and unclean circuits shall be arranged at
perpendicular keeping parallel run to minimum.
10. Most axle counters are influenced by metallic part of vehicles within 100mm of top of
the rail. Wheel flange and wheel base of a wheel are the most influential part of the
total wheel in process of wheel sensing and wheel suppressing. Following are the
properties of push trolley wheels that need to be suppressed and motor trolley wheels
that need to be detected by axle counters. Any deviation in these parameters,
especially flange, tends to send axle counter into error state.
S.N. Wheel profile Push trolley Motor trolley 1. A

1. Flange height 16-22 mm 27-35 mm ppropria
2. Flange width 10mm 15mm te Surge
protectio
3. Wheel base 100mm 110mm
n (SPD)
4 Wheel type 4 spokes (spoke width 10mm) No spokes, solid
provided
on data, power and reset lines at entry point to electronics sub-systems. This ensures
that surge energy is not allowed into electronic circuits that work on low energies and
get quickly influenced by surges.
2. Suitable filter at data line to suppress power line harmonics up to 150 hz. High
common mode induced voltage can also be cause of concern since modems have
limited rejection of such common mode voltages that can corrupt the telegrams.
3. Overvoltage and Surge Protection on receiver and transmitter lines of detection point
for core to core & core to earth protections.
4. Maintenance free earth with solid dependable connections (preferably CADweld).
Any rusting at connections makes it useless. Earth wire shall be as straight as possible
to keep its impedance low.
5. All surge & overvoltage protections can function only if they get low impedance path
to earth. If impedance from SPD to earth is high then SPD is totally ineffective.
6. Proper soldering of Cable armour/screen for continuity and earthing at every cable
joint/termination. This ensures an overall low resistance path for induced currents in
armour/screen and hence better screening factor. Overall armour to earth resistance
value of 4 ohms provides reasonable screening factor less than 0.2 but if the armour to
earth resistance goes up to 10 ohms the screening factor becomes more than 0.8 and
hence screening becomes ineffective. Continuity joints ensure that even if one earth
becomes bad overall resistance to earth is kept low by other earth paths.
7. Ripple free (<50mv) power supply. Any ripples in power supply, above certain level,
reaching electronic circuits can make them behave erratically.
8. Relay circuits shall be avoided in the quad cable used for signaling data circuits to
avoid excessive heat generation by dc circuits and also to avoid switching transients
affecting data circuits.
9. Earthing wire from various equipment in location to earth terminals of locations shall
be routed away from other wiring and kept as straight as possible. Any bends and
turns introduce inductance and resultant high impedance will affect the utility of earth
connection negatively.
10. Engineering work to be accompanied by S&T staff to avoid machine disturbing the
detection points. There is no other solution to rail dolly except to keep the flange
dimensions as low as possible and less than those recommended for push trolley
above.
11. In case of rail dolley movement, engineering people shall be educated to run the same
on the rail not having axle counter DP and no metallic part of th edolley or load
thereon shall reach within 100mm of DP periphery.
12. Engineering maintenance staff shall be educated to not bring any metallic part within
100 mm around the periphery of axle counter device. Any metallic part like hammer,
shovel, spanner etc within 100mm of Detection point periphery is known to disturb
axle counter into error state.
A Modem Overview
The word "Modem" is derived from two words; "MODulator" and "DEModulator". From a data
communications perspective, a modem is a device that converts the digital bit stream into analog
signals that are suitable for transport over standard voice circuits.
Typical modems operate using Frequency Shift Keying (FSK), Phase Shift Keying (PSK),
Amplitude Shift Keying (ASK), or a combination of basic schemes.
Frequency Shift Keying (FSK)

Bell 103 Modem
This modem supports asynchronous rates up to 300 baud using Frequency Shift Keying (FSK)
modulation. Different carrier frequencies are used at each end of a 103 modem link, allowing
full-duplex operation on a 2-Wire switched voice circuit.
The Originating modem transmits signals of either 1070 Hz (Space) or 1270 Hz (Mark). The
Answering modem transmits signals of either 2025 Hz (Space) or 2225 Hz (Mark).
This modem was predominant until the early 1980s, when the Bell 212 modems became
available.
V.21 Modem
This modem supports asynchronous transmission at rates up to 300 baud. Modulation is

Frequency Shift Keying (FSK). In this modulation scheme, different carrier frequencies are used
between the Originating and Answering modems. A Space is transmitted by a change in carrier
frequency of +100 Hz. A Mark is represented by a change in carrier frequency of -100 Hz. For
the carrier frequency of 1080 Hz, a Space is represented by a 1180 Hz signal and a Mark is
represented by a 980 Hz signal. For the carrier frequency of 1750 Hz, a Space is represented by a
1850 Hz signal and a Mark is represented by a 1650 Hz signal.
This modem modulation scheme is specified in CCITT (now ITU-T) Recommendation V.21,
naturally.
Bell 202 Modem
This Bell System modem was designed to support asynchronous data at rates of up to 1200 baud
on 2-wire dial-up circuits, and up to 1800 baud on conditioned leased lines. Operation is half-
duplex and the modem modulation scheme used is Frequency Shift Keying (FSK).
A Mark is represented by a frequency of 1200 Hz, while a Space is represented by a frequency of

2200 Hz.
This modem specification also describes an optional "Reverse" channel, for slow, general
purpose use. While the specification calls for this "Reverse" channel to operate at 5 BPS, many
modem manufacturers implement 75 to 150 baud versions.
Phase Shift Keying (PSK)

201 Modem
These Bell System modems support synchronous data rates up to 2400 BPS. Full-duplex is
available, but the modem operates in a Half-Duplex mode when using a 2-Wire switched voice
circuit. This modem uses a modulation scheme that encodes data by using four specific "phase
shifts" of the transmitted carrier. This type of modulation is known as DPSK (Differential Phase
Shift Keying), but is sometimes called QPSK (Quad Phase Shift Keying).
In this modulation scheme, two bits (called a "dibit") are represented with a single phase change:
00 = 45 degrees
10 = 135 degrees
11 = 225 degrees
01 = 315 degrees
The actual modem modulation rate is 1200 BAUDS, with each BAUD capable of supporting two
data bits.
The CCITT (now "ITU-T") has specified a compatible modulation scheme in Recommendation
V.26, Alternative "B".
V.26 Modem
CCITT Recommendation V.26, Alternative "A" describes a modulation type that is similar to the
Bell 201 series of modems, except that different phase shift values are specified to encode the
"dibit":
00 = 0 degrees
10 = 90 degrees
11 = 180 degrees
01 = 270 degrees
The actual modem modulation rate is 1200 bauds, with each baud capable of supporting two data
bits.
In the second release of the V.26 Recommendation (called "V.26bis"), fallback operation to 1200
BPS is defined. V.26bis also recommends that the modulation type used be "Alternative B", as
described above (Bell 212). The third iteration of this Recommendation (called "V.26ter")
incorporates echo cancelation techniques within the modem to delineate the Originating and
Answering modem signals. V.26ter allows full-duplex operation on a 2-Wire, switched, voice
circuit.
Bell 212 Modem
This Bell System modem supports either asynchronous or synchronous data rates up to 1200
BPS on switched 2-wire dial-up circuits. Operation is full-duplex with different carrier
frequencies used between the Originating and Answering modems. The modulation method
employed is DPSK, using "dibits" to represent up to four phase changes.
The actual modem modulation rate is 600 bauds, with each baud consisting of two data bits.
The 212 modem series also incorporates a 300 baud, Type 103, modem for compatibility with
pre-existing Bell 103 modems.
This modem type was widely used in the early to mid 1980s, and is still commonly found in use
today.
V.22 Modem
This modulation is described in CCITT Recommendation V.22 and FED-STD-1008! It utilizes

Differential Phase Shift Keying (DPSK) and is designed for synchronous or asynchronous
operation at 1200 BPS. Operation is full-duplex with different carrier frequencies used between
the Originating and Answering modems.
The modem modulation rate is 600 bauds, with each baud representing two data bits.
This modem modulation scheme supports a "fallback" rate of 600 BPS.
00 = 90 degrees
10 = 0 degrees
11 = 270 degrees
01 = 180 degrees
V.22bis Modem
The "bis" qualifier is a French (also, Latin) term for "duo" or "twice". Thus, as the name would
suggest, this modulation scheme is described in the second release of CCITT's V.22
Recommendation.
This modulation scheme supports transmission of full-duplex 2400 BPS synchronous or

asynchronous data over a switched, 2-Wire, voice circuit. Alternatively, these modems may be
employed on leased-lines as well. The modulation scheme used is QAM (Quadrature Amplitude
Modulation). In this modulation scheme, the data stream is divided up into groups of four bits,
known as "quadbits". The first two bits of each "quadbit" are encoded as a phase change,
changing the "quadrant" (except in cases where the first two bits are "01"; in this case, the
"quadrant" is not changed from its previous state). The second two bits of each "quadbit" define
one of four signal states in the new "quadrant".
The modulation rate is 600 bauds, with each baud representing four data bits.
These modems support fallbacks to V.22 modulation schemes also. Most of the popular V.22bis
PC modems support fallback operation to Bell 212 modulation also, depending upon the
capabilities of both Originating and Answering modems.
Although the V.22bis specification was defined in 1984, practical deployment of these modems
did not occur until the late 1980s.
V.27 Modem
CCITT Recommendation V.27 describes a modulation scheme that is capable of supporting 4800
BPS, full-duplex, synchronous data. Operation may be full-duplex on a 4-Wire leased line or
half-duplex on a 2-Wire, switched, voice circuit. The modulation scheme is known as D8PSK
(Differential 8 Phase Shift Keying) and operates by breaking the incoming data stream into
groups of three bits ("tribit"). These "tribits" are represented by one of eight possible phase
shifts:
001 = 0 degrees
000 = 45 degrees
010 = 90 degrees
011 = 135 degrees
111 = 180 degrees
110 = 225 degrees
100 = 270 degrees
101 = 315 degrees
The modulation rate is 1600 bauds, with each baud representing three data bits.
The second and third releases of the V.27 Recommendation (V.27bis and V.27ter, respectively)
added the ability to fallback to a 2400 BPS rate using V.26, Alternative "A" modulation. Also,
the start-up/training times are reduced in the V.27bis Recommendation.
V.29 Modem
This modulation scheme was first standardized by the CCITT in 1976. It uses a form of
Quadrature Amplitude Modulation (QAM), which transports data in groups of four bits
("quadbits"). The first bit determines the amplitude of the signal while the next three bits
represent one of eight phase changes. The phase shifts are similar to the "tribit" modulation
scheme described in Recommendation V.27:
001 = 0 degrees
000 = 45 degrees
010 = 90 degrees
011 = 135 degrees
111 = 180 degrees
110 = 225 degrees
100 = 270 degrees
101 = 315 degrees
V.29 modulation is capable of transporting synchronous data at rates up to 9600 BPS. It operates
full-duplex on a 4-Wire leased line or half-duplex on a 2-Wire, switched, voice line.
The V.29 modulation rate is 2400 bauds, with each baud representing four data bits.
V.29 modulation also incorporates fallback to 7200 BPS. In this mode, three bits ("tribit") are
combined to represent one of eight possible phase changes. In this mode of operation, the
modem's modulation rate is still 2400 baud, but each baud now represents three data bits.
V.29 modulation also incorporates fallback to 4800 BPS. In this mode, two bits ("dibit") are
combined to represent up to four phase changes (0, 90, 180, and 270 degrees). The modem's
modulation rate remains at 2400 baud, but each baud now represents only two data bits:
00 = 0 degrees
10 = 90 degrees
11 = 180 degrees
01 = 270 degrees
V.29 modems were highly popular in the 1970s and 1980s for use on 4-Wire leased lines and are
still found in use today. The Group 3 FAX machines that are popular today operate in a half-
duplex fashion using V.29 modulation.
V.32 Modem
First defined in 1984 by the CCITT, V.32 defines a modem that can support 9600 BPS
asynchronous or synchronous data. Operation is full-duplex over a 2-Wire, switched, voice
circuit. The modulation used may be Quadrature Amplitude Modulation (QAM), or QAM with
Trellis coding. Trellis coding is actually a Forward Error Correcting (FEC) scheme.
The modulation rate is 2400 baud, in both "Nonredundant" and "Trellis" modes of operation. In
the "Nonredundant" mode, each baud represents four bits. In the "Trellis" mode, each baud
represents five bits; the four data bits, plus a coded, redundant bit that is the result of
convolutional coding of the first two bits in the previous "quadbit" modulation process.
The use of echo cancellation techniques allows the same carrier frequency (1800 Hz) to be used
at each end of a modem system.
Delays in the development of cost-effective echo cancelation techniques resulted in practical

deployment of V.32 modems in the early 1990s.
V.32bis Modem
This standard modulation scheme was developed by the CCITT at the end of the 1980s (1988),
although practical deployment of such systems did not occur until the early 1990s. This
modulation method allows the transport of asynchronous or synchronous data at line rates up to
14400 BPS (14.4 KBPS). Operation is full-duplex over 2-Wire, switched, voice circuits, using
echo cancelation techniques to differentiate between the Originating and Answering modem's
signals.
The modulation rate is 2400 bauds, and use the Forward Error Correcting (FEC) capabilities of
Trellis coding. Quadrature Amplitude Modulation (QAM) is employed, using groupings of seven
bits. Only six of these bits contain actual user data, the remaining bit is the convolutional coded,
redundant bit generated from the previous bits.
V.FC Modem
V.FC (or "V.Fast Class") is a non-standard 28.8 KBPS modulation scheme developed by, and
proprietary to, Rockwell. It was first released in 1993 and has enjoyed some success. As a
mature product, most of the "bugs" have been worked out, thus improving reliability. However,
the majority of the industry has been awaiting the recent release of the new CCITT V.34
Recommendation.
It is capable of supporting full-duplex synchronous or asynchronous data and supports either 4-

Wire leased lines or 2-Wire switched voice circuits.
V.34 Modem
Recently approved in the summer of 1994 was the new 28.8 KBPS modulation scheme described
in CCITT (ITU-T) Recommendation V.34. During the development of this modulation method,
this scheme was known as "V.FAST".
It is capable of supporting full-duplex synchronous or asynchronous data over 4-Wire leased

lines or 2-Wire circuits.
The modulation rate (baud or "symbol" rate) can vary. The carrier frequency can vary. The V.34
Recommendation also describes a "line probing" process that allows the modem to automatically
setup optimally for any type of line connection. The training time has been reduced, but the
modem will recover automatically from most line disturbances.
Multi-dimensional Trellis coding is employed for robust Forward Error Correcting. A "Reverse
Channel" option is also described in V.34!
Increasing speeds (V.21, V.22, V.22bis)
The 300 bit/s modems used audio frequency-shift keying to send data. In this system the stream
of 1s and 0s in computer data is translated into sounds which can be easily sent on the phone
lines. In the Bell 103 system the originating modem sends 0s by playing a 1,070 Hz tone, and 1s
at 1,270 Hz, with the answering modem putting its 0s on 2,025 Hz and 1s on 2,225 Hz. These
frequencies were chosen carefully, they are in the range that suffer minimum distortion on the
phone system, and also are not harmonics of each other.
In the 1,200 bit/s and faster systems, phase-shift keying was used. In this system the two tones
for any one side of the connection are sent at the similar frequencies as in the 300 bit/s systems,
but slightly out of phase. By comparing the phase of the two signals, 1s and 0s could be pulled
back out, Voiceband modems generally remained at 300 and 1,200 bit/s (V.21 and V.22) into the
mid 1980s. A V.22bis 2,400-bit/s system similar in concept to the 1,200-bit/s Bell 212 signaling
was introduced in the U.S., and a slightly different one in Europe. By the late 1980s, most
modems could support all of these standards and 2,400-bit/s operation was becoming common.
Increasing speeds (V.21, V.22, V.22bis)
The 300 bit/s modems used audio frequency-shift keying to send data. In this system the stream
of 1s and 0s in computer data is translated into sounds which can be easily sent on the phone
lines. In the Bell 103 system the originating modem sends 0s by playing a 1,070 Hz tone, and 1s
at 1,270 Hz, with the answering modem putting its 0s on 2,025 Hz and 1s on 2,225 Hz. These
frequencies were chosen carefully, they are in the range that suffer minimum distortion on the
phone system, and also are not harmonics of each other.
In the 1,200 bit/s and faster systems, phase-shift keying was used. In this system the two tones
for any one side of the connection are sent at the similar frequencies as in the 300 bit/s systems,
but slightly out of phase. By comparing the phase of the two signals, 1s and 0s could be pulled
back out, Voiceband modems generally remained at 300 and 1,200 bit/s (V.21 and V.22) into the
mid 1980s. A V.22bis 2,400-bit/s system similar in concept to the 1,200-bit/s Bell 212 signaling
was introduced in the U.S., and a slightly different one in Europe. By the late 1980s, most
modems could support all of these standards and 2,400-bit/s operation was becoming common.
Reasons identified for failures
Failsafe design features leading to failures
Fault Sensor broken, loosened or fallen off, or,

Rx coil is cut/disconnected.
Risk Receiver coil is not affected by wheels and
train can pass without being counted in.
Mitigation If Rx voltage goes below 20% for more
than 3s without a valid count then axle
counter latches into error mode
How this any wheel standing over wheel sensor for
leads to > 3s will simulate the mitigation condition
failures and system will latch into error
Fault Reset is applied while a train is in the

section
Risk Section goes into false clear/ preparatory
mode while train is in section
Mitigation Conditional reset policy- Last count must
be out before reset is accepted
How this System will not accept any Reset if:
leads to 1. a trolley was counted in and taken off
failures midsection
2. an error has occurred at sensor as
discussed in previous slide
Fault Two units report different status of track section

Risk Different decisions can be taken by
signalling/operator at two ends of section
Mitigation System goes into error if status packet from
other unit is not received within 3 cycles (3.2 s)
How this Following can lead to loss/corruption of data
leads to packets.
failures • Health of cable (higher dB loss)
• Poor screening factor (high EMI)
• Capacitive imbalance (non twisted wiring)
• Parallel high energy circuit in same cable
• Parallel power/relay circuit in location
CEL specific design features leading to failures
CEL- single channel Others – Both channel
System expects a valid count System expects a valid count

within 3s of any one channel after second channel is also
getting influenced, and goes influenced. This is more
into error if same is not tolerant to single channel
received in time. influences.
CEL specific design features leading to failures
CEL- High Frequency of Others –

performing 2oo2
Software matching of outputs Imported Sytems do not part
among two MLB’s is done with this kind of information.
very frequently and some
times this leads to mismatch
due to different processing
times in analog & digital
circuits of two channels
This is a known issue and is
being planned for
modification in next upgrade
Other failure areas and improvements
Electronics
Installation ABC
Sensor Others
Power
Modem Trolley Redundancy
Supply
card wheels policy
Ripples
Track
Cable Processor EM
Recording
Condition card Interference
Car
Armor &
DC-DC
sheath
converter
Earthing
DAC Installation
• PCCL for each DAC has detailed guidelines for installation
parameters to be observed before commissioning
• Voltage level and ripples at DAC location.
• Cable pair quality (dB loss, cross talk)
• Re -Twisting of cable pair after cleaning- one twist/inch.
• Earthing of electronic systems- functional earth
• Earthing of cable armor & sheath at every joint- to achieve a low
screening factor. SF can vary from 0.1 to 0.8 –requirement <0.4
• Wiring practice- TAN 6001 should be strictly followed.
• SPD & their wiring – short and straight wire with low inductance
away from other wiring of electronics, SPD of proper quality
needs to be ensured by Railways.
• DP should be away from neutral section by 30m
DAC Electronics -CEL
• Failure of cards – ABC analysis -Modem card, DC-DC card & MLB card (CEL makes).
• Component level analysis identified changes as below to achieve higher reliability level.
• Modem card –
• Dip switch - changed to OEN make- All new cards after Aug 2011 have this and in old
cards this is being changed on card failures.
• Transorb- Being removed in latest drive of modem card change. This was failing after
2-3 years in service, 100% complied by CEL.
• New modem card developed due to obsolence of chip in old card and put in trial in
NR and WCR – advance stage of approval
• DC-DC Converter Card- high efficiency card developed and now being used.
• Same PWM for all voltages 5v, 12v & 15v – now separate PWM
• Efficiency increased from 0.5 to 0.75- use of IC instead of discrete components- Low
dissipation will enhance reliability of other associated electronics also.
• Use of Electrolytic capacitor of low resistance and high ambient temp
• MLB card-
• No trend in component failures -mismatch in 2oo2 comparison due to high
frequency of comparison.
DAC Sensor disturbance Issues
Track EMI @
Trolley/ TRC
machines Sensor
Any metallic body These have some Thyristor/ IGBT

near sensor can metallic parts in
affect flux the influence
drives generate
geometry zone of DAC harmonics
4 spoke trolley Any metal part Ret Curr can

& modified TRC within 100mm produce
frame to reduce can affect magnetic field
failures sensor in RX band
TRC failures, Loco drives reqd

Co-ord & trg of
old type with to employ
machine
flangeless suitable filters to
operators reduce EMI
wheels
DAC Sensor level
• Trolley influence- Railway board guidance and RDSO
drawing for 4 spoke trolley has been issued in 2007.
This is being re- emphasized for implementation with
other details like flange dimensions in consultation with
TM directorate.
• TRC frame has been modified and response has been
encouraging. Nil failures on UAC, 5-10% on other DAC’s
except AM type SSDAC used only in SCR (50%).
• Software change for Increased tolerance for health
signal when section is occupied.
DAC other Issues
• Redundancy policy for electronic equipment- hot
standby to take over failed equipment on high
density lines. RDSO has developed a High
availability scheme with SSDAC for BPAC
applications having auto resetting facility.
• Electromagnetic compatibility study for axle

counters with rolling stock & traction (both RSF
and WSF can be caused by induction and rail
currents)
DAC Improvement – RDSO outputs
SN Item Problem Achievement Remarks
1. SSDAC Large nos of To reduce the large nos of one time
resetting cases resetting cases of Axle counter,
of Axle counter • High availability SSDAC developed
which hampers by 2 approved vendors.
the train • Successful trials are being conducted
operation badly, over SCR,NCR [for M/s CEL make
SSDAC]and SR,SWR & ECR [for
M/s GGT make SSDAC]
• SSDAC spec[RDSO/SPN/177/2005
ver-2] has been modified by including
the feature of High Availability
SSDAC .
STATION STATION
Block Section
A B
Quad for media-1

High Availability SSDAC High Availability SSDAC
OFC/Quad (different Quad cable for media-2 if OFC not available)
Notes:
1. Sensors shall be put on any one of the rails (Track) . It should be ensured that sensor should preferably be
deployed on the inner rail at the curvature of track for better reliability.
2. Communication from duplicated SSDAC modules shall be preferably using diverse media (Quad/OFC).
3. when one of the output is showing clear whereas other is showing occupied for more than 10 seconds, the
unit/module showing clear will automatically reset the failed one.
4. All resetting will only be of preparatory reset type.
5. A high availability SSDAC system having redundant modules i.e Processor card , Modem card & Relay Driver
card within a single chassis is developed, details shall be advised once approved.
6. Maximum distance is actual circuit length (including tail cables length) between SSDAC units and not just the
block section length.
7. SSDAC can work up to a maximum distance of 18 Kms on 0.9 mm quad cable and 28 Kms on 1.4 mm quad
cable.
8. Maximum circuit length of 18/28 Kms is based on a 30 dB max. attenuation limit @2 Khz.
9. Use of dual sensors on different rail with high availability system is optional.
Title: Arrangement for High availability SSDAC for BPAC application Signal Directorate, RDSO Lucknow. dsig7@rdso.railnet.gov.in
Drawing/Schematic Number Page x of y Filed at Month/Year JE/SE ADE Director/Signal
2012/DAC/001 1 of 2 STS/E/AC/SPN/177 May/2012

High availability SSDAC for BPAC application (Typical Layout)
Duplicated card Duplicated card Duplicated card Duplicated

card
Processor card Processor card Modem card Relay Driver

for SSDAC for SSDAC for module --1 card for module
module -1/1 module -2/1 --1
Power
Signal Signal supply
Event
Processing Processing card for
Logger card
card card SSDAC
Processor card Processor card Modem card Relay Driver
for SSDAC for SSDAC for module --2 card for module
module -1/2 module -2/2 --2
Notes:
1. SSDAC shall be preferably using redundant diverse media (Quad/OFC).
2. Details of duplicated modules in high availability SSDAC is shown as above.
3. When one of the outputs is showing clear whereas other is showing occupied for more than 10 seconds,
the unit/module showing clear will automatically reset the failed one.
4. Above is typical card arrangement only.
Title: Arrangement for High availability SSDAC for BPAC application Signal Directorate, RDSO Lucknow. dsig7@rdso.railnet.gov.in
Drawing/Schematic Number Page x of y Filed at Month/Year JE/SE ADE Director/Signal
2012/DAC/001 2 of 2 STS/E/AC/SPN/177 May/2012

DAC & BPAC Improvement – RDSO outputs
2. SSBPAC Cumbersome To make block operational working 2 more vendors are
Block easier and reduce a little operational time showing interest to
operational and also have hassle free working, develop this
working in ‘A’ 1. Developed a Solid State Block product,
& ‘B’ route proving by Axle counter by 1 source. 1. M/s GGTronics,
which took 2. Based on successful standalone trial, Bangalore
more time Limited supply approval to one 2. M/s Medha
To increase the vendor has been accorded (M/s Servo Ltd,
section Efftronics). Hyderabad
capacity by
reducing the
block
operational
time, there is
need to
develop a solid
state Block
proving by
Axle counter
system
SSBPAC
• Embedded system used for
replacing relay logic and
communication between two
stations for block working
• 2oo3 architecture of hardware for
redundancy
• Two separate modules for single
line and D/L working
• Fast operation due to digital data
exchange between Stns
• Data logging and alarm
generation for fault rectification
• Limited supply approval given to
M/s Efftronics on 30/3/12
• M/s Medha have also registered
for developing the system.
SSBPAC
DAC & BPAC Improvement – RDSO outputs
3. BPAC Cumbersome To make block operational working
using Block operational easier and reduce a little operational
UFSBI working in ‘A’ & time and have hassle free working,
‘B’ route which • Develop more vendors for
took more time supplying a BPAC with UFSBI
To increase the system
section capacity
by reducing the • Based on successful trial, Limited
block operational supply approval to one vendor
time, there is [M/s Webfill, Kolkata] has been
need to develop a accorded .
system using
OFC/Quad for • Another vendor’s case (M/s
inter station CEL)is in advance stage of trial
information permission.
exchange
DAC further Improvement areas (CEL)
• DC-DC converters have been modified in 2009. Older cards need to be
progressively replaced by Railways.
• Software modification
i. To have higher tolerance to single channel influence causing system going to
error. Presently this is 3 influences.
ii. To incorporate one improper wheel pulse if followed by a proper wheel pulse
will be counted as a proper wheel pulse and system will not go into error.
iii. To incorporate communication break during occupied state – when system
gains communication it will check if there was any change in counts at both
sensors and if so then it will go into error otherwise it will regain occupied
state.
• For Error 61 – Mismatch in 2 out of 2 Decision making – Tolerance in declaring
the Error 61 may be increased to match with relay contact switching times.
• For Error 37 – Supervisory Error – If Level Detector output drops for more than
3.5 secs, then Error 37 is declared. This error duration can be increased
suitably.
• CEL’s suggestions for declaring the section as Occupied after influence on
second channel of sensor instead of wheel influence on first channel of sensor
has already been agreed by RDSO. This has to be implemented.
• If SVPD has gone out of order & earthing is also not proper it can also introduce
noise in communication channels. SVPD monitoring & replacement is needed.
DAC Further Improvement areas
(Eldyne make MSDACs)
• Upgraded Version 6.1.11 is having CPU hanging issues noticed in Kolkatta
Metro and BPL division. M/s Thales is analyzing the problem and likely
solution to the issue. Early action from M/s Thales and Eldyne is needed.
• Railways need to have spares which are tested atleast once a year.
• Multiple systems need to be networked for better monitoring.
• Cable parameters to be monitored periodically especially attenuation loss.
• GDI interface can be extended to the ASM to enable proper reporting of
failure and accordingly quick restoration.
• Need to have separate ACE for UP/DN lines in ABS applications.
DAC Further Improvement areas (GGTronics )
• Display of BER/packets dropped on existing display of reset
box – this will help in monitoring of cable parameters
• Railways have reported too many indications cause confusion
– a rethink is needed to deliberate and if possible reduce the
number of indications
• Event logger is not user friendly – selective downloading and
understandable data format is needed.
• Colour coding for LDs of power and modem is needed for
ease in maintenance.
DAC Further Improvement areas (SIEMENS)
• Lightning protection is found inadequate, need for

improvements like better quality of SPDs as used in OEM
systems.
• Deciphering of indications is difficult for maintainers.
• Separate Evaluators for UP/DN lines in ABS is needed
• Usage of modem to transmit sig data also leads to big failures
if modem gives trouble. Cables should be used for this
purpose.
NAND
A NAND gate is made using an AND gate in series with a NOT gate:
Desired Gate
Truth Table
Input A Input B Output Q
0 0 1
0 1 1
1 0 1
1 1 0
XOR
An XOR gate is constructed similarly to an OR gate, except with an additional NAND gate
inserted such that if both inputs are high, the inputs to the final NAND gate will also be high,
and the output will be low. This effectively represents the formula: "NAND(A NAND (A
NAND B)) NAND (B NAND (A NAND B))".
Desired Gate NAND Construction
Truth Table
Input A Input B Output Q
0 0 0
0 1 1
1 0 1
1 1 0
What is the difference between "Simplex, Diplex, Half Duplex & Duplex" in
communication systems.?
Simplex :- Comunication possible in one direction only .. like a one way road , so data can only
be transmitted from A to B
Duplex : Communication is possible in both the directions, i . e From A to B and B to A
Half - duplex : Communication possible in both directions , but only one at a time , either from
A to B or B to A
Semi Duplex (Diplex) :Semi-duplex operation is a method which is simplex operation at one
end of the circuit and duplex operation at the other
The following circuits are affected.
CCC-
line cancellation/close
line clear
LSS clearance
Page 1 of 34 Issued date - Specification of SSDAC RDSO/SPN/177/2012 Ver. 3
Draft copy for comments
SINGLE SECTION DIGITAL AXLE COUNTER
SPECIFICATION NO. RDSO/SPN/177/2012
Version 3.0
RESEARCH, DESIGNS & STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
MANAK NAGAR
LUCKNOW - 226011
DOCUMENT DATA SHEET
Designation
Version 3.0
RDSO/SPN/177/2012
Title of Document
Single Section Digital Axle Counter Specification
Authors: See Document Control Sheet

Signed by:
Name: Prashant K Varma
Designation: Director / Signal
Approved By RDSO
Name: Shri Mahesh Mangal
Designation: Sr. ED/Signal, RDSO
Abstract
This document defines Single Section Digital Axle Counter Specification.

Document Control Sheet
Designation Organization Function Level
Director/Signal RDSO Member Prepare
Sr.ED/ED/Signal RDSO - Approval

AMENDMENTS
Version Chapter/ Amendments Effective Date

Annexes
1.0 - First issue 14.01.2003
1.0 with Amendment 1 Clause 10 modified for 10.02.2003
Typographical errors,
regrouping/inclusion of
tests etc.
1.0 with Amendment 2 - (i) Clause 4.8, 4.13, 5.2, 1.7.2003
5.10, 10.3.1, 10.4.1.1,
10.4.2.1, 10.5.11.2
(ii) New addition of clause
10.5.12.
2.0 - - 15.04.2005
2.0 with Amendment 1 - (i) Cl. 4.0.23, 4.0.27,
4.0.28, 4.4.6, 4.4.7,
4.6.5, 5.1.2, 10.5.5.6
modified.
(ii) New addition of
clauses – 3.0.18,
4.0.35, 4.0.36, 4.2.5,
4.4.12, 4.5.7 & 18.1.
3.0 (i) Cl. 4.04 Inclusion of
SSC comments.
(ii) Inclusion of ver-2.0,
amndt-1
(iii) New addition of
clauses inclusion of
High availability
system
le of Content
Cl. No. Item Page No.
1.0 Scope. 6
2.0 Terminology & Abbreviations 6
3.0 Applicable document/drawings 7
4.0 General requirements. 8
5.0 Diagnostics 17
6.0 Traction & Supply 18
7.0 DC Input Power Supply 18
8.0 Hardware standards. 18
9.0 Performance. 21
10.0 Inspection & Testing. 30
11.0 Quality assurance 30
12.0 Marking & Identification 30
13.0 Packing. 30
14.0 Warranty. 31
15.0 Documentation. 31
16.0 Purchaser’s responsibility. 31
17.0 Supply of documents. 31
18.0 Item to be specified by Purchaser. 31
19.0 Tools for maintenance 32
Annexure – I (Schematic HA-SSDAC) 33-34
SPECIFICATION FOR SINGLE SECTION DIGITAL AXLE COUNTER

1.0 Scope
1.1 This document sets forth general, operational, technical, performance & type
tests requirements of Single Section Digital Axle counter.
1.2 This specification does not cover requirements of external cable and protective
devices to be used in conjunction with Digital Axle Counter for its installation.
2.0 Terminology & Abbreviations:
2.1 Terminology
2.1.1 The terminology referred to in the specification is covered by the definitions
given in IRS Specification no. S-23, IS Specification No. 9000 and as given
below.
2.1.2 Axle detector/Track Device: The track device comprising of the coils sealed in
a cover mounted on the rail. It will detect the wheel of rolling stock axle passing
over the device.
2.1.3 Counting device/Digital Axle Counter field unit (track side): Counting
device/digital axle counter field unit is the track side electronic assembly that
energise the axle detectors for detecting the passing wheels determining the
direction of movement and supervision of track section or occupancy/output
device, keeping the count of wheels. It is capable of communicating with other
counting device at the other end of the track section.
2.1.4 Detection Point: Detection point comprises of one axle detector/track device
and the field unit connected to it.
2.1.5 Track Section: The portion of track confined by associated axle detectors & field
units. The occupancy of this section being supervised by the axle detectors.
2.1.6 Section Balancing: Axle counter determines whether the track section in question
is clear / occupied, based on the information of detected (in counts and out
counts) numbers of axles, which is received from the axle detectors confining the
section in question.
2.1.7 Resetting: Resetting results in bringing to zero the records of counted axles.
2.1.8 Preparatory Reset: After resetting, axle counter shall continue to show occupied
until one train movement through the section carries out correct balancing of track
section.
2.1.9 Conditional Hard Reset: The reset is activated after physical verification of a
condition from different location like the clearance of the track section from site
using line verification box. The axle counter will show clear after the conditional
reset.
2.1.10 Event Logger: logs the events occurring in the field unit with date and time
stamping.
2.2 Abbreviations
2.2.1 dB - Decibel
2.2.2 AWS - Auxiliary Warning System
2.2.3 TPWS - Train Protection & Warning System
2.2.4 TX - Transmitter
2.2.5 RX - Receiver
2.2.6 KHz - Kilo Hertz
2.2.7 LED - Light Emitting Diode
2.2.8 LCD - Liquid Crystal Display
2.2.9 AFTC - Audio Frequency Track Circuit
3.0 Applicable documents/drawings:
1 IS: 9000 Basic environmental testing procedures for electronic

and electrical items.
2 IRS-S-23 Electric Signaling and Interlocking Equipment
3 ISO 9001 Quality systems – model for quality assurance in

design, development, production, installation and
serving.
4 IEC529/ EN 60529 Specification for degree of protection provided by

enclosures (IP code).
5 EN 61000.4.2 Electromagnetic compatibility (EMC) – testing and

measurement techniques- electrostatic discharge
immunity test and basic EMC
6 EN 61000.4.4 Electromagnetic compatibility – testing and

measurement techniques- electrical fast transient/burst
immunity test and basic EMC publication
7 EN 61000.4.5 Electromagnetic compatibility – testing and

measurement techniques – surge and immunity test
8 PrEN50126 Railway applications - specification and

demonstration of - reliability, availability,
maintainability and safety
9 PrEN50128 Railway applications – Signalling and

Communications – Software for Railway Control and
Protection system
10 PrEN50129 Railway application: Safety related electronic

systems for signalling
11 EN 50159-1 & 2 Railway Application: Signalling and Communication

Safety related communication in closed and open
Transmission system
12 IRS: S TC-30 Underground Railway Jelly filled Quad Cables for

S&T installations.
13 RDSO/SPN/TC/72 1.4mm dia Copper conductor 4/6 Quad cable
14 IRS S 99 Datalogger system
15 RDSO/SPN/165 SMPS based IPS.
16 IRS: S 86 Battery Charger-Self Regulating.
17 IRS: TC 41 PIJF Telephone Cable.
18 RDSO/SPN/144 Safety and Reliability Requirement of Electronic

Signalling Equipment.
19 –
RDSO/S/20003 Drawing for Digital Axle Counter Reset Box with
display (fascia)
20 RDSO/S/20004 Drawing for High Availability SSDAC system reset

box with display.
21 RDSO/TM/05/10 Wheel for Inspection (Push) trolley
22 RDSO/S/20002 Drawing for Verification Box
3.1 Wherever in this specification, any of the above-mentioned specification is

referred; the latest issue of the same is implied.
4.0 General Requirements:

4.0.1 Single section digital Axle counter consists of axle detectors & associated
electronics (1 or 2 or 3 or 4) confining a track section connected together by a
transmission medium where transmission is in VF range. It is capable of counting

axles, doing count comparison, finding direction of axle movement, supervision,
relay drive and transmission of counts and health of axle detectors & field units.
4.0.2 Track clear indication shall only be given when IN count and OUT count are
equal and equipment is functioning all right. This implies that until all axles that
enter a section are completely counted out, the section concerned shall not show
as clear.
4.0.3 Axle counter shall show occupied the moment any of the axle counter sub-
assemblies belonging to the section is damaged, missing or has become faulty.
4.0.4 Axle Counter shall use amplitude/phase change techniques or any other fail
safe techniques for safe and reliable wheel detection functions.
4.0.5 Axle counter shall have arrangement so that wheels of push trolleys, dip lorry, rail
dollies etc. are not counted by it. These wheels shall not result in axle counter
going to error. Trolley protection track circuit shall not be required with phase
detection. (RDSO drawing no. RDSO/TM/05/10 for push trolley).
4.0.6 Axle counter operation shall be independent of wear & tear of wheels as
permitted vide Indian Railway’s Schedule of Dimension, lateral displacement of
wheels on rails etc. The manufacturer shall specify the minimum diameter of the
wheels, condition of wheels etc., to which the performance of equipment shall not
be affected.
4.0.7 Axle Counter operation must be independent of type of sleepers in the section
such as wooden, RCC, or steel etc. and shall work on all types of rail profiles and
construction such as welded or non-welded rails of 52 kg / 60 kg / 90R etc. Axle
counter shall operate up to the limit for wornout rail as given below:
Sl. No. Rail section Vertical wear in mm.

1. 60 Kg / metre 13.00
2. 52 Kg / metre 8.00
3. 90 R 5.00
4.0.8 Axle counter shall be suitable for train speeds up to 250 Km/h.
4.0.9 Axle counter system shall be designed for ease of maintainability and testability.
4.0.10 The equipment shall be robust in construction and shall work on the permanently
energized principle. Any defect occurring in the equipment shall not result in a
condition that will lead to unsafe situation.
4.0.11 The equipment shall be of continuously self-checking type and shall have separate
indication to show conditions of track clear and track occupied (including fault).
Any disturbance or failure in the equipment including power supply failure shall
result in withdrawal of clear indication and occupied indication shall be lit.
4.0.12 Card wise failure indication shall be provided. It is desirable to give suitable
indication of the nature of failure. Also total system failure and O.K. indications
shall be provided.
4.0.13 Axle detector/Track Device & field units shall have no moving parts and shall
require negligible maintenance.
4.0.14 The equipment shall be so constructed as to prevent unauthorized/irregular access
to sub-assemblies of the system. Authorized persons should, however, have
access to these sub-assemblies for the purpose of installation and maintenance by
unlocking the outer cover/breaking of seal provided on the outer cover.
4.0.15 The field unit shall be provided with testing, measuring and adjusting facilities for
maintenance.
4.0.16 The equipment shall be fully solid-state using carefully chosen components of
grade as per details given in SPN/144.
4.0.17 The system shall provide for continuous supervision of axle detector including the
cable connecting the counting device and axle detector. Any defect in these shall
be immediately detected, error code displayed and the system should go in error
mode.
.0.18 The maximum axle count, the axle counter can handle should be > 1024.
4.0.19 Response time of train occupancy for any track section shall be less than 1.0
second.
4.0.20 Clearance time of any track section after train leaves the section shall be less than
2.5 sec.
4.0.21 Axle counter system design shall take into consideration system growth
capability and architecture of digital axle counter shall be such that it is fit to be
used on all the sections of Indian Railways including suburban sections.
4.0.22 Environmentally, slight moisture condensation shall not lead to malfunction or
failure of equipment.
4.0.23 The design of axle counter shall take into account switching transients that may
occur either inside or outside the system and of any magnitude., up to and
including interruption of full short circuit current.
4.0.24 Axle counter shall withstand the effect of lightning & surges incorporating
lightning & surge protection as per RDSO/SPN/144.
4.0.25 The equipment shall conform to the Safety Integrity Level 4 as per CENELEC
Standard.
4.0.26 The axle counter should not affect the operation of other wayside signalling
equipments.
4.0.27 The axle counter shall neither affect or be affected by presence in vicinity of track
side signalling equipments like AFTC, TPWS, AWS etc. 4.0.28 Error rate
should not be more than 2 errors per million correctly counted axles, and if there
is error, it should not result in unsafe condition.
4.0.29 The equipment shall be capable of simultaneously counting in and / or counting
out from the ends of the monitored section.
4.0.30 Response of rocking of wheels on Axle Detector: If any sensor is influenced two
or more times consecutively without a proper count pulse, the system should go to
error. If both sensors are influenced four or more times consecutively without a
proper count pulse the system should go to error.
4.0.31 Axle counter should tolerate induced voltage of at least 150V AC, 50Hz on the
quad cable. Any external surge protection device required to achieve this shall be
part of SSDAC supply.
4.0.32 It shall fulfill fail safety requirements as per RDSO/SPN/144.
4.0.33 It shall fulfill the requirements of Signal Engineering Manual as per
RDSO/SPN/144.
4.0.34 The software shall fulfil the software requirements as per RDSO/SPN/144.
4.0.35 Both hardware and software functions will be partitioned to ensure that integrity
of certified design will not be compromised through routine software and
hardware upgrades.
4.0.36 Design of axle counter will maximize the use of vendor independent
implementations.
4.1 Configuration: Single section axle counter will work in following

configurations:
4.1.1 One detection point Single section: In terminal lines / siding.
4.1.2 Two detection points Single section: In straight line.
4.1.3 Three detection points Single section: In point zone.
4.1.4 Four detection points Single section: In point zone.
4.1.5 Three-detection points two sections and also scalable for consecutive sections in a
straight line.
4.1.6 Use as High Availability SSDAC system (HA-SSDAC) (e.g. for BPAC
applications): High availability system uses proven electronic circuits of standard
SSDAC, duplicated on same board/card. This system also facilitates use of
redundant communication channels by using quad/OFC to overcome common
mode failures. System provides two vital relay outputs from two channels that are
used in ‘OR’ mode to interface with interlocking/block circuits. System uses
‘Auto-reset Feature’ to reset the failed channel of system by correctly working

channel under steady state conditions. Complete electronics of high availability
SSDAC system is integrated in the same chassis of a standard single channel
SSDAC. Interfaces for the operator still remains the same and he is required to
manually reset the system only when both channels of the systems have failed.
Single reset interface will send reset command to both the channels and the reset
command is extended to electronic via drop contact of vital relay of concerned
channel. The High Availability SSDAC system can be provided with
4.1.6.1 Single track sensor input fed to both channels of HA-SSDAC (Annexure – I
Drg:2012/SSDAC/001 sheet 1 of 2 attached )
4.1.6.2 Dual track sensor inputs fed to different channels of HA SSDAC. (Annexure I
Drg:2012/SSDAC/001 sheet 2 of 2 attached)
Note: The option [selection] of single track sensor/dual track sensor can be
exercised by the ordering authority based on density of traffic and considering
MTBF requirements.
4.2 Vital Relay Drive
4.2.1 Free and occupied indications of the axle counter section shall be available in the
form of vital relay pick up and drop contacts.
4.2.2 For one detection point single section and two detection point single section
configurations, each field unit shall drive its vital relay. The field unit of the
common detection point mentioned in para 4.1.5 shall drive two relays of
adjacent sections.
4.2.3 For three detection point single section and four detection point single section
configuration, vital relay may be provided in any one of the field units.
4.2.4 The relay to be used is 24V DC, 1000-ohm plug-in type. In section clear
condition, the relay driver output shall be more than 20V DC and in occupied
condition, it should be less than 2.0V DC.
4.2.5 The design should incorporate fail safety feature such that when the vital relay is
in drop condition as per status of the track section, if any external voltage appears
across the vital relay coil which can pick-up the vital relay, then the system
should detect it and the concerned axle counter section/track section will go to
error state.
Spark quenching arrangement should be provided across vital relay coil operated
by the field unit.
4.3 Axle detector:
4.3.1 It comprises of two sets of TX/RX coils / sensors.
4.3.2 The TX/RX coils shall operate at frequencies above 20 KHz.
4. 3.3 Different frequencies shall be used for each set of TX/RX coils.
4.3.4 These shall be capable of withstanding environmental conditions given and

specified later. The inductance of axle detectors shall not vary more than ±6%
within the specified temperature range.
4.3.5 The transmitter/receiver coils in the track shall be of web mounted type. The
fasteners should be tightened at specified torque using torque wrench.
4.3.6 Axle counter performance shall not be affected by the flooding of track.
4.3.7 The axle detector shall be actuated only by wheel flanges and not by other parts of
trains e.g. rail brakes, toilet pipes, suspended chains, electrical inductors in
locomotives, air-conditioning equipments and other electrical /electronic
equipment in train /engine.
4.3.8 One set of axle detector shall not influence another set of detector mounted ≥ 2
meters away.
4.3.9 The axle detector should not infringe with the Schedule of Dimensions of Indian
Railways.
4.3.10 The length of inbuilt cable with Axle Detector shall be 5 / 10 / 15 Mtr. Only.
4.3.11 Only shielded cable is to be used to carry track device signal to field unit.
4.4 Resetting:
4.4.1 A voltage sensitive feature shall ensure that without the operation of re-setting
key, the system will not come back to initial or original condition for the
following cases:
4.4.1.1 Power fails and restores back
4.4.1.2 Voltage fluctuation beyond upper and lower limits

4.4.1.3 Removal of printed circuit cards from the system.
4.4.1.4 In case OUT count has been registered before any IN count.
4.4.2 It shall be possible to reset each field unit from reset box only. For HA-SSDAC
auto-resetting module will send reset automatically if one channel only has
failed.
4.4.3 If all the field units of an axle counter section are placed in the same station,
same/one reset box can be used to reset all the field units of one section in
parallel.
4.4.4 If any field unit of an axle counter section is placed in different station, then
separate reset box shall be used for resetting that field unit.
4.4.5 If reset is applied to only one field unit, the axle counter section will not reset and
will continue in occupied condition.
4.4.6 In two detection point single section and three detection point two section
configuration, when reset is applied to both the field units the axle counter
section should go in “preparatory reset mode”. The preparatory reset LED in both
reset boxes should glow and reset counter should increment. The axle counter
section will be still in occupied state although the axle counts of individual field
units will become zero. The axle counter section will become clear only after
more than one in count from one end and same number of out count from the
other end have taken place. The common field unit in three detection point two
section configuration shall accept reset command from two separate reset boxes
for adjacent sections.
4.4.7 In one detection point single section, three detection point single section and in
four detection point single section configuration, the reset command from reset
box will be transmitted only after verifying that verification switch have been
pressed & turned in the verification box at site as a proof of the axle counter
section being clear physically. On availability of reset command to all the field
units of a section, the section will reset and show clear and reset counter should
increment.
4.4.8 The reset box with LCD display should work from 24V DC supply. The
following should be provided in the reset box (as per Reset Box drawing no.
RDSO/S/ 20003 and 20004).
4.4.8.1 A six-digit (min.) non-resettable type counter
4.4.8.2 Reset switch with keyReset push button – Red
4.4.8.3 Axle counter section clear indication (LED-10mm) –Green
4.4.8.4 Axle counter section occupied indication (LED-10mm)-Red
4.4.8.5 Power OK indication (LED-3mm)-Yellow
4.4.8.6 Preparatory state indication (LED-3mm) –Green
4.4.8.7 Line verification indication (LED-3mm)-Yellow
4.4.8.8 Reset box shall have provision for a data download port along with necessary
memory to store last thousand events.
4.4.9 The possibility of reset will be as per table below. This shall be controlled by
software:
S.No. Conditions Whether reset permitted
(Yes/No)
1. No in count, No out count, No
section clear & healthy.
2. No in count, No out count, Yes
Error has occurred.
3. Only in count, No out count, No
System healthy
4. Only in count, No out count, Yes
Error has occurred.
5. In count & out count started, Yes
System healthy
6. In count & Out count started, Yes
Error has occurred
7. No in count, but only out Yes
counts, system goes to error.
8. System in preparatory mode No
4.4.10 Provision shall be made for recording every operation of resetting by means of
non-resettable counter. For one reset operation, the counter should not increment
by more than one.
4.4.11 There shall be provision of sealing in the reset box.
4.4.12 The line verification box shall be as per RDSO Drg. No. RDSO/S/20002
4.4.13 Auto reset modules (either separate entity or inbuilt in the main reset module)
shall be part of high availability SSDAC for both ends of a SSDAC system. Auto
reset module will generate reset pulse whenever there is a steady state mismatch
in VR/VPR’s for more than 10 seconds of two channels of high availability
system. Reset pulse will be connected to system in the field through drop contact
of VR/VPR’s of respective systems.
4.5 Digital Axle Counter field Unit.
4.5.1 It shall have 2 out of 2 architecture.
4.5.2 It shall detect and count axles passing over the axle detector.
4.5.3 It shall determine the direction of passing of axles.
4.5.4 Provision should be there for lightning & surge protection in the field unit power
supply input and communication line input/output.
4.5.5 The field units should be able to communicate with each other for transmission
loss up to 30dB.
4.5.6 Suitable arrangements shall be made for providing electrical isolation between
external relay circuit and internal circuit.
4.5.7 It shall have provision for setting unique address of each field unit. The address
shall be of minimum 8 bits.
4.6 Communication:
4.6.1 It shall be possible to use copper cable or voice channel in optical fibre cable
communication for transmission of data between field units. The copper cable will
be quad cable as per IRS: TC: 30-2005 (0.9 mm dia) or quad cable as per
RDSO/SPN/TC/72/2007 (1.4 mm dia) or PIJF Telecom Cable as per IRS: TC
41/97 (0.9 mm dia.). No separate external interface should be required for using
any of these two transmission mediums.
4.6.2 Impedance matching between communication channel and modem shall be
provided.
4.6.3 It shall be capable of transmission of axle counts, health status and other
information between connected field units on a transmission link. The
transmission link, in case of copper cable, shall be ½ quad telecom cable or 1 pair
in PIJF cable or one 2-wire voice channel in case of OFC. The rate of
transmission should be minimum1200 baud.
4.6.4 Fault tolerant telegrams shall be used for transmission of axle counts and other
information between field units. CRC to be used for error detection and the
hamming distance of the message protocol shall be at least 5. The code
transmission should be safety validated. Communication should be as per CCITT
standard.
4.6.5 Minimum 2 (two) consecutive telegrams will be required to verify the integrity of
the status of direction and counts transmitted. However, for the information that
in count has started, action may be taken after receiving first telegram itself to
take the axle counter section to occupied state (a safe state). The manufacturer
shall specify the minimum length of the axle counter section for which the axle
counter section shall work properly for train running at maximum speed as
specified.
4.7 Earthing:
4.7.1 Provision of earthing should be there in the field unit and reset box. The earth
terminal shall be suitable for taking upto 4mm dia. copper wire with lug.
4.8 Event Logger
4.8.1 Each field unit should be provided with in-built event logger.
4.8.2 The event logger should work automatically without any other input required to
be given by staff.
4.8.3 Digital Axle Counter failures shall not affect in any way the correctness of the
information recorded in the Event Logger, neither shall it cause its loss nor
change.
4.8.4 The event logger shall record events happening in the axle counter system.
4.8.5 The data registered in the event logger must be secured against erasing by
unauthorized persons.
4.8.6 Event logged should be date/time stamped.
4.8.7 It should be possible to download logged events to a commercial computer
through standard port.
4.8.8 The process of event logging and downloading of logged events should not
hamper the normal working of axle counters in any manner.
4.8.9 The event logger shall record following events as the minimum:
4.8.9.1 Resetting of a track-section, field unit.
4.8.9.2 Failures/errors in field units.
4.8.9.3 Breakdown of communication link (s).
4.8.9.4 Change in relay status for section occupied / clear.
4.8.9.5 Changes in 5 V output of DC-DC converter beyond limits.
4.8.9.6 Change in date / time.
4.8.10 Provision should be there to log minimum 1000 events. In case of its memory
becoming full, the event deletion should be on first in first out principle.
5. Diagnostics
5.1 Diagnostic system of the axle counter shall provide the following :-
5.1.1 Local and remote diagnostics and testing of system through a serial connection
5.1.2 Self-detection of errors and display through error codes and brief description in
reset box through alphanumeric LED/LCD display. The same display should
normally show in count / out count and software version no. when the system is
switched on initially
5.2 Diagnostic information should not be considered vital.
5.3 Diagnostic functions shall be carried out on a permanent basis without disturbing
normal operation of the equipment.
5.4 Information on the state of the equipment in failure mode and on operations
performed by the staff shall be registered.
6. Traction and supply

6.1 Axle Counter system shall be capable of working in all sections including non-
electrified, 25 kV 50 Hz AC, 1500 V DC & 750V DC electrified areas.
6.2 The axle counter should operate correctly under traction return currents of up to
following magnitudes
6.2.1 25 kV / 50Hz 1000 A
6.2.2 1.5kV/dc 6000 A
6.2.3 750V/ dc 3000 A
6.3 The currents or their harmonics flowing in the rolling stock & rails shall not
affect the digital axle counter.
6.4 The equipment shall be immune to extraneous magnetic or electric fields such as
due to traction return currents on electrified sections, traction motor failures,
vehicle magnetism or due to any other source.
6.5 The electromagnetic brakes in its both on and off states should not affect the axle
counter.
7. DC Input Power Supply:

7.1 The field unit shall work with power supply of 24V DC fed from a remote
location. The input voltage range is +24V DC (+20% to –30%) & will have a
maximum ripple of 50mV peak to peak/10 mV rms.
7.2 The power consumption in the equipment shall be low. It should be less than
1.0A for SSDAC and less than 1.25A for HA-SSDAC system having display for
field unit at 24VDC (nominal).
7.3 There should be protection of over voltage, under voltage and polarity reversal.
8.0 Hardware Standards
8.1 Component types
8.1.1 The ICs used in the equipment shall be of industrial grade.
8.1.2 The discrete components like diodes, transistors, SCRs etc., should conform to
HIREL program of CDIL or equivalent.
8.1.3 All resistors and rectifiers used shall be rated for at least double the power, which
is supposed to be dissipated in them. The voltage rating of the capacitor shall be
at least 50% above peak value. The resistors shall be of tolerances not more than
5%. Tolerance of capacitors shall be as under:
Metallised Polycarbonate (MPCAR) : 5%

Polypropylene (PPSAR/PSAR) : 5%
Polystyrene (PFD) : 2%
Electrolytic : 20%
8.1.4 All power supplies on cards should be locally decoupled where digital ICs are
used using a capacitor with good high frequency characteristics. Recommended
value of capacitor is 0.01 uf.
8.1.5 Shielding at card level by providing a metallic plate over the cards.
8.1.6 Shielding at chassis/rack level.
8.1.7 Terminals provided for cable connections shall be of cage clamp type of Wago or
Phoenix or any other reputed make.
8.1.8 Screw type couplers used for any connections shall be of MIL grade.
8.2 Printed Circuit Board
8.2.1 PCB material: Material for the PCB shall be copper clad glass epoxy of grade FR-
4 or equivalent.
8.2.2 Outline Dimensions: PCBs shall be of standard Euro extended size.

8.2.3 Track Width: The track width shall be as per current industrial standards .
8.2.4 Spacing between tracks: Spacing between tracks shall be as per current
industrial standards .
8.2.5 Printed circuit cards shall be fitted with gold plated Euro/ D type plug in
connectors with locking arrangement. Mechanical arrangement e.g. a clip or a
screw to hold the PCB in inserted position shall be provided. Screws should be
countersunk and held on PCB when it is pulled out. The PCB shall be
mechanically polarized so that it is not possible to insert the PCB into wrong slot..
8.2.6 The printed circuit cards shall be specifically designed to suit the circuitry used
and no extra wires or jumpers shall be used for interconnection of components on
the PCB. No piggyback PCB shall be connected to any PCB. The components
shall be soldered with wave-soldering machine. Any exception to wave-soldering
machine shall have specific approval of RDSO, Lucknow.
8.2.7 The cards shall be provided with testing points and the corresponding voltages /
waveforms shall be indicated in the fault diagnostic procedure and service manual
to facilitate testing and fault tracing.
8.2.8 Heat Dissipating Components: All components dissipating 3 W or more power
shall be mounted in such a manner that the body is not in contact with the board
unless a clamp, heat sink or other means are used for proper heat dissipation.
8.2.9 Conformal Coatings: Assembled PCBs should be given a conformal coating to

enable them for functioning under adverse environmental conditions. The coating
material should be properly chosen to protect the assembly from the following
hazards:
8.2.9.1 Humidity
8.2.9.2 Dust and dirt
8.2.9.3 Airborne contaminates like smoke and chemical vapours
8.2.9.4 Conducting particles like metal clips and filings
8.2.9.5 Accidental short circuit by dropped tools, fasteners etc
8.2.9.6 Abrasion damage and
8.2.9.7 Vibration and shock (to a certain extent)
8.2.10 Burning in Test
8.2.10.1 All the electronic components used in the equipment shall be subjected to “Burn-
in” test for 48±1 hours at temperature of 65ºC. Record of failed components in
this test should be maintained.
8.2.10.2 After mounting of components, the populated PCB cards kept in proper chassis
in energized condition shall be burnt in for 168 hrs at 60ºC. Record of failed PCB
Cards in this test should be maintained.
8.2.11 Following description shall be screen printed on the component side of the PCB:
8.2.11.1 Component outline in the proximity of the component.
8.2.11.2 Manufacturer’s name.
8.2.11.3 PCB name.
8.2.11.4 Equipment name.
8.2.11.5 Part number.
8.2.12 Following description shall be marked on the PCB:
8.2.12.1 The manufacturing serial number.
8.2.12.2 Month and year of manufacture.
8.2.13 Solder Mask: Solder mask shall be applied on solder side and component side of
the board.
8.2.14 The distribution of the power supply on the cards should be such that different
voltage tracks (0, 5V etc) follow the same route as far as possible. The track of
power supplies should be as thick and wide as possible.
8.2.15 Housing Rack shall be as per RDSO/SPN/144.

9.0 Performance
9.1 Time for failure detection: Failure indication shall occur not later than after the
passage of the first train over the relevant track section.
9.2 Occurrence of any failure or error of operation in the axle counter component
parts must not lead to any hazards. It may slowly result in transition to a safe
state.
9.3 The Axle counter service life shall not be less than 20 years.
9.4 The Axle Counter (equipment only) shall have MTBF of not lower than 70,000
hrs.
10.0 Inspections and Testing

10.1 General
10.1.1 Inspection and tests shall be carried out to ensure that requirements of this
specification are complied. Conditions of tests – Unless otherwise specified, all
tests shall be carried out at ambient atmospheric conditions. For inspection of
material, relevant clauses of IRS: S 23 and RDSO/SPN/144 shall also apply.
10.2 Type Approval

10.2.1 Initial Type Approval
10.2.1.1 Manufacturer shall furnish following information at the time of initial type
approval:
10.2.1.1.1 Design approach for the system and Salient feature through which fail-safety
has been achieved
10.2.1.1.2 Proof of safety report or its equivalent giving complete tests and their results
that have been undertaken by manufacturer or independent safety assessor
10.2.1.1.3 The system shall conform to the CENELEC standards for SIL-4 Railway
Signalling. Software & hardware validation shall be done by accredited /
reputed independent third party. The agency to be engaged for validation shall
be got approved by RDSO.
10.2.1.2 While granting initial type approval it shall be ensured that the system
conforms to all the clauses & passes all type tests as mentioned in clause 10.3.
10.2.2 Maintenance Type Approval
At the end of validity period, RDSO may call for fresh samples for type
testing for the purpose of maintenance of Type Approval as per the provisions
of Directorate Operating Procedure. The sample must pass all type tests as per
Clause 10.3.
10.3 Type tests

10.3.1 The following shall comprise type tests:
10.3.1.1 Visual inspection (Cl.10.5.1)
10.3.1.2 Performance test (Cl.10.5.2)
10.3.1.3 Applied high voltage test (Cl.10.5.3)
10.3.1.4 Insulation resistance (Cl.10.5.4)
10.3.1.5 Climatic tests (Cl.10.5.5)
10.3.1.6 Shock tests (Cl. 10.5.6)
10.3.1.7 7 KV static discharge test (Cl. 10.5.7)
10.3.1.8 Vibration Test (Cl. 10.5.8)
10.3.1.9 Fail safety tests (Cl. 10.5.9)
10.3.1.10 The test for Software check–sum (Cl.10.5.11)

10.3.2 One equipment shall be tested for this purpose. The equipment shall
successfully pass the entire type test for proving conformity with this
specification. If the equipment fails in any of the tests, RDSO at their
discretion, may call for another equipment of the same type and subject it to
all tests or to the test(s) in which failures occurred. No failure shall be
permitted in the repeat test.
10.3.2 To obtain a type approval certificate, the manufacturer or supplier shall submit
to the testing authority two numbers of samples, for conducting all the tests
mentioned. In case of maintenance type approval, the samples shall be
selected at random from regular production lots so as to be as representative as
possible of the type under consideration. A Type approval certificate shall be
issued to a manufacturer if samples pass all the prescribed tests in accordance
with this specification.
10.3.4 A type approval certificate once issued shall not be valid if a change in design,
construction, material used or manufacturing process is made subsequently,
unless this change has the approval of RDSO.
10.4 Acceptance Test & Routine Test

10.4.1 Acceptance Test
10.4.1.1 Inspecting authority shall carry out acceptance tests on all the equipment/sub
units. The following shall comprise acceptance tests
10.4.1.1.1 Visual inspection (Cl.10.5.1)

10.4.1.1.2 Performance test (Cl.10.5.2)
10.4.1.1.3 Insulation resistance (Cl.10.5.4)

10.4.1.1.4 Records of Environmental Stress Screening Tests (ESS) (Cl. 10.5.10)
10.4.1.1.5 The test for Software check–sum (Cl.10.5.11)
10.4.1.2 A complete test report of all the tests conducted shall be submitted by
inspecting authority giving the detailed observations made in every case and
actual values recorded. Specific mention shall be made whenever the
equipment has failed to comply with the requirements and indicating as to
how far it has failed to comply.
10.4.1.3 Disposal of samples: Sample equipment, which has been subjected to type
tests, shall not form part of supply.
10.4.2 Routine test
10.4.2.1 Following shall constitute routine tests and shall be conducted by
manufacturer on every equipment/sub units and test results shall be submitted
during the inspection.
10.4.2.1.4 Environmental Stress Screening Tests (ESS) (Cl. 10.5.10)
10.5 Test Procedure

10.5.1 Visual Inspection
The equipment/sub units shall be examined for provisions of all facilities
stipulated in this specification such as correct wiring, proper mounting and
marking of components, marking, workmanship and finish for which no tests
have been specified.
10.5.2 Performance tests

10.5.2.1 Equipment sub units
DC-DC converter No load current
Output load
Line regulation
Effect of frequency variation
Signal conditioner
card
CPU
Modem
Relay driver
Software Functional tests
10.5.2.2 System level checking

10.5.2.2.1 Constructional detail
10.5.2.2.2 Dimensional check
10.5.2.2.3 General workmanship
10.5.2.2.4 Configuration
10.5.2.2.5 Functional tests
10.5.2.3 Card level checking
10.5.2.3.1 PCB laminate thickness
10.5.2.3.2 Quality of soldering
10.5.2.3.3 General track layout
10.5.2.3.4 Conformal coating and shielding
10.5.2.3.5 Legend printing
10.5.2.3.6 Green masking
10.5.2.3.7 Mechanical polarization

10.5.2.3.8 General shielding arrangement of individual cards
10.5.2.3.9 Indication and display
10.5.2.3.10 Mounting and clamping of connectors
10.5.2.3.11 Proper housing of cards
10.5.3 Applied High voltage test
The equipment shall withstand for one minute without puncture and arcing at a
test voltage of 2000 AC, r.m.s applied between power components and the body
of equipment, which shall be earthed. The test voltage shall be approximately
sine wave of any frequency between 50 and 100 Hz. Any electronic component,
which is likely to get damaged by the application of high voltage, shall be
disconnected during the test.
10.5.4 Insulation Resistance Test

10.5.4.1 This test shall be carried out:
10.5.4.1.1 Before the high voltage test
10.5.4.1.2 After the high voltage test
10.5.4.1.3 After completion of the each climatic test/severities in type test.
There shall be no appreciable change in the values measured before and after
high voltage test. After the completion of climatic test, the values shall not be
less than 10 Mega ohms for the equipment at a temperature of 40 deg. C and
relative humidity 60%. The measurement shall be made at a potential of 500V
DC. During acceptance test, high voltage test and climatic test will not be
done.
10.5.5 Climatic Test
Climatic Test shall be done as per the sub clauses mentioned below. After
completion of all the tests, high voltage test (Clause 10.5.3) & insulation
resistance test (Clause 10.5.4) shall be repeated.
10.5.5.1 Change of Temperature Test:

10.5.5.1.1 The equipment shall be tested as per IS-9000/Pt.XIV Sec-2.
10.5.5.1.2 The test severity shall be -
i) Lower Temperature: -10ºC ± 3ºC
ii) Higher Temperature: +70ºC ±2ºC
Rate of cooling and heating 1 degree per minute. Duration of test: 3 cycles
of 3 hrs each (after stability in the chamber has been reached). The
equipment shall be kept energized during the test and status of relay shall
be recorded. After completion of test, the equipment shall be subjected for
standard recovery of 2 hours (15 - 35 degree C, RH 45 –75 %), After
recovery, the equipment shall be checked visually for any damage and its
insulation resistance shall be measured which shall not be less than 10
Mega ohms at 40 degree C and 60 % RH.
10.5.5.2 Dry Heat test:
The equipment shall be tested as per IS-9000/Pt.III Sec. 5. The test
severity shall be + 70 ± 2 deg. C and duration of exposure 16 hrs. (After
stability in the chamber has been reached). Rate of change of temperature
shall be 1 degree per minute. The equipment shall be switched ON when
the temperature in the chamber has stabilized and remained active during
the above tests and status of relay shall be recorded. After completion of
test, the equipment shall be subjected for standard recovery of 2 hours (15
- 35 degree C, RH 45 –75 %), After recovery, the equipment shall be
checked visually for any apparent damage or deterioration and insulation
resistance shall be measured which shall not be less than 10 Mega ohms at
40 degree C and 60 % RH.
10.5.5.3 Cold test:

The equipment shall be tested as per IS-9000/Pt.II Sec. 3. The test
severity shall be - 10 ± 2 deg. C and duration of exposure 2 hrs. (After
10.5.5.4 Damp Heat Test (Cyclic):
The equipment shall be tested as per IS-9000 / Pt.V Sec-2. The upper
temperature shall be + 40 deg C, lower temperature + 25 degree C, RH 95
%, Variant 1, 1 cycle 12 + 12 hours and 6 number of cycles. The
equipment shall be kept energized during the test. No intermediate
measurements required only relay status to be recorded. After standard
recovery of 2 hours, the equipment shall be checked visually for any
apparent damage or deterioration and insulation resistance shall be
measured which shall not be less than 10 Meg ohms at 40 degree C and 60
% RH.
10.5.5.5 Damp Heat Test (Steady state):
The equipment shall be tested as per IS-9000 / Pt.IV. The temperature
shall be maintained + 40 ± 2 deg C, and relative humidity 95 %, (+2%
3%). The duration of the test is 4 days. The equipment shall be kept
energized during the test. No intermediate measurements required only

relay status to be recorded. After standard recovery of 2 hours, the
equipment shall be checked visually for any apparent damage or
deterioration and insulation resistance shall be measured which shall not
be less than 10 Meg ohms at 40 degree C and 60 % RH.
10.5.5.6 Salt Mist Test:

This test shall be carried out as per RDSO/SPN/144.
10.5.5.7 Driving Rain Test (for Axle Detectors):
The unit shall be subjected to this test for 1 hr. as per IS: 9000 Pt. XVI and
shall withstand the same. The equipment shall be kept de-energized
during the test and in its normal operational position. The item shall be
sprayed from eight showerheads, four of them being directed at an angle
of 45 degree on each of the uppermost corners of the item and remaining
four being directed horizontally at the center of the area of each of the four
sides of the item. After standard recovery, the equipment shall be checked
for any deterioration and insulation resistance shall be measured which
shall not be less than 10 Meg ohms at 40 degree C and 60% RH.
10.5.5.8 Water Immersion Test (for Axle Detectors):

The equipment shall be subjected to this test for 24 hrs as per IS: 9000 Pt.-
XV Section 7. Water head shall be 40 cms above the highest point of item
under test. The equipment shall be kept in the chamber in its normal
operational position and in de energized state. After the completion of the
test external surface of the item shall be dried by wiping or by applying a
blast of air at room temperature. After standard recovery of 2 hours, the
equipment shall be checked visually for undue penetration of water and
for any apparent damage or deterioration. Insulation resistance shall be
% RH.
10.5.5.9 Dust Test:

The equipment shall be tested as per IS-9000 Pt. XII. The item shall be
subjected in the chamber at laboratory temperature in switched off
condition. The temperature of the chamber shall then be raised to a value
of 40 deg C ± 3 deg C with a relative humidity not exceeding 50% shall be
maintained in the test chamber. When the temperature stability has been
attained, the test item shall then be subjected to a stream of dust-laden air
for a period of one hour. After standard recovery of 2 hours, the
equipment shall be checked for any deterioration and insulation resistance
shall be measured which shall not be less than 10 Meg ohms at 40 deg C
and 60% RH.
10.5.6 Shock Test: (on axle detectors only)

Axle detectors shall be tested for this test.
Shock test as per IS Peak acceleration 40 g.
9000 Pt. VII Sec. 1
Clause 9 Duration of the pulse 11 m. sec.
No. of shocks 18
Velocity change Half sine pulse
Equipment in unpacked condition shall be subjected to

Bump test. In addition to physical checks, the assembly
shall be subjected to performance test.
10.5.7 7 KV Static Discharge Test:

10.5.7.1 The test shall be done as per RDSO/SPN/144.
10.5.8 Vibration Test:
The equipment shall be subjected to vibration test as per IS: 9000 (Part
VIII).
Specification Severities Observation

Details. /Remarks
Vibration test Frequency range 10 Hz – 55 Hz

as per IS 9000
Pt. VIII Amplitude 0.35mm (0 to peak) Equipment
shall be
or 5g visually
examined for
No. of axis 3
any apparent
No. of sweep cycles 20 sweep cycle per axis damage.
Total duration for the 20 1 hour 45 minutes when

sweep cycles frequency of vibration is
After
changed as per clause
completion of
6.3 of IS-9001 Pt.XIII-
the test the
81 during each sweep
equipment
If resonance is observed, 10 minutes at each shall be tested
endurance tests at resonant resonant frequency for its normal
frequency. operation.
10.5.9 Fail-safety test:

Fail safety tests shall be carried out as per RDSO/SPN /144as covered
under the clause 4.0 and as per CENELEC EN50129.
10.5.10 Environmental Stress Screening Tests (ESS) for Printed Assembly
Boards (PAB) and Subsystems
The manufacturer shall carry out the following ESS tests on all modules
on 100% basis (except bump test) during production/testing in the
sequence as follows. Suitable records shall be maintained regarding the
compliance of these tests.
10.5.10.1 Vibration Test
PCBs in unpacked condition shall be subjected to vibration test for 10

minutes at the resonant frequency/frequencies at 3.0 g minimum
acceleration in the axis /axes perpendicular to the mounting of
components. In addition to physical checks, the electrical parameters are
also to be monitored after the vibration test.
10.5.10.2 Bump Test
PCBs /modules/units in packed condition shall be subjected to bump test

at 40 g for 1000 bumps. This test shall be carried out as per sampling
plan given in Clause 7.2.5, 7.2.6 & 7.2.7 of IRS:S 42/85 for Axle Counter
Equipment. In addition to physical checks, electrical parameters are also to
be monitored after the bump test.
10.5.10.3 Thermal Cycling
The PCBs shall be subjected to thermal cycling as per the procedure given
below:
The Assembled Boards are to be subjected to the Rapid Temperature

Cycling as mentioned below in the power OFF condition. This
temperature cycling is from 0 to 70ºC, ½ hour at each temperature for 9
cycles and 1 hour at each temperature for the 10th cycle. Dwell time of 1
hour is provided for the last cycle in order to oxidize defective solder
joints exposed through thermal stress.
½ hr
70oC
Ambient
0oC 1 hr
½ hr
The rate of rise /fall of temperature shall be minimum 10ºC/minute.

In addition to physical checks, the electrical parameters are also to be
monitored after this test.
10.5.10.4 Power Cycling
The power supply modules shall be subjected to 60 (sixty) ON-OFF cycles for
one hour. (The ON-OFF) switch usually provided in the modules may not be
used for this purpose.
10.5.11 The test for Software check–sum
Through suitable means, the total size of the software of each sub-system shall
be measured and recorded. The manufacturer shall specify the size of software
with version number of each sub-system at the time of applying for type
approval.
11.0 Quality Assurance

11.1 All materials shall be of the best quality and the workmanship shall be of the
highest class as per QAP standards laid down by RDSO.
11.2 The equipment shall be manufactured as per quality assurance procedure laid
down so as to meet the requirement of the specification.
11.3 Along with other requirement of the specification, validation and system of
monitoring of QA procedure shall form a part of type approval. The required
plant machinery and test instruments as per RDSO’s Standards shall be available
with the manufacturer.
12.0 Marking and Identification
12.1 It shall conform to the clause on Marking given in RDSO/SPN/144.
12.2 Terminals, which are to be connected to track, power supply etc., shall be marked
clearly.
12.3 A nameplate shall be provided in a conspicuous position giving manufacturer’s
name, specification reference, serial no of the equipment, date of manufacture,
version no., local address, remote address etc.
12.4 A plate indicating the configuration to be adopted for entry point unit and exit
point unit shall be provided in a conspicuous position on the equipment.
12.5 Proper marking should be on Tx/Rx coil.
13.0 Packing
Packing shall be done to RDSO/SPN/144.
14.0 Warranty
The warranty of the equipment shall be in accordance with IRS Specification No.
S- 23.
15.0 Documentation
15.1 Documents shall be prepared to meet EN 50128 and EN 50129 requirements.
15.2 Safety case documents as per CENELEC standards for SIL-4 Railway Signalling
to be submitted for type approval.
15.3 Guaranteed performance data, technical & other particulars of the equipment to be
submitted for type approval.
15.4 Details of hardware e.g. schematic diagrams of the system circuits / components,
details for each type of assembled PCB and part list to be submitted for type
approval.
16. Purchaser’s Responsibility

16.1 The commissioning of the equipment shall be done under the supervision of the
manufacturer. However, purchaser, at his own discretion may waive off this
clause by specifying so in the tender conditions.
17. Supply of documents:
17.1 Two copies of the following shall be supplied during type approval and one copy
each shall be supplied along with each equipment. Documents have to be
approved by RDSO.
17.1.1 Instruction Manual.
17.1.2 Installation & maintenance manual including Dos & Don’ts.
17.1.3 Mechanical drawings of each sub-system/rack.
17.1.4 Schematic block diagram showing mounting arrangement of various components
& details of each type of assembled PCB.
17.1.5 Trouble shooting procedures along with test voltages and waveforms at various
test points in the PCBs.
17.1.6 Pre-commissioning checklist.
18. Item to be specified by Purchaser:
18.1 The configuration of which SSDAC’s (by default 2 DP 1 section) are required.
18.2 The length of cable (5/10/15 m) required with each track device. Default length is
10m.
18.3 Supply option i.e.

18.3.1 Standard SSDAC or
18.3.2 High availability SSDAC system using
18.3.2.1 With Single track sensor device or
18.3.2.2 With Dual track sensor devices
19. Tools for maintenance:
19.1 The manufacturer shall indicate special maintenance instruments and tools that
may be necessary for proper adjustment and maintenance of equipment and
supply these, if so required by the purchaser
******
Annexure- I
Specification for MULTI SECTION DIGITAL AXLE COUNTER RDSO/ SPN /176 /2005
MULTI SECTION DIGITAL AXLE COUNTER
Version 2.0
Number of pages 33
RESEARCH, DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR
LUCKNOW - 226011
Effective from 15.05.2005 Version 2 Page 1 of 33

DOCUMENT DATA SHEET
Version
Designation
2.0
RDSO/SPN/176/2005
Title of Document
Multi Section Digital Axle Counter Specification

Signed by:
Name: Sudip Mukhopadhyay
Approved By RDSO
Name: Shri G.D.Bhatia

Abstract
This document defines Multi Section Digital Axle Counter Specification.

Document control Sheet

AMENDMENTS
Version Chapter/ Amendments Effective Date

Annexes
1.0 - First issue 13.09.02
2.0 - 15.05.2005

SPECIFICATION FOR
SIGNAL DIRECTORATE
RESEARCH DESIGN& STANDARDS ORGANISATION
LUCKNOW-226011

Table of Content
Page No.
1.0 Scope. 7
2.0 Terminology & Abbreviations 7-8
3.0 Applicable document/drawings 8-9
4.0 System requirements 9
5.0 General requirements. 10-19
6.0 Diagnostics 19-20
7.0 Traction & Supply 20
8.0 DC Input Power Supply 20
9.0 Hardware standards. 21-23
10.0 Performance. 23
11.0 Inspections & Testing. 23-32
12.0 Quality assurance 32
13.0 Marking & Identification 32
14.0 Packing. 32
15.0 Warranty. 32
16.0 Documentation. 32-33
17.0 Purchaser’s responsibility. 33
18.0 Supply of documents. 33
19.0 Purchaser should specify. 33
20.0 Tools for maintenance. 33

SPECIFICATION FOR MULTI SECTION DIGITAL AXLE COUNTER

1.0 Scope
1.1 This document sets forth general, operational, technical, performance & type
tests requirements of Multi Section Digital Axle counter.
1.2 This specification does not cover the specification of external cable and
protective devices to be used in conjunction with Multi Section Digital Axle
Counter for its installation.
1.3 The Development of MSDAC covers-
1.3.1 Phase modulated Axle detectors.
2.0 Terminology & Abbreviations

2.1 Terminology
2.1.1 The terminology referred to in the specification is covered by the definitions
given in IRS Specification no. S-23, IS Specification No. 9000 and as given
below.
2.1.2 Axle detector: The track device comprising of the coils fixed in cover mounted on
the rail. It will detect the wheel (rolling stock axle) passing over the device.
2.1.3 Counting device/Digital Axle Counter field unit (track side): Counting
device/digital axle counter field unit is the track side electronic assembly that
energise the axle detectors for detecting the passing wheels determining the
direction of movement and keeping the count of wheels. It transmits the count
and health information to the Central Evaluator at regular intervals.
2.1.4 Detection Point: Detection point comprises of one axle detector and the field
unit connected to it.
2.1.5 Track Section: The portion of track confined by associated axle detectors & field
units. The axle counter is checking the occupancy of this section.
2.1.6 Section Balancing: Axle counter determines whether the track section in question
is clear / occupied, based on the information on detected (in counts and out
counts) numbers of axles, which is received from the axle detectors confining the
section in question.
2.1.7 Resetting: Resetting commands the setting to zero the records of counted axles.
2.1.8 Preparatory Reset: After resetting, axle counter shall continue to show occupied
until one train movement in the section carries out correct balancing of track
section.
condition from different location like the clearance of the track section from site
using line verification box. The axle counter will show clear after the conditional
reset .
2.1.10 Event Logger: Logs the events occurring in axle counter system with date and
time stamping.
2.1.11 Central Evaluator (Indoor): The Central Evaluator receives count and health
information from Digital Axle Counter Field units. It evaluates the counts
received from the digital axle counter field units to generate relay-driving signals
for individual track-sections.
2.2 Abbreviations
2.2.1 dB - Decibel
2.2.2 AWS - Auxiliary Warning System
2.2.3 TPWS - Train Protection & Warning System
2.2.4 TX - Transmitter
2.2.5 RX - Receiver
2.2.6 KHz - Kilo Hertz
2.2.7 LED - Light Emitting Diode
3.0.1 IS: 9000 Basic environmental testing procedures for electronic

and electrical items.
3.0.2 IRS-S-23 Electric Signaling and Interlocking Equipment
3.0.3 ISO 9001 Quality systems – model for quality assurance in

design, development, production, installation and
serving.
3.0.4 IEC529/ EN Specification for degree of protection provided by

60529 enclosures (IP code).
3.0.5 EN 61000.4.2 Electromagnetic compatibility (EMC) – testing and

measurement techniques- electrostatic discharge
immunity test and basic EMC
3.0.6 EN 61000.4.4 Electromagnetic compatibility – testing and

measurement techniques- electrical fast transient/burst
immunity test and basic EMC publication
3.0.7 EN 61000.4.5 Electromagnetic compatibility – testing and

measurement techniques – surge and immunity test

3.0.8 PrEN50126 Railway applications - specification and

demonstration of - reliability, availability,
maintainability and safety
3.0.9 PrEN50128 Railway applications – Signalling and

Communications – Software for Railway Control and
Protection system
3.0.10 PrEN50129 Railway application: Safety related electronic

systems for signalling
3.0.11 EN 50159-1 & 2 Railway Application: Signalling and Communication

Safety related communication in closed and open
Transmission system
3.0.12 IRS: S TC-30 Underground Railway Jelly filled Quad Cables for
Special purposes in Electrified Area.
3.0.13 RDSO/SPN/165 SMPS based IPS.
3.0.14 IRS: S- 86 Battery Charger-Self Regulating.
3.0.15 IRS: TC 41 PIJF Telephone Cable.
3.0.16 RDSO/SPN/144 Safety and Reliability Requirement of Electronic

Signalling Equipment.
3.0.17 RDSO/S/20001 Drawing for Reset – Box and Reset Panel
3.0.18 RDSO/SPN/99 Data Logger
3.0.19 RDSO/SPN/148 Electronic Interlocking
3.0.20 RDSO/S/20002 Drawing for line verification box.
3.1 Wherever in this specification, any of the above-mentioned specification is

referred; the latest issue of the same is implied.
4.0 System Requirements
The MSDAC system comprises of Axle Detectors, DAC field units, Central
Evaluator, Reset unit, Relay unit, Event Logger and diagnostic terminal. It shall
support up to 40 detection points and generate vital relay outputs for up to 39
track sections. The Central Evaluator shall be connected to DAC field units in star
configuration. Each track section can be reset independently from the Reset
Box/Reset Module of Reset Panel. The Event Logger shall record all the events
occurring in the multiple section digital axle counter.


5.0.1 Multi section digital Axle counter consists of axle detectors & field units
(maximum upto 40 detection points) configuring maximum upto 39 track
sections. It is capable of counting axles, count comparison, finding direction of
axle movement, supervision, relay drive and transmission of counts and health of
axle detectors & field units. The field units are connected to the Central Evaluator
by a transmission medium where transmission is in VF range.
5.0.2 Track clear indication shall only be given when IN count and OUT count are
equal and equipment is functioning all right. This implies that until all axles that
enter a section are completely counted out, the section concerned shall not show
as clear.
5.0.3 Axle counter shall show occupied the moment any of the axle counter sub-
assemblies belonging to the section is damaged, missing or has become faulty.
5.0.4 The axle counter shall detect change of both amplitude and phase of the axle
detector receiver signal. In exceptional cases, detection of only change of
amplitude of the axle detector receiver signal may be allowed with approval of
Railway Board.
dollies etc. are not counted by it. Trolley protection track circuit shall not be
required with phase detection.
5.0.6 Axle counter operation shall be independent of wear & tear of wheels as
permitted vide Indian Railway’s Schedule of Dimension, lateral displacement of
wheels on rails etc. The manufacturer shall specify the minimum diameter of the
wheels, condition of wheels etc., to which the performance of equipment shall not
be affected.
5.0.7 Axle Counter operation must be independent of type of sleepers in the section
such as wooden, RCC, or steel etc. and shall work on all types of rail profiles and
construction such as welded or non-welded rails of 52 kg / 60 kg / 90R/71 kg etc.
Axle counter shall operate up to the vertical limit for wornout rail as given
below:

1. 60 Kg / metre 13.00
2. 52 Kg / metre 8.00
3. 90 R 5.00
5.0.8 Axle counter shall be suitable for train speed from 0 to 250 Km/h.
5.0.11 The equipment (central evaluator & field unit) shall be of continuously self-
checking type and shall have separate indication to show conditions of track clear
and track occupied (including fault). Any disturbance or failure in the equipment
including power supply failure shall result in withdrawal of clear indication and
occupied indication shall be lit. . Disturbance /failure related to a track section
shall not influence the normal working of other track sections.
5.0.12 Card wise failure indication shall be provided in Central Evaluator & Field Unit.
It is desirable to give suitable indication of the nature of failure. Also total system
failure and O.K. indications shall be provided.
5.0.13 Axle detector & field unit shall have no moving parts and shall require little
maintenance.
5.0.14 The equipment (central evaluator & field unit) shall be so constructed as to
prevent unauthorized/irregular access to sub-assemblies of the system. Authorized
persons should, however, have access to these sub-assemblies for the purpose of
installation and maintenance by unlocking the outer cover/breaking of seal
provided on the outer cover.
5.0.15 The central evaluator & field units shall be provided with testing, measuring and
adjusting facilities for indicating proper functioning of equipment and for facility
of maintenance.
5.0.16 The equipment shall be fully solid-state using carefully chosen industrial grade
components.
5.0.17 The system shall provide for continuous supervision of field units including
cables connecting the field units with central evaluator and detectors with field
units. Any defect in these shall be immediately detected, error code displayed and
the system / section should go to error mode.
5.0.18 The maximum axle count, each field unit can handle, should be > 1024.
5.0.19 Response time of train occupancy for any track section shall be less than 1.0
second.
5.0.20 Clearance time of any track section after train leaves the section shall be less than
2.5 sec.
5.0.21 Axle counter system design shall take into consideration system growth
capability and architecture of digital axle counter shall be such that it is fit to be
used on all the sections of Indian Railways including suburban sections.
5.0.22 Environmentally slight moisture condensation shall not lead to malfunction or
failure of equipment.
5.0.23 The design of axle counter shall take into account switching transients that may
occur either inside or outside the system and of any magnitude upto and including
interruption of full short circuit current.

5.0.24 Axle counter shall withstand the effect of lightning & surges incorporating
lightning and surge protection as per RDSO/SPN/144.
5.0.25 The equipment shall conform to the Safety Integrity Level 4 as per CENELEC
Standard.
5.0.26 The axle counter should not affect the operation of other wayside signalling
equipments.
5.0.27 The axle counter should not be affected by on track signaling equipments of
AFTC, TPWS etc.
5.0.28 Error rate should not be more than 2 errors per 1 million correctly counted axles,
and if there is error, it should not result in unsafe condition.
5.0.29 The equipment shall be capable of simultaneously counting in and / or counting
out from the ends of any track section.
5.0.30 Response of rocking of wheels on Axle Detector: If any sensor is influenced two
or more times consecutively without a proper count pulse, the system should go to
error. If both sensors are influenced four or more times consecutively without a
proper count pulse, the system should go to error.
5.0.31 Axle counter should tolerate induced voltage of at least 400V AC, 50Hz on the
quad cable.
5.0.32 It shall fulfill fail safety requirement as per RDSO/SPN/144.
5.0.33 It shall fulfill the requirement of Signal Engineering Manual as per
RDSO/SPN/144.
5.0.34 The software shall fulfil the software requirements as per RDSO/SPN/144.
5.0.35 Axle counter system shall adopt a structured design process including but not
limited to the System architecture, Software requirements specification, software
architecture, flow charts, Man machine Interface for prototypes, verification and
test approach.
5.0.36 Detection point at the junction of two consecutive sections shall be capable of
giving feed to both the monitoring sections.
5.0.37 Both hardware and software functions will be partitioned to ensure that integrity
of certified design will not be compromised though routine software and hardware
upgrades.
5.0.38 Design of the axle counter will maximize the use of vendor independent
implementations.

5.0.39 Digital axle counter interconnection diagram is shown in figure 1.
RELAY CONTROL
/ STATUS
DIGITAL UNIT
CENTRAL
EVALUATOR
DACF #1 DACF #8 DACF #33 DACF #40
TRACK INPUT 1 TRACK INPUT 8 TRACK INPUT 33 TRACK INPUT 40
SYSTEM INTERCONNECTION (NETWORK MODE)
5.1 Configuration: Multi section axle counter shall be easily configurable as per yard
layout in different track sections as given below:

5.1.5 Multiple detection points single section: In ladder.

5.1.6 Consecutive single section in a straight line.
5.2 Vital Relay Drive & Relay Unit
5.2.1 Free and occupied indication of an axle counter section (track section) shall be
available in the form of vital relay pick up and drop contact respectively. Vital
relay/s will be driven by central evaluator.
5.2.2 The vital relay shall be 24V DC, 1000-ohm plug-in type. In section clear
condition, the relay driver output shall be more than 20V DC and in occupied
condition, it should be less than 2.0V DC.
5.2.3 The design should incorporate fail safety feature such that when the vital relay is
in dropped condition as per status of the track section, if any external voltage
appears across the vital relay coil which can pick up the vital relay, then the
system should detect it and the concerned axle counter section/track section will
go to error state.
5.2.4 The relay unit shall provide housing for all vital relays.
5.2.5 The relay unit shall have enough space for mounting vital relays (upto 39) for
max. no. of track sections supported by MSDAC.
5.3 Axle detector:
5.3.3 Different frequencies shall be used for each set of TX/RX coils.
5.3.4 These shall be capable of withstanding environmental conditions given and

specified later. The inductance of axle detectors shall not vary more than ±6%
within the specified temperature range.
5.3.5 The transmitter/receiver coils in the track shall be of web mounted type. The
5.3.7 The axle detector shall be actuated only by wheel flanges and not by other parts of
trains e.g. rail brakes, toilet pipes, suspended chains, electrical inductors in
locomotives, air-conditioning equipment and other electrical /electronic
equipment in train /engine.
5.3.8 One set of axle detector shall not influence another set of detector mounted ≥ 2
meters away.
Railways.
5.3.10 The length of inbuilt cable with Axle Detector shall be 5 / 10 / 15 mtr. only.
5.4 Resetting:
5.4.1 User input track section wise reset shall be possible.
5.4.2 Whenever any yard is provided with MSDAC, reset boxes shall be incorporated
in a panel depicting yard layout so that respective reset boxes are easily co-related
with the track section they pertain to. Refer drawing No.RDSO/S/20001 for
details.
5.4.3 Track section wise resetting shall be easily configurable as preparatory reset or
conditional hard reset.
5.4.4 Resetting of a track-section shall not disturb other track-sections in any way.
5.4.5 The resetting of the track section shall be recorded in the event logger.
5.4.6 A voltage sensitive feature shall ensure that without the operation of re-setting
key, the system will not come back to initial or original condition for the
following cases:
5.4.6.1 Power fails and restores back in field unit and/or central evaluator.
5.4.6.2 Voltage fluctuation beyond upper and lower limits in field unit and/or central
evaluator.
5.4.6.3 Removal of printed circuit cards from the system (field unit and/or central
evaluator.)
5.4.7 It shall be possible to reset each track section from reset box/reset module of reset
panel only.
5.4.8 Provision shall be made for recording every operation of resetting by means of
non-resettable counter. For one reset operation, the counter should not increment
by more than one.
5.4.9 For track section on a straight line confined by two detection points, when reset is
applied, the axle counter section shall go to “preparatory reset mode”. The
preparatory reset LED in reset box/reset module of reset panel shall glow and
reset counter shall increment. The axle counter section will be still in occupied
state. The axle counter section will become clear only after more than one incount
from one end and same number of outcount from the other end have taken place.
5.4.10 For track section on a terminating line/siding line, point zone and ladder, the reset
command from reset box/reset module of reset panel will be transmitted only after
verifying that verification switch have been pressed & turned in the line
verification box at site as a proof of the axle counter section being clear
physically. On availability of reset command, the section will reset and show clear
and counter shall increment.

5.4.11 The reset box./reset module of reset panel should work from 24V DC supply. The
following should be provided in the reset box/reset module of reset panel (as per
Reset Box drawing no. RDSO/S/20001).
5.4.11.1 A six-digit (min.) non-resettable type counter.
5.4.11.2 Reset switch with key.
5.4.11.3 Reset push button – Red.
5.4.11.4 Axle counter section clear indication (LED-10mm) –Green
5.4.11.5 Axle counter section occupied indication (LED-10mm)-Red
5.4.11.7 Preparatory reset indication (LED-3mm) –Green or
5.4.12 The possibility of reset will be as per table below:
(Yes/No)
Error has occurred.
System healthy
Error has occurred.
5. In count & out count started, Yes
System healthy
Error has occurred
7. No in count, but only out Yes
counts, system goes to error.

5.4.14 The line verification box shall be as per RDSO Drg. No. RDSO/S/20002.
5.5 Central Evaluator
5.5.1 The Central Evaluator Unit shall be housed in a pre-fabricated rack to be supplied
along with the system.
5.5.2 The Central Evaluator shall be based on 2 out of 3 logic.

5.5.3 Central Evaluator based on 2 out of 2 logic may be considered through cross
acceptance/ approval.
5.5.4 The Central Evaluator shall be able to connect up to 40 detection points.

5.5.5 The Central Evaluator shall connect to Digital Axle Counter field units in star
configuration.
5.5.6 The Central Evaluator shall communicate with the Digital Axle Counter field
units at minimum1200 Baud.
5.5.7 The Central Evaluator will provide one vital relay output for each track section.
5.5.8 The Central Evaluator shall be able to generate relay outputs for upto 39 track
sections.
5.5.9 Each detection module in central evaluator shall support track section of 8
detection points.
5.5.10 The Central Evaluator shall be able to receive the reset command generated from
Reset unit for section wise resetting of track section(s).
5.5.11 The Central Evaluator shall provide input to the Event Logger for registration and
recording of events occurring in the multiple section digital axle counter.
5.5.12 The Central Evaluator will have an RS-232 port to interface with Electronic
Interlocking (SSI) system as per RDSO/SPN/148.
5.5.13 The Central Evaluator will have a separate port to connect to the station data
logger for monitoring the section wise clear/occupied information. Standard Data
Logger protocol as specified in RDSO/SPN/99 shall be used for this purpose.
5.5 13.1 The following information shall be sent to station data logger:
5.5.13.1.1 Track section nomenclature as per signalling plan.
5.5.13.1.2 Status of track section i.e. clear, occupied, failed or preparatory reset.
5.5.13.1.3 Application of reset command track section wise
5.5.14 Provision should be there for lightning & surge protection in the central evaluator
power supply input and communication line input/output.
5.5.15 The field units should be able to communicate with central evaluator for
transmission loss upto 20dB.
5.5.16 Suitable arrangements shall be made for providing electrical isolation between
external relay circuits and internal circuits.

5.6 Digital Axle Counter field Unit

5.6.4 Provision should be there for lightning & surge protection in the field unit power
5.6.5 The field units should be able to communicate with central evaluator for
transmission loss upto 20dB.
5.6.6 It shall identify and communicate in the following conditions to the Central
Evaluator:

5.6.6.3 Removal of printed circuit card(s) from the unit
5.6.6.4 In case out count has been registered before any in count.
5.6.7 It shall transmit axle counts and health status to Central Evaluator at regular
intervals
5.6.8 It shall have provision for setting unique address of each field unit. The address
shall be minimum 8 bit.
5.7 Communication:
5.7.1 It shall be possible to use copper cable or voice channel in optical fiber
communication for transmission of data between field units and central evaluator.
The copper cable will be quad cable as per IRS: TC: 30-97 (0.9 mm dia) or PIJF
Telecom Cable as per IRS: TC 41/97 (0.9 mm dia.) No separate external interface
should be required for using any of these two transmission mediums.
5.7.2 Impedance matching between communication channel and modem shall be
provided.
5.7.3 It shall be capable of transmission of axle counts, health status and other
information between field units & central evaluator on a transmission link. The
transmission link, in case of copper cable, shall be ½ quad telecom cable or 1 pair
in PIJF cable or one 2-wire voice channel in case of OFC. The rate of
transmission should be minimum1200 baud.
information between field units and central evaluator. CRC to be used for error
detection and the hamming distance of the message protocol shall be at least 5.
The code transmission should be safety validated. Communication should be as
per CCITT standard.

5.7.5 Minimum 2 (two) consecutive telegrams will be required to verify the integrity of
the status of direction and counts transmitted. However, for the information that in
count has started, action may be taken after receiving first telegram itself to take
the axle counter section to occupied state (a safe state). The manufacturer shall
specify the minimum length of the axle counter section for which the axle counter
section shall work properly for train running at maximum speed as specified.
5.8 Earthing:
5.8.1 Provision of earthing should be there in the central evaluator, field unit and reset
box. The earth terminal shall be suitable for taking upto 4mm dia. copper wire
with lug.
5.9 Event Logger
5.9.1 The Event Logger shall be inbuilt in the Central Evaluator.
5.9.2 The event logger should work automatically without any other input required to
be given by staff.
information recorded in the Event Logger. Neither shall it cause its loss or
change.
5.9.4 The data registered in the event logger must be secured against erasing by
unauthorized persons.
5.9.5 It should be possible to download logged events to a commercial computer
5.9.6 The process of event logging and downloading of logged events should not
hamper the normal working of axle counter in any manner.
5.9.7 The event logger shall record following events at the minimum:
5.9.7.1 Resetting of a track-section, field unit or central evaluator.
5.9.7.2 Failures/errors in field units or central evaluator.
5.9.8 Provision should be there to log minimum 40,000 events. In case of its memory
becoming full, the event logging should be on last in first out principle.
5.9.9 All data will be recorded with date & time stamp.
6. Diagnostics
6.1 Diagnostic system of the axle counter shall provide-
6.1.1 Local and remote diagnostics and testing of system through a serial connection.
diagnostic terminal. The same display should normally show in count / out count
detection point wise and section wise and software version no. when the system is
switched on initially.
6.3 Diagnostic functions shall be carried out on a permanent basis without disturbing
normal operation of the equipment.
6.4 Information on the state of the equipment in failure situations and on operations
performed by the staff shall be registered with time stamping.

electrified, 25 kV 50 Hz AC, 1500 V DC & 750V DC electrified areas.
7.2.1 25 kV / 50Hz 1000 A
7.2.2 1.5kV/dc 6000 A
7.2.3 750V/ dc 3000 A
7.3 The currents or their harmonics flowing in the rolling stock & rails shall not
affect the digital axle counter.
7.4 The equipment shall be insensitive to extraneous magnetic or electric fields such
as due to traction return currents on electrified sections, traction motor failures,
vehicle magnetism or due to any other source.
7.5 The electromagnetic brakes in both on and off states should not affect the axle
counter.
8. DC Input Power Supply

8.1 The field unit shall work with power supply of 24V DC fed from a remote
location. The input voltage range is +24V DC (+20% to –30%) & will have a
maximum ripple as per Para 5.4.23 of RDSO/SPN/165 or Para 5.4.2 of IRS: S
86/2000.
8.2 The Central Evaluator shall work with same type of power supply as mentioned in
Para 8.1 but range will be 24V+ 20%, -10%.
8.3 The power consumption in the equipment shall be low. It should be less than
0.75A for field unit at 24VDC (nominal).


9.1 Component types
9.1.2 The discrete components like diodes, transistors, SCRs etc., should conform to
HIREL program of CDIL or equivalent.
9.1.3 All resistors used shall be rated for at least double the power, which is supposed
to be dissipated in them. The voltage rating of the capacitor shall be at least 50%
above peak value. The resistors shall be of tolerance not more than 5%.
Tolerance of capacitors shall be as under:
Electrolytic : 20%
These shall be procured from RDSO approved sources, wherever specified.
9.1.4 All power supplies on cards should be locally decoupled where digital ICs are
used using a capacitor with good high frequency characteristics. Recommended
value of capacitor is 0.01 uf.
Phoenix make.

9.2.1 PCB material: Material for the PCB shall be copper clad glass epoxy of grade FR-
4 or equivalent.
9.2.3 Track Width: The track width shall be 0.5mm nominal. In no case it should be
less than 0.3mm.
9.2.4 Spacing between tracks: Spacing between tracks shall be 0.5mm nominal and in
no case it shall be less than 0.3mm.
9.2.5 Printed circuit cards shall be fitted with gold plated Euro/ D type plug in
connectors with locking arrangement. Mechanical arrangement e.g. a clip or a
screw to hold the PCB in inserted position shall be provided. Screws should be
countersunk and held on PCB when it is pulled out. The PCB shall be
mechanically polarized so that it is not possible to insert the PCB into wrong slot.
Suitable mechanical arrangement shall be provided against wrong insertion of

connections.
9.2.6 The printed circuit cards shall be specifically designed to suit the circuitry used
and no extra wires or jumpers shall be used for interconnection of components on
the PCB. No piggyback PCB shall be connected to any PCB. The components
shall be soldered with wave-soldering machine. Any exception to wave-soldering
machine shall have specific approval of RDSO, Lucknow.
waveforms shall be indicated in the fault diagnostic procedure and service manual
to facilitate testing and fault tracing.
9.2.8 Heat Dissipating Components: All components dissipating 3 W or more power
shall be mounted in such a manner that the body is not in contact with the board
unless a suitable heat sink is provided.
9.2.9 Conformal Coatings: Assembled PCBs should be given a conformal coating to
enable them for functioning under adverse environmental conditions. The coating
material should be properly chosen to protect the assembly from the following
hazards:
9.2.9.1 Humidity
9.2.10.1 All the electronic components used in the equipment shall be subjected to “Burn-
in” test for 48±1 hours at temperature of 65ºC. Record of failed components in
9.2.10.2 After mounting of components, the populated PCB cards kept in proper chassis
in energized condition shall be burnt in for 168 hrs at 60ºC. Record of failed
PCB Cards in this test should be maintained.
9.2.11.3 PCB name.


9.2.13 Solder Mask: Solder mask shall be applied on solder side and component side of
the board.
9.2.14 The distribution of the power supply on the cards should be such that different
voltage tracks (0, 5V etc) follow the same route as far as possible. The track of
power supplies should be as thick and wide as possible.
9.2.15 Housing rack shall be as per RDSO/SPN/144.
10.0 Performance
10.1 Time for failure detection: Failure indication shall occur not later than after the
passage of the first train over the relevant track section.
10.2 Occurrence of any failure or error of operation in the axle counter component
parts must not lead to any hazards but can solely result in transition to a
distinguished safe state.
10.4 The Axle Counter (equipment only) shall have MTBF of not lower than 70,000
hrs.

11.1 General
11.1.1 Inspection and tests shall be carried out to ensure that requirements of this
specification are complied. Conditions of tests – Unless otherwise specified, all
tests shall be carried out at ambient atmospheric conditions. For inspection of
material, relevant clauses of IRS: S 23 and RDSO/SPN/144 shall also apply.
11.2 Type Approval
11.2.1.1 Manufacturer shall furnish following information at the time of initial type
approval:
11.2.1.1.1 Design approach for the system and Salient feature through which fail-safety
has been achieved
11.2.1.1.2 Proof of safety report or its equivalent giving complete tests and their results
that have been undertaken by manufacturer or independent safety assessor

11.2.1.1.3 The system shall conform to the CENELEC standards for SIL-4 Railway
Signalling. Software & hardware validation shall be done by accredited /
reputed independent third party. The agency to be engaged for validation shall
be got approved by RDSO.
11.2.1.2 While granting initial type approval it shall be ensured that the system
conforms to all the clauses & passes all type tests as mentioned in clause 10.3.
At the end of validity period, RDSO may call for fresh samples for type
testing for the purpose of maintenance of Type Approval as per the provisions
of Directorate Operating Procedure. The sample must pass all type tests as per
Clause 10.3.
11.3 Type tests
11.3.1.6 Shock tests (Cl. 11.5.6)
11.3.1.9 Fail safety tests (Cl 11.5.9)
11.3.2 One equipment shall be tested for this purpose. The equipment shall
successfully pass the entire type test for proving conformity with this
specification. If the equipment fails in any of the tests, the purchaser or his
nominee at his discretion, may call for another equipment of the same type and
subject it to all tests or to the test(s) in which failures occurred. No failure shall
be permitted in the repeat test.
11.3.3 To obtain a type approval certificate, the manufacturer or supplier shall submit
to the testing authority two numbers of samples, for conducting all the tests
mentioned. In case of maintenance type approval, the samples shall be
selected at random from regular production lots so as to be as representative as
possible of the type under consideration. A Type approval certificate shall be
issued to a manufacturer if samples pass all the prescribed tests in accordance
with this specification.

construction, material used or manufacturing process is made subsequently,
unless this change has the approval of the Purchaser or his nominee.
11.4 Acceptance Test & Routine Test
11.4.1.1 Inspecting authority shall carry out acceptance tests on all the equipment/sub
units. The following shall comprise acceptance tests:
11.4.1.2 A complete test report of all the tests conducted shall be submitted by
inspecting authority giving the detailed observations made in every case and
actual values recorded. Specific mention shall be made whenever the
equipment has failed to comply with the requirements and indicating as to
how far it has failed to comply.
11.4.1.3 Disposal of samples: Sample equipment, which has been subjected to type
tests, shall not form part of supply.
11.4.2 Routine test
11.4.2.1 Following shall constitute routine tests and shall be conducted by
manufacturer on every equipment/sub units and test results shall be submitted
during the inspection.
11.5 Test Procedure

The equipment/sub units shall be examined for provisions of all facilities
stipulated in this specification such as correct wiring, proper mounting and
marking of components, marking, workmanship and finish for which no tests
have been specified.


Output load
Line regulation
Signal conditioner card
CPU
Modem
Relay driver





The equipment shall withstand for one minute without puncture and arcing at a
test voltage of 2000 AC, r.m.s applied between power components and the body
of equipment, which shall be earthed. The test voltage shall be approximately
sine wave of any frequency between 50 and 100 Hz. Any electronic component,
which is likely to get damaged by the application of high voltage, shall be
disconnected during the test.

There shall be no appreciable change in the values measured before and after
high voltage test. After the completion of climatic test, the values shall not be
less than 10 Mega ohms for the equipment at a temperature of 40 deg. C and
relative humidity 60%. The measurement shall be made at a potential of 500V
DC. During acceptance test, high voltage test and climatic test will not be
done.
Climatic Test shall be done as per the sub clauses mentioned below. After
completion of all the tests, high voltage test (Clause 11.5.3) & insulation
resistance test (Clause 10.5.4) shall be repeated.

ii) High Temp: 70°C±2°C
Rate of cooling and heating 1 degree per minute. Duration of test: 3 cycles
of 3 hrs each (after stability in the chamber has been reached). The
equipment shall be kept energized during the test and status of relay shall
be recorded. After completion of test, the equipment shall be subjected for
standard recovery of 2 hours (15 - 35 degree C, RH 45 –75 %), After
recovery, the equipment shall be checked visually for any damage and its
insulation resistance shall be measured which shall not be less than 10
Mega ohms at 40 degree C and 60 % RH.

The equipment shall be tested as per IS-9000/Pt.III Sec. 5. The test
severity shall be + 70 ± 2 deg. C and duration of exposure 16 hrs. (After
11.5.5.3 Cold test:

The equipment shall be tested as per IS-9000/Pt.II Sec. 3. The test
severity shall be - 10 ± 2 deg. C and duration of exposure 2 hrs. (After
The equipment shall be tested as per IS-9000 / Pt.V Sec-2. The upper
temperature shall be + 40 deg C, lower temperature + 25 degree C, RH 95
%, Variant 1, 1 cycle 12 + 12 hours and 6 number of cycles. The
equipment shall be kept energized during the test. No intermediate
measurements required only relay status to be recorded. After standard
recovery of 2 hours, the equipment shall be checked visually for any
apparent damage or deterioration and insulation resistance shall be
% RH.
The equipment shall be tested as per IS-9000 / Pt.IV. The temperature
shall be maintained + 40 ± 2 deg C, and relative humidity 95 %, (+2% -
3%). The duration of the test is 4 days. The equipment shall be kept
energized during the test. No intermediate measurements required only
relay status to be recorded. After standard recovery of 2 hours, the
equipment shall be checked visually for any apparent damage or

deterioration and insulation resistance shall be measured which shall not

be less than 10 Meg ohms at 40 degree C and 60 % RH.


The unit shall be subjected to this test for 1 hr. as per IS: 9000 Pt. XVI and
shall withstand the same. The equipment shall be kept de-energized
during the test and in its normal operational position. The item shall be
sprayed from eight showerheads, four of them being directed at an angle
of 45 degree on each of the uppermost corners of the item and remaining
four being directed horizontally at the center of the area of each of the four
sides of the item. After standard recovery, the equipment shall be checked
for any deterioration and insulation resistance shall be measured which
shall not be less than 10 Meg ohms at 40 degree C and 60% RH.

The equipment shall be subjected to this test for 24 hrs as per IS: 9000 Pt.-
XV Section 7. Water head shall be 40 cms above the highest point of item
under test. The equipment shall be kept in the chamber in its normal
operational position and in de energized state. After the completion of the
test external surface of the item shall be dried by wiping or by applying a
blast of air at room temperature. After standard recovery of 2 hours, the
equipment shall be checked visually for undue penetration of water and
for any apparent damage or deterioration. Insulation resistance shall be
% RH.
11.5.5.9 Dust Test:

The equipment shall be tested as per IS-9000 Pt. XII. The item shall be
subjected in the chamber at laboratory temperature in switched off
condition. The temperature of the chamber shall then be raised to a value
of 40 deg C ± 3 deg C with a relative humidity not exceeding 50% shall be
maintained in the test chamber. When the temperature stability has been
attained, the test item shall then be subjected to a stream of dust-laden air
for a period of one hour. After standard recovery of 2 hours, the
equipment shall be checked for any deterioration and insulation resistance
shall be measured which shall not be less than 10 Meg ohms at 40 deg C
and 60% RH.


Shock test as per IS Peak acceleration 40 g.

9000 Pt. VII Sec. 1
Clause 9 Duration of the pulse 11 m. sec.
No. of shocks 18


11.5.7.1 The test shall be done as per RDSO/SPN/144 except for diagnostic
terminal, external event logger, reset box/panel.

The equipment shall be subjected to vibration test as per IS: 9000 (Part VIII).

Details. /Remarks

as per IS 9000
Pt. VIII Amplitude 0.35mm (0 to peak) or Equipment
5g shall be
visually
No. of axis 3 examined for
any apparent
No. of sweep cycles 20
damage.
changed as per clause After
6.3 of IS-9001 Pt.XIII- completion of
81 during each sweep the test the
equipment
If resonance is observed, 10 minutes at each shall be tested
endurance tests at resonant resonant frequency for its normal
frequency. operation.

Fail safety tests shall be carried out as per RDSO/SPN /144/2004 as
covered under the clause 4.0 and as per CENELEC EN50129.
11.5.10 Environmental Stress Screening Tests (ESS) for Printed Assembly
Boards (PAB) and Subsystems
The manufacturer shall carry out the following ESS tests on all modules
on 100% basis (except bump test) during production/testing in the
sequence as follows. Suitable records shall be maintained regarding the

compliance of these tests.
PCBs in unpacked condition shall be subjected to vibration test for 10

minutes at the resonant frequency/frequencies at 3.0 g minimum
acceleration in the axis /axes perpendicular to the mounting of
components. In addition to physical checks, the electrical parameters are
also to be monitored after the vibration test.
11.5.10.2 Bump Test
PCBs /modules/units in packed condition shall be subjected to bump test

at 40 g for 1000 bumps. This test shall be carried out as per sampling
plan given in Clause 7.2.5, 7.2.6 & 7.2.7 of IRS:S 42/85 for Axle Counter
Equipment. In addition to physical checks, electrical parameters are also to
be monitored after the bump test.
The PCBs shall be subjected to thermal cycling as per the procedure given
below:
The Assembled Boards are to be subjected to the Rapid Temperature

Cycling as mentioned below in the power OFF condition. This
temperature cycling is from 0 to 70ºC, ½ hour at each temperature for 9
cycles and 1 hour at each temperature for the 10th cycle. Dwell time of 1
hour is provided for the last cycle in order to oxidize defective solder
joints exposed through thermal stress.
½ hr
70º C
Ambient
0ºC ½ hr 1hr

In addition to physical checks, the electrical parameters are also to be
monitored after this test.

The power supply modules shall be subjected to 60 (sixty) ON-OFF cycles for
one hour. (The ON-OFF) switch usually provided in the modules may not be
used for this purpose.
Through suitable means, the total size of the software of each sub-system shall
be measured and recorded. The manufacturer shall specify the size of software
with version number of each sub-system at the time of applying for type
approval.
12.0 Quality assurance

12.1 All materials shall be of the best quality and the workmanship shall be of the
highest class as per QAP standards laid down by RDSO.
12.2 The equipment shall be manufactured as per quality assurance procedure laid
down so as to meet the requirement of the specification.
12.3 Along with other requirement of the specification, validation and system of
monitoring of QA procedure shall form a part of type approval. The required
plant machinery and test instruments as per RDSO’s Standards shall be available
with the manufacturer.

13.1 It shall conform to the clause of marking given in RDSO/SPN/144.
clearly.
13.3 A nameplate shall be provided in a conspicuous position giving manufacturer’s
name, specification reference, serial no of the equipment, date of manufacture,
version no., local address, remote address etc.
13.4 A plate indicating the configuration to be adopted for entry point unit and exit
point unit shall be provided in a conspicuous position on the equipment.
14.0 Packing
Packing shall be done to RDSO/SPN/144.
15.0 Warranty
The warranty of the equipment shall be in accordance with IRS Specification No.
S- 23.
16.0 Documentation
16.2 Safety case documents as per CENELEC standards for SIL-4 Railway Signalling
to be submitted for type approval.
details for each type of assembled PCB and part list to be submitted for type
approval.
16.5 The manufacturer shall provide report containing detailed analysis of hardware
and software of axle counter verifications and validation documents approved
from accredited validation agency.
17.0 Purchaser’s Responsibility

manufacturer. However, purchaser, at his own discretion may waive off this
clause by specifying so in the tender conditions.
18.0 Supply of documents:
each shall be supplied along with each equipment. Documents shall be approved
by RDSO.
19.0 Purchaser should specify:
19.1 Number of detection points and track sections required.
19.2 The length of cable required with each track device (Refer Cl. 5.3.10).
20.0 Tools for maintenance:
20.1 The manufacturer shall indicate special maintenance instruments and tools that
may be necessary for proper adjustment and maintenance of equipment and
supply these, if so required by the purchaser
****

PRESENTATION
ON
MSDAC SRS
By
Shri M.K.RAO,
PS-2
Requirements of MSDAC
The equipment shall be robust in construction and shall work on the
permanently energized principle.
The fail safe feature shall be built in to the system by means of 2oo3
architecture.
The equipment shall be of continuously self-c hecking type.
Any defect occurring in the equipment shall not result in a condition that
will lead to an unsafe situation.
The system shall have separate indication to show track clear / occupied/
fault condition.
Any disturbance or failure in the equipment, including power supply

failure shall result in the withdrawal of clear indication and occupied
indication shall be lit.
Any failure or disturbance related to a track section shall not influence

the normal working of other track sections.
The system shall support maximum of 40 detection points and 39 track
sections.
The system shall have event logger to record all the events occurring in
the multi section digital axle counter with minimum of 40,000 events.
The system shall comprise a central evaluator which houses the

3 computing modules to perform 2oo3 logic.
The system shall include a digital axle counter field unit of 2oo2
architecture that energizes the axle detectors for detecting the passing
wheels, determining the direction of axle movement and keep counting
of axles.
The system shall include a reset panel/unit in order to reset each track
section independently.
The system shall comprise a relay unit to house the vital output relays of
each track section.
The Central Evaluator shall be connected to FDP units in star

configuration.
Card wise failure indication shall be provided in both central evaluator

and field unit.
A total system failure and OK indication should be provided.
Both axle detector and FDP unit shall have no moving parts and shall
require little maintenance.
The equipment shall be constructed as to prevent unauthorized or

irregular access to sub assemblies of the system.
A lock or seal shall be provided to the outer cover of central evaluator &
FDP Unit to access the subassemblies by an authorized person for
installation and maintenance purpose.
The equipment shall be provided with testing, measuring and adjusting

facilities for indicating proper functioning of equipment and for facility
of maintenance.
The equipment shall be fully solid-state using carefully chosen industrial

grade components.
The system shall continuously supervise the FDP units, axle detectors,
cables connecting the FDP units with central evaluator and cables
connecting axle detectors with field units. Any defect in these shall be
immediately detected; error code displayed and system or section should
go to error mode.
Response time of train occupancy for any Local track section shall be
less than 1.0 second.
Clearance time of any Local track section of train leaves the section
shall be less than 2.5 seconds .
Response time of train occupancy for any Remote track section

shall be less than 2.0seconds .
Clearance time of any Remote track section of train leaves the section
shall be less than 4 seconds.
The design of axle counter shall take system growth capability in to

consideration.
The system architecture shall be fit to use in all the sections of Railways
/Indian railways including suburban sections. Environmentally slight
moisture condensation shall not lead to malfunction or failure of
equipment. .
The design of axle counter shall take into account switching transients
that may occur either inside or outside the system and of any magnitude
up to and including interruption of full short circuit current.
The equipment shall withstand the effect of lightning & surges

incorporating lightning and surge protection as per RDSO/SPN/144.
The equipment shall conform to the Safety Integrity Level 4 as per the
CENELEC Standard.
The axle counter should not affect the operation of any other wayside
signaling equipment.
The axle counter should not be affected by on track signaling equipments
of AFTC, TPWS etc.
The error rate of the system should not be more than 2 errors per 1
million correctly counted axles, and if there is error, it should not result
in unsafe condition.
The equipment shall be capable of simultaneously counting in and /or
counting out from the ends of any track section.
The system should go to error mode when any sensor is influenced two
or more times consecutively without a proper count pulse.
The system should go to error mode when both sensors are influenced
four or more times consecutively without a proper count pulse.
The equipment should tolerate induced voltage of at least 400Vac, 50Hz

on the quad cable.
The system shall fulfill fail safety requirements as per
RDSO/SPN/144/2004.
The software shall fulfill the software requirements as per

RDSO/SPN/144/2004.
The system shall fulfill the requirement of Signal Engineering Manual as

per RDSO/SPN/144.
The system shall adopt a structured design process including but not
limited to the System architecture, Software requirements specification,
Software architecture, flow charts, and Man-machine interface for
prototypes, verification and test approach.
Both hardware and software functions will be partitioned to ensure that

integrity of certified design will not be compromised through routine
software and hardware upgrades.
Design of the axle counter will maximize the use of vendor independent
implementations.
Detection point at the junction of two consecutive sections shall be

capable of giving feed to both the monitoring sections.
Basic Functions
The system shall be capable of counting axles at entry and exit of each
track section.
The system shall detect direction of axle movement.
The system shall compare the in count and out count of each track
sections separately.
The system shall supervise the occupancy, clear and health status of each
track section.
The system shall drive track clear indication only when IN count and
OUT count are equal and equipment is functioning all right.
The system shall drive vital output for each track section independently.
The system shall show occupied the moment any of the subassemblies
belonging to a particular track section is damaged, missing or has
become faulty.
Requirements of Axle Detection
The axle detector principle shall be based on change of both amplitude
and phase of the receiver signal.
In case of axle detection based on phase detection principle the trolley

protection circuit should be avoided.
The axle counter shall have arrangement so that wheels of push trolleys,
dip lorry, rail dollies etc. are not counted by it.
The axle counter operation shall be independent of wear & tear of

wheels as permitted by Railways/Indian railways schedule of dimension,
lateral displacement of wheels on rails etc.
The axle counter shall capable of detecting an axle with diameter greater
than 300mm.
Axle counter shall be independent of type of sleepers in the section as

wooden, RCC, or steel etc.
Axle counter shall work on all types of rail profiles and construction
such as welded or non welded rails of 52Kg/ 60Kg/ 90R/ 71Kg etc.
Axle counter shall operate up to vertical worn out limit of 13.00mm in

60Kg /meter rail section.

52Kg /meter rail section.

90R rail section.
Axle counter shall be suitable for train speed from 0 to 250 Km/hr.
Axle counter shall be designed for ease of maintainability and testability.

Requirements of Track Device
The axle detector shall comprise two sets of TX/RX coils/sensors.
The TX/RX coils shall operate at 21.05 kHz and 25 kHz.
The inductance of axle detectors shall not vary more than ±6% within
the specified temperature range.
The TX/RX coils in the track shall be of web mounted type. The
The axle detectors shall be actuated only by wheel flanges and not by
other parts of trains. E.g. rail breaks, toilet pipes, suspended chains,
electrical inductors in locomotives, air conditioning equipment and other
Electrical/electronic equipment in train/engine.
One set of axle detector shall not influence another set of detector
mounted ≥2meters away.
The axle detector should not infringe the schedule of dimensions of

Indian railways.
The length of inbuilt cable with axle detector shall be 5/10/15 meters
only.
Requirements of Central Evaluator
The Central Evaluator shall be based on 2oo3 logic.
It shall be capable of monitoring, maximum of 39 track sections and drives a vital

output for each track section independently.
The central evaluator shall be capable of communicating with maximum of 40

detection point units .
The Central Evaluator unit shall be housed in a pre-fabricated rack to be supplied

along with the system.
The Central Evaluator shall communicate with Field detection points at
1200 baud rate in FSK V.23 standard or it shall support various baud rates like
1200, 4800, 9600 and 19200 in RS232C standard.
The Central Evaluator shall be able to generate relay outputs for up to 39 track
sections.
The Central Evaluator shall be able to receive the reset command generated
from reset unit for section wise resetting of track section.
The Central Evaluator shall provide input to the event logger for
registration and recording of events occurring in the Multi Section Digital
Axle Counter.
The Central Evaluator will have an RS232/RS485 port to interface with
Electronic Interlocking system as per RDSO/SPN/148.
Provision should be there for lightning & surge protection in the central evaluator
power supply input and communication line input/output.
Suitable arrangements shall be made for providing electrical isolation between

external relay circuits and internal circuits.
The Central Evaluator will have a separate port to connect to the station data
logger for monitoring the section –wise clear/occupied information. Standard
Data Logger Protocol as specified in RDSO/SPN/99 shall be used for this
purpose.
CSTE CONFERENCE
3,4 MAY 2013
BPAC RELIABILITY IMPROVEMENT

BPAC subsystems
Block
Operator Working
Section Clear Comm.
Interface Logic
Proving system
Block UFSBI
Digital axle
Relay logic over
Panel counter
Cu/OFC
Analog
Processor Analog
Axle
Software Mux
counter
High Onboard
availability chip over
DAC Cu/OFC
BPAC Types
BPAC using BPAC using SSBPAC

Analog MUX UFSBI
Uses Block Panel Uses embedded

Uses Block Panel with UFSBI as
with Analog MUX systems to
interface replace relay
and UAC
logic
CEL make 1. M/s Deltron

systems – M/s Efftronics
presently 2. M/s CEL
given LSA for 20
approved for 3. M/s Webfill systems
spares only
BPAC with Panel- supplier base
CEL Deltron Efftronics Others
Approved Webfill
UAC & under Pt. LSA for 20 LSA-20
Analogue II systems - nos for
Mux – SSBPAC BPAC
population using
approx. 400 UFSBI as
2oo3 Mux UFSBI
nos. in
NCR/WCR/ No systems Medha
WR commissioned SSBPAC
so far
– under
LSA for 20 parallel
systems for trial and
BPAC using type test
UFSBI
BPAC with Block Panel & UFSBI- Population
80
71
70
No. Of Commissioning
60
50
40
Series1
30 27 27
24
20
12
10 6
2
0
ECR ER NR SER WCR WR CR
Railway Name
BPAC using UFSBI -Advantages
n Non Co-operative type, consent based Block working, with integrated
Auto-TOL and Auto Line closed feature with Block occupancy
detection using SSDAC.
n Reduced operator involvement to one-third thereby reducing chances
of operational errors.
n The time taken for Line clear reduced to less than 2 seconds.
n In case of copper cable damages in Single / Double Line conventional
Block Instrument with LVCD, the SSDAC can be switched over to OFC,
but Block remains suspended owing to the inability of Block Instrument to
work on OFC. This problem can be completely avoided by the usage of
BPAC using Block Panel & UFSBI. The system is compatible with all
brands of SSDAC.
n Designed to work in RE areas, in conjunction with PI / RRI / SSI /
MACLS. For Gauge conversion projects or doubling, the Single Line
Block can be modified to a Double Line Instrument by replacing the
relay rack & Block Panel. While the costliest part – UFSBI, can be re-
used.
Performance - BPAC with Block Panel using UFSBI
FRPCPY of
Block Panel
No. of A/C P/S and Total Block
Railway Equpt. & UFSBI
months. failure others failures Panel &
failure.
UFSBI
SER 12 12 3 - - 3 25
WR 58 1137 166 256 - 422 3
WCR 24 12 3 18 10 31 12.5
NR 6 105 10 129 - 139 19
Total 100 1266 182 403 10 595 15

BPAC Reliability improvement
Dual Detection Arrangement Using SSDAC For BPAC Application
STATION A Block Section STATION B
1.25M 1.25M
SSDAC 1 SSDAC 3
SSDAC 2 SSDAC 4
LOCATION STATION
VR1 VR2 VR1
Reset Pulse to
Auto Reset SSDAC1
VR1 VR2 Module
VR2
Reset Pulse to
SSDAC2
Reset Pulse from SM’s

SM’s Reset Box Reset Box
VR1
VR2 VPR
To VPR at Station
VR1
VR2
PR1 PR2
To PPR at Station PPR

PR1 PR2
BPAC Scheme (Schematic) for A,B Route
Block Block
Panel Panel
1Quad
UFSBI COP
OFC
COP UFSBI
½ Quad
Redundant Redundant
½ Quad/OFC
Axle Counter Axle Counter
COP- Change Over Panel – manual or auto. Auto system under

development
BPAC Reliability improvement
• Existing block logic replaced with 2oo2 hardware logic (using
Complex Program Logic Devices ,CPLD). No relays hence no
relay failures.
• NFR and ECR given permission for trial working over Radio
in theft prone sections
• Auto media changeover with logging facility to avoid manual
changeovers and reduce time
Solid State BPAC
• Embedded system used for

replacing relay logic and
communication between two
stations for block working
• 2oo3 architecture of hardware for

redundancy
• Two separate modules for single

line and D/L working
• Fast operation due to digital data

exchange between Stations
• Data logging and alarm

generation for fault rectification
Comparison of Analog BPAC
SN Item feature Deployment Remarks
1 BPAC using Panel, Develope 1.11 Block section in ALD Div, NCR Due to obsolescence
Mux ,Combiner & d in mid 2.AGC- Datia section in AGC Div, of analog technology
Conv and UAC 80s NCR and having limited
(Analog) 3.JHS- Bina section in JHS Div, NCR features, supply is
For SL & DL 4.MTH- KTT section in KTT Div, stopped.
WCR Approved only for
5.KTT- RTM section in RTM Div, supplying SPARES.
WR
2 BPAC using Panel, Develope 1. Based on Rlys requirement Costing is @ around
without Mux d in 2000 where cable cores are available in 5-6 lacs /set
,Combiner & Conv plenty, this system is developed.
and UAC 2. Trial in MB div of N.Rlys over 10
(Analog) block-section
For SL (Non RE)
Comparison of BPAC
SN Item feature Deployment Remarks
3. BPAC using Developed It is a integration of RDSO appd Requires large nos of relays
block Panel, in 2000 sub items. (29/31 relays for DL/SL)
using UFSBI & 1. Appd telephone Costing is @ around 6-7 lacs
SSDAC 2. Appd UFSBI /set
3. Appd Relay logic based Ckts
Complies to IRS: S 105/2012 ver-0
4. SSBPAC (D) & Developed Complies to RDSO/SPN/175/2005 1. Only external relays are
SSDAC in 2012 ver-0 required to feed the
external information (11
relays)
2. Appd relay logics are a part
of SSBPAC , reducing no. of
relays.
3. Costing is @ around 9-10
lacs /set
DAC Performance and
Improvements
Comparative DAC Performance
Failures – FRPCPY – 2012-

Rly. Make Eqpts
2012-13 13
IR CEL 3199 17509 547

2208 3212 145
IR Thales
IR Siemens 528 696 132
658 2372 360
IR GG Tronics
6593 23789 361
IR All makes
*source: Railway Board’s failure data

Zone wise FRPCPY figures - DAC
Rly. Make Total No. C.Hours C.Fail. C.F.Time MTBF MTTR FRPCPY
CEL 158 578424 254 286 2277 1 161
CR Alcatel 513 147 718200 116 92 6191 1 79
Siemens 208 982392 353 301 2783 1 170
CEL 405 3547800 9472 7488 375 1 2339
Eldine 138 1208880 471 565 2567 1 341
ER Siemens 734 60 525600 46 81 11426 2 77
GG Tronics 131 1147560 768 615 1494 1 586
CEL 281 2264520 804 1184 2817 1 286
Alcatel 11 96360 15 22 6424 1 136
NR Siemens 338 11 59736 52 76 1149 1 473
GG Tronics 35 249576 88 26 2836 0 251
CEL 22 192720 65 210 2965 3 295
NFR Alcatel 85 28 245280 255 516 962 2 911
GG Tronics 35 296856 15 46 19790 3 43
CEL 224 1962240 750 919 2616 1 335
SR Alcatel 343 24 210240 31 7408 6782 239 129
GG Tronics 95 832200 216 7100 3853 33 227
CEL 484 2595744 1337 4672 1941 3 276
SCR Alcatel 576 84 505968 56 687 9035 12 67
GG Tronics 8 70080 31 45 2261 1 388
CEL 103 902232 365 1122 2472 3 354
SER 314
Alcatel 211 1760448 373 877 4720 2 177
CEL 97 623472 80 106 7793 1 82
Alcatel 550 4273440 151 154 28301 1 27
WR Siemens 830 172 1134000 21 24 54000 1 12
GG Tronics 11 96360 8 5 12045 1 73
CEL 326 2843280 997 1842 2852 2 306
ECR 385
GG Tronics 59 481272 323 436 1490 1 547
CEL 233 1953786 186 265 10504 1 80
NWR Alcatel 296 58 492672 17 30 28981 2 29
GG Tronics 5 27768 3 4 9256 1 60
CEL 304 2622256 1761 564 1489 0 579
ECoR 307
Alcatel 3 23979 0 0 0
CEL 101 884760 167 67 5298 0 165
Alcatel 147 1287720 57 49 22592 1 39
NCR Siemens 395 44 385440 135 146 2855 1 307
GG Tronics 103 902280 32 19 28196 1 31
CEL 262 2295120 710 852 3233 1 271
Alcatel 25 219000 92 95 2380 1 368
SECR Siemens 325 24 210240 76 97 2766 1 317
GG Tronics 14 122640 20 29 6132 1 143
CEL 60 525289 149 307 3525 2 248
SWR Alcatel 211 3 26267 3 12 8756 4 100
GG Tronics 148 1144307 807 1910 1418 2 545
CEL 139 1158984 412 500 2813 1 296
Alcatel 779 6824040 1575 1461 4333 1 202
WCR Siemens 941 9 78840 13 11 6065 1 144
GG Tronics 14 43656 61 60 716 1 436
Cause wise analysis
Reset after one train
Engg. M/C/ Staff

wkg/Push trolley/Rail dolly
Equpt/Card Defect
Disc/S&T Staff working
Others
Cable Defect
TX/RX coil defective
Power Supply/Fuses
Improvement measures
M/s CEL, Sahibabad

ü OEN DIP switches replaced with Gold plated ones and Transorb removed.
Complied by CEL in all working installations.
ü New Modem card developed has been tested and approved.
ü New DC-DC Converter developed in 2011 to have better efficiency
ü Technical audits jointly with firms – approx. 500 locations done in last year
ü High Availability SSDAC developed having single track sensor. System now
approved for use over IR.
ü Indigenous MSDAC developed and tested. Limited supply approval for
performance assessment given to M/s CEL.
ü On site training as per request of Zones and troubleshooting courses at
Manufacturer premises.
ü Maintenance guidelines advised by RDSO to all zones.
ü Technical advisory note no. 6001 (wiring discipline), 6002 (Schemes for ABS
and IBS) and 6003 (Paralleling of UAC and DAC) issued.
M/s Ggtronics, Bangalore
ü Technical audits jointly with firms – approx. 200 locations done in this year
ü High Availability SSDAC developed having single/dual track sensor. System
now approved for use over IR.
ü On site training as per request of Zones and troubleshooting courses at
Manufacturer premises.
ü Maintenance guidelines advised by RDSO to all zones.
M/s Eldyne, Kolkatta

ü Technical audits jointly with firms – approx. 100 locations audited jointly.
ü For AzLM, issues with version 6.1.11 have been sorted out by Thales,
Germany. Final report from Thales is awaited to progress on this issue.
M/s Siemens, Mumbai

ü Technical audits jointly with firms – approx. 60 locations audited jointly.
ü Around 50 DPs replaced against target of 80 given
ü Line wise segregation of Evaluators in BSL & JHS division – under progress
Software modifications for M/s CEL and Ggtronics make SSDAC
• More tolerances during communication failures/trips – system
does not go to error for break in communication upto 2 mts, when
in occupied state.
• Improper wheel pulse if followed by proper wheel will be counted
as a proper wheel.
• For CEL SSDAC - Section declared as Occupied on influence of
wheel on second sensor.
• For Ggtronics SSDAC- in Occupied state, frequent check of
Supervisory signal is now reduced to 1 check per minute. But
definite check for SUP high before clearing system.
• Modified software tested and is under V&V.
Digital Axle Counters- Main interfaces
MSDAC- SIEMENS
Potentiometer for adjusting Frequencies
Backplane
Pot for adjusting

F2(6.37KHz)
Pot for
adjusting
Fs(43KHz)
Band pass filter Generator Card
card
Pot for adjusting
F1(3.50KHz)
MSDAC- SIEMENS
M S D A C - A z L M – E l d y n e / T h a l es
ACE- Layout
Concept of IN COUNT & OUT COUNT:
INCREMENT
DECREMENT
ENTRY End SSDAC:
INCREMENT= IN COUNT
DECREMENT=OUT COUNT
EXIT End SSDAC:

INCREMENT= OUTCOUNT
DECREMENT=INCOUNT
Working- CPU/MLB Card
•The Micro controller Logic Block Card (MLB) is the heart of the
system.
• These cards implement the wheel detection, train direction
checking and wheel counting functions.
• In addition, it receives the remote wheel count and computes
the status of the section for clear or occupied.
• It also Checks various supervisory signal levels like supervisory
of TX/Rx coils, presence of various cards, LED check,
communication link failure etc.
Working- MLB Card
The card design is based on 8051 compatible micro
controllers. The salient features of the card are as follows:
a. Micro controller is based on industry standard 89C51

b. RS232C compatible serial port for modem
connectivity
c. 10K byte on chip Flash ROM for program storage
d. 256 byte on chip RAM
e. Parallel ports for address/mode input, pulse inputs
and Vital Relay output and relay read back.
f. Extensive LED display – A block of 8 LED indicators
for count progress / error display, 2 independent LED
indicators for section status.
SSDAC – PACKET DETAILS – CEL system
Once the system is connected and user starts getting the packet information, the packets can be read as
follows. The packet will appear after every 0.8 sec’s and the packet carries the latest information.
XX ? N2F2 G : U42 0005 FFFB
FFFB – The second MLB card count status in decrement mode from highest
counts. With every count this gets decremented by 1 (5 counts are
decremented)
0005 – First MLB card count status in incremented mode from 0000 counts.
With every count this increments by 1 (0005 in 5 counts incremented)
U – Update packet
42 – Address marked in the system is given below
Entry Exit System state
02 03 Prep. Reset
42 43 Clear
82 83 Error
‘:’ –Start of Block
‘G’ – The section clear condition or Green ‘G” character is sent every 0.8
sec interval. OR
‘r’ – The section is occupied or Red ‘r’ character is sent every 0.8 secs time
interval in case of any error or section is occupied.
N2F2 – This is additional information
“?” – Line feed
XX – Error code is displayed (Refer systems error code chart)

OO – No error
Vital relay Box:
Vital Relay (VR)

VR – HN.1K type, 24 V, 1000Ω,
6F/6B are supplied along with the
system.
1N5408 DIODE is connected across
the R1, R2 in reverse bias condition.
Preparatory Reset Relay (PR)

PR – HN.1K type, 24 V,1000Ω,
6F/6B.
1N5408 DIODE is connected across
the R1, R2 in reverse bias condition.
Back contact D3-D4 of VR is proved in series with its coil circuit.
SSDAC – Relay Status
Sl. Condition RELAY STATUS CHART FOR SSDAC
No.
Station-A Station-B
(Relay Room) (Location) (Relay Room) (Location)
1. 24V connected VPR↓PPR↓ VR↓PR↓ VPR↓PPR↓ VR↓PR↓
2. Reset applied VPR↓PPR↓ VR↓PR↓ VPR↓PPR↓ VR↓PR↓
3. System enters VPR ↓PPR↑ VR ↓PR↑ VPR ↓PPR↑ VR ↓PR↑

preparatory reset mode
4(a) First train –First wheel VPR↓PPR↓ VR↓PR↓ VPR↓PPR↓ VR↓PR↓
enters section
4(b) First train clears the VPR↑PPR↑ VR↑PR↑ VPR↑PPR↑ VR↑PR↑
section
5(a) Subsequent train VPR↓PPR↑ VR↓PR↑ VPR↓PPR↑ VR↓PR↑
occupy section
5(b) Subsequent train clears VPR↑PPR↑ VR↑PR↑ VPR↑PPR↑ VR↑PR↑
section
d) Between SSDAC Units for modem
communication:
0.9mm half quad cable:
1 pair:S/Line
2 pairs:D/Line
e) Between SSDAC Unit & SM’s Reset Box:
0.9 mm half quad cable.

Failure
Failures
s – FRPCPY FRCPY
Rly. Make Eqpts Eqpts in April
2012- 2012-13 Apr’13
2013
13
3199 17509 547 1288 226 210.6

IR CEL
IR Thales 2208 3212 145 587 42 85.86
528 696 132 198 10 60.61
IR Siemen
GG
658 2372 360 242 87 431.4
IR Tronics
Data Performance of 6 Railways
Failure
Failures – FRPCPY FRCPY
Rly. Make Eqpts Eqpts in May
2012-13 2012-13 May’13
2013
3199 17509 547 584 84 172.60

IR CEL
2208 3212 145 83 12 173.49
IR Thales
528 696 132 58 9 186.21
IR Siemens
GG
658 2372 360 171 118 828.07
IR Tronics

Failures Failure
FRPCPY FRCPY
Rly. Make Eqpts – 2012- Eqpts in June
2012-13 June'13
13 2013
3199 17509 547 585 59 121

IR CEL
2208 3212 145 83 11 159
IR Thales
528 696 132 58 6 124
IR Siemens
GG 658 2372 360 171 95 667
IR Tronics

MULTI SECTION DIGITAL AXLE
COUNTER
CENTRAL ELECTRONICS LIMITED
(MSDAC)
• Con figu rabl e up to 40 Dete ct io n Po int s (DP ) & 40 t ra ck
outputs.
• System scalabl e in multiple s of 8 DPs.
• C en t ra l Eva lu a to r m o du l e wi th 2 o u t o f 3 h a rd wa re
architecture.
• Power & Data on single pair Quad cable.
• O n s it e C o n fi g u ra b l e .
2
MSDAC - APPLICATION
• IN TERMINAL LINES / SIDING – 1D- Single Section

• IN STRAIGHT LINE: 2D point - Single Section
• IN POINT ZONE: 3D point - Single Section
• IN POINT ZONE: 4D point - Single Section
• IN LADDER: Multi Detection – Single Section
• CONSECUTIVE SINGLE SECTION IN A STRAIGHT LINE.
• A U T O M AT I C B L O C K S I G N A L L I N G
• I N T E R M D I AT E B L O C K S I G N A L L I N G
3
MSDAC – SYSTEM COMPONENTS
• C e n tr al Eva l u a to r U n i t
• D i g i ta l A x l e C o u nt e r F i e l d u n i ts
• S t a t i o n M a s t e r ’s R e s e t Pa n e l
• M o n i t o r in g U n i t
• High Frequency Axle Detectors
• C o n f i g urat io n t e r m i n al
4
5
Monitoring Unit
6
Central
Evaluator
7
Vital Relay
8
MSDAC – CENTRAL EVALUATOR
• Evaluator Module Card
– 2 out of 3 hardware architecture
– Caters to 8 DP
• Relay Driver card
– 8 vital relay outputs
• Configuration Card
– Easy configuration using GUI tool
• Event Logger Card
• Redundant DC to DC converter
• 1 9 ” p r ew i re d r a c k fo r d i ffe r e n t c o n fi g u ra t i o n s
available
– 8 DP model in 20U rack
– 16/24 DP model in 30U rack
– 32/40 DP model in 40U rack
– D u a l 8 D P/ 1 6 D P i n 40U rack
9
MSDAC –CENTRAL EVALUATOR
10
CEU – DUAL DC TO DC CARD
11
CEU – 8 CH. EVALUATOR CARD
12
CEU – 8 CH. RELAY DRIVER CARD
13
CEU – CONFIGURATION CARD
14
CEU – EVENT LOGGER CARD
15
MSDAC –8 DP SYSTEM
16
MSDAC –40 DP MODEL
MOD 1 MOD 2 MOD 3 MOD4 MOD 5
17
5th & 6th May 2010 18
MSDAC - FIELD UNIT
• 2 out of 2 hardware
architecture .
– Tra n s m i t s c o u n t a n d
health information to
Central Evaluator
• Connected in Star
Configuration with CE U.
• Optional Relay Driver Card

in case of IBS & ABS
applications.
19
DETECTION POINT
CEU
20
MSDAC – AXLE DETECTORS
• O p e ra ti n g F re q u en c y –
21KHz / 23KHz
• Phase Reversal type
• We b M o u nt i n g
21
MSDAC – RESET PANEL
• Domino Based Design

• Section-wise Resetting
• S e c t i o n C l e a r, O c c u pi e d, P re p a rato r y re s e t
& L i n e Ve r i f i c at i o n i n d i c a t i o ns
• Re s e t B u t to n
• S M ’s C o n t ro l Ke y
• S e c t i on w i se c o u nte r fo r r e co rd i ng re s et
22
23
24
• Domino Based Design

• Section-wise Resetting
• S e c t i o n C l e a r, O c c u p i e d ,
Preparatory reset & L ine
Ve r i f i c a t io n i n d i c at i o n s
• Reset Button
• S M ’s C o n t r o l K e y
• Section wise counter for
recording reset
25
MSDAC – MONITORING UNIT
• LCD based touch screen
for maintainer staff
• Provides information of
counts, Section status,
Error condition, health
etc of Field units &
Central Evaluator
26
MSDAC- CONFIGURATION TOOL
• U s er F r i e n d l y c o n f i g u ra t i o n t o o l fo r co n f i g u r i n g
system in factory or at site.
• Configuration using Windows Application
Serial Cable
Configuration
terminal
27
MSDAC – POWER ARRANGEMENT
• C E N T R A L E V A L U AT O R
– 2 4 D C B AT T E R Y B A N K
• FIELD UNITS
– OPTION 1
• 2 4 V D C V O LTA G E ( W H E R E P O W E R C A B L E I S AV A I L A B L E )
– OPTION 2
• 1 1 0 V D C V O LTA G E ( W H E R E I P S I S AV A I L A B L E )
– OPTION 3
• 9 6 V D C V O LTA G E F R O M C E L’ S C E N T R A L I S E D D C T O D C
CONVERTER
• R E S E T PA N E L
– 2 4 V D C B AT T E R Y B A N K
28
29
Field distribution with no wheel in vicinity
When the wheel is
at a distance
greater than 200
mm from the
imaginary center
line of contact
between wheel
and rail lines
Electromagnetic flux meets receiver coil at an angle

“A” to perpendicular and EMF is in phase with
transmitted signal .
Field distribution with wheel at centre
Electromagnetic
flux meet on the
receiving coil at
an angle “B” to
perpendicular
and EMF
produced is de-
phased by 1800
“This change in phase is detected as one passing wheel”

Field distribution with no wheel present : Siemens technology
Field distribution in presence of wheel : Siemens technology
Detection of wheel : Frauscher technology
DAC- Logic signals
Wheel movement
causes EMF and
hence receiver
voltage signals to
change in amplitude
and phase.
These changes are

converted into logic
pulses for detected
wheels.
PART V
PRINCIPLE
Frauscher msdac works on the principle of electromagnetic waves.

Compress the electromagnetic wave by wheel. Flux is cut amplitude less
electromagnetic wave flow parallel to rail.
Adjacent track section and are proved in circuit so that the track pickup
.any object move over rail will not cause track down .so this
arrangement is not in Siemens. For trolley protection.
ISO9001:2008 Document No :RDSO/SPN/176/2013 Version:3.0 Date Effective :
31.03.2014
Document Title: Specification For Multi Section Digital Axle Counter
RESEARCH DESIGNS & STANDARDS ORGANIZATION

MANAK NAGAR, LUCKNOW – 226011

Version 3.0
Number of pages 29
RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR
LUCKNOW - 226011
Page 1 of 29
Prepared By JE/Signal Checked By ADE/Signal Issued By Director/Signal
31.03.2014
DOCUMENT DATA SHEET

Designation RDSO/SPN/176/2013 Version3
Title of Document Multi Section Digital Axle Counter Specification
Signed by:
Name: Prashant Kumar Varma
Approved By RDSO
Name: Mahesh Mangal

Abstract
This document defines Multi Section Digital Axle Counter Specification.
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Document Control Sheet
Page 3 of 29
31.03.2014
AMENDMENTS
Version Chapter/ Amendments Effective

Annexes Date
1.0 - First issue 13.09.2002

2.0 - Second issue 15.05.2005
3.0 - Revised to incorporate 81st SSC 31.03.2014
Recommendations
Page 4 of 29
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Table Of Content
Page No.
0.0 Foreword 6
1. Scope. 6
2. Terminology & Abbreviations 6
3. Applicable document/drawings 8
4. System requirements 9
5. General requirements. 9
6. Diagnostics 17
7. Traction & Supply 18
8. DC Input Power Supply 18
9. Hardware standards. 18
10. Performance. 20
11. Inspections & Testing. 20
12. Quality assurance 28
13. Marking & Identification 28
14. Packing. 28
15. Warranty 28
16. Documentation. 28
17. Purchaser’s responsibility. 29
18. Supply of documents. 29
19. Purchaser should specify. 29
20. Tools for maintenance. 29
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31.03.2014
SPECIFICATION FOR MULTI SECTION DIGITAL AXLE COUNTER

0.0 Foreword:
0.1 This specification is issued under the fixed serial No. RDSO/SPN/176/2013 followed by
the year of original adoption as standard or in case of revision, the year of latest revision
1.0 Objective and Scope
1.1 This document sets forth general, operational, technical, performance & type tests
requirements of Multi Section Digital Axle counter.
1.2 This specification does not cover the specification of external cable and protective
devices to be used in conjunction with Multi Section Digital Axle Counter for its
installation.
1.3 Axle Counter shall use amplitude/phase change techniques or any other fail safe
techniques for safe and reliable wheel detection functions
2.0 Terminology & Abbreviations

2.1 Terminology
2.1.1 The terminology referred to in the specification is covered by the definitions given in
IRS Specification no. S-23, IS Specification No. 9000 and as given below.
2.1.2 Axle detector: The track device comprising of the coils fixed in cover mounted on the
rail. It will detect the wheel (rolling stock axle) passing over the device.
2.1.3 Counting device/Digital Axle Counter field unit (track side): Counting device/digital
axle counter field unit is the track side electronic assembly that energizes the axle
detectors for detecting the passing wheels determining the direction of movement and
keeping the count of wheels. It transmits the count and health information to the
Central Evaluator at regular intervals.
2.1.4 Detection Point: Detection point comprises of one axle detector and the field unit
connected to it.
2.1.5 Track Section: The portion of track confined by associated axle detectors & field units.
The axle counter is checking the occupancy of this section.
2.1.6 Section Balancing: Axle counter determines whether the track section in question is
clear / occupied, based on the information on detected (in counts and out counts)
numbers of axles, which is received from the axle detectors confining the section in
question.
2.1.7 Resetting: Resetting commands the setting to zero the records of counted axles.
2.1.8 Preparatory Reset: After resetting, axle counter shall continue to show occupied until
one train movement in the section carries out correct balancing of track section.
condition from different location like the clearance of the track section from site using
line verification box. The axle counter will show clear after the conditional reset .
2.1.10 Event Logger: Logs the events occurring in axle counter system with date and time
stamping.
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2.1.11 Central Evaluator (Indoor): The Central Evaluator receives count and health
information from Digital Axle Counter Field units. It evaluates the counts received from
the digital axle counter field units to generate relay-driving signals for individual track-
sections.
2.2 Abbreviations
2.2.1 dB Decibel
2.2.2 AWS Auxiliary Warning System
2.2.3 TPWS Train Protection & Warning System
2.2.4 TX Transmitter
2.2.5 RX Receiver
2.2.6 KHz Kilo Hertz

2.2.7 LED Light Emitting Diode
2.2.8 LCD Liquid Cristal Display
2.2.9 VF Voice Frequency
2.2.10 AFTC Audio Frequency Track Circuit
2.2.11 DACFU Digital Axle Counter Field Unit
Page 7 of 29
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3.0.1 IS: 9000 Basic environmental testing procedures for electronic and electrical items.
3.0.2 IRS-S-23 Electric Signaling and Interlocking Equipment
3.0.3 ISO 9001 Quality systems – model for quality assurance in design, development,
production, installation and serving.
3.0.4 IEC529/EN 60529 Specification for degree of protection provided by enclosures (IP code).
3.0.5 EN 61000.4.2 Electromagnetic compatibility (EMC) – testing and measurement

techniques- electrostatic discharge immunity test and basic EMC
3.0.6 EN 61000.4.4 Electromagnetic compatibility – testing and measurement techniques-

electrical fast transient/burst immunity test and basic EMC publication
3.0.7 EN 61000.4.5 Electromagnetic compatibility – testing and measurement techniques –

surge and immunity test
3.0.8 PrEN50126 Railway applications - specification and demonstration of - reliability,

availability, maintainability and safety
3.0.9 PrEN50128 Railway applications – Signalling and Communications – Software for

Railway Control and Protection system
3.0.10 PrEN50129 Railway application: Safety related electronic systems for signaling
3.0.11 EN 50159-1 & 2 Railway Application: Signalling and Communication Safety related
communication in closed and open Transmission system
3.0.12 IRS: S TC-30 Underground Railway Jelly filled Quad Cables for Special purposes in
Electrified Area.
3.0.13 RDSO/SPN/165 SMPS based IPS.
3.0.14 IRS: S- 86 Battery Charger-Self Regulating.
3.0.15 IRS: TC 41 PIJF Telephone Cable.
3.0.16 RDSO/SPN/144 Safety and Reliability Requirement of Electronic Signalling Equipment.
3.0.17 RDSO/S/20001 Drawing for Reset – Box and Reset Panel
3.0.18 RDSO/SPN/99 Data Logger
3.0.19 RDSO/SPN/192 Electronic Interlocking
3.0.20 RDSO/S/20002 Drawing for line verification box.
3.1 Wherever in this specification, any of the above-mentioned specification is referred; the
latest issue of the same is implied.
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4.0 System Requirements

The MSDAC system comprises of Axle Detectors, Track side electronics/DAC
field units, Central Evaluator, Reset unit, Relay unit, Event Logger and diagnostic
terminal.. MSDAC system should be scalable and support detection points & generate
vital relay outputs for requisite track sections as per user’s requirement. The Central
Evaluator shall be connected to Track side electronics/ DAC field units in star
configuration through 2wire or if track side electronics are to be reduced then 4 wire
arrangements can be used to transmit information from field unit to central unit.. Each
track section can be reset independently from the Reset Box/Reset Module of Reset
Panel/Visual Display Unit (VDU). The Event Logger shall record all the events occurring
in the multiple sections of axle counter.

5.0.1 Multi section digital Axle counter consists of axle detectors & field units scalable upto
user’s requirement shall be configured for desired track sections as per user’s
requirement/site specific conditions. It is capable of counting axles, count comparison,
finding direction of axle movement, supervision, relay drive and transmission of counts
and health of axle detectors & field units. The field units are connected to the Central
Evaluator by a transmission medium where transmission is in VF range or Central
Evaluator may be connected to detection point through track side electronics on 2 wire
arrangements or 4 wire arrangements may be used to reduce the track side electronics
considerably
5.0.2 Track clear indication shall only be given when IN count and OUT count are equal and
equipment is functioning all right. This implies that until all axles that enter a section
are completely counted out, the section concerned shall not show as clear.
5.0.3 Axle counter shall show occupied the moment any of the axle counter sub-assemblies
belonging to the section is damaged, missing or has become faulty.
5.0.4 The axle counter shall use Amplitude/ Phase change techniques or any other fail safe
techniques for safe & reliable wheel detection function
dollies etc. are not counted by it. Trolley protection track circuit shall not be required
with phase detection.
5.0.6 Axle counter operation shall be independent of wear & tear of wheels as permitted vide
Indian Railway’s Schedule of Dimension, lateral displacement of wheels on rails etc.
The manufacturer shall specify the minimum diameter of the wheels, condition of
wheels etc., to which the performance of equipment shall not be affected.
5.0.7 Axle Counter operation must be independent of type of sleepers in the section such as
wooden, RCC, or steel etc. and shall work on all types of rail profiles and construction
such as welded or non-welded rails of 52 kg / 60 kg / 90 lbs etc. Axle counter shall
operate up to the vertical limit for worn-out rail as given below:
1. 60 Kg / metre 13.00
2. 52 Kg / metre 8.00
3. 90 R 5.00
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5.0.8 Axle counter shall be suitable for train speed from 0 to 250 Km/h.
5.0.11 The equipment (central evaluator & field unit) shall be of continuously self-checking
type and shall have separate indication to show conditions of track clear and track
occupied (including fault). Any disturbance or failure in the equipment including power
supply failure shall result in withdrawal of clear indication and occupied indication shall
be lit. . Disturbance /failure related to a track section shall not influence the normal
working of other track sections.
5.0.12 Card wise failure indication shall be provided in Central Evaluator & Field Unit. It is
desirable to give suitable indication of the nature of failure. Also total system failure
and O.K. indications shall be provided.
5.0.13 Axle detector & field unit shall have no moving parts and shall require little
maintenance.
5.0.14 The equipment (central evaluator & field unit) shall be so constructed as to prevent
unauthorized/irregular access to sub-assemblies of the system. Authorized persons
should, however, have access to these sub-assemblies for the purpose of installation and
maintenance by unlocking the outer cover/breaking of seal provided on the outer cover.
5.0.15 The central evaluator & field units shall be provided with testing, measuring and
adjusting facilities for indicating proper functioning of equipment and for facility of
maintenance.
5.0.16 The equipment shall be fully solid-state using carefully chosen industrial grade
components.
5.0.17 The system shall provide for continuous supervision of field units including cables
connecting the field units with central evaluator and detectors with field units. Any
defect in these shall be immediately detected, error code displayed and the system /
section should go to error mode.
5.0.18 The maximum axle count, each track section can handle, should be > 1024.
5.0.19 Response time of train occupancy for any track section shall be less than 1.0 second.
5.0.20 Clearance time of any track section after train leaves the section shall be less than 2.5
sec.
5.0.21 Axle counter system design shall take into consideration system growth capability and
architecture of digital axle counter shall be such that it is fit to be used on all the
sections of Indian Railways including suburban sections.
5.0.22 Environmentally slight moisture condensation shall not lead to malfunction or failure of
equipment.
5.0.23 The design of axle counter shall take into account switching transients that may occur
either inside or outside the system and of any magnitude upto and including interruption
of full short circuit current.
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5.0.24 Axle counter shall withstand the effect of lightning & surges incorporating lightning and
surge protection as per RDSO/SPN/144.
5.0.25 The equipment shall conform to the Safety Integrity Level 4 as per CENELEC Standard
and as per Clause 3 of this specification i.e. Applicable Documents/drawings.
5.0.26 The axle counter should not affect the operation of other wayside signalling equipments.
5.0.27 The axle counter shall neither affect nor be affected by presence in vicinity of other
trackside signaling equipments like AFTC, TPWS, AWS, DC track circuit, 50Hz and 83-
1/3 AC track circuit etc and Telecommunication equipments.
5.0.28 Error rate should not be more than 2 errors per 1 million correctly counted axles, and if
there is error, it should not result in unsafe condition.
5.0.29 The equipment shall be capable of simultaneously counting in and / or counting out from
the ends of any track section.
5.0.30 Response of rocking of wheels on Axle Detector: If any sensor is influenced two or more
times consecutively without a proper count pulse, the system should go to error. If both
sensors are influenced four or more times consecutively without a proper count pulse, the
system should go to error.
5.0.31 Axle counter should tolerate induced voltage of at least 400V AC, 50Hz on the quad
cable.
5.0.32 It shall fulfill fail safety requirement as per RDSO/SPN/144.
5.0.33 It shall fulfill the requirement of Signal Engineering Manual as per RDSO/SPN/144.
5.0.34 The software shall fulfill the software requirements as per RDSO/SPN/144.
5.0.35 Axle counter system shall adopt a structured design process including but not limited to
the System architecture, Software requirements specification, software architecture, flow
charts, Man machine Interface for prototypes, verification and test approach.
5.0.36 Detection point at the junction of two consecutive sections shall be capable of giving feed
to both the monitoring sections.
5.0.37 Both hardware and software functions will be partitioned to ensure that integrity of
certified design will not be compromised though routine software and hardware upgrades.
5.0.38 Design of the axle counter will maximize the use of vendor independent
implementations.
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5.0.39 Digital axle counter interconnection diagram is shown in figure 1.
RELAY CONTROL / STATUS
CENTRAL
EVALUATOR
Track side Track side Track side Track side

Electronics Electronics Electronics Electronics
or or or or
DACFU DACFU DACFU DACFU
TRACK INPUT 1 TRACK INPUT 8 TRACK INPUT 33 TRACK INPUT n
Power Line Communication Line or

Power and Data Line when no separatePower Line
System (Scalable) with Trackside Electronics Interconnection (Network Mode)
5.0.40 Digital Axle Counter system should be provided with a spare set of
application/configuration data which should be site specific and labeled accordingly,
wherever such requirement is applicable.
5.1 Configuration: Multi section axle counter shall be easily configurable as per yard layout
in different track sections as given below:
5.1.5 Multiple detection points single section: In ladder.
5.1.6 Consecutive single section in a straight line.
5.2 Vital Relay Drive& Relay Unit
5.2.1 Free and occupied indication of an axle counter section (track section) shall be available
in the form of vital relay pick up and drop contact respectively. Vital relay/s will be
driven by central evaluator.
5.2.2 The vital relay shall be 24V DC, 1000-ohm plug-in type. In section clear condition, the
relay driver output shall be more than 20V DC and in occupied condition, it should be
less than 2.0V DC.
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5.2.3 The design should incorporate fail safety feature such that when the vital relay is in
dropped condition as per status of the track section, if any external voltage appears across
the vital relay coil which can pick up the vital relay, then the system should detect it and
the concerned axle counter section/track section will go to error state.
5.2.4 The relay unit shall provide housing for all vital relays.
5.2.5 The relay unit shall have enough space for mounting vital relays for max. no. of track
sections supported by MSDAC.
5.3 Axle detector:
5.3.3 Different frequencies shall be used for each set of TX/RX coils.
5.3.4 These shall be capable of withstanding environmental conditions given and specified
later. The inductance of axle detectors shall not vary more than ±6% within the specified
temperature range.
5.3.5 The transmitter/receiver coils in the track shall be of web mounted type. The fasteners
should be tightened at specified torque using torque wrench.
5.3.7 The axle detector shall be actuated only by wheel flanges and not by other parts of trains
e.g. rail brakes, toilet pipes, suspended chains, electrical inductors in locomotives, air-
conditioning equipment and other electrical /electronic equipment in train /engine.
5.3.8 One set of axle detector shall not influence another set of detector mounted ≥ 2 meters
away.
Railways.
5.3.10 The length of inbuilt cable with Axle Detector shall be 5 / 10 / 15 mtr. only.
5.4 Resetting:
5.4.1 User input track section wise reset shall be possible.
5.4.2 Whenever any yard is provided with MSDAC, reset boxes/Visual Display Unit (VDU)
shall be incorporated in a panel depicting yard layout so that respective reset boxes are
easily co-related with the track section they pertain to. Refer drawing No.
RDSO/S/20001 for details.
5.4.3 Track section wise resetting shall be easily configurable as preparatory reset or
conditional hard reset.
5.4.4 Resetting of a track-section shall not disturb other track-sections in any way.
5.4.5 The resetting of the track section shall be recorded in the event logger.
5.4.6 A voltage sensitive feature shall ensure that without the operation of re-setting key, the
system will not come back to initial or original condition for the following cases:
5.4.6.1 Power fails and restores back in field unit and/or central evaluator.
5.4.6.2 Voltage fluctuation beyond upper and lower limits in field unit and/or central evaluator.
5.4.6.3 Removal of printed circuit cards from the system (field unit and/or central evaluator.)
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5.4.7 It shall be possible to reset each track section from reset box/reset module of reset panel
only.
5.4.8 Provision shall be made for recording every operation of resetting by means of non-
resettable counter. For one reset operation, the counter should not increment by more
than one.
5.4.9 For track section on a straight line confined by two detection points, when reset is
applied, the axle counter section shall go to “preparatory reset mode”. The preparatory
reset LED in reset box/reset module of reset panel shall glow and reset counter shall
increment. The axle counter section will be still in occupied state. The axle counter
section will become clear only after more than one incount from one end and same
number of outcount from the other end have taken place.
5.4.10 For track section on a terminating line/siding line, point zone and ladder, the reset
command from reset box/reset module of reset panel will be transmitted only after
verifying that verification switch have been pressed & turned in the line verification box
at site as a proof of the axle counter section being clear physically. On availability of
reset command, the section will reset and show clear and counter shall increment.
5.4.11 The reset box./reset module of reset panel should work from 24V DC supply. The
following should be provided in the reset box/reset module of reset panel (as per Reset
Box drawing no. RDSO/S/20001).
5.4.11.1 A six-digit (min.) non-resettable type counter.
5.4.11.2 Reset switch with key.
5.4.11.3 Reset push button – Red.
5.4.11.4 Axle counter section clear indication (LED- minimum 5mm) –Green
5.4.11.5 Axle counter section occupied indication (LED-minimum 5mm)-Red
5.4.11.7 Preparatory reset indication (LED-3mm) –Green or
5.4.12 The possibility of reset will be as per table below:
(Yes/No)
Error has occurred.
System healthy
Error has occurred.
5. In count & out count, registered Yes
System healthy
Error has occurred
7. No in count, but only out counts, Yes
system goes to error.
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5.4.14 The line verification box shall be as per RDSO Drg. No. RDSO/S/20002.
5.5 Central Evaluator

5.5.1 The Central Evaluator Unit shall be housed in a pre-fabricated rack to be supplied along
with the system.
5.5.2 The Central Evaluator shall be based on 2 out of 3 logic.
5.5.3 Central Evaluator based on 2 out of 2 logic may be considered through cross acceptance/
approval.
5.5.4 The Central Evaluator shall be able to connect up to 40 detection points.
5.5.5 The Central Evaluator shall connect to Digital Axle Counter field units in star
configuration.
5.5.6 The Central Evaluator shall communicate with the Digital Axle Counter field units at
minimum1200 Baud.
5.5.7 The Central Evaluator will provide one vital relay output for each track section.
5.5.8 The Central Evaluator shall be able to generate relay outputs for upto 39 track sections.
5.5.9 The Evaluator should be configurable as per site specific requirements to handle the
associated DPs for a track section.
5.5.10 The Central Evaluator shall be able to receive the reset command generated from Reset
unit for section wise resetting of track section(s).
5.5.11 The Central Evaluator shall provide input to the Event Logger for registration and
recording of events occurring in the multiple section digital axle counter.
5.5.12 The Central Evaluator will have an RS-232 port to interface with Electronic Interlocking
(EI) system as per RDSO/SPN/192.
5.5.13 The Central Evaluator will have a separate port to connect to the station data logger for
monitoring the section wise clear/occupied information. Standard Data Logger protocol
as specified in RDSO/SPN/99 shall be used for this purpose.
5.5 13.1 The following information shall be sent to station data logger:
5.5.13.1.1 Track section nomenclature as per signalling plan.
5.5.13.1.2 Status of track section i.e. clear, occupied, failed or preparatory reset.
5.5.13.1.3 Application of reset command track section wise
5.5.14 Provision should be there for lightning & surge protection in the central evaluator power
5.5.15 The field units should be able to communicate with central evaluator for transmission
loss upto 20dB.
5.5.16 Suitable arrangements shall be made for providing electrical isolation between external
relay circuits and internal circuits.
5.6 Digital Axle Counter field Unit
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5.6.4 Provision should be there for lightning & surge protection in the field unit power supply
input and communication line input/output.
5.6.5 The field units should be able to communicate with central evaluator for transmission
loss upto 20dB.
5.6.6 It shall identify and communicate in the following conditions to the Central Evaluator:
5.6.6.3 Removal of printed circuit card(s) from the unit
5.6.6.4 In case out count has been registered before any in count.
5.6.7 It shall transmit axle counts and health status to Central Evaluator at regular intervals
5.6.8 It shall have provision for setting unique address of each field unit. The address shall be
minimum 8 bit.
5.7 Communication:
5.7.1 It shall be possible to use copper cable or voice channel in optical fiber communication
for transmission of data between field units and central evaluator. The copper cable will
be quad cable as per IRS: TC: 30-97 (0.9 mm dia) or PIJF Telecom Cable as per IRS: TC
41/97 (0.9 mm dia.) No separate external interface should be required for using any of
these two transmission mediums.
5.7.2 Impedance matching between communication channel and modem shall be provided.
5.7.3 It shall be capable of transmission of axle counts, health status and other information
between field units & central evaluator on a transmission link. The transmission link, in
case of copper cable, shall be ½ quad telecom cable or 1 pair in PIJF cable or use 2 pairs
of cable to reduce the trackside electronics or one 2-wire voice channel in case of OFC.
The rate of transmission should be minimum1200 baud.
information between field units and central evaluator. CRC to be used for error detection
and the hamming distance of the message protocol shall be at least 5. The code
transmission should be safety validated. Communication should be as per CCITT
standard.
5.7.5 Minimum 2 (two) consecutive telegrams will be required to verify the integrity of the
status of direction and counts transmitted. However, for the information that in count has
started, action may be taken after receiving first telegram itself to take the axle counter
section to occupied state (a safe state). The manufacturer shall specify the minimum
length of the axle counter section for which the axle counter section shall work properly
for train running at maximum speed as specified.
5.8 Earthing:
5.8.1 Provision of earthing should be there in the central evaluator, field unit and reset box.
The earth terminal shall be suitable for taking upto 4mm dia. copper wire with lug.
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5.9 Event Logger

5.9.1 The Event Logger shall be inbuilt in the Central Evaluator.
5.9.2 The event logger should work automatically without any other input required to be given
by staff.
information recorded in the Event Logger. Neither shall it cause its loss or change.
5.9.4 The data registered in the event logger must be secured against erasing by unauthorized
persons.
5.9.5 It should be possible to download logged events to a commercial computer/Pen Drive
5.9.6 The process of event logging and downloading of logged events should not hamper the
normal working of axle counter in any manner.
5.9.7 The event logger shall record following events at the minimum:
5.9.7.1 Resetting of a track-section, field unit or central evaluator.
5.9.7.2 Failures/errors in field units or central evaluator.
5.9.8 Provision should be there to log minimum 40,000 events. In case of its memory
becoming full, the event logging should be on first in first out principle.
5.9.9 All data will be recorded in a user-friendly form with date & time stamp in English
Language.
5.9.10 It shall be possible to download the data for a user-selected time interval or it should be
possible to generate report for a user selectable date/period.
6. Diagnostics
6.1 Diagnostic system of the axle counter shall provide-
6.1.1 Local and remote diagnostics and testing of system through a serial connection.
diagnostic terminal. The same display should normally show in count / out count
detection point wise and section wise and software version no. when the system is
switched on initially.
6.3 Diagnostic functions shall be carried out on a permanent basis without disturbing normal
operation of the equipment.
6.4 Information on the state of the equipment in failure situations and on operations
performed by the staff shall be registered with time stamping.
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electrified, 25 kV 50 Hz AC, 1500 VDC& 750V DC electrified areas.
7.2.1 25 kV / 50Hz 1000 A
7.2.2 1.5kV/dc 6000 A
7.2.3 750V/ dc 3000 A
7.3 The currents or their harmonics flowing in the rolling stock & rails shall not affect the
digital axle counter.
7.4 The equipment shall be insensitive to extraneous magnetic or electric fields such as due
to traction return currents on electrified sections, traction motor failures, vehicle
magnetism or due to any other source.
7.5 The electromagnetic brakes in both on and off states should not affect the axle counter.
8. DC Input Power Supply
8.1 The field unit shall work with power supply of 24V DC fed from a remote location. The
input voltage range is +24V DC (+20% to –30%) & will have a maximum ripple as per
Para 5.4.23 of RDSO/SPN/165 or Para 5.4.2 of IRS: S 86/2000.
8.2 The Central Evaluator shall work with same type of power supply as mentioned in Para
8.1 but range will be 24V+ 20%, -10%.
8.3 The power consumption in the equipment shall be low. It should be less than 0.75A for
field unit at 24VDC (nominal).
9.1 Component types
9.1.2 The discrete components like diodes, transistors, SCRs etc., should conform to HIREL
program of CDIL or equivalent.
9.1.3 All resistors used shall be rated for at least double the power, which is supposed to be
dissipated in them. The voltage rating of the capacitor shall be at least 50% above peak
value. The resistors shall be of tolerance not more than 5%. Tolerance of capacitors
shall be as under:
Electrolytic : 20%
These shall be procured from RDSO approved sources, wherever specified.
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9.1.4 All power supplies on cards should be locally decoupled where digital ICs are used using
a capacitor with good high frequency characteristics. Recommended value of capacitor is
0.01 µf.
Phoenix make.
9.2.1 PCB material: Material for the PCB shall be copper clad glass epoxy of grade FR-4 or
equivalent.
9.2.3 Track Width: The track width shall be 0.5mm nominal. In no case it should be less than
0.3mm.
9.2.4 Spacing between tracks: Spacing between tracks shall be 0.5mm nominal and in no case
it shall be less than 0.3mm.
9.2.5 Printed circuit cards shall be fitted with gold plated Euro/ D type plug in connectors with
locking arrangement. Mechanical arrangement e.g. a clip or a screw to hold the PCB in
inserted position shall be provided. Screws should be countersunk and held on PCB
when it is pulled out. The PCB shall be mechanically polarized so that it is not possible
to insert the PCB into wrong slot. Suitable mechanical arrangement shall be provided
against wrong insertion of connections.
9.2.6 The printed circuit cards shall be specifically designed to suit the circuitry used and no
extra wires or jumpers shall be used for interconnection of components on the PCB. No
piggyback PCB shall be connected to any PCB. The components shall be soldered with
wave-soldering machine. Any exception to wave-soldering machine shall have specific
approval of RDSO, Lucknow.
waveforms shall be indicated in the fault diagnostic procedure and service manual to
facilitate testing and fault tracing.
9.2.8 Heat Dissipating Components: All components dissipating 3 W or more power shall be
mounted in such a manner that the body is not in contact with the board unless a suitable
heat sink is provided.
9.2.9 Conformal Coatings: Assembled PCBs should be given a conformal coating to enable
them for functioning under adverse environmental conditions. The coating material
should be properly chosen to protect the assembly from the following hazards:
9.2.9.1 Humidity
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9.2.10.1 All the electronic components used in the equipment shall be subjected to “Burn-in” test
for 48±1 hours at temperature of 65ºC. Record of failed components in this test should
be maintained.
9.2.10.2 After mounting of components, the populated PCB cards kept in proper chassis in
energized condition shall be burnt in for 168 hrs at 60ºC. Record of failed PCB Cards in
9.2.11.3 PCB name.
9.2.13 Solder Mask: Solder mask shall be applied on solder side and component side of the
board.
9.2.14 The distribution of the power supply on the cards should be such that different voltage
tracks (0, 5V etc) follow the same route as far as possible. The track of power supplies
should be as thick and wide as possible.
9.2.15 Housing rack shall be as per RDSO/SPN/144.
10.0 Performance
10.1 Time for failure detection: Failure indication shall occur not later than after the passage
of the first train over the relevant track section.
10.2 Occurrence of any failure or error of operation in the axle counter component parts must
not lead to any hazards but can solely result in transition to a distinguished safe state.
10.4 The Axle Counter (equipment only) shall have MTBF of not lower than 70,000 hrs.
11.1 General
11.1.1 Inspection and tests shall be carried out to ensure that requirements of this specification
are complied. Conditions of tests – Unless otherwise specified, all tests shall be carried
out at ambient atmospheric conditions. For inspection of material, relevant clauses of
IRS: S 23 and RDSO/SPN/144 shall also apply.
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11.2 Type Approval

11.2.1.1 Manufacturer shall furnish following information at the time of initial type approval:
11.2.1.1.1 Design approach for the system and Salient feature through which fail-safety has been
achieved
11.2.1.1.2 Proof of safety report or its equivalent giving complete tests and their results that have
been undertaken by manufacturer or independent safety assessor
11.2.1.1.3 The system shall conform to the CENELEC standards for SIL-4 Railway Signalling.
Software & hardware validation shall be done by accredited / reputed independent
third party. The agency to be engaged for validation shall be got approved by RDSO.
11.2.1.2 While granting initial type approval it shall be ensured that the system conforms to all
the clauses & passes all type tests as mentioned in clause 10.3.
At the end of validity period, RDSO may call for fresh samples for type testing for the
purpose of maintenance of Type Approval as per the provisions of Directorate
Operating Procedure. The sample must pass all type tests as per Clause 11.3.
11.3 Type tests
11.3.1.6 Shock tests (Cl. 11.5.6)
11.3.1.9 Fail safety tests (Cl 11.5.9)
11.3.2 One equipment shall be tested for this purpose. The equipment shall successfully pass
the entire type test for proving conformity with this specification. If the equipment
fails in any of the tests, the purchaser or his nominee at his discretion, may call for
another equipment of the same type and subject it to all tests or to the test(s) in which
failures occurred. No failure shall be permitted in the repeat test.
11.3.3 To obtain a type approval certificate, the manufacturer or supplier shall submit to the
testing authority two numbers of samples, for conducting all the tests mentioned. In
case of maintenance type approval, the samples shall be selected at random from
regular production lots so as to be as representative as possible of the type under
consideration. A Type approval certificate shall be issued to a manufacturer if
samples pass all the prescribed tests in accordance with this specification.
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construction, material used or manufacturing process is made subsequently, unless this
change has the approval of the Purchaser or his nominee.
11.4 Acceptance Test& Routine Test
11.4.1.1 Inspecting authority shall carry out acceptance tests on all the equipment/sub units. The
following shall comprise acceptance tests:
11.4.1.2 A complete test report of all the tests conducted shall be submitted by inspecting
authority giving the detailed observations made in every case and actual values
recorded. Specific mention shall be made whenever the equipment has failed to
comply with the requirements and indicating as to how far it has failed to comply.
11.4.1.3 Disposal of samples: Sample equipment, which has been subjected to type tests, shall
not form part of supply.
11.4.2 Routine test
11.4.2.1 Following shall constitute routine tests and shall be conducted by manufacturer on
every equipment/sub units and test results shall be submitted during the inspection.
11.5 Test Procedure
The equipment/sub units shall be examined for provisions of all facilities stipulated in
this specification such as correct wiring, proper mounting and marking of
components, marking, workmanship and finish for which no tests have been specified.
Output load
Line regulation
Signal conditioner card
CPU
Modem
Relay driver
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The equipment shall withstand for one minute without puncture and arcing at a test
voltage of 2000 AC, rms applied between power components and the body of equipment,
which shall be earthed. The test voltage shall be approximately sine wave of any
frequency between 50 and 100 Hz. Any electronic component, which is likely to get
damaged by the application of high voltage, shall be disconnected during the test.
There shall be no appreciable change in the values measured before and after high
voltage test. After the completion of climatic test, the values shall not be less than 10
Mega ohms for the equipment at a temperature of 40 deg. C and relative humidity
60%. The measurement shall be made at a potential of 500V DC. During acceptance
test, high voltage test and climatic test will not be done.
Climatic Test shall be done as per the sub clauses mentioned below. After completion
of all the tests, high voltage test (Clause 11.5.3) & insulation resistance test (Clause
10.5.4) shall be repeated.
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ii) High Temp: 70ºC±2ºC
Rate of cooling and heating 1 degree per minute. Duration of test: 3 cycles of 3
hrs each (after stability in the chamber has been reached). The equipment shall be
kept energized during the test and status of relay shall be recorded. After
completion of test, the equipment shall be subjected for standard recovery of 2
hours (15 - 35 degree C, RH 45 –75 %), After recovery, the equipment shall be
checked visually for any damage and its insulation resistance shall be measured
which shall not be less than 10 Mega ohms at 40 degree C and 60 % RH.
The equipment shall be tested as per IS-9000/Pt.III Sec. 5. The test severity shall
be + 70 ± 2 deg.C and duration of exposure 16 hrs. (After stability in the chamber
has been reached). Rate of change of temperature shall be 1 degree per minute.
The equipment shall be switched ON when the temperature in the chamber has
stabilized and remained active during the above tests and status of relay shall be
recorded. After completion of test, the equipment shall be subjected for standard
recovery of 2 hours (15 - 35 degree C, RH 45 –75 %), After recovery, the
equipment shall be checked visually for any apparent damage or deterioration and
insulation resistance shall be measured which shall not be less than 10 Mega
ohms at 40 degree C and 60 % RH.
11.5.5.3 Cold test:
The equipment shall be tested as per IS-9000/Pt.II Sec. 3. The test severity shall
be - 10 ± 2 deg.C and duration of exposure 2 hrs. (After stability in the chamber
has been reached). Rate of change of temperature shall be 1 degree per minute.
The equipment shall be switched ON when the temperature in the chamber has
stabilized and remained active during the above tests and status of relay shall be
recorded. After completion of test, the equipment shall be subjected for standard
recovery of 2 hours (15 - 35 degree C, RH 45 –75 %), After recovery, the
equipment shall be checked visually for any apparent damage or deterioration and
insulation resistance shall be measured which shall not be less than 10 Mega
ohms at 40 degree C and 60 % RH.
The equipment shall be tested as per IS-9000 / Pt.V Sec-2. The upper temperature
shall be + 40 deg C, lower temperature + 25 degree C, RH 95 %, Variant 1, 1
cycle 12 + 12 hours and 6 number of cycles. The equipment shall be kept
energized during the test. No intermediate measurements required only relay
status to be recorded. After standard recovery of 2 hours, the equipment shall be
resistance shall be measured which shall not be less than 10 Meg ohms at 40
degree C and 60 % RH.
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The equipment shall be tested as per IS-9000 / Pt.IV. The temperature shall be
maintained + 40 ± 2 deg C, and relative humidity 95 %, (+2% -3%). The duration
of the test is 4 days. The equipment shall be kept energized during the test. No
intermediate measurements required only relay status to be recorded. After
standard recovery of 2 hours, the equipment shall be checked visually for any
apparent damage or deterioration and insulation resistance shall be measured
which shall not be less than 10 Meg ohms at 40 degree C and 60 % RH.
The unit shall be subjected to this test for 1 hr. as per IS: 9000 Pt. XVI/should
comply the requirements of IP 66 and shall withstand the same. The equipment
shall be kept de-energized during the test and in its normal operational position.
The item shall be sprayed from eight showerheads, four of them being directed at
an angle of 45 degree on each of the uppermost corners of the item and remaining
four being directed horizontally at the center of the area of each of the four sides
of the item. After standard recovery, the equipment shall be checked for any
deterioration and insulation resistance shall be measured which shall not be less
than 10 Meg ohms at 40 degree C and 60% RH.
The equipment shall be subjected to this test for 24 hrs as per IS: 9000 Pt.-XV
Section 7/ should comply the requirement of IP 68. Water head shall be 40 cm
above the highest point of item under test. The equipment shall be kept in the
chamber in its normal operational position and in de energized state. After the
completion of the test external surface of the item shall be dried by wiping or by
applying a blast of air at room temperature. After standard recovery of 2 hours,
the equipment shall be checked visually for undue penetration of water and for
any apparent damage or deterioration. Insulation resistance shall be measured
which shall not be less than 10 Meg ohms at 40 degree C and 60 % RH.
11.5.5.9 Dust Test:
The equipment shall be tested as per IS-9000 Pt. XII./ It should comply the
requirement of IP 60 The item shall be subjected in the chamber at laboratory
temperature in switched off condition. The temperature of the chamber shall then
be raised to a value of 40 deg C ± 3 deg C with a relative humidity not exceeding
50% shall be maintained in the test chamber. When the temperature stability has
been attained, the test item shall then be subjected to a stream of dust-laden air for
a period of one hour. After standard recovery of 2 hours, the equipment shall be
checked for any deterioration and insulation resistance shall be measured which
shall not be less than 10 Meg ohms at 40 deg C and 60% RH.
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Peak acceleration 40 g.
Shock test as Duration of the pulse 11 m. sec.
per IS 9000 Pt.
VII Sec. 1 No. of shocks 18
Clause 9


11.5.7.1 The test shall be done as per RDSO/SPN/144 except for diagnostic terminal,
external event logger, reset box/panel.
The equipment shall be subjected to vibration test as per IS: 9000 (Part VIII).

Details. /Remarks

as per IS 9000
Pt. VIII Amplitude 0.35mm (0 to peak) or Equipment
5g shall be
visually
No. of axis 3 examined for
any apparent
No. of sweep cycles 20 damage.
After
changed as per clause
completion of
6.3 of IS-9001 Pt.XIII-
the test the
81 during each sweep
equipment
shall be tested
If resonance is observed, 10 minutes at each for its normal
endurance tests at resonant resonant frequency operation.
frequency.

Fail safety tests shall be carried out as per RDSO/SPN /144/2004 as covered
under the clause 4.0 and as per CENELEC EN50129.
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11.5.10 Environmental Stress Screening Tests (ESS) for Printed Assembly Boards
(PAB) and Subsystems
The manufacturer shall carry out the following ESS tests on all modules on 100%
basis (except bump test) during production/testing in the sequence as follows.
Suitable records shall be maintained regarding the compliance of these tests.
PCBs in unpacked condition shall be subjected to vibration test for 10 minutes at

the resonant frequency/frequencies at 3.0 g minimum acceleration in the axis
/axes perpendicular to the mounting of components. In addition to physical
checks, the electrical parameters are also to be monitored after the vibration test.
11.5.10.2 Bump Test
PCBs /modules/units in packed condition shall be subjected to bump test at 40 g

for 1000 bumps. This test shall be carried out as per sampling plan given in
Clause 7.2.5, 7.2.6 & 7.2.7 of IRS:S 42/85 for Axle Counter Equipment. In
addition to physical checks, electrical parameters are also to be monitored after
the bump test.
The PCBs shall be subjected to thermal cycling as per the procedure given below:
The Assembled Boards are to be subjected to the Rapid Temperature Cycling as

mentioned below in the power OFF condition. This temperature cycling is from 0
to 70ºC, ½ hour at each temperature for 9 cycles and 1 hour at each temperature
for the 10th cycle. Dwell time of 1 hour is provided for the last cycle in order to
oxidize defective solder joints exposed through thermal stress.
700C1/2 Hr 700C1 Hr
Ambient
00C1/2 Hr 00C1 Hr

In addition to physical checks, the electrical parameters are also to be monitored after
this test.
The power supply modules shall be subjected to 60 (sixty) ON-OFF cycles for one
hour. (The ON-OFF) switch usually provided in the modules may not be used for this
purpose.
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Through suitable means, the total size of the software of each sub-system shall be
measured and recorded. The manufacturer shall specify the size of software with
version number of each sub-system at the time of applying for type approval.
12.0 Quality assurance
12.1 All materials shall be of the best quality and the workmanship shall be of the highest
class as per QAP standards laid down by RDSO.
12.2 The equipment shall be manufactured as per quality assurance procedure laid down so
as to meet the requirement of the specification.
12.3 Along with other requirement of the specification, validation and system of monitoring
of QA procedure shall form a part of type approval. The required plant machinery and
test instruments as per RDSO’s Standards shall be available with the manufacturer.
13.1 It shall conform to the clause of marking given in RDSO/SPN/144.
clearly.
13.3 A nameplate shall be provided in a conspicuous position giving manufacturer’s name,
specification reference, serial no of the equipment, date of manufacture, version no.,
local address, remote address etc.
13.4 A plate indicating the configuration to be adopted for entry point unit and exit point unit
shall be provided in a conspicuous position on the equipment.
14.0 Packing
Packing shall be done to RDSO/SPN/144/2006 or latest.
15.0 Warranty
The warranty of the equipment shall be in accordance with IRS Specification No. S- 23.
16.0 Documentation
16.2 Safety case documents as per CENELEC standards for SIL-4 Railway Signalling to be
details for each type of assembled PCB and part list to be submitted for type approval.
16.5 The manufacturer shall provide report containing detailed analysis of hardware and
software of axle counter verifications and validation documents approved from
accredited validation agency.
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17.0 Purchaser’s Responsibility

manufacturer. However, purchaser, at his own discretion may waive off this clause by
specifying so in the tender conditions.
18.0 Supply of documents:
each shall be supplied along with each equipment. Documents shall be approved by
RDSO.
19.0 Purchaser should specify:
19.1 Number of detection points and track sections required.
19.2 The length of cable required with each track device (Refer Cl. 5.3.10).
19.3 Specialized tools and measuring instruments required.
20.0 Tools for maintenance:
20.1 The manufacturer shall indicate special maintenance instruments and tools that may be
necessary for safe and reliable adjustment and maintenance of equipment and supply
these, if so required by the purchaser
****
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AXLE COUNTERS – HISTORY
SNo Type Year Track Circuit Application
1 Single Entry/Exit 1977 Single Section
2 Multi Entry/Exit 1985 Single Section/Point Zones
3 Universal Axle Counter 1994 -do-

4 Digital Axle Counter 2003 Single Section(approved by RDSO)
5. Digital Axle Counter 2004 Multi Section (developed, under
field trial & approval by RDSO)
6. Train Actuated Warning 2005 Warning to Road users at level
Device crossings
Ø More than 5000 nos. of CEL make Axle Counters of first three types are
deployed in various locations of Indian Railways.
Ø CEL & RDSO have designed & developed Digital Axle Counter for single &
multi sections.
SSDAC
28TH & 29th Dec 2011 Digital axle Counter at IRISET 12

WHEEL DETECTION – PHASE
MODULATION
WHEEL DETECTION-AMPLITUDE
MODULATION
SSDAC CURRENTLY SUPPLIED
PHASE MODULATION
S. No. Item Model No.
1. SSDAC DACF – 710P
2. Axle Detectors AD - 711
3. Vital Relay Box(Dual Relay)with PR VR – 721
4. Reset Box RB – 259
5. Surge Voltage Protection device SV - 121
AMPLITUDE MODULATION
S. No. Item Model No.

1. SSDAC DACF – 710A
2. Axle Detectors AD - 710
3. Vital Relay Box(Dual Relay)with PR VR – 721
4. Reset Box RB – 259
5. Surge Voltage Protection device SV - 121
28TH & 29th Dec 2011 Digital axle Counter at IRISET

AXLE DETECTORS

AXLE DETECTORS
l WEB MOUNTING
l PHASE & AMPLITUDE TYPE
l CENTRE TO CENTRE DISTANCE 138 MM FOR
PHASE
l CENTRE TO CENTRE DISTANCE 172 MM FOR
AMPLITUDE
l 3D ANGLE & FREQUENCY TUNING FACTORY SET
l WATER RESISTANT. CAN WORK EVEN IF TRACK IS
FLOODED.

SSDAC

COMPARISON WITH S005
S. No. Parameter S005 S006

1. Checksum 16 Bytes 24 Bytes
2. Motor trolley Gives error – 44/45 Section becomes clear
following train after passing motor
trolley after train
3. Error – 44/45 Appears after first Appears after third
independent pulse consecutive independent
pulse
4. Irrecoverable Error 37, 41 & 42 are These errors are made
Errors recoverable irrecoverable.
5. New Error Codes --- NA --- 46 & 48 are newly added
error codes.
MODIFICATIONS IN SSDAC 710A/P w.r.t.
SSDAC 700AP (CONTD …)
Pulse generation on
movement of train wheel
21 KHz
Local DP 00005 00 Occupied
Remote DP 00003 00 Occupied
23 KHz
Axle Error Status
Counts Code
LCD Status of Reset Box
Pulse generation on
movement of motor trolley wheel
21 KHz
Local DP 00004 44 Independent pulse forward
Remote DP 00003 80 Remote error
23 KHz Axle Error Status
Counts Code
28TH & 29th Dec 2011 Digital axle Counter at IRISET LCD Status of Reset Box
VITAL RELAY BOX
l Dual Relay - 24V,
1000 ohms
l Doubling of Contacts
for read back
l Reverse bias diodes
at coil
l PR pick up indication
l Coupler to Coupler
connection for VR
relay
RESET BOX
l Alphanumeric 20 x 2 row LCD
Display for
l Axle Counts of Local and
Remote unit
l Error Code in Numeric
format
l Section Status
l Last 10 Errors with date
and time
l Provision of downloading of
data from reset box
l Provision of Interfacing with
Data Logger

SVPD
l Four modules provided
for all the input lines of
SSDAC, i.e. Power
supply (24V), Reset
(48V) & both the
modem lines (i.e.
SSDAC to SSDAC and
SSDAC to reset box)
l Added protection is
given for input 24V
power line.

FIXING OF MARKING JIG
Fixing of marking Jig as shown
Mark using punching guide as

per rail size.

DRILLING OF HOLES
3 holes of 14mm are

drilled

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

FITTING OF AXLE DETECTORS
TX1 RX1
TX2 RX2

FIXING OF DEFLECTOR PLATES
Deflector plates
on both sides to
be fitted

INSTALLATION OF COUNTING UNIT
Electronic Counting unit Vital Relay Box

SETTING UP OF LOCATION BOX
INSTALLATION DETAILS
INSTALLATION OF LOCATION – HALF LOCATION BOX
Vital Relay Box
Electronic Counting
unit

RESET BOX
l INDOOR EQUIPMENTS
l WOODEN PLANK
l EARTHING TO BE PROVIDED

INSTALLATION – Surge Voltage Protection
Device
l For installation of Phoenix make devices, refer drawing no W008425A on
page D32 of CEL’s Installation Manual of SSDAC.
l For installation of OBO make devices, refer drawing no W008425A on
page D33 of CEL’s Installation Manual of SSDAC.
Note:
1. It is recommended to use as short wire as possible for connections and earthing to
these devices for better protection.
2. All the screen of cables should be properly earth.
3. Always verify the physical state of these modules for any damage due to lightening.
4. In case of any damage kindly replace these modules with respective part Nos only.

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

SSDAC - POWER SUPPLY ARRANGEMENT
l It consists of
l 24V, 40 AH Battery and 24V, 5A Battery charger or
l 24V, 5A output from one of the modules of IPS.
l 2 core, 25 sq. mm Power cable for connection from battery to
SSDAC unit.

PRECOMMISSIONING CHECKLIST
l Pre commissioning checklist needs to be filled & signed by railways & CEL
or contractor’s representative should be sent to CEL & RDSO. Main points
includes
l Use of 1000 ohms relays at location
l Use of Diodes at location for PR & repeater relays
l Use of CEL marking jig for drilling holes
l Condition of rail
l Drilling of holes in straight line
l Loss in quad cable at 1KHz should be <20db
l Insulation of quad cable >10Mohms
l Use of Axle counter type Battery charger
l Proper Earthing as specified in manual
l Effect of trolley movement should be recorded at time of commissioning
l Training

INSTALLATION - ADVICE
l USE OF SAME QUAD PAIR. AVOID USING DIFFERENT PAIR OR MULTI

PAIR OF QUAD CABLE
l EARTHING OF CABLE SHIELDS, UNITS AS RECOMMENDED IN SSDAC

MANUAL.
l USE OF TOOLKIT SUPPLIED BY CEL ONLY
l USE OF 1000 OHM RELAY FOR PPR & VPR
l USE OF REVERSE BIAS DIODES
l MAINTAIN MIN DISTANCE FOR TP WHEREVER APPLICABLE

COMMISSIONING OF SSDAC
l SIGNED PRECOMMISSIONING CHECKLIST

l RESET BOX WIRING TO BE VERIFIED
l SURGE VOLTAGE PROTECTION DEVICE TO BE INSTALLED
l COMMISSIONING INTO SIGNALLING CIRCUITS AFTER
PARALLEL WORKING OF 3 TO 4 DAYS

TOOLKIT – PORTABLE DATA ANALYZER
l Portable data Analyzer

tool with data analysis
software
l Serial cable

TOOLKIT – MULTIMETER & TRAIN SIMULATOR
l DIGITAL MULTIMETER
l TRAIN SIMULATOR FOR
PHASE & AMPLITUDE

TOOLKIT – MARKING JIG & TORQUE WRENCH
l Use only marking jig

provided along with
toolkit
l Torque wrench for
correct installation

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

TROUBLE SHOOTING OF SSDAC
FAMILIARITY WITH ERROR CODES
FRONT VIEW VALUE GIVEN TO LED’s
1 2 1 2
LSB LSB
3 4 4 8
10 20
5 6
MSB MSB
40 80
7 8

INSTALLATION MANUAL
HIGH AVAILABILITY SINGLE SECTION DIGITAL AXLE COUNTER

DACF - 720P
(PHASE REVERSAL TYPE)
RDSO/SPN/177/2012
CENTRAL ELECTRONICS LIMITED

(AN ISO 9001 CERTIFIED COMPANY)
High Availability Single Section Digital Axle Counter
DIGITAL
AXLE COUNTER
(SSDAC)
The V.23 standard was an early modem standard approved by
the ITU in 1988. It specifies audio frequency-shift keying
(AFSK) to encode and transfer data at a rate of 1200 bits per
second, half-duplex at 1200 baud (Mode 2), (or at a "fallback
rate" of 600 baud, mode 1) for the forward data-transmission
channel, and an optional 75 baud backward channel.
· V.23 Mode 1 AFSK uses a 1300 Hz tone (FZ) for mark
(typically a binary 1) and 1700 Hz (FA) for space
(typically a binary 0), and a 1500 Hz center frequency
(F0.)
· V.23 Mode 2 AFSK uses a 1300 Hz tone (FZ) for mark
(typically a binary 1) and 2100 Hz (FA) for space
(typically a binary 0), and a 1700 Hz center frequency
(F0.)
· V.23 backward channel AFSK uses a 390 Hz tone (FZ)
for mark (typically a binary 1) and a 450 Hz (FA) for
space (typically a binary 0).)
In some European countries,(and perhaps elsewhere), V.23
Mode 2 AFSK modulation, (without the backward channel) is
used to transmit Caller ID information over POTS lines in the
public telephone network.
The 75 baud backward channel was originally envisioned for
use in error correction schemes, but V.23 was also widely
used in Videotex applications where the backward channel
was used to send keyboard data in an asymmetrical full
duplex scheme in devices such as the Minitel.
General standards[edit]
Applies to V.1–V.9
· V.1 is an ITU-T recommendation, entitled Equivalence
between binary notation symbols and the significant
conditions of a two-condition code.
· V.2 is an ITU-T recommendation, approved in
November 1988, titled Power levels for data
transmission over telephone lines.
November 1988, titled General structure of signals of
International Alphabet No. 5 code for character oriented
data transmission over public telephone networks.
· V.5 was an ITU-T recommendation, approved in
November 1988, titled Standardization of data signalling
rates for synchronous data transmission in the general
switched telephone network. It has been withdrawn since.
· V.6 was an ITU-T recommendation, approved in
November 1988, titled Standardization of data signalling
rates for synchronous data transmission on leased
telephone-type circuits. It has been withdrawn since.
November 1988, titled Definitions of terms concerning
data communication over the telephone network.
· V.8 is an ITU-T recommendation, first approved in
September 1994, titled Procedures for starting sessions
of data transmission over the public switched telephone
network. It has been superseded three times. The current
version was approved in November 2000.
· V.8bis is an ITU-T recommendation, first approved in
August 1996, titled Procedures for the identification and
selection of common modes of operation between data
circuit-terminating equipments (DCEs) and between data
terminal equipments (DTEs) over the public switched
telephone network and on leased point-to-point
telephone-type circuits. It has been superseded twice.
The current version was approved in November 2000.
Interfaces and voiceband modems[edit]

· V.10 is an ITU-T recommendation, first agreed in 1976,
for unbalanced electrical circuits for data communication
at up to 100 kbit/s. It can interwork with V.28, provided
it is not exposed to signals greater than 12 volts. Used
with the 37-pin ISO 4902 connector, it is compatible
with EIA RS-423.
· V.11 is an ITU-T recommendation, first agreed in 1976,
for balanced electrical circuits for data communication at
up to 10 Mbit/s. Used with the 37-pin ISO 4902
connector, it is compatible with EIA-422. The 15-pin
ISO 4903 connector is recommended for data network
interface.
· V.17 is an ITU-T fax protocol that uses TCM modulation
at 12 and 14.4 kbit/s.
· V.21 is an ITU-T recommendation for full-duplex
communication between two analogue dial-up modems
using audio frequency-shift keying modulation at 300
baud to carry digital data at 300 bit/s. It is a variant of the
original Bell 103 modulation format.
· V.22 is an ITU-T recommendation for full-duplex
using PSK modulation at 600 baud to carry data at 1200
or 600 bit/s. It is a variant of the Bell 212A modulation
format.
· V.22bis is an ITU-T recommendation extending V.22
with a faster rate using QAM at 600 baud to carry digital
data at 2400 or 1200 bit/s. The 1200 bit/s mode is
compatible with V.22.
· V.23 is an ITU-T recommendation for half-duplex
using FSK modulation at up to 600 or 1200 baud to carry
digital data at up to 600 or 1200 bit/s respectively. An
optional 75 baud reverse channel carries 75 bit/s.
· V.24 is referenced as RS-232 which also includes V.28.
· V.250 (also known as V.25ter) is extended data modems
ITU-T recommendation .[2]
· V.27ter is an ITU-T recommendation for a half-duplex
modem, allowing 2400 and 4800 bit/s (PSK modulation).
· V.28 is an ITU-T recommendation defining the electrical
characteristics for unbalanced double-current interchange
circuits.
· V.29 is an ITU-T recommendation for a modem,
allowing 4.8 kbit/s, 7.2 kbit/s and 9.6 kbit/s transfer
modes (PSK and QAM modulations).
· V.32 is an ITU-T recommendation for a modem
operating as full-duplex on a 4-wire circuit, or half-
duplex on a two-wire circuit, allowing bidirectional data
transfer at either 9.6 kbit/s or 4.8 kbit/s at a symbol rate
of 2,400 baud instead of the 600 baud of the V.22
standards.
· V.32bis is an ITU-T recommendation for a modem,
allowing up to 14.4 kbit/s bidirectional data transfer.
Other additional defined data transfer rates are 12.0
kbit/s, 9.6 kbit/s, 7.2 kbit/s, and 4.8 kbit/s. The standard
was extended by several modem manufacturers to allow
bidirectional data transfer rates of 19.2 kbit/s, but never
ratified as a V.32ter standard. These non-ITU-T standard
modems were often referred to as 'V.32terbo' modems.[3]
· V.33 is an ITU-T recommendation for a modem
operating as full-duplex on a 4-wire point-to-point leased
line allowing bidirectional data transfer at either 14.4
kbit/s.
· V.34 (09/94) is an ITU-T recommendation (superseded)
for a modem, allowing up to 28.8 kbit/s bidirectional
data transfer. Other additional defined data transfer rates
are 24.0 kbit/s and 19.2 kbit/s as well as all the permitted
V.32 and V.32bis rates. Additionally, V.34 modems
employ shell mapping as shaping code to reduce the
transmit power.
· V.34 (10/96) is an updated ITU-T recommendation for a
modem, building on the V.34 standard but allowing up to
33.8 kbit/s bidirectional data transfer. Other additional
defined data transfer rates are 33.6, 31.2 kbit/s, as well as
all the permitted V.34 rates. Modems implementing this
standard were often marketed under the moniker V.34+.
It was later superseded by V.34 (02/98), commonly
rendered as V.34bis, which corrected some errata in the
original 1996 document, and capped the speed to 33.6
kbit/s.
Ad hoc standards[edit]
In order to gain first-mover advantage, many modem
companies introduced models based on upcoming V-series
standards before they reached final ratification. In other cases,
companies introduced non-standard systems but gave them
ITU-like names.
· V.32terbo, or V.32ter for short, was a 19.2 kbit/s
standard introduced by AT&T Paradyne. It was based on
V.32bis and did little other than increase the data rate.
V.32ter is compatible with V.32bis at speeds of 14.4
kbit/s and lower, but it is not compatible with V.34 at
19.2.
· V.FC, short for V.Fast Class or V.FAST, was developed
by Hayes and Rockwell to introduce a 28.8 kbit/s
standard while the V.34 efforts dragged on. V.FC was
not compatible with V.34, although most V.34 modems
could support V.FC, notably those using Rockwell chip
sets.[4]
· K56flex was developed by Rockwell and Lucent while
the V.90 standards were underway. Compatibility
problems between the two company's implementations
were a concern, and the standard quickly disappeared.
· X2 was USRobotics' answer to K56flex, and likewise
disappeared rapidly with the introduction of V.90.
Wideband modems[edit]
· V.35 is an ITU-T standard located on layer 1 on the OSI
model. Max speed is 2 Mbit/s. Withdrawn ITU-T
recommendation for 48 kbit/s data transmission over
wideband circuits. The physical and electrical
characteristics of this interface are now specified in ITU-
T recommendation V.11.
· V.36 is an ITU-T standard located on layer 2 on the OSI
model called Modems For Synchronous Data
Transmission Using 60-108 kHz Group Band Circuits.
Error control and data compression[edit]

· V.41 is a code-independent error control system. Defines
the ITU-T standard CRC-16 polynomial as x16 + x12 + x5 +
1
· V.42 is an error correction protocol. Its function is to
allow the receiver to immediately request re-transmission
of any lost data packets. However, it does not guarantee
how quickly the error-free data will be delivered to the
receiving end. V.42 is generally included in dialup
modems. Also defines the ITU-T standard CRC-32
polynomial as
x32+x26+x23+x22+x16+x12+x11+x10+x8+x7+x5+x4+x2+x+1, and
includes the LAPM framing protocol.
· V.42bis, also an adaptive data compression standard, is
based on the Lempel Ziv dynamic dictionary approach,
and may go to "transparent mode," in which data is
transmitted uncompressed. The specific algorithm is
"BTLZ" (British Telecom Lempel Ziv), which was
developed by Alan Clark (then with BT).
· V.44 is based on LZJH (Lempel-Ziv-Jeff-Heath)
adaptive data compression developed by Hughes
Electronics for its DirecPC satellite Internet, and
incorporated into the v.92 dial-up modem standard. V.44
offers somewhat better compression performance for
certain types of data than the V.42bis standard, on
average allowing 15% greater throughput. For instance, a
53.3 kbit/s connection with V.44 can transmit up to
53.3×6 = 320 kbit/s using pure text. In reality, the overall
data rate rarely exceeds 3:1 compression (~150 kbit/s). It
should be noted that the compression tends to get better
and worse over time due to noise on the line, or due to
the transfer of already-compressed files (ZIP files, JPEG
images, MP3 audio, MPEG video). At some points the
modem will be sending compressed files at 53 kbit/s,
uncompressed files at 160 kbit/s, and pure text at 320
kbit/s, or any value in between.[5][6]
Simultaneous transmission of data and

other signals[edit]
· V.61 Analog Simultaneous Voice and Data (ASVD)
· V.70 Digital Simultaneous Voice and Data (DSVD)
· V.80: videoconferencing. It is generally compatibilized
with H.324 standard point-to-point video telephony over
regular phone lines.
· V.90 is an ITU-T recommendation for a modem,
allowing 56 kbit/s download and 33.6 kbit/s upload. It
replaced two vendor standards (K56flex and X2) and was
designed to allow modems from both prior standards to
be flash upgraded to support it. It was developed between
March 1998 and February 1999. It is also known as
V.Last as it was anticipated to be the last standard for
modems operating near the channel capacity of POTS
lines to be developed. V.90 is generally used in concert
with the V.42bis compression standard. A follow-on
standard, V.92, was developed later in 1999 to replace
V.90.
· V.92 is an ITU-T recommendation, titled Enhancements
to Recommendation V.90, that establishes a modem
standard allowing 56 kbit/s download, 48 kbit/s upload
rates, and the new V.44 compression method. V.92 was
first presented in August 1999. It is intended to succeed
the V.90 standards. With V.92, PCM is used for both the
upstream and downstream connections; previously 56K
modems only used PCM for downstream data.
Interworking with other networks[edit]
· V.110 is an ITU-T recommendation for using terminal
adaptor functions for the connection of terminals having
interfaces conforming to V-series to the ISDN.
· V.120 is an alternative to V.110 based on the LAPD
protocol.
· V.150.1 is an ITU-T recommendation for using a modem
over IP networks.
Interface layer specifications for data

communication[edit]
November 1988, titled General data communications
interface layer 1 specification.
Control procedures[edit]
Digital circuit modems[edit]

· V.300 is an ITU-T recommendation, first approved in
July 1999, titled A 128 (144) kbit/s data circuit-
terminating equipment standardized for use on digital
point-to-point leased circuits.
History[edit]
RS-232 was first introduced in 1962 by the Radio Sector of
the EIA.[2][3] The original DTEs were electromechanical
teletypewriters, and the original DCEs were (usually)
modems. When electronic terminals (smart and dumb) began
to be used, they were often designed to be interchangeable
with teletypewriters, and so supported RS-232. The C revision
of the standard was issued in 1969 in part to accommodate the
electrical characteristics of these devices.[citation needed]
Since the requirements of devices such as computers, printers,
test instruments, POS terminals and so on were not foreseen
by the standard, designers implementing an RS-232
compatible interface on their equipment often interpreted the
standard idiosyncratically. The resulting common problems
were non-standard pin assignment of circuits on connectors,
and incorrect or missing control signals. The lack of
adherence to the standards produced a thriving industry of
breakout boxes, patch boxes, test equipment, books, and other
aids for the connection of disparate equipment. A common
deviation from the standard was to drive the signals at a
reduced voltage. Some manufacturers therefore built
transmitters that supplied +5 V and -5 V and labeled them as
"RS-232 compatible".[citation needed]
Later personal computers (and other devices) started to make
use of the standard so that they could connect to existing
equipment. For many years, an RS-232-compatible port was a
standard feature for serial communications, such as modem
connections, on many computers. It remained in widespread
use into the late 1990s. In personal computer peripherals, it
has largely been supplanted by other interface standards, such
as USB. RS-232 is still used to connect older designs of
peripherals, industrial equipment (such as PLCs), console
ports and special purpose equipment.
The standard has been renamed several times during its
history as the sponsoring organization changed its name, and
has been variously known as EIA RS-232, EIA 232, and most
recently as TIA 232. The standard continued to be revised and
updated by the Electronic Industries Alliance and since 1988
by the Telecommunications Industry Association (TIA).[4]
Revision C was issued in a document dated August 1969.
Revision D was issued in 1986. The current revision is TIA-
232-F Interface Between Data Terminal Equipment and Data
Circuit-Terminating Equipment Employing Serial Binary
Data Interchange, issued in 1997. Changes since Revision C
have been in timing and details intended to improve
harmonization with the CCITT standard V.24, but equipment
built to the current standard will interoperate with older
versions.[citation needed]
Related ITU-T standards include V.24 (circuit identification)
and V.28 (signal voltage and timing characteristics).[citation needed]
In revision D of EIA-232, the D-subminiature connector was
formally included as part of the standard (it was only
referenced in the appendix of RS 232 C). The voltage range
was extended to +/- 25 volts, and the circuit capacitance limit
was expressly stated as 2500 pF. Revision E of EIA 232
introduced a new, smaller, standard D-shell 26-pin "Alt A"
connector, and made other changes to improve compatibility
with CCITT standards V.24, V.28 and ISO 2110.[5]
Limitations of the standard[edit]

Because RS-232 is used beyond the original purpose of
interconnecting a terminal with a modem, successor standards
have been developed to address the limitations. Issues with
the RS-232 standard include:[6]
· The large voltage swings and requirement for positive and
negative supplies increases power consumption of the interface
and complicates power supply design. The voltage swing
requirement also limits the upper speed of a compatible
interface.
· Single-ended signaling referred to a common signal ground
limits the noise immunity and transmission distance.
· Multi-drop connection among more than two devices is not
defined. While multi-drop "work-arounds" have been devised,
they have limitations in speed and compatibility.
· The definitions of the two ends of the link are asymmetric. This
makes the assignment of the role of a newly developed device
problematic; the designer must decide on either a DTE-like or
DCE-like interface and which connector pin assignments to use.
· The handshaking and control lines of the interface are intended
for the setup and takedown of a dial-up communication circuit;
in particular, the use of handshake lines for flow control is not
reliably implemented in many devices.
· No method is specified for sending power to a device. While a
small amount of current can be extracted from the DTR and
RTS lines, this is only suitable for low power devices such as
mice.
· The 25-way connector recommended in the standard is large
compared to current practice.
· The standard does not address the possibility of connecting a
DTE directly to a DTE, or a DCE to a DCE.
Role in modern personal computers[edit]

PCI Express x1 card with one RS-232 port
Main article: Serial port
In the book PC 97 Hardware Design Guide,[7] Microsoft

deprecated support for the RS-232 compatible serial port of
the original IBM PC design. Today, RS-232 has mostly been
replaced in personal computers by USB for local
communications. Compared with RS-232, USB is faster, uses
lower voltages, and has connectors that are simpler to connect
and use. However, USB is limited by standard to no more
than 5 meters of cable, thus favoring RS-232 when longer
distances are needed. Both standards have software support in
popular operating systems.
USB is designed to make it easy for device drivers to
communicate with hardware. USB is more complex than the
RS-232 standard because it includes a protocol for
transferring data to devices. This requires more software to
support the protocol used. There is no direct analog to the
terminal programs used to let users communicate directly with
serial ports.
Serial ports of personal computers are also sometimes used to
directly control various hardware devices, such as relays or
lamps. Personal computers may use a serial port to interface
to devices such as uninterruptible power supplies. In some
cases, serial data is not exchanged, but the control lines are
used to signal conditions such as loss of power or low battery
alarms. An application program can detect or change the state
of RS 232 control lines in the registers of the serial hardware
using only a few input/output instructions; by contrast, a USB
interface requires software to decode the serial data.
Devices that convert between USB and RS-232 do not work
with all software or on all personal computers.
In fields such as laboratory automation or surveying, RS 232
devices may continue to be used. PLCs, VFDs, servo drives,
and CNC equipment are programmable via RS-232. Some
manufacturers have responded to this demand: Toshiba re-
introduced the DE-9M connector on the Tecra laptop.
Serial ports with RS-232 are also commonly used to
communicate to headless systems such as servers, where no
monitor or keyboard is installed, during boot when operating
system is not running yet and therefore no network connection
is possible. An RS-232 serial port can communicate to some
embedded systems such as routers as an alternative to network
mode of monitoring.
Physical interface[edit]
In RS-232, user data is sent as a time-series of bits. Both
synchronous and asynchronous transmissions are supported
by the standard. In addition to the data circuits, the standard
defines a number of control circuits used to manage the
connection between the DTE and DCE. Each data or control
circuit only operates in one direction, that is, signaling from a
DTE to the attached DCE or the reverse. Since transmit data
and receive data are separate circuits, the interface can operate
in a full duplex manner, supporting concurrent data flow in
both directions. The standard does not define character
framing within the data stream, or character encoding.
Voltage levels[edit]
Diagrammatic oscilloscope trace of voltage levels for an ASCII "K"
character (0x4B) with 1 start bit, 8 data bits, 1 stop bit. This is typical
for start-stop communications, but the standard does not dictate a
character format or bit order.
RS-232 data line on the terminals of the receiver side (RxD) probed
by an oscilloscope (for an ASCII "K" character (0x4B) with 1 start bit,
8 data bits, 1 stop bit and no parity bits).
The RS-232 standard defines the voltage levels that

correspond to logical one and logical zero levels for the data
transmission and the control signal lines. Valid signals are
either in the range of +3 to +15 volts or the range -3 to -15
volts with respect to the "Common Ground" (GND) pin;
consequently, the range between -3 to +3 volts is not a valid
RS-232 level. For data transmission lines (TxD, RxD and
their secondary channel equivalents) logic one is defined as a
negative voltage, the signal condition is called "mark". Logic
zero is positive and the signal condition is termed "space".
Control signals have the opposite polarity: the asserted or
active state is positive voltage and the deasserted or inactive
state is negative voltage. Examples of control lines include
request to send (RTS), clear to send (CTS), data terminal
ready (DTR), and data set ready (DSR).
RS232 logic and voltage levels
Data circuits Control circuits Voltage
0 (space) Asserted +3 to +15 V

1 (mark) Deasserted -15 to -3 V
The standard specifies a maximum open-circuit voltage of 25

volts: signal levels of ±5 V, ±10 V, ±12 V, and ±15 V are all
commonly seen depending on the voltages available to the
line driver circuit. Some RS-232 driver chips have inbuilt
circuitry to produce the required voltages from a 3 or 5 volt
supply. RS-232 drivers and receivers must be able to
withstand indefinite short circuit to ground or to any voltage
level up to ±25 volts. The slew rate, or how fast the signal
changes between levels, is also controlled.
Because the voltage levels are higher than logic levels
typically used by integrated circuits, special intervening driver
circuits are required to translate logic levels. These also
protect the device's internal circuitry from short circuits or
transients that may appear on the RS-232 interface, and
provide sufficient current to comply with the slew rate
requirements for data transmission.
Because both ends of the RS-232 circuit depend on the ground
pin being zero volts, problems will occur when connecting
machinery and computers where the voltage between the
ground pin on one end, and the ground pin on the other is not
zero. This may also cause a hazardous ground loop. Use of a
common ground limits RS-232 to applications with relatively
short cables. If the two devices are far enough apart or on
separate power systems, the local ground connections at either
end of the cable will have differing voltages; this difference
will reduce the noise margin of the signals. Balanced,
differential, serial connections such as USB, RS-422 and RS-
485 can tolerate larger ground voltage differences because of
the differential signaling.[8]
Unused interface signals terminated to ground will have an
undefined logic state. Where it is necessary to permanently set
a control signal to a defined state, it must be connected to a
voltage source that asserts the logic 1 or logic 0 level, for
example with a pullup resistor. Some devices provide test
voltages on their interface connectors for this purpose.
Connectors[edit]
RS-232 devices may be classified as Data Terminal
Equipment (DTE) or Data Communication Equipment (DCE);
this defines at each device which wires will be sending and
receiving each signal. The standard recommended but did not
make mandatory the D-subminiature 25-pin connector.
According to the standard, male connectors have DTE pin
functions, and female connectors have DCE pin functions.
Other devices may have any combination of connector gender
and pin definitions. Many terminals were manufactured with
female connectors but were sold with a cable with male
connectors at each end; the terminal with its cable satisfied the
recommendations in the standard. The standard specifies 20
different signal connections. Since most devices use only a
few signals, smaller connectors can often be used.
Personal computer manufacturers replaced the DB-25M
connector by the smaller DE-9M connector. Different pin
numbers were used for the signals (for this see serial port).
This connector, with varying pinouts, became common for
personal computers and related devices.
Presence of a 25-pin D-sub connector does not necessarily
indicate an RS-232-C compliant interface. For example, on
the original IBM PC, a male D-sub was an RS-232-C DTE
port (with a non-standard current loop interface on reserved
pins), but the female D-sub connector on the same PC model
was used for the parallel Centronics printer port. Some
personal computers put non-standard voltages or signals on
some pins of their serial ports.
Cables[edit]
Main article: Serial cable
The standard does not define a maximum cable length but

instead defines the maximum capacitance that a compliant
drive circuit must tolerate. A widely used rule of thumb
indicates that cables more than 50 feet (15 m) long will have
too much capacitance, unless special cables are used. By
using low-capacitance cables, full speed [clarification needed]
communication can be maintained over larger distances up to
about 1,000 feet (300 m).[9] For longer distances, other signal
standards are better suited to maintain high speed.
Since the standard definitions are not always correctly
applied, it is often necessary to consult documentation, test
connections with a breakout box, or use trial and error to find
a cable that works when interconnecting two devices.
Connecting a fully standard-compliant DCE device and DTE
device would use a cable that connects identical pin numbers
in each connector (a so-called "straight cable"). "Gender
changers" are available to solve gender mismatches between
cables and connectors. Connecting devices with different
types of connectors requires a cable that connects the
corresponding pins according to the table above. Cables with
9 pins on one end and 25 on the other are common.
Manufacturers of equipment with 8P8C connectors usually
provide a cable with either a DB-25 or DE-9 connector (or
sometimes interchangeable connectors so they can work with
multiple devices). Poor-quality cables can cause false signals
by crosstalk between data and control lines (such as Ring
Indicator).
If a given cable will not allow a data connection, especially if
a gender changer is in use, a null modem cable may be
necessary. Gender changers and null modem cables are not
mentioned in the standard, so there is no officially sanctioned
design for them.
3-wire and 5-wire RS-232[edit]
A minimal "3-wire" RS-232 connection consisting only of

transmit data, receive data, and ground, is commonly used
when the full facilities of RS-232 are not required. Even a
two-wire connection (data and ground) can be used if the data
flow is one way (for example, a digital postal scale that
periodically sends a weight reading, or a GPS receiver that
periodically sends position, if no configuration via RS-232 is
necessary). When only hardware flow control is required in
addition to two-way data, the RTS and CTS lines are added in
a 5-wire version.
Data and control signals[edit]

The following table lists commonly used RS-232 signals
(called "circuits" in the specifications) and pin assignments.[10]
See serial port (pinouts) for non-standard variations including
the popular DE-9 connector.
Circuit Origin DB-
25
Name Typical purpose Abbreviation DTE DCE
pin
Data
DTE is ready to receive,
Terminal DTR ● 20
initiate, or continue a call.
Ready
Data Carrier DCE is receiving a carrier
DCD ● 8
Detect from a remote DCE.
Data Set DCE is ready to receive
DSR ● 6
Ready commands or data.
DCE has detected an
Ring
incoming ring signal on the RI ● 22
Indicator
telephone line.
Request To DTE requests the DCE
RTS ● 4
Send prepare to transmit data.
DTE is ready to receive data
Ready To from DCE. If in use, RTS is
RTR ● 4
Receive assumed to be always
asserted.
Clear To DCE is ready to accept data
CTS ● 5
Send from the DTE.
Transmitted Carries data from DTE to
TxD ● 2
Data DCE.
Received Carries data from DCE to
RxD ● 3
Data DTE.
Common Zero voltage reference for all
GND common 7
Ground of the above.
Protective Connected to chassis
PG common 1
Ground ground.
The signals are named from the standpoint of the DTE. The
ground pin is a common return for the other connections, and
establishes the "zero" voltage to which voltages on the other
pins are referenced. The DB-25 connector includes a second
"protective ground" on pin 1; this is connected to equipment
frame ground.
Data can be sent over a secondary channel (when
implemented by the DTE and DCE devices), which is
equivalent to the primary channel. Pin assignments are
described in following table:
Signal Pin
Common Ground 7 (same as primary)
Secondary Transmitted Data (STD) 14
Secondary Received Data (SRD) 16
Secondary Request To Send (SRTS) 19
Secondary Clear To Send (SCTS) 13
Secondary Carrier Detect (SDCD) 12
Ring indicator[edit]
Ring Indicator (RI), is a signal sent from the DCE to the DTE
device. It indicates to the terminal device that the phone line is
ringing. In many computer serial ports, a hardware interrupt is
generated when the RI signal changes state. Having support
for this hardware interrupt means that a program or operating
system can be informed of a change in state of the RI pin,
without requiring the software to constantly "poll" the state of
the pin. RI does not correspond to another signal that carries
similar information the opposite way.
On an external modem the status of the Ring Indicator pin is
often coupled to the "AA" (auto answer) light, which flashes
if the RI signal has detected a ring. The asserted RI signal
follows the ringing pattern closely, which can permit software
to detect distinctive ring patterns.
The Ring Indicator signal is used by some older
uninterruptible power supplies (UPS's) to signal a power
failure state to the computer.
Certain personal computers can be configured for wake-on-
ring, allowing a computer that is suspended to answer a phone
call.
RTS, CTS, and RTR[edit]
Further information: Flow control (data)
The RTS and CTS signals were originally defined for use with
half-duplex (one direction at a time) modems that disable their
transmitters when not required, and must transmit a
synchronization preamble to the receiver when they are re-
enabled. The DTE asserts RTS to indicate a desire to transmit
to the DCE, and in response the DCE asserts CTS to grant
permission, once synchronization with the DCE at the far end
is achieved. Such modems are no longer in common use.
There is no corresponding signal that the DTE could use to
temporarily halt incoming data from the DCE. Thus RS-232's
use of the RTS and CTS signals, per the older versions of the
standard, is asymmetric.
This scheme is also employed in present-day RS-232 to RS-
485 converters. RS-485 is a multiple-access bus on which
only one device can transmit at a time, a concept that is not
provided for in RS-232. The RS-232 device asserts RTS to
tell the converter to take control of the RS-485 bus so that the
converter, and thus the RS-232 device, can send data onto the
bus.
Modern communications environments use full-duplex (both
directions simultaneously) modems. In that environment,
DTEs have no reason to deassert RTS. However, due to the
possibility of changing line quality, delays in processing of
data, etc., there is a need for symmetric, bidirectional flow
control.
A symmetric alternative providing flow control in both
directions was developed and marketed in the late 1980s by
various equipment manufacturers. It redefined the RTS signal
to mean that the DTE is ready to receive data from the DCE.
This scheme was eventually codified in version RS-232-E
(actually TIA-232-E by that time) by defining a new signal,
"RTR (Ready to Receive)," which is CCITT V.24 circuit 133.
TIA-232-E and the corresponding international standards
were updated to show that circuit 133, when implemented,
shares the same pin as RTS (Request to Send), and that when
133 is in use, RTS is assumed by the DCE to be asserted at all
times.[11]
In this scheme, commonly called "RTS/CTS flow control" or
"RTS/CTS handshaking" (though the technically correct name
would be "RTR/CTS"), the DTE asserts RTR to whenever it is
ready to receive data from the DCE, and the DCE asserts CTS
whenever it is ready to receive data from the DTE. Unlike the
original use of RTS and CTS with half-duplex modems, these
two signals operate independently from one another. This is
an example of hardware flow control. However, "hardware
flow control" in the description of the options available on an
RS-232-equipped device does not always mean RTS/CTS
handshaking.
Note that equipment using this protocol must be prepared to
buffer some extra data, since a transmission may have begun
just before the control line state change.
Seldom used features[edit]

The EIA-232 standard specifies connections for several
features that are not used in most implementations. Their use
requires 25-pin connectors and cables.
Signal rate selection[edit]
The DTE or DCE can specify use of a "high" or "low"
signaling rate. The rates as well as which device will select
the rate must be configured in both the DTE and DCE. The
prearranged device selects the high rate by setting pin 23 to
ON.
Loopback testing[edit]
Many DCE devices have a loopback capability used for
testing. When enabled, signals are echoed back to the sender
rather than being sent on to the receiver. If supported, the
DTE can signal the local DCE (the one it is connected to) to
enter loopback mode by setting pin 18 to ON, or the remote
DCE (the one the local DCE is connected to) to enter
loopback mode by setting pin 21 to ON. The latter tests the
communications link as well as both DCE's. When the DCE is
in test mode it signals the DTE by setting pin 25 to ON.
A commonly used version of loopback testing does not
involve any special capability of either end. A hardware
loopback is simply a wire connecting complementary pins
together in the same connector (see loopback).
Loopback testing is often performed with a specialized DTE
called a bit error rate tester (or BERT).
Timing signals[edit]
Some synchronous devices provide a clock signal to
synchronize data transmission, especially at higher data rates.
Two timing signals are provided by the DCE on pins 15 and
17. Pin 15 is the transmitter clock, or send timing (ST); the
DTE puts the next bit on the data line (pin 2) when this clock
transitions from OFF to ON (so it is stable during the ON to
OFF transition when the DCE registers the bit). Pin 17 is the
receiver clock, or receive timing (RT); the DTE reads the next
bit from the data line (pin 3) when this clock transitions from
ON to OFF.
Alternatively, the DTE can provide a clock signal, called
transmitter timing (TT), on pin 24 for transmitted data. Data is
changed when the clock transitions from OFF to ON and read
during the ON to OFF transition. TT can be used to overcome
the issue where ST must traverse a cable of unknown length
and delay, clock a bit out of the DTE after another unknown
delay, and return it to the DCE over the same unknown cable
delay. Since the relation between the transmitted bit and TT
can be fixed in the DTE design, and since both signals
traverse the same cable length, using TT eliminates the issue.
TT may be generated by looping ST back with an appropriate
phase change to align it with the transmitted data. ST loop
back to TT lets the DTE use the DCE as the frequency
reference, and correct the clock to data timing.
Synchronous clocking is required for such protocols as SDLC,
HDLC, and X.25.
Secondary channel[edit]
There is a secondary data channel, identical in capability to
the first. Five signals (plus the common ground of the primary
channel) comprise the secondary channel: Secondary
Transmitted Data (STD), Secondary Received Data (SRD),
Secondary Request To Send (SRTS), Secondary Clear To
Send (SCTS), and Secondary Carrier Detect (SDCD).
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PRESENTATION

1 Single Entry/Exit 1977 Single Section

2 Multi Entry/Exit 1985 Single Section/Point Zones

3 Universal Axle Counter 1994 -do-

4 Digital Axle Counter 2003 Single Section

5. Digital Axle Counter 2012 Multi Section Under Trial

Single Section Digital Axle Counter at IRISET 10

0.9 mm O AXC CABLE

SSDAC CLEAR CLEAR SSDAC

S S D A C PROVIDED IN BLOCK SECTION -- DIAGRAM

Generation of carrier signal for TX coils

• Communication between two SSDAC units is in

– ‘C’ language used

Power Cable 25 Sq. mm, 2 Core Aluminium

Single Section Digital Axle Counter at IRISET 13

2 Core ½ quad 2 Core

ENTRY Maximum 20 Kms EXIT

21 KHz 23 KHz 21 KHz 23 KHz

Rx-1 Rx-2 Rx-1 Rx-2

TX2 RELAY VITAL RELAY

V.22 is an ITU-T recommendation for full-duplex communication between

V.22bis is an ITU-T recommendation extending V.22 with a faster rate

V.23 is an ITU-T recommendation for half-duplex communication between

Receiver Coil Output

Tx / Reference Signal t0 Time t1 t2

Receiver Coil Output

SCC Card Output

Equivalent Digital data 1 1 1 1 0 0 1 1 1 1

Receiver Coil Output

Trolley Wheel between

SCC Card Output 5 V

Motor Trolley Wheel - No Count

The Dip Lorry wheel with Diameter less

Every evaluator was assigned with a two digit hexadecimal Address

Default Factory address setting is 02 for Entry end evaluator

The corresponding weight of each bit 0 0 0 0 0 0 1 0

Exit Entry Exit Entry

Exit Entry Exit Entry

Exit Entry Exit Entry

Exit Entry Exit Entry

Set the DIP switches SW2 and

Single Section Digital Axle Counter at IRISET 6

Output: i) Drive for vital relay (Q type, 24V, 1000 )

Power supply: i) 24V DC Battery- IPS

Single Section Digital Axle Counter at IRISET 7

Single Section Digital Axle Counter at IRISET 8

It has eight Cards

Carrier Signal Generation

Process the Analog signals

Convert in Digital form

Sends the pulses to MLB card

LD OK: LEVEL DETECTOR(LD) indicates that the signal from Rx coil is

LD OK: LEVEL DETECTOR(LD) indicates that the signal from Rx coil is

MLB performs following functions

These 8 LEDs denotes a 2-digit

Red LED glows if the MLB decision is

Green LED glows if the MLB decision

Following signals are recorded in 2MB

Event logger card is designed to capture and store important data

The data is initially stored in the buffer and subsequently

The cell to be replaced

RS232 port to connect to

Rx (Green LED) : Receiving the Signal from