SOUTHERN RAILWAY

SIGNAL & TELECOMMUNICATION TRAINING CENTRE

PODANUR

BLOCK PROVING AXLE COUNTER

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 INDEX

SL. NO Description Page

1 Introduction 3
2 Parts and function of SSDAC Unit 4
3 DO’S and DON’Ts 11
4 Trouble Shooting 12
5 Cable Plan and Interlocking circuits 13
Test your knowledge 15

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 BLOCK PROVING AXLE COUNTER
RDSO/SPN/177/2005

Introduction
The axle counter equipment is working on high frequency and using amplitude modulation or phase
modulation for detection of presence of wheel. The equipment described in this notes is Phase modulation
type for the detection of presence of wheel. In the Phase modulation type track device, the detection of
presence of wheel is with the phase reversal of 180 out of phase, which enables this system to be more
healthy and safe.

AIM: To Verify the complete arrival of Train by a system itself.

AXLE COUNTER

 It is a train detection device used to detect presence of vehicle on a portion of track.

 It has two sets of transducers & a processor.
 One set is installed at the entrance end on a portion of a track. Which is counts in
 Another set is installed at the exit end on a portion of track which counts out.
 The processor processes the IN count & OUT count and shows the line is clear, if they are equal & shows
occupied if they are not equal.
 The entry and exit Axle counter are interconnected by means of Quad Cable, Two conductors are required for
Axle Counter Modem communication.

ADVANTAGES OF AXLE COUNTERS

 Monitors very long track sections

 Immune to ballast resistance
 Insensitive to temperature variation
 Independent of type & quality of rails, sand formation & water logged tracks
 Immune to traction return currents

APPLICATION OF AXLE COUNTERS

 Track circuiting of berthing tracks

 Track circuiting of point zone tracks
 Verification of complete arrival of train
 Intermediate block signaling
 Automatic signaling
 Train actuated warning device

CLASSIFICATON

1. Analog Axle Counters

Universal Axle Counter- UAC
2. Digital Axle Counters
a. SSDAC o CEL Make o Alcatel (eldyne) Make. o GG TRONICS Make
b. MSDAC o SIEMENS Make

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 DEFICIENCIES IN ANALOG AXLE COUNTERS .

 Trolley suppression track circuit relay contacts.

 No diagnostic features.
 Requires interface equipment with other transmission media.
 Accessories such as relays, cable conductors, space & equipments as well as maintenance is more
 no. of hardware for fixing track devices
 Interference of 5 khz. Signal with harmonics.

PARTS AND FUCTIONS OF SINGLE SECTION DIGITAL AXLE COUNTER ( SSDAC) – SYSTEM (CEL – MAKE)

 AXLE DETECTOR – 2 NOS.

 SSDAC COUNTING UNITS – 2 NOS.
 RESET BOX – 1 NO.
 – 2 NOS. (INDEPENDENT RESETTING)
 VITAL RELAY - QS3 (24V) 2 NO.
 POWER SUPPLY ARRANGEMENT - 24 V DC (2 Nos.)
 COMMUNICATION & SIGNALLING CABLES
 TROLLEY SUPPRESSION TRACK CIRCUIT - 2 Nos.

Functional diagram of CEL SSDAC:

LEGEND
SCC 1 & 2 : SIGNAL CONDITIONER CARD
MLB 1 & 2 : MICROCONTROLLER LOGIC BLOCK
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AXLE DETECTORS

 Frequency of 21 kHz & 23 kHz Tx/Rx coils are used.

 web type axle detectors
 Deflector bracket assembly used to protect Tx/RX from hanging part.
 Compatible with 90r,52 kg & 60 kg rail profiles
 Detection of all wheels with wheel dia > 400 mm

FIG: AXLE DETECTER

SSDAC UNIT

FUNCTIONS OF SSDAC UNIT:

 Generation of carrier signal for TX coils

 Demodulation of signal from RX coils
 Generation of valid pulses
 Count the pulses to compute the number of passing wheels
 Exchange & comparison of counts between two SSDAC units
 Giving a vital relay output
 Error checking and display

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 SSDAC COUNTING UNIT – CONSTIUENTS (CEL – MAKE)

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  CARD 1 SCC-1 SIGNAL CONDITIONING CARD FOR 21 KHz
CARD 2 SCC-2 SIGNAL CONDITIONING CARD FOR 23 KHz
 CARD 3 MLB - 1 MICRO CONTROLLER LOGIC & ERROR DISPLAY CARD
 CARD 4 MLB - 2 MICRO CONTROLLER LOGIC & ERROR DISPLAY CARD
 CARD 5 EVENT LOGGER CARD(OPTIONAL)
 CARD 6 MODEM CARD
 CARD 7 RELAY DRIVER CARD
 CARD 8 DC-DC CONVERTOR CARD

FUNCTIONS OF SIGNAL CONDITIONING CARD :

• Generation of carrier signals of 21 khz or of 23 khz for TX coils

• Demodulation of receiver coil signal of 21 khz or of 23 khz from RX coils
• Adjustment of receiver signal with potentiometer
• Generation of wheel pulse
• Trolley suppression track circuit
• Generation of supervisory signal

FIG: CEL MAKE – SINGLE SECTION DIGITAL AXLE COUNTER

SIGNAL CONDITIONING CARD – INDICATIONS

• OSC OK ON OSCILLATOR WORKING PROPERLY

• LD OK ON LD WORKING PROPERLY
• PULSE OK ON PULSE SHAPER WORKING PROPERLY
• TP CONNECTED/ ON TRACK CIRCUIT CONNECTED TPR PICKED UP

MICRO CONTROLLER LOGIC CARD- FUNCTIONS

• Two identical cards to have 2 out of 2 logic

• Monitor & receive pulse signal
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 • Output pulse signal to other micro controller logic card
• Detect the direction of movement
• Counting the wheels passing over detector
• Supervision of axle detectors, presence of cards
• Code message packets for transmission to remote counting unit
• Decode message packets received from remote counting unit
• Determine the number of axles in the section
• Control & supervise the status of vital relay.
• Generation of system error codes
• Generation of clock
• Receiving the reset command from modem card

MICROCONTROLLER LOGIC BOARD – INDICATIONS

• CLEAR ON CLEAR CONDITION

• OCCUPIED ON OCCUPIED CONDITION
• ERROR CODE DETECTING LEDs

MODEM CARD- FUNCTIONS

• It provides signal conversion from digital to analog and vice-versa as per CCITT v.21 standard.
• It is used for communication between two counting units which is in the form of data packets
• Data packets consists of count change information, count update information, power on/reset information &
error information if any.
• It interfaces with serial RS232C port of both micro controller logic cards.
• Multiplex RS232C inputs & selects one channels

MODEM CARD – INDICATIONS

• TX FLASHING TRANSMITTING THE SIGNAL

• RX FLASHING RECEIVING THE SIGNAL
• MODE OFF NOT IN NETWORKING
• CD ON CARRIER IS DETECTED

RELAY DRIVER CARD- FUNCTIONS

• It checks & generates the vital relay drive output.

• This output is used to drive fail safe vital relay
• The output is generated only when the self count & remote counts are matched and equal
• Also the supervisory signals are normal at both locations.

RELAY DRIVER CARD – INDICATIONS

• MLB1 CLEAR COUNTS ARE BALANCED

• MLB1 CLOCK FLASHING SECTION IS CLEAR
• MLB2 CLEAR COUNTS ARE BALANCED
• MLB2 CLOCK FLASHING SECTION IS CLEAR
• RELAY DRIVE ON 24V DC AVAILABLE
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DC-DC CONVERTOR CARD- FUNCTIONS

• It receives Ripple Free 24v battery/IPS input.

• It generates 5v,12v,24v output with common ground
• A separate 15v with isolated ground is also generated
• It generates led indication for both input & output supply.

DC-DC CONVERTOR CARD – INDICATIONS

• 5V ON PRESENCE OF 5V
• 12V ON PRESENCE OF 12V
• 24V ON PRESENCE OF 24V
• 15V ON PRESENCE OF 15V

RESETTING SYSTEM- FUNCTIONS

• It is required to make the system normal in case axle counter has failed/switching on power supply.
• It is done with the help of sm’s reset box. (preparatory reset)
• As per safety requirement, to normalize the axle counter, the first train shall be piloted in the section after
resetting to register balance of counts in the system

RESET BOX (CEL – MAKE)

RESET BOX – INDICATIONS

• CLEAR ON SECTION IS CLEARED

• OCCUPIED ON SECTION IS OCCUPIED
• PREPARATORY RESET ON PREPARATORY RESET STATE
• POWER ON ON PRESENCE OF 24

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 FIG: Special earth RDSO/SPN/197/2005
FIG: VITAL RELAY & PREPARATORY RELAY

Note: This BPAC system shall be provided with maintenance free earth
of RDSO/Spn/197/2005 to achieve less than 1 ohm earth resistance.

Address setting for SSDAC units

 SSDAC units are provided with8-way DIP switch on motherboard for address setting.
 The switches can be slide to move Right (ON) or LEFT (OFF) as required.
 For selecting a pair of units (e.g. pair 5) and its switch position is given below.

(i) BPAC with Double line Block Instruments

In this system conventional Double line Block Instruments are used at the either station
of the block section with SSDAC/UAC for each block section on double line. The contacts of
SSDAC/UAC Axle counter as VR/BPACZR relay contacts are used in the Indication circuit, the LSS
circuit, the Block clearance circuits, the other circuits like Bell circuit & also the Operations of Block
Instrument remain as it is in the regular Double line block instrument working.

(ii) BPAC with F.M. Handle type Tokenless Block Instruments on Single line.
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 In this system, conventional F.M. Handle type token less block instrument are used at the
either station of the block section with SSDAC/UAC for block section on single line. The contacts of
SSDAC/UAC Axle counter as VR/ACPR relay contacts are used in the PBPR circuit, TAR circuit &
ASR circuit.

(iii) BPAC with Push Button Tokenless Block Instruments on Single line.

In this system conventional Push button token less block instrument are used at the
either station of the block section with SSDAC/UAC for block section on single line. The contacts of
SSDAC/UAC Axle counter as VR/ACPR relay contacts are used in the SNR circuit, TAR circuit &
ASCR circuit.

LED Status for ERROR Conditions

Example: LEDs 1 & 3 of LSB : Value=1+4=5 , LEDs 5 & 6 of MSB: Value=10+20=30, Add LSB+MSB=Error code 35
=Negative count error.

STATION STATION
A B
BLOCK SECTION

TYPICAL 10 - 20 KM
AS
4 4 4 4

BLOCK/ VITAL RELAY 2 VITAL RELAY BLOCK/

INTERLOCKING SSDAC-1 SSDAC-2 INTERLOCKING
EQUIPMENT
EQUIPMENT POWER POWER

PROVISION OF SSDAC IN BLOCK SECTION

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 DO’s & DON’Ts
1. Do’s
• Follow specified interconnection drawings for connecting the TX and RX Coils.
• Ensure that RX and TX coil cables have been laid in different pipes.
• Ensure that both the TX coils and RX coils are having proper alignment on Rail.
• Ensure that packing of sleepers with ballast on both sides of Axle detector is proper.
 Check that metal sheaths of the outdoor cable are connected to earth at both ends.
• The recommended cables for wiring of the system at site should be used.
• The steady battery voltage 24 V should be maintained.
• The cable connections should not be connected loosely.
• The MS Coupler connectors of SSDAC System are checked and maintained firmly.
• Check that the SSDAC unit and Reset box are provided with sealing arrangement
• Resetting should be done only after ensuring that there is no train in the Section.
• It is recommended that heat resisting paint to be used on the apparatus case so that the temperature inside apparatus
case is maintained lower in comparison to other normal paints.
• Caution Board has to be placed near the SSDAC Axle Detectors to avoid damaging of coils from packing machines.
• Deflector Plates must be mounted near the SSDAC Axle Detectors to avoid damaging of coils.
• Usage of Spoken Trolley wheel is desirable as it reduces the SSDAC system entering the Error mode. The straight
movements or passing of Motor Trolley or Push Trolley with solid mass wheel may create error sometimes.

2. Don’ts

• Don’t install the Axle detectors near the rail joint. (Not less than 6 sleepers away).
• Don’t install the Axle detectors where the rail is badly worn out
• Don’t cut or join the Transmitter / Receiver cables supplied along with the coil. It would result in change of
input Receiver signal.
• Don’t remove the modules from SSDAC System under Power ON condition.
• Always remove the modules if necessary after switching OFF the power to the SSDAC System.
• Address settings of the SSDAC System should not be changed at the field.
• When Section is in Occupied / Preparatory Mode, Motor Trolley wheel, Push Trolley with solid mass wheel
and Material Trolley wheel must not be allowed to Enter / Exit the Section to avoid SSDAC System going to
Error condition.

Troubleshooting

1. Count related errors

􀁺 Error code 0x33, 0x34 & 0x35: the remote unit’s error code is checked and diagnosed.
􀁺 Error code 0x36 & 0x37: the Tx/Rx coils and SCC card are to be checked.
2. Error due to wrong wheel movement
􀁺 Error 0x38 & 0x43: output of coil and SCC cards should be checked.
􀁺 Error 0x44, 0x45, 0x46, 0x47 & 0x48: comes due to formation of non-overlap
pulse. Any movement of trolley in the section should be checked.
3. Vital relay related errors
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􀁺 Error 0x15, 0x50, 0x51, 0x52 & 0x53: the VR should be checked for proper insertion.
4. Power & communication related errors
􀁺 Error 0x30: link between the two SSDAC units should be checked.
􀁺 Error 0x40, 0x41, 0x42: the communication media between the local and remote
units should be checked for noise or other interfering element.
􀁺 Surge Devices to be checked
􀁺 Error 0x3F, 0x7F: reset operation for the local and/or remote unit should be proper
􀁺 Error 0x80: remote unit should be checked and analyzed for error.
5. Hardware synchronization related errors
􀁺 Error 0x60, 0x62: Reset the system. If problem persists, MLB cards should be replaced
􀁺 In case of lightning, the SVPD devices should be checked for proper working.
􀁺 Power line & reset line surge modules are indicative type surge devices.
􀁺 Modem line devices are non indicative type.
􀁺 The damaged module(s), if found should be replaced with fresh module(s) of similar type.

CABLE PLAN AND INTERLOCKING CIRCUITS:

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VR,VPR,PR,PPR CIRCUIT:

ZSR, BPAC ZR CIRCUIT:

INDICATION/LINE CLEAR CIRCUIT:

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 LSS CIRCUIT AT SENDING STATION:

BLOCK CLEARENCE CIRCUIT

TEST YOUR KNOELEDGE

Objective questions : SAY TRUE OR FALSE

1. Two sets of Tx / Rx coils are required at one detection point to establish the direction of traffic. ( )
2. Transmitter coils are always connected inside the rail. ( )
3. Preparatory reset prepares to reset the axle counter and ensures that the SM/ASM pilot the train. ( )
4. In preparatory reset, after resetting, axle counter continues to show occupied until one train movement in
the section carries out correct balancing of track section. ( )
5. In UAC, both the Transmitter coils are connected in Series. ( )
6. In analog type, the receiver output signal due to passage of train is an amplitude modulated signal. ( )
7. In axle counter for each axle passing over detection point causes a ‘dip’ in the receiver signal. ( )
8. In Universal Axle counter, the transmitter signal frequency is 5 KHz. ( )
9. Transmitter & Receiver cables should be put in HDPE pipe for safety and laid at a depth of >1 meter
from bottom of rail. ( )
10. In CEL single section digital axle counters, event logger card is optional with each set of axle counters
used for monitoring the one track section. ( )
11. Phase reversal modulation technique is used in digital axle counters to avoid the trolley suppression
track circuit. ( )
12. In SSDAC of CEL make, SCC-1 generates the frequencies of 21KHz carrier signals, which is transmitted to
1ST set of Tx coils. ( )
13. In SSDAC of CEL make, SCC-2 generates the frequencies of 21KHz carrier signals, which is transmitted to
2nd set of Tx coils. ( )

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14. In SSDAC of CEL make, when the train wheel passes over the axle detectors, the Rx signal gets phase
modulated. ( )
15. In SSDAC of CEL make, the SCC conditions the modulated signal and demodulates it to generate valid train
pulses. ( )

CHOOSE THE CORRECT ANSWER:

1. SSDAC used with block working, type of reset used is ________ ( )

A) Direct Hard Reset B) Conditional Hard Reset C) Preparatory Reset D) Any one these can be used

2. In SSDAC of CEL make, card no 5 is _________ ( )

A) Modem Card. B) Event Logger Card. C) Micro controller Logic Board D) Relay Driver Card.

3. In SSDAC of CEL make, card no 6 is _________ ( )

A) Modem Card. B) Event Logger Card. C) Micro controller Logic Board D) Relay Driver Card.

4. In SSDAC of CEL make, card no 7 is _________ ( )

A) Modem Card. B) Event Logger Card. C) Micro controller Logic Board D) Relay Driver Card.

5. In SSDAC of CEL make, card no 8 is _________ ( )

A) Modem Card. B) Event Logger Card. C) DC-DC Converter Card D) Relay Driver Card.

6. In SSDAC of CEL make, card no 1&2 are _________ ( )

A) Modem Card. B) Signal Conditioning Cards. C) Micro controller Logic Boards D) Relay Driver Card.

7. In SSDAC of CEL make, card no 3&4 are _________ ( )

A) Modem Card. B) Signal Conditioning Cards. C) Micro controller Logic Boards D) Relay Driver Card.

8. In SSDAC of CEL make, input voltage to DC-DC Convertor is --------------- ( )

A) 12V & 24V DC respectively B) 110 V AC C) 24V DC D) 12V DC

9. In SSDAC of CEL make, DC-DC converter output voltages are ____, _____ & _______ ( )
A) +5 V, +12V, +12V(ISO) B) +5 V, -12V, +12V(ISO)
C) +5 V, +12V,24V +15V (ISO) D) +5 V, -10V,12V, +10V(ISO)

10. Preparatory reset can be used in case of the __________sections provided with axle counters. ( )
A) Main line B) Section between Advance starter and IBS
C) BPAC D) all of these
FILL IN THE BLANKS:

1. BPAC means _______________________________

2. RDSO Specification number of BPAC ________________________

3. AIM of BPAC is_____________________________

4. Parts of BPAC are 1. ___________, 2.__________, 3.___________ 4.___________ 5.___________

6. In SSDAC of CEL make, the error code LED indication provided in ____________ card.

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7. Track devices at entry & exit points of the section, should be fixed on the ________ rail.

8. In Modem card Tx -Transmitting the signal, when LED is ______________.

9. SSDAC of CEL units are provided with8-way DIP switch on __________board for address setting.

10. The normal condition of VR is _____________

11. The Normal condition of PR is _____________

12. In Double line Block instrument VPR, BPACZR proved in 1._______ 2.________ 3.______ circuit.

13. In single line F.M Block instrument VPR,ACPR proved in 1._______ 2.________ 3.______ circuit.

14. In single line P.B Block instrument VPR, ACPR proved in 1._______ 2.________ 3.______ circuit.

15. The earth resistance of special earth is __________ ohm

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