Document number: Page:

USER DOCUMENTATION D215600-0501060102 1 of 65

Product: Order codes:
AXLE COUNTER
1. AP215600
Type:
BO23

AXLE COUNTER BO23 USER DOCUMENTATION

Version: Date: Prepared by / signature: Verified by / signature: Validated by / signature:

6 08.12.2016. 0074 0049 0083
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Company ALTPRO is the manufacturer of all devices listed in the user

documentation. During installation and maintenance, it is forbidden to use
similar devices from another manufacturer. Information about wheel sensor
with product name ZK24-2 in this document are also valid for wheel sensor
with product name ZK24-2 FM.

For further assistance, please contact us: [email protected]

This product uses components that can be damaged by electrostatic

discharge (ESD). When handling, care must be taken so that the
devices are not damaged. Damage due to inappropriate handling is
not covered by the warranty.

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TABLE OF CONTENTS
1. TECHNICAL DESCRIPTION ................................................................................................ 6
1.1 APPLICATION ................................................................................................................... 6
1.2 DESCRIPTION AND SYSTEM STRUCTURE ................................................................... 6
1.2.1 OUTDOOR EQUIPMENT STRUCTURE .............................................................................. 7
1.2.2 INDOOR UNIT BO23-UNUR STRUCTURE ......................................................................... 8
1.2.3 POWER SUPPLY .............................................................................................................. 10
1.2.4 OUTPUT SIGNALS ............................................................................................................ 10
2. WIRING AND APPLICATION MANUAL ............................................................................ 11
2.1 OUTDOOR EQUIPMENT WIRING .................................................................................. 11
2.2 WIRING AND SETTING OF THE INDOOR UNIT BO23-UNUR ...................................... 12
2.2.1 CONFIGURATION 1 (BO23-8A): ONE SECTION WITH UP TO 8 COUNTING POINTS ... 13
2.2.2 CONFIGURATION 2 (BO23-4A-4B): TWO INDEPENDENT SECTIONS WITH UP TO 4
COUNTING POINTS.......................................................................................................... 14
2.2.3 CONFIGURATION 3 (BO23-3A-3B-2C): 3 INDEPENDENT SECTIONS ............................ 14
2.2.4 CONFIGURATION 4 (BO23-2A-2B-2C-2D): 4 INDEPENDENT SECTIONS WITH 2
COUNTING POINTS.......................................................................................................... 15
2.2.5 CONFIGURATION 5 (BO23-3A3B3C2D): 4 CONSECUTIVE SECTIONS ......................... 15
2.2.6 CONFIGURATION 6 (BO23-2A2B2C-2D2E2F): TWO TIMES 3 CONSECUTIVE SECTIONS
WITH UP TO 2 COUNTING POINTS ................................................................................. 16
2.2.7 CONFIGURATION 7 (BO23-2A2B2C2D4E): 5 CONSECUTIVE SECTIONS ..................... 17
2.2.8 CONFIGURATION 8 (BO23-2A2B2C2D2E3F): 6 CONSECUTIVE SECTIONS ................. 17
2.2.9 CONFIGURATION 9 (BO23-3A-2B-2C-2D): 3 INDEPENDENT STATION SECTIONS AND
SINGLE BLOCK BETWEEN STATIONS USING RS232 SERIAL CONNECTION ............. 17
2.2.10 SETTING THE POWER SUPPLY FOR COUNTING POINTS AND CONNECTION........... 18
2.2.11 SETTING THE COUNTING DIRECTION ........................................................................... 22
2.2.12 SAFETY RELAYS OUTPUT SIGNALS .............................................................................. 23
2.2.13 CONNECTION OF RELAY OUTPUTS TO DIFFERENT SIGNALLING SYSTEMS ............ 26
2.2.14 RESETTING THE SECTION.............................................................................................. 27
2.2.15 CONNECTING SEVERAL INDOOR UNITS IN RELAY ROOM FOR STATION SECTIONS
CONTROL ......................................................................................................................... 34
2.2.16 AUXILIARY INPUTS/OUTPUTS OF BO23-UNUR INDOOR UNIT ..................................... 35
2.2.17 INDICATORS ON THE BO23-UNUR FRONT PANELS ..................................................... 36
3. INSTALLATION MANUAL ................................................................................................. 38
3.1 MOUNTING OF THE WHEEL SENSOR ZK24-2 ON THE TRACK ................................. 38
3.1.1 SENSOR MOUNTING LOCATION .................................................................................... 38
3.1.2 TOOLS .............................................................................................................................. 38
3.1.3 MOUNTING, SETTING THE HEIGHT AND SIDE DISTANCE OF THE SENSOR WITH
CLAMP BRACKET ............................................................................................................. 38
3.2 INSTALLATION OF THE OUTDOOR UNIT BO23-VUR .................................................. 40
3.2.1 TOOLS .............................................................................................................................. 40
3.2.2 ASSEMBLY PARTS PER ONE COUNTING POINT .......................................................... 40
3.2.3 BURYING THE BO23-VUR ................................................................................................ 40
3.2.4 PROTECTION OF SENSOR CABLE AND PLACING THE CABLE INTO THE BO23-VUR
HOUSING .......................................................................................................................... 41
3.2.5 OUTDOOR EQUIPMENT GROUNDING............................................................................ 42
3.3 INSTALLATION OF THE INDOOR UNIT BO23-UNUR ................................................... 42
3.3.1 PREPARING THE INDOOR UNIT BO23-UNUR ................................................................ 42
3.3.2 MOUNTING THE INDOOR UNIT BO23-UNUR SUBRACK................................................ 42
3.3.3 GROUNDING..................................................................................................................... 43
3.3.4 WIRING THE INDOOR UNIT BO23-UNUR........................................................................ 43
3.3.5 FUNCTION AND COUNTING DIRECTION CHECK .......................................................... 44
3.4 DISMOUNTING AND REMOUNTING THE SENSOR DURING THE TRACK
RECONSTRUCTION ....................................................................................................... 44
3.4.1 TOOLS .............................................................................................................................. 44
3.4.2 WITH SENSOR MOUNTED ON THE CLOSER RAIL ........................................................ 44
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3.4.3 WITH SENSOR MOUNTED ON THE MORE DISTANT RAIL ............................................ 45

4. MAINTENANCE MANUAL ................................................................................................. 46
4.1 SIX-MONTHS PERIOD MAINTENANCE PROPOSAL – OUTDOOR EQUIPMENT ........ 46
4.1.1 MECHANICAL MEASURING AND JOINT TIGHTENING ................................................... 46
4.1.2 ELECTRICAL MEASURING .............................................................................................. 46
4.2 SIX-MONTHS PERIOD MAINTENANCE PROPOSAL – INDOOR UNIT BO23-UNUR ... 47
4.2.1 VISUAL CHECK................................................................................................................. 47
4.2.2 ELECTRICAL MEASUREMENT ........................................................................................ 48
4.2.3 FUSE VALUES ON THE INDOOR UNIT BO23-UNUR ...................................................... 48
5. TROUBLESHOOTING AND DIAGNOSTICS MANUAL .................................................... 49
5.1 FAILURE DETECTION ON THE OUTDOOR EQUIPMENT ............................................ 49
5.1.1 POWER FAILURE – THE FAILURE AFTER CLOSE LIGHTNING STRIKE ....................... 49
5.1.2 FAILURE IN THE SENSOR CIRCUIT ................................................................................ 49
5.1.3 FAILURE IN OUTPUT CIRCUITRY OF BO23-VUR ........................................................... 49
5.2 FAILURE DETECTION ON THE INDOOR UNIT BO23-UNUR........................................ 50
5.2.1 FAILURES CAUSED BY ATMOSPHERE DISCHARGES .................................................. 50
5.2.2 FAILURE ON THE INPUT AMPLIFIER MODULE UP ........................................................ 50
5.2.3 MPU MICROPROCESSOR MODULE FAILURE ............................................................... 51
5.2.4 POWER SUPPLY FAILURE .............................................................................................. 51
5.2.5 RELAY OUTPUT MODULE RE FAILURE.......................................................................... 52
6. TECHNICAL SPECIFICATIONS ........................................................................................ 53
6.1 OUTDOOR EQUIPMENT (BO23-VUR + sensor ZK24-2) ................................................ 53
6.2 INDOOR UNIT BO23-UNUR BO23-UNUR ...................................................................... 54
6.3 SIGNAL TRANSMISSION FROM OUTDOOR TO INDOOR UNIT BO23-UNUR ............. 55
APPENDIX A – DIMENSION DRAWINGS .............................................................................. 56
APPENDIX B – MOUNTING DRAWINGS............................................................................... 59
APPENDIX C – MEASURING LIST PROPOSAL FOR SIX-MONTH MAINTENANCE .......... 61
APPENDIX D – LIST OF SPARE PARTS AND TOOLS FOR INSTALLATION AND
MAINTENANCE ....................................................................................................................... 63
APPENDIX E – RECOMMENDATION FOR SPARE PART QUANTITIES TO BE KEPT
DURING THE EXPLOITATION ............................................................................................... 65

Figure 1: Axle counter BO23 structure for 2 counting point section control ................................ 7
Figure 2: Sensor on mounting bracket with a clamp mounted on the rail with shields ............... 7
Figure 3: Outdoor unit BO23-VUR in the box beside the track ................................................... 8
Figure 4: Indoor unit BO23-UNUR of the axle counter BO23 – module positions (front view) ... 8
Figure 5: Top view to opened box of the outdoor unit BO23-VUR ........................................... 11
Figure 6: Two examples of track configuration setup using the SW1 switch and reset mode
setup using the J25 jumper ............................................................................................... 13
Figure 7: A single section with 2 to 8 counting points controlled by one BO23-UNUR indoor unit
set to configuration 1 (BO23-8A)....................................................................................... 13
Figure 8: Example of two independent sections with 4 counting points controlled by one BO23-
UNUR indoor unit set to configuration 2 (BO23-4A-4B) .................................................... 14
Figure 9: Example of three independent sections controlled by one BO23-UNUR indoor unit set
to configuration 3 (BO23-3A-3B-2C) ................................................................................. 14
Figure 10: Two examples of 4 independent sections controlled by one BO23-UNUR indoor unit
set to configuration 4 (BO23-2A-2B-2C-2D)...................................................................... 15
Figure 11: Three examples of controlling 4 consecutive sections using one BO23-UNUR indoor
unit set to configuration 5 (BO23-3A3B3C2D) .................................................................. 16
Figure 12: Two examples of two times 3 consecutive sections control using one BO23-UNUR
indoor unit set to configuration 6 (BO23-2A2B2C-2D2E2F) .............................................. 16
Figure 13: Example of 5 consecutive sections control (only automatic block or automatic block
+ station area) using one BO23-UNUR indoor unit set to configuration 7 (BO23-
2A2B2C2D4E) .................................................................................................................. 17

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Figure 14: Example of 6 consecutive sections control (only automatic block or automatic block
+ station area) using one BO23-UNUR indoor unit set to configuration 8 (BO23-
2A2B2C2D2E3F) .............................................................................................................. 17
Figure 15: Example of control of 3 independent station sections and single block between
stations using serial connection between two BO23-UNUR indoor units set to configuration
9 (BO23-3A-2B-2C-2D) ..................................................................................................... 18
Figure 16: Setting the power supply of counting points ............................................................ 19
Figure 17: Indoor unit BO23-UNUR with connection markings (rear view) .............................. 20
Figure 18: BO23-UNUR with removed ZAG2Z modules (rear view) ........................................ 21
Figure 19: Setting the counting direction .................................................................................. 22
Figure 20: Output contacts of FREE and OCCUPIED relays for sections A, B and C .............. 24
Figure 21: Output contacts for FREE and OCCUPIED relays for sections D, E and F ............. 25
Figure 22: Connection of clear / occupied relay outputs on 3 types of signalling systems ....... 27
Figure 23: Digital inputs for reset of sections A, B and C on BO23-UNUR indoor unit ............. 29
Figure 24: Digital inputs for reset of sections D, E and F on BO23-UNUR indoor unit ............. 30
Figure 25: Example of connection of reset outputs from microprocessor interlocking .............. 32
Figure 26: Example of safety connection of reset push buttons on the control desk ................ 33
Figure 27: Example of optimal connection of axle counters BO23 for small station control ..... 34
Figure 28: Auxiliary inputs/outputs of the BO23-UNUR indoor unit .......................................... 36
Figure 29: Position of sensor on the rail ................................................................................... 38
Figure 30: Setting the sensor’s side distance ........................................................................... 39
Figure 31: Correct position of sensor mounted on the rail type UIC60 ..................................... 40
Figure 32: Location of the control unit BO23-VUR beside the track ......................................... 41
Figure 33: Mounting the indoor unit BO23-UNUR into a standard 19˝ rack ............................. 43
Figure 34: LED indication of a non-active state of the wheel sensor ZK24-2 on the trackside
control unit BO23-VUR...................................................................................................... 46
Figure 35: LED indication of an active state of both sensing systems (H and L) of the wheel
sensor ZK24-2 on the trackside control unit BO23-VUR ................................................... 47
Figure 36: Dimension drawing – sensor ZK24-2 ...................................................................... 56
Figure 37: Dimension drawing – trackside control unit BO23-VUR .......................................... 57
Figure 38: Dimension drawing – indoor unit BO23-UNUR ....................................................... 58
Figure 39: Mounting the sensor ZK24-2 on mounting bracket on the rail – cross section ........ 59
Figure 40: Mounting of the wheel sensor ZK24-2 on the mounting bracket with shields on the
rail ..................................................................................................................................... 60

Table 1: Purpose and basic characteristics of each module of indoor unit BO23-UNUR ........... 9
Table 2: Setting the counting direction on consecutive section configurations ......................... 23
Table 3: Meaning of each LED indication on the BO23-UNUR indoor unit .............................. 37
Table 4: MPU module error codes explanation ........................................................................ 51
Table 5: Wheel flange height (according to UIC 510-2) ........................................................... 54
Table 6: Wheel flange thickness (according to UIC 510-2) ...................................................... 54
Table 7: Maximal cable length from outdoor to indoor unit BO23-UNUR ................................. 55
Table 8: One counting point’s assemble parts of the axle counter BO23 ................................. 63
Table 9: Parts for BO23 indoor unit BO23-UNUR .................................................................... 63
Table 10: Other parts ............................................................................................................... 64
Table 11: Spare parts recommendation ................................................................................... 65

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1. TECHNICAL DESCRIPTION

1.1 APPLICATION

The axle counter BO23 applies to the railway track section clearance or occupancy
control wherever it needs to be controlled; primary for vital control of the section clearance or
occupancy, but can be used in similar applications without safety significance. Examples for
the application of the axle counter BO23 are:
- Clearance or occupancy control of station sections within the station interlocking system
- Clearance or occupancy control of an open railroad sections within the automatic block
system
- Clearance or occupancy control of an open railroad as a single block between stations
- Clearance or occupancy control of several sections in wide level crossing area for the
purpose of switching-on / switching-off the level crossing within the level crossing
protection system
- Clearance or occupancy control of shunting station / marshalling yard sections within the
automatic coach shunting system etc.
The axle counter BO23 continuously controls the entrance and exit of the train axles by its
sensors on the counting point on each end of the section and gives the output information that
the track section is clear only if the current number of axles on the section is equal to zero and
no disturbance, error or fault is detected. In each other case the “track section occupied”
information is outputted. With the BO23 equipment the track section clearance or occupancy
can be controlled on the section with two counting points (on the open railroad section or the
station track section), on the section with 3 counting points (switch point section), on the dead
end section with one counting point, on the double slip switch point section (4 counting points)
or the multiple switch points section with maximum 8 counting points.

1.2 DESCRIPTION AND SYSTEM STRUCTURE

Axle counter BO23 consists of outdoor equipment on the track and indoor unit BO23-
UNUR in the station or in the block section equipment shelter near the railroad as shown on
the figure 1. The station’s relay chambers and equipment shelters where the indoor unit BO23-
UNUR is installed are the restricted access locations and they are locked, sealed and
accessible only for signalling maintenance personnel.

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Section A

OUTDOOR Sensor ZK24-2 Sensor ZK24-2

EQUIPMENT
4 4
(sensor mounted COUNTING COUNTING
POINT 1 POINT 2
on rail and
trackside control VUR VUR
unit VUR)

TRANSMISSION
PATH
(existing 2-wire
2 2
telecommunication
twisted pairs)

BT1 BT2

INDOOR
EQUIPMENT
Indoor equipment
(power supply,
processor and BO23-UNUR
output units)

Section A Power supply,

occupancy reset
information

Figure 1: Axle counter BO23 structure for 2 counting point section control

It is possible to use the existing railway signalling and telecommunication cables instead
of the new ones. There is a 2-wire connection between indoor and outdoor equipment (single
2-wire telecommunication twisted pair).

1.2.1 OUTDOOR EQUIPMENT STRUCTURE

The outdoor equipment consists of a wheel sensor ZK24-2 mounted on the inner side of
one rail on the mounting bracket with a clamp or mounting bracket for drilled rail, left and right
sensor shield mounted on the same rail, and the outdoor unit BO23-VUR (trackside control unit
VUR) in the box beside the track. Figure 2 shows the sensor on the mounting bracket with a
clamp mounted on the rail with sensor shields. The ZK24-2 sensor has a double structure of
wheel detection (two sensing systems in one housing) that enables detection of direction and
increases safety of the system.

Figure 2: Sensor on mounting bracket with a clamp mounted on the rail with shields
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Figure 3 shows the outdoor unit BO23-VUR placed in the box on a short column beside
the track. BO23-VUR supplies and controls the sensor and sends the modulated signal that
keeps the information from both sensing systems on the same 2-wire twisted pair to indoor unit
BO23-UNUR. On the same 2-wire twisted pair the outdoor equipment receives the DC power
supply.

Figure 3: Outdoor unit BO23-VUR in the box beside the track

Each railway network region department for signalling equipment maintenance should
have at least one plastic template for sensor position adjustment on rail.

1.2.2 INDOOR UNIT BO23-UNUR STRUCTURE

Indoor unit BO23-UNUR of the axle counter BO23 has a modular structure in 19˝
Eurocard subrack, 3U height (figure 4). On the first position from the left there is a
microprocessor module MPU that contains three vital microcontrollers and one diagnostic
microcontroller with display unit showing number of axles and other important data (direction,
disturbance, errors etc.). Each vital microcontroller runs multi-structured safety program that
processes signals from the sensors, distinguishes wheel pulses from disturbances, counts
axles and gives information of clearance or occupancy of each section. Output information
about clearance or occupancy of the sections is given based on a 2-out-of-3 principle and is
forwarded to relay output modules RE.

MPU
NUMBER OF AXLES ON SECTION
(SECTION / COUNTING POINT) SEC UP UP UP UP UP UP UP UP RE RE RE ZANAP DC12

ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE

CLEAR CLEAR CLEAR
H L H L H L H L H L H L H L H L POWER
SECTION 1

SECTION 1

SECTION 1

COUNTING
LINK

SECITION
POINT OCCUPIED OCCUPIED OCCUPIED

ON
SECTION RESET 1 RESET 1 RESET 1
ENTRANCE Tx Rx
DIAGNOSTICS

+12V
READY READY READY READY READY READY READY READY
DIAGNOSTICS

H L H L H L H L H L H L H L H L
DISTURB. CLEAR CLEAR CLEAR
FF1.6A
SECTION 2

SECTION 2

SECTION 2

OCCUPIED OCCUPIED OCCUPIED

ERROR Tx Rx

RESET 2 RESET 2 RESET 2

-12V
FAILURE
MPU LINK

RESET 1 RESET 1 RESET 1

FF1.6A
LED-TEST +4V … +6V +4V … +6V +4V … +6V +4V … +6V +4V … +6V +4V … +6V +4V … +6V +4V … +6V
RESET 2 RESET 2 RESET 2

MPU LINK
GND GND GND GND GND GND GND GND

Figure 4: Indoor unit BO23-UNUR of the axle counter BO23 – module positions (front view)
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Purpose and basic characteristics of each module of the indoor unit BO23-UNUR is described
in Table 1 below.

Table 1: Purpose and basic characteristics of each module of indoor unit BO23-UNUR
Module Module name / Description Additional features
Microprocessor Module (Micro Processor Unit):
 Performs the processing of the wheel impulses on all 8 counting
points
 Distinguishes disturbances from the wheel impulses
 Counts in / counts out axles form each section and decides on
clearance / occupancy of the section based on a 2-out-of-3
LED-display for axle
principle
number indication /
 Drives the coils of output safety clear / occupancy relays on RE
error code, LED for
modules
direction /
 Processes section reset signals on digital inputs and, if necessary, disturbance / error /
MPU resets / clears each section failure indication,
 Pronounces eventual disturbances or axle counting errors and NVRAM memory,
indicates them on the front panel (LED) outside
 Registers train passages and stores them in the NVRAM memory communication
 If necessary, MPU communicates with a PC during memory channels 2×RS232
reading
 If necessary, MPU communicates with another / distant MPU
module in order to exchange the data regarding 9th / distant
counting point and clear / occupancy status of a long block section
between stations (“MPU link” RS232 communication channel in
configuration 9)
Communication Module:
 Converts RS232 diagnostics communication channel into 2 Ethernet RJ45
Ethernet, so that diagnostics memory can be read over certain port and one DB9
Ethernet network RS232 port, LED
SEC
 Converts RS232 „MPU Link“ communication channel into indication of
Ethernet, so that the communication between two distant indoor information flow on
units BO23-UNUR can be carried out over a certain Ethernet ports (Rx/Tx)
network
Input Amplifier:
LED for indication of
 Powers the counting point (outdoor unit BO23-VUR and wheel
a certain detection
sensor ZK24-2) with galvanically isolated 98V DC voltage
sensing system,
 Receives multiplexed AC signal from the counting point and
trimming resistors
UP separates the signal of H and L wheel detection sensing system
and input voltage
 Corrects the AC wheel detection signals, filtrates them and adapts measurement
itself for MPU module digital inputs (adjustment)
 Indicates correct input signal range on the front panel and on connectors
certain (mutual) digital input of the MPU module
Relay output module:
 Contains two safety output relays (clearance relay and occupancy LED for indication of
relay) per two counting sections according to EN 50205 a certain section
 Provides clear / occupied output signals according to the status (clear /
supervisory safety signaling system in form of non-potential occupied / reset
RE
contacts of safety relays pending), indented
 Provides control of the output relay state by connecting auxiliary pushbuttons for
contacts on to the digital inputs of the MPU module auxiliary section
 Adjusts the reset command signals on to the digital inputs of the reset
MPU module

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Module Module name / Description Additional features

Power supply protection module:
 Monitors if the internal ±12V DC power supply is in correct range,
LED for indication of
and if not, switches off the DC/DC converter on the DC12 module
input and internal
(switches off complete power supply and tries to switch it on after
ZANAP power supply, fuses
approximately 10s)
for internal ±12V DC
 Monitors if the input power supply is in correct range (18V…80V power supply
DC) and indicates it on the front panel, as well as on the digital
inputs of the MPU module
LED for indication of
Power supply module (DC/DC converter):
correct operation of
DC12  Galvanically isolates and converts input power supply 18V…80V the power supply
DC in to internal power supply of the indoor unit BO23-UNUR module
Lightning protection module (on the back side of the indoor
unit BO23-UNUR ):
 Provides 3-stage lightning overvoltage protection of the indoor unit One fuse for each
BO23-UNUR from each counting point wire, together towards outdoor connection
ZAG2Z
ground and differentially between wires (for each wire that
 Provides 3-stage lightning overvoltage protection of the indoor unit goes outside)
BO23-UNUR from main DC power supply connection together
towards ground and differentially between wires

One indoor unit BO23-UNUR of the axle counter BO23 (one rack 19˝×3U) can process up
to 8 counting points and give information about clearance or occupancy of 1 to 6 sections.

1.2.3 POWER SUPPLY

The axle counter BO23 is supplied from a DC source 18V…80V. When the axle counter
operates within vital safety signalling system it is usually supplied from a permanently charged
battery power supply (24V, 36V, 48V or 60V DC).
Outdoor equipment is power supplied internally from the indoor unit BO23-UNUR and is
galvanically isolated for each counting point and stabilised to 98V DC (on the UP module).

1.2.4 OUTPUT SIGNALS

Section occupancy output signals of the axle counter BO23 are outputted over contacts of
the safety relays on relay output module RE. The other information, such as current axle
number, direction of train movement, sensor disturbances, axle counting errors, failures and
other, that can be seen on LED-indicators of the microprocessor module MPU, can also be
monitored with a personal computer or laptop connected to RS232 port (9-pin connector
"Diagnostics") on the front panel of the MPU module of the indoor unit BO23-UNUR , or
remotely using various forms of Ethernet network, if a SEC module is inserted in the slot right
of the MPU module, and Ethernet RJ45 connection of the SEC module is connected to a
certain network.

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2. WIRING AND APPLICATION MANUAL

2.1 OUTDOOR EQUIPMENT WIRING

Marks on the connection terminals of the outdoor unit BO23-VUR are shown on the figure
5. The ZK24-2 sensor is delivered with fixed 4-wire 6-meter long sensor cable (other cable
lengths and connectors available upon request). The sensor cable should be connected to the
BO23-VUR unit terminals H+, H-, L+, L- as shown below:

H+ YELLOW-GREEN WIRE (Positive pole of the sensing system H)

H- BROWN WIRE (Negative pole of the sensing system H)
L+ BLACK WIRE (Positive pole of the sensing system L)
L- GREY WIRE (OR BLUE) (Negative pole of the sensing system L)

Figure 5: Top view to opened box of the outdoor unit BO23-VUR

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The H sensing system is located on the left and the L sensing system is located on the
right side of the ZK24-2 sensor housing, looking from the inner side of the track (take care of
this while setting the counting direction on indoor unit BO23-UNUR , 2.2.11).
The two wires for connection between outdoor unit BO23-VUR and indoor unit BO23-
UNUR have to be connected to terminals VOD1+, VOD1- (to one indoor unit) and optionally
another two wires to the terminals VOD2+, VOD2- (to the other indoor unit – for neighbouring
section control, if it is used). Cable VOD1 always has to be connected to the indoor unit BO23-
UNUR because this line is used for two applications: transmission of the counting information
from BO23-VUR to BO23-UNUR and power supply for the BO23-VUR (40V-98V DC), which is
supplied from the indoor unit BO23-UNUR. Output stage of cable VOD2 has a serial capacitor
(DC voltage separation) and it is not possible to use this line for supplying BO23-VUR (the line
is used only for transmission of counting signal to another indoor unit BO23-UNUR, for
neighbouring section). In case the terminals VOD2 are not used, it is necessary to connect one
resistor 180 Ohm, 1/4W between the terminals VOD2+ and VOD2-.
In case of very long distance between BO23-VUR and BO23-UNUR units (longer than
the values from the technical datasheet for telecommunication cables diameter) it is possible to
supply BO23-VUR with one local (battery) source 60V DC or with the other kind of power
supply source 40V DC to 98V DC which is placed not far from the outdoor unit BO23-VUR. In
this case maximum distance between indoor and outdoor equipment is defined just according
to maximal permitted attenuation of the counting signal (40dB). These distances (relative to
diameter of wire) are also shown in technical data. Local power supply have to be connected to
"LOCAL POWER +" (“+” pole of power supply) and "LOCAL POWER -" (“-” pole of power
supply).

2.2 WIRING AND SETTING OF THE INDOOR UNIT BO23-UNUR

One indoor unit BO23-UNUR of the BO23 axle counter (one 19˝×3U subrack) can
process up to 8 counting points and output occupancy information for 1 to 6 sections. Hereafter
a description of nine possible section occupancy control configurations for single BO23-UNUR
indoor unit is given. Each section occupancy control configuration has its own operating
program that runs in the microprocessor module MPU. Choosing of configuration (operating
program) for the MPU module (MPU programming) is performed during installation of the
BO23-UNUR by setting the 4-bit SW1 switch located on the rear side of the unit. After
installation a sealed cover can be placed over the SW1 switch. In the BO23-UNUR subrack
any MPU module can now be inserted and after applying the power it will always start running
the operating software defined by the switch located on the rear side of the subrack. Position of
the SW1 switch is in fact a 4-bit binary number that also represents number of the track/section
configuration. Figure 6 shows two examples of the configuration setup defined by the SW1
switch and examples of the section reset mode defined by the J25 jumper, which is described
in detail in the section 2.2.14.

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ON DIP
EXAMPLE 1: TRACK CONFIGURATION SWITCH SW1:
CONFIGURATION SET TO "CONFIGURATION 1"

SW1
(BINARY: 0001) OR "BO23-8A" (ONE SECTION WITH UP
MSB 1 2 3 4 LSB TO 8 COUNTING POINTS)

3
RESET MODE JUMPER J25:

2
RESET MODE SET TO "MODE 0" OR "IMMEDIATE RESET"

J25

1
ON DIP
EXAMPLE 2: TRACK CONFIGURATION SWITCH SW1:
CONFIGURATION SET TO "CONFIGURATION 4" (BINARY:

SW1
0100) OR "BO23-2A-2B-2C-2D" (FOUR INDEPENDENT
MSB 1 2 3 4 LSB SECTIONS WITH 2 COUNTING POINTS EACH)
3

RESET MODE JUMPER J25:

2

RESET MODE SET TO "MODE 1" OR "PREPARATORY RESET"

J25

Figure 6: Two examples of track configuration setup using the SW1 switch and reset mode
setup using the J25 jumper

2.2.1 CONFIGURATION 1 (BO23-8A): ONE SECTION WITH UP TO 8 COUNTING POINTS

Configuration BO23-8A for controlling a single section with up to 8 counting points using
one BO23-UNUR indoor unit is chosen by setting the binary number 0001 on the SW1 switch
located on the rear side of the unit (figure 6).
To control one section with only two counting points (as on figure 1), the input amplifier
modules UP have to be inserted in first two positions UP1 and UP2, while other positions
(UP3÷UP8) are covered with blank panels. One BO23-UNUR indoor unit and the same
configuration of the MPU module can also be used for controlling one switch point with three
counting points or multiple switch points (total of 8 counting points), as on figure 7.

SECTION A

CP1 CP2

CP3

CP4

CP5

CP6

CP7

CP8

Figure 7: A single section with 2 to 8 counting points controlled by one BO23-UNUR indoor unit
set to configuration 1 (BO23-8A)

Each of 8 counting points on figure 7 can be passed over by the vehicle simultaneously
with any other counting point; axle counter BO23 at any time monitors real current number of
axles on the section and clears the section only when all axles had left the section.
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2.2.2 CONFIGURATION 2 (BO23-4A-4B): TWO INDEPENDENT SECTIONS WITH UP TO 4

COUNTING POINTS

Configuration BO23-4A-4B for controlling clearance or occupancy of two independent

sections with up to 4 counting points per section with a single BO23-UNUR indoor unit is
chosen by setting the binary number 0010 on SW1 switch on the rear side of the indoor unit
(figure 6). Figure 8 shows the example of two independent sections with 4 counting points in
railway station.

SECTION A SECTION B
4
CP CP
8

CP1 CP2 CP5 CP6

7
CP CP
3

Figure 8: Example of two independent sections with 4 counting points controlled by one BO23-
UNUR indoor unit set to configuration 2 (BO23-4A-4B)

Each of controlled sections (section A or section B) can have less counting points (1, 2 or
3) than shown on figure 8. Simultaneous passage of the train over each two or more counting
points is allowed.

2.2.3 CONFIGURATION 3 (BO23-3A-3B-2C): 3 INDEPENDENT SECTIONS

Configuration BO23-3A-3B-2C for clearance or occupancy control of three independent

sections using one BO23-UNUR indoor unit is chosen by setting the binary number 0011 on
the SW1 switch on the rear side of the indoor unit (figure 6). In this configuration first and
second section (A and B) can have up to 3 counting points and the third one (C) can have up
to 2 counting points. Figure 9 shows the example of three independent sections in railway
station.

SECTION A SECTION B
3
CP CP
6

CP1 CP2 CP4 CP5

SECTION C

CP7 CP8

Figure 9: Example of three independent sections controlled by one BO23-UNUR indoor unit set
to configuration 3 (BO23-3A-3B-2C)

Each controlled section can have smaller number of counting points than shown on figure
9. Simultaneous passage of the train over several counting points is allowed.

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2.2.4 CONFIGURATION 4 (BO23-2A-2B-2C-2D): 4 INDEPENDENT SECTIONS WITH 2

COUNTING POINTS

Configuration BO23-2A-2B-2C-2D for clearance or occupancy control of 4 independent

sections using one BO23-UNUR indoor unit is chosen by setting the binary number 0100 on
the SW1 switch on the rear side of indoor unit BO23-UNUR (figure 6). Each of 4 independent
sections (A, B, C and D) can have up to 2 counting points. Figure 10 shows two examples of
controlling 4 independent sections with 2 counting points inside or outside of railway station.

SECTION A

CP1 CP2
SECTION B

CP3 CP4
SECTION C

CP5 CP6
SECTION D

CP7 CP8

SECTION A SECTION C

CP1 CP2 CP5 CP6

CP3 CP4 CP7 CP8

SECTION B SECTION D

Figure 10: Two examples of 4 independent sections controlled by one BO23-UNUR indoor unit
set to configuration 4 (BO23-2A-2B-2C-2D)

2.2.5 CONFIGURATION 5 (BO23-3A3B3C2D): 4 CONSECUTIVE SECTIONS

Configuration BO23-3A3B3C2D for clearance or occupancy control of 4 consecutive

sections using one BO23-UNUR indoor unit is chosen by setting the binary number 0101 on
the SW1 switch on the rear side of the indoor unit BO23-UNUR (figure 6). In this configuration
the first three sections (A, B and C) can have up to 3 counting points and the fourth one (D)
can have up to 2 counting points. Figure 11 shows two examples of controlling 4 consecutive
station sections and one example of controlling 4 sections of automatic block.

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CP1 CP2
SECTION A

CP3 CP4
SECTION B

CP5 CP6
SECTION C SECTION D

CP7 CP8

SECTION A 2 SECTION C
CP CP
SECTION B 6 SECTION D

CP1 CP3 CP5 CP7 CP8

SECTION A SECTION B SECTION C SECTION D

CP1 CP3 CP5 CP7 CP8

(C
P6
)

Figure 11: Three examples of controlling 4 consecutive sections using one BO23-UNUR indoor
unit set to configuration 5 (BO23-3A3B3C2D)

2.2.6 CONFIGURATION 6 (BO23-2A2B2C-2D2E2F): TWO TIMES 3 CONSECUTIVE

SECTIONS WITH UP TO 2 COUNTING POINTS

Configuration BO23-2A2B2C-2D2E2F for clearance or occupancy control of 2 times 3

consecutive sections using one BO23-UNUR indoor unit is chosen by setting the binary
number 0110 on the SW1 switch on the rear side of the indoor unit BO23-UNUR (figure 6).
This configuration can be used whenever there is a need to control three consecutive sections
with up to 2 counting points; in station area or within automatic block. The first example on
figure 12 shows control of two times 3 automatic block sections using one indoor unit located in
station relay room. The second example on figure 12 shows clearance or occupancy control of
two times 3 sections on a double track level crossing when axle counter BO23 is used as a
train detection unit for switching on/off the level crossing system.
SECTION A SECTION B SECTION C

CP1 CP2 CP3 CP4

CP5 CP6 CP7 CP8

SECTION D SECTION E SECTION F

SECTION D SECTION E SECTION F

CP5 CP6 CP7 CP8

CP1 CP2 CP3 CP4

SECTION A SECTION B SECTION C

Figure 12: Two examples of two times 3 consecutive sections control using one BO23-UNUR
indoor unit set to configuration 6 (BO23-2A2B2C-2D2E2F)
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2.2.7 CONFIGURATION 7 (BO23-2A2B2C2D4E): 5 CONSECUTIVE SECTIONS

Configuration BO23-2A2B2C2D4E for clearance or occupancy control of 5 consecutive

sections using one BO23-UNUR indoor unit is chosen by setting the binary number 0111 on
the SW1 switch on the rear side of the indoor unit BO23-UNUR (figure 6). In case the most
distant counting point is within the maximum indoor-outdoor distance range, clearance or
occupancy control of 5 consecutive sections of the automatic block system can be performed
using one BO23-UNUR indoor unit (figure 13). Some of 5 consecutive sections can be used to
control station area (for example entrance switch points, section E).

)
P8
(C
SECTION A SECTION B SECTION C SECTION D SECTION E

CP1 CP2 CP3 CP4 CP5 CP6

(C
P7
)

Figure 13: Example of 5 consecutive sections control (only automatic block or automatic block +
station area) using one BO23-UNUR indoor unit set to configuration 7 (BO23-2A2B2C2D4E)

2.2.8 CONFIGURATION 8 (BO23-2A2B2C2D2E3F): 6 CONSECUTIVE SECTIONS

Configuration BO23-2A2B2C2D2E3F for clearance or occupancy control of 6 consecutive

sections using one BO23-UNUR indoor unit is chosen by setting the binary number 1000 on
the SW1 switch on the rear side of the indoor unit BO23-UNUR (figure 6). In case the most
distant counting point is within the maximum indoor-outdoor distance range, clearance or
occupancy control of 6 consecutive sections of automatic block can be performed using one
BO23-UNUR indoor unit (figure 14). Some of 6 consecutive sections can be used to control
station sections (for example entrance switch point, section F).

)
P8
(C
SECTION A SECTION B SECTION C SECTION D SECTION E

CP1 CP2 CP3 CP4 CP5 CP6 SECTION F CP7

Figure 14: Example of 6 consecutive sections control (only automatic block or automatic block +
station area) using one BO23-UNUR indoor unit set to configuration 8 (BO23-2A2B2C2D2E3F)

2.2.9 CONFIGURATION 9 (BO23-3A-2B-2C-2D): 3 INDEPENDENT STATION SECTIONS

AND SINGLE BLOCK BETWEEN STATIONS USING RS232 SERIAL CONNECTION

Configuration BO23-3A-2B-2C-2D for clearance or occupancy control of 3 independent

station sections and single block between stations using one BO23-UNUR indoor unit is
chosen by setting the binary number 1001 on the SW1 switch on the rear side of the indoor
unit BO23-UNUR (figure 6). When the operating program is set to BO23-3A-2B-2C-2D one
BO23-UNUR indoor unit can control clearance or occupancy of three independent station
sections (section A with 3 counting points, section B and C with 2 counting points), together
with single block between stations with 2 counting points using RS232 serial connection to
indoor unit in the neighbouring station (figure 15).

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4
SECTION D
VUR
(SINGLE BLOCK BETWEEN STATIONS)
SECTION A ZK24-2 ZK24-2
4 4 4 4
VUR VUR VUR VUR

SECTION B
4 4
VUR VUR 2
2 2 2
SECTION C
4 4 2 2
VUR 2 VUR
2 2

SECTION D

MPU LINK

MPU LINK
SECTION A, B, C AND D BT1 BT2 BT3 BT4 BT5 BT6 BT7 BT8 BT8
TWO-WIRE TELECOMMUNICATION OCCUPANCY
OCCUPANCY INDOOR EQUIPMENT RS232 OR FIBER OPTIC LINK RS232 INDOOR EQUIPMENT
INFORMATION,
INFORMATION, RESET, BO23-UNUR BO23-UNUR
RESET, POWER
POWER SUPPLY
SUPPLY
MODEM OR MODEM OR
FIBER OPTIC FIBER OPTIC
CONVERTER CONVERTER
RELAY ROOM OF THE STATION A RELAY ROOM OF THE STATION B

Figure 15: Example of control of 3 independent station sections and single block between
stations using serial connection between two BO23-UNUR indoor units set to configuration 9
(BO23-3A-2B-2C-2D)

The main purpose of this way of single block between stations clearance or occupancy
control is to avoid usage a copper wire connection to the most distant counting point when it is
located outside of the maximum indoor-to-outdoor equipment distance range (when the
distance between two stations is large) or when you simply want to avoid copper wire
connection between stations (e.g. because of lack of telecommunication pairs) and the optical
cable or similar connection is preferred. The closer counting point in this case is connected
using two-wire twisted pair directly to BO23-UNUR indoor unit (on the position of 8th counting
point, receiving module UP8) same as in previous examples. Information from the further
counting point of the block between stations is received via RS232 serial connection between
local BO23-UNUR indoor unit and remote indoor unit in the neighbouring station that directly
controls further (or closer from the aspect of remote indoor unit) counting point and processes
the same operating software BO23-3A-2B-2C-2D. This link is on both indoor units connected
to connector MPU LINK located on the front panel of the MPU microprocessor module.
Communication between two indoor units is carried out using closed transmission system
safety principle according to EN50159-1.
The length of a block between stations controlled this way is dependent only on
parameters of used telecommunication system (optical cable with related devices, type of
modem for two-wire communication, etc.) and can be long up to several tens of kilometres.

2.2.10 SETTING THE POWER SUPPLY FOR COUNTING POINTS AND CONNECTION

Each input module UP (input amplifier) that receives signals from counting points also
contains circuitry that provides galvanically isolated 98V DC power supply for counting point.
On the rear side of the main board there are jumpers which define whether the counting point
has to be power supplied or not by the UP module for each position (UP1…UP8). The indoor
unit BO23-UNUR of the neighbouring section can already supply some of the counting points,
so it will not need power supply from this BO23-UNUR indoor unit. Figure 16 shows the setup
of jumpers J1…J16 defining power supply of certain counting point.

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1
J2

J1
POWER SUPPLY 96V DC IS SENT TO THE COUNTING POINT
4

4
1

1
J2

J1 POWER SUPPLY 96V DC IS NOT CONNECTED TO THE

COUNTING POINT; ONLY AC SIGNAL IS RECEIVED AND THE
COUNTING POINT IS POWERED FROM ANOTHER INDOOR UNIT
4

COUNTING POINT 1  JUMPERS J1, J2 COUNTING POINT 5  JUMPERS J9, J10

COUNTING POINT 2  JUMPERS J3, J4 COUNTING POINT 6  JUMPERS J11, J12
COUNTING POINT 3  JUMPERS J5, J6 COUNTING POINT 7  JUMPERS J13, J14
COUNTING POINT 4  JUMPERS J7, J8 COUNTING POINT 8  JUMPERS J15, J16

Figure 16: Setting the power supply of counting points

Jumpers J1…J16 are located on the main board on the rear side of the BO23-UNUR
indoor unit beneath the ZAG2Z lightning protection module. Figure 17 shows rear view of the
BO23-UNUR subrack with connection marks for transmission pairs to counting points 1…8,
main power supply and ground connection on modules ZAG2Z. Pairs for connecting counting
points BT1, BT2, BT3 and BT4 are connected to X2 and X3 connectors of one ZAG2Z module
(rear side to the right). Pairs for connecting counting points BT5, BT6, BT7 and BT8 are
connected to X2 and X3 connectors of the other ZAG2Z module (rear side to the left). To
access the jumpers J1…J16 for setting the power supply of certain counting point the ZAG2Z
module has to be temporarily removed. Position of jumpers J1…J16 on the main board with
removed ZAG2Z modules is shown on figure 18.

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JUMPER J25 FOR

SETTING THE RESET
MODE

SWITCH SW1 FOR

SETTING THE TRACK GROUND (EARTH)
CONFIGURATION GROUND (EARTH)
F2A BT1-

COUNTING POINTS
TWISTED PAIRS TO
BT1+
LIGHTNING PROTECTION MODULE

F2A
BT2-
(FOR COUNTING POINTS 1...4)

F2A
BT2+

1...4
F2A BT3-
F2A BT3+
ZAG2Z

BT4-
F2A
BT4+
F2A
NAP-

MAIN DC
F2A

POWER
SUPPLY
NAP-
F6.3A
NAP+
F6.3A NAP+

F2A
GROUND (EARTH)
LIGHTNING PROTECTION MODULE

F2A GROUND (EARTH)

(FOR COUNTING POINTS 5...8)

F2A
BT1-

COUNTING POINTS
TWISTED PAIRS TO
F2A BT1+
F2A BT2-
ZAG2Z

BT2+

1...4
F2A
BT3-
F2A BT3+
F2A BT4-
F6.3A
BT4+
F6.3A NAP-
MAIN DC
POWER
SUPPLY

NAP-
NAP+
NAP+
X2

X5

X9
CONNECTOR PLATE
(MODULE KP)

1 1
X4 X7
1

1 1
X3 X6
1

X8
X1

1 X11 1 X12
1

1
X10

Figure 17: Indoor unit BO23-UNUR with connection markings (rear view)
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JUMPER J25 FOR

SETTING THE RESET
MODE

SWITCH SW1 FOR

SETTING THE TRACK
CONFIGURATION
JUMPER J17 FOR SETTING
JUMPERS J1, J2 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 1
COUNTING POINT 1
JUMPER J18 FOR SETTING
JUMPERS J3, J4 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 2
COUNTING POINT 2
JUMPER J19 FOR SETTING
JUMPERS J5, J6 FOR SETTING THE COUNTING DIRECTION
THE POWER SUPPLY OF THE ON COUNTING POINT 3
COUNTING POINT 3
JUMPER J20 FOR SETTING
JUMPERS J7, J8 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 4
COUNTING POINT 4
JUMPER J21 FOR SETTING
JUMPERS J9, J10 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 5
COUNTING POINT 5
JUMPER J22 FOR SETTING
JUMPERS J21, J12 FOR SETTING THE COUNTING DIRECTION
THE POWER SUPPLY OF THE ON COUNTING POINT 6
COUNTING POINT 6
JUMPER J23 FOR SETTING
JUMPERS J13, J14 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 7
COUNTING POINT 7
JUMPER J24 FOR SETTING
JUMPERS J15, J16 FOR SETTING
THE COUNTING DIRECTION
THE POWER SUPPLY OF THE
ON COUNTING POINT 8
COUNTING POINT 8

Figure 18: BO23-UNUR with removed ZAG2Z modules (rear view)

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2.2.11 SETTING THE COUNTING DIRECTION

As shown on figure 18, the jumpers for setting the counting direction for each counting
point are located on the main board at the rear side of the BO23-UNUR subrack, beneath the
ZAG2Z lightning protection module. It is necessary to remove the ZAG2Z to set the counting
direction. Counting direction should be set according to figure 19, depending on the position of
ZK24-2 sensor on track (to which side of the sensor the related section begins). In case the
counting point is not in use it should be terminated with jumpers as on figure 19.

COUNTING-IN COUNTING-IN COUNTING-OUT

1

COUNTING-OUT COUNTING-OUT COUNTING-IN

4

J17

H L H L
SYSTEM SYSTEM SENSOR
3

SENSOR
ZK24-2 ZK24-2
SENSOR ZK24-2
6

L H

COUNTING-OUT COUNTING-OUT COUNTING-IN

1

COUNTING-IN COUNTING-IN COUNTING-OUT

4

J17

H L H L
SYSTEM SYSTEM SENSOR
3

SENSOR
ZK24-2 ZK24-2
SENSOR ZK24-2
6

L H

COUNTING POINT 1  JUMPER J17

1

COUNTING POINT COUNTING POINT 2  JUMPER J18

4

NOT USED COUNTING POINT 3  JUMPER J19

J17

(NO OUTDOOR COUNTING POINT 4  JUMPER J20

EQUIPMENT COUNTING POINT 5  JUMPER J21
3

CONNECTED) COUNTING POINT 6  JUMPER J22

6

COUNTING POINT 7  JUMPER J23

COUNTING POINT 8  JUMPER J24

Figure 19: Setting the counting direction

The rule for setting the counting direction shown on figure 19 applies to all configurations
of the system when the independent sections are controlled; configuration 1 (BO23-8A), 2
(BO23-4A-4B), 3 (BO23-3A-3B-2C), 4 (BO23-2A-2B-2C-2D) and 9 (BO23-3A-2B-2C-2D). On
other configurations where the consecutive sections are also controlled, the rule applies only to
terminal counting points. Each counting point shared by two neighbouring sections in
configuration of single indoor unit BO23-UNUR must simultaneously count-in axles on one
section and count-out for the other section. Therefore the rule from figure 19 can only be
applied to one section, while on the other section the counting direction must be opposite to
figure 19. Table 2 shows sections (one of two neighbouring sections) on which the rule from
figure 19 applies for each counting point on each configuration with consecutive sections of
indoor unit BO23-UNUR.

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Table 2: Setting the counting direction on consecutive section configurations

Counting Counting point / Related section (sections)
direction
Configuration Counting Counting Counting Counting Counting Counting Counting Counting
according
to figure 19 point 1 point 2 point 3 point 4 point 5 point 6 point 7 point 8
5 Correct Section A Section A Section B Section B Section C Section C Section D Section D
3A3B3C2D Opposite - - Section A - Section B - Section C -
6 (2A2B2C- Correct Section A Section B Section B Section C Section D Section E Section E Section F
2D2E2F) Opposite - Section A Section C - - Section D Section F -
7 Correct Section A Section B Section C Section D Section E Section E Section E Section E
2A2B2C2D4E Opposite - Section A Section B Section C Section D - - -
8 Correct Section A Section B Section C Section D Section E Section F Section F Section F
2A2B2C2D2E3F Opposite - Section A Section B Section C Section D Section E - -

If the counting direction is not properly set, this will be clearly visible after passage of the
first train (wrong counting direction on the display) or while simulating the wheel passage on
the field. In that case the jumpers of that counting point must be set to opposite position (figure
19).

2.2.12 SAFETY RELAYS OUTPUT SIGNALS

Relay output signals clear/occupied for each section are formed by two safety relays on
relay output module RE. Up to three RE modules can be inserted into one BO23-UNUR indoor
unit; positions RE1, RE2, RE3 (figure 4). One relay module RE gives relay outputs for 2
sections which are marked as SECTION 1 and SECTION 2 on the front panel of the RE
module. According to the application and configuration of the axle counter that is in use, 1, 2 or
3 RE modules are inserted into BO23-UNUR subrack. Each RE module can use both or only
one relay output (SECTION 1 and/or SECTION 2). Relay outputs on certain position of RE
module are fixed to sections of indoor unit in the following way:

SECTION 1 position RE1 SECTION A

SECTION 2 position RE1 SECTION B

SECTION 1 position RE2 SECTION C

SECTION 2 position RE2 SECTION D

SECTION 1 position RE3 SECTION E

SECTION 2 position RE3 SECTION F

Each section is fixed to one safety relay SECTION CLEAR and one safety relay
SECTION OCCUPIED, and combination of their contacts give final outputs for occupancy /
clearance. Figure 20 shows output contacts of safety relays for occupancy / clearance of the
first three sections (A, B and C) and figure 21 shows output contacts for sections D, E and F,
with connections on the KP module (connection plate) on the rear side of the BO23-UNUR
subrack. The SECTION CLEAR relay status of each section of RE module is indicated by a
green LED (LED lights while the relay is energised), and the SECTION OCCUPIED relay
status of each section is indicated with a red LED on the front panel of the RE module.
The section is clear only when the SECTION CLEAR relay is picked-up and SECTION
OCCUPIED relay is dropped. The section is occupied by at least one axle when the SECTION
OCCUPIED relay is picked-up and SECTION CLEAR relay is dropped.

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Section A Section A
Free Relay Occupied Relay
TCA1 TCA2 TRACK CLEAR CONTACT
X2:15 X2:11
TCA1-TCA2 (SECTION A)
SECTION A SAFETY RELAY Section A Section A
Free Relay Occupied Relay
TCA3 TCA4 TRACK CLEAR CONTACT
X2:13 X5:26
CONTACT OUTPUTS
TCA3-TCA4 (SECTION A)
Section A Section A
Free Relay Occupied Relay
TOA1 TOA2 TRACK OCCUPIED CONTACT
X2:14 X5:18
TOA1-TOA2 (SECTION A)
FRA1 FRA2
X5:16 X5:25 SECTION A FREE RELAY
Section A
CHANGEOVER CONTACT
Free Relay FRA3
X5:17 (AUXILIARY OUTPUT)

OCA2
X5:19 SECTION A OCCUPIED RELAY
Section A
CHANGEOVER CONTACT
OCA1 Occupied Relay OCA3
X5:28 X5:27 (AUXILIARY OUTPUT)

Section B Section B
Free Relay Occupied Relay
TCB1 TCB2 TRACK CLEAR CONTACT
X9:19 X9:13
TCB1-TCB2 (SECTION B)
Section B Section B
SECTION B SAFETY RELAY

Free Relay Occupied Relay

TCB3 TCB4 TRACK CLEAR CONTACT
X9:17 X9:16
CONTACT OUTPUTS

TCB3-TCB4 (SECTION B)
Section B Section B
Free Relay Occupied Relay
TOB1 TOB2 TRACK OCCUPIED CONTACT
X9:20 X9:6
TOB1-TOB2 (SECTION B)
FRB1 FRB2
X9:18 X5:22 SECTION B FREE RELAY
Section B
CHANGEOVER CONTACT
Free Relay FRB3
X5:23 (AUXILIARY OUTPUT)

OCB2
X5:14 SECTION B OCCUPIED RELAY
Section B
CHANGEOVER CONTACT
OCB1 Occupied Relay OCB3
X5:15 X5:24 (AUXILIARY OUTPUT)

Section C Section C
Free Relay Occupied Relay
TCC1 TCC2 TRACK CLEAR CONTACT
X2:1 X1:5
TCC1-TCC2 (SECTION C)
Section C Section C
SECTION C SAFETY RELAY

Free Relay Occupied Relay

TCC3 TCC4 TRACK CLEAR CONTACT
X1:7 X5:12
CONTACT OUTPUTS

TCC3-TCC4 (SECTION C)
Section C Section C
Free Relay Occupied Relay
TOC1 TOC2 TRACK OCCUPIED CONTACT
X1:10 X5:3
TOC1-TOC2 (SECTION C)
FRC1 FRC2
X5:1 X5:11 SECTION C FREE RELAY
Section C
CHANGEOVER CONTACT
Free Relay FRC3
X5:2 (AUXILIARY OUTPUT)

OCC2
X1:8 SECTION C OCCUPIED RELAY
Section C
CHANGEOVER CONTACT
OCC1 Occupied Relay OCC3
X1:9 X5:13 (AUXILIARY OUTPUT)

AXLE COUNTER BO23-UNUR

Connector Plate KP (rear side)

Figure 20: Output contacts of FREE and OCCUPIED relays for sections A, B and C

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Section D Section D
Free Relay Occupied Relay
TCD1 TCD2 TRACK CLEAR CONTACT
X9:4 X8:8
TCD1-TCD2 (SECTION D)
SECTION D SAFETY RELAY Section D Section D
Free Relay Occupied Relay
TCD3 TCD4 TRACK CLEAR CONTACT
X9:2 X9:1
CONTACT OUTPUTS
TCD3-TCD4 (SECTION D)
Section D Section D
Free Relay Occupied Relay
TOD1 TOD2 TRACK OCCUPIED CONTACT
X9:5 X8:1
TOD1-TOD2 (SECTION D)
FRD1 FRD2
X9:3 X5:8 SECTION D FREE RELAY
Section D
CHANGEOVER CONTACT
Free Relay FRD3
X5:9 (AUXILIARY OUTPUT)

OCD2
X5:4 SECTION D OCCUPIED RELAY
Section D
CHANGEOVER CONTACT
OCD1 Occupied Relay OCD3
X5:5 X5:10 (AUXILIARY OUTPUT)

Section E Section E
Free Relay Occupied Relay
TCE1 TCE2 TRACK CLEAR CONTACT
X4:6 X3:5
TCE1-TCE2 (SECTION E)
Section E Section E
SECTION E SAFETY RELAY

Free Relay Occupied Relay

TCE3 TCE4 TRACK CLEAR CONTACT
X3:7 X4:10
CONTACT OUTPUTS

TCE3-TCE4 (SECTION E)
Section E Section E
Free Relay Occupied Relay
TOE1 TOE2 TRACK OCCUPIED CONTACT
X4:7 X3:9
TOE1-TOE2 (SECTION E)
FRE1 FRE2
X3:11 X4:11 SECTION E FREE RELAY
Section E
CHANGEOVER CONTACT
Free Relay FRE3
X3:10 (AUXILIARY OUTPUT)

OCE2
X3:8 SECTION E OCCUPIED RELAY
Section E
CHANGEOVER CONTACT
OCE1 Occupied Relay OCE3
X4:8 X4:9 (AUXILIARY OUTPUT)

Section F Section F
Free Relay Occupied Relay
TCF1 TCF2 TRACK CLEAR CONTACT
X7:12 X7:6
TCF1-TCF2 (SECTION F)
Section F Section F
SECTION F SAFETY RELAY

Free Relay Occupied Relay

TCF3 TCF4 TRACK CLEAR CONTACT
X7:10 X7:9
CONTACT OUTPUTS

TCF3-TCF4 (SECTION F)
Section F Section F
Free Relay Occupied Relay
TOF1 TOF2 TRACK OCCUPIED CONTACT
X7:13 X6:9
TOF1-TOF2 (SECTION F)
FRF1 FRF2
X7:11 X7:3 SECTION F FREE RELAY
Section F
CHANGEOVER CONTACT
Free Relay FRF3
X7:2 (AUXILIARY OUTPUT)

OCF2
X6:1 SECTION F OCCUPIED RELAY
Section F
CHANGEOVER CONTACT
OCF1 Occupied Relay OCF3
X6:2 X7:1 (AUXILIARY OUTPUT)

AXLE COUNTER BO23-UNUR

Connector Plate KP (rear side)

Figure 21: Output contacts for FREE and OCCUPIED relays for sections D, E and F

In normal operation, the axle counter can shortly be in a transition phase when both
SECTION CLEAR and SECTION OCCUPIED relays are dropped; this happens when the first
axle of train enters the section, or when the last axle of train leaves the section. Though it is
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possible for this phase to last longer in case the train stops with its first or last axle in the area
above the sensor, the maximal transition phase time (both relays dropped) can be calculated
when using a minimal train speed of 1km/h:

Transition phase when the first axle enters the section <0.5 seconds
Transition phase when the last axle exits the section <0.5 seconds

Some types of disturbances or errors can also lead to condition with both output relays
dropped; the more often case is to have a short disturbance that can be cleared by resetting
the section. The status with both SECTION CLEAR and SECTION OCCUPIED relays picked-
up is possible only in case of a major failure.
Because of mechanical sloth of the relays and time necessary to process the signal in the
microprocessor module MPU, there is a small delay in occupying the section after the first axle
enters the section, or delay in clearing when the last axle exits the section. The maximal delays
are as follows:

Delay in occupying the section after physical occupation <100ms

Delay in clearing the section after physical clearing <100ms

The exception of this is section D in configuration 9 (BO23-3A-2B-2C-2D) because the

information about one of its counting points is transferred via serial connection RS232 over
modem or optical cable from another indoor unit. The maximal delay for section D in
configuration 9 is as follows:

Delay in occupying the section after physical occupation <1s

Delay in clearing the section after physical clearing <2s.

2.2.13 CONNECTION OF RELAY OUTPUTS TO DIFFERENT SIGNALLING SYSTEMS

Figure 22 shows the connection of safety relay output contacts for "track clear" and „track
occupied" information of section (A) with three types of station interlocking or automatic block
systems. The first case on figure 22 is a typical connection to relay signalling system that
usually contains two repeating relays, one for section clear and the other for section occupied.
For additional safety, it is recommended to connect both positive and negative pole of
repeating relay coil power supply over the " track clear" and " track occupied" output contacts
of BO23 axle counter (as on figure 22).
On microprocessor interlocking systems, two digital inputs are always used; separate
input for "track clear" and separate for "track occupied" signal for each section. With regards to
additional safety advantages that microprocessor signalling systems usually have (e.g. current
control on digital inputs with small tolerances) it is enough to connect only one branch with
"section free" and "section occupied" relay contacts that are closed in basic state (no train) to
the "track clear" digital input, and one branch with "section free" and "section occupied" relay
contacts that are open in basic state to the "track occupied" digital input, as in example 2 on
figure 22. There are also signalling systems that send coded signal to output contacts of the
axle counter and receive it back on their antiparalel optocoutpler digital inputs. In that case the
"track clear" and "track occupied" outputs of the BO23 axle counter should be connected as in
example 3 on figure 22. The level crossings systems are also connected to the axle counter
BO23 relay outputs as in one of these three examples.

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RELAY INTERLOCKING
Section A Section A OR AUTOMATIC BLOCK
Free Relay Occupied Relay
TCA1 TCA2 EQUIPMENT
+
X2:15 X2:11
Interlocking Section A Section A Track clear
power supply Free Relay Occupied Relay relay
TCA3 TCA4
-
X2:13 X5:26
Section A Section A
Free Relay Occupied Relay
TOA1 TOA2
X2:14 X5:18
Track occupied
AXLE COUNTER BO23-UNUR relay
Connector plate KP (rear side)
Section A relay output contacts

MICROPROCESSOR
Section A Section A INTERLOCKING OR
Free Relay Occupied Relay
TCA1 TCA2 BLOCK EQUIPMENT
+
X2:15 X2:11 Track
Interlocking
Clear
power supply
digital
- input
Section A Section A
Free Relay Occupied Relay
TOA1 TOA2
X2:14 X5:18 Track
AXLE COUNTER BO23-UNUR Occupied
Connector plate KP (rear side) digital
Section A relay output contacts input

MICROPROCESSOR
FRA1 FRA2 INTERLOCKING OR
X5:16 Section A X5:25 BLOCK EQUIPMENT
Free Relay FRA3
X5:17 Coded signal
OCA2 output
Section A X5:19
OCA1 Occupied Relay OCA3
X5:28 X5:27
AXLE COUNTER BO23-UNUR Track Track
Coded signal

Connector plate KP (rear side) Occupied Clear

input

Section A relay output contacts

Figure 22: Connection of clear / occupied relay outputs on 3 types of signalling systems

2.2.14 RESETTING THE SECTION

Figures 6, 17 and 18 shows position of J25 jumper for setting the section reset mode on
the main board on the rear side of the BO23-UNUR indoor unit. There are two possible reset
modes:

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A. Immediate (or direct) section reset – for this mode of reset the jumper J25 on the rear
side of the BO23-UNUR must be closed on pins 1 and 2 (figure 6).
Applying the voltage on reset inputs or pressing the indented RESET button on the front
panel of RE module will clear the section in about 1s in case all the conditions for clearing
the section are met. In this case the personnel resetting the section must be
absolutely sure that there is no train on the section (according to railway
regulations).
B. Preparatory section reset– for this mode of reset the jumper J25 on the rear side of the
BO23-UNUR must be closed on pins 2 and 3 (figure 6).
Applying the voltage on reset inputs or pressing the indented RESET button on the front
panel of RE module will reset the number of axles on the section to zero, SECTION
OCCUPIED relay will drop (in case it was picked-up), but the SECTION CLEAR relay will
not jet pick-up; the section will not be clear until the next train occupies the section by
regular counting-in of the axles and leaves the section by regular counting-out ("sweep
train"). Only after this procedure the section will become clear, i.e. the SECTION CLEAR
relay will pick-up.

Regarding different regulations of railways worldwide, the MPU module can be delivered
in two different options (different software versions) of “immediate/direct” reset mode:
 Clearing the section immediately after giving the reset command (if all parts of the system
operate correctly and all of the wheel sensors are in the basic state) – this option of
“immediate/direct” reset mode is delivered as default option
 Clearing the section immediately after giving the reset command, but only in case the last
axle counting action on any counting point of the section was not counting-in (train
entrance) – this option of “immediate/direct” reset mode is delivered on demand; it is
necessary to contact the manufacturer for delivery of different software version of MPU
module.

Each section contains two digital inputs for reset: single reset RSTS and common reset
RSTT, as it is shown on figures 23 and 24. For each reset digital input there is a rule that it will
be activated in case there is a voltage higher than 14V DC connected between + and –
terminals (for example RSTSA+, RSTSA-) and will be deactivated in case the voltage is lower
than 4V DC. So, there is a hysteresis between 4…14V, which reduces the influence of EMC
disturbances on reset inputs activation. The main condition for section reset is that both
RSTS and RSTT must be activated simultaneously and that the time period of activation
of both inputs is greater than 100ms. When the station interlocking or automatic block
system resets the section, the section reset pulse duration must be taken care of in the
following way:

Duration of active state of RSTS reset input: 100ms < RSTS < 5s
Duration of active state of RSTT reset input: 100ms < RSTT < 5s
Time period while both RSTS and RSTT inputs are active: min. 100ms

If the immediate reset mode is set on main board of the indoor unit, the section will
become clear when both RSTS and RSTT inputs deactivate (<4V), after both of them have
been active for at least 100ms simultaneously. To reduce the EMC influences, each reset
pulse (RSTS, RSTT) must last for at least 100ms continuously; i.e. if the section is reset
directly by the push buttons on the command table, each button must be pressed for at least
0.1s. Basically, there is no maximal limit for duration of pressing the push button, the buttons
can be pressed longer than 5 seconds, and the section will clear only after both buttons are
released.

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SINGLE RESET Section A Section A

DIGITAL INPUT
RSTSA+

(SECTION A)
X2:20 Occupied Relay Reset Relay RSTZA1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Section A
Logic high >14V X2:17

Free Relay

SECTION A RESET RELAY

Section A
Logic low <4V

RSTSA- RSTZA2
X2:7 X2:12
RSTRA1
COMMON RESET

X2:9
DIGITAL INPUT

RSTTA+ Section A
(SECTION A)

X2:19 RSTRA2
Reset Relay
Logic high >14V X2:18
Logic low <4V
RSTMA1
RSTTA- X2:16
Section A
X2:8 RSTMA2
Reset Relay
X2:10
SINGLE RESET

Section B Section B
DIGITAL INPUT

RSTSB+
(SECTION B)

X5:20 Occupied Relay Reset Relay RSTZB1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Logic high >14V Section B X9:12

Free Relay

SECTION B RESET RELAY

Section B
Logic low <4V

RSTSB- RSTZB2
X9:10 X9:14
RSTRB1
COMMON RESET

X9:15
DIGITAL INPUT

RSTTB+ Section B
(SECTION B)

X9:11 RSTRB2
Reset Relay
Logic high >14V X9:7
Logic low <4V
RSTMB1
RSTTB- X9:9
Section B
X5:21 RSTMB2
Reset Relay
X9:8
SINGLE RESET

Section C Section C
DIGITAL INPUT

RSTSC+
(SECTION C)

X2:6 Occupied Relay Reset Relay RSTZC1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Section C

Logic high >14V X2:3

Free Relay

SECTION C RESET RELAY

Section C

Logic low <4V

RSTSC- RSTZC2
X1:1 X1:6
RSTRC1
COMMON RESET

X1:3
DIGITAL INPUT

RSTTC+
(SECTION C)

Section C
X2:5 RSTRC2
Reset Relay
Logic high >14V X2:4
Logic low <4V
RSTMC1
RSTTC- X2:2
Section C
X1:2 RSTMC2
Reset Relay
X1:4

AXLE COUNTER BO23-UNUR

Connector Plate KP (rear side)

Figure 23: Digital inputs for reset of sections A, B and C on BO23-UNUR indoor unit

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SINGLE RESET Section D Section D

DIGITAL INPUT
RSTSD+

(SECTION D)
X5:6 Occupied Relay Reset Relay RSTZD1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Section D
Logic high >14V X8:7

Free Relay

SECTION D RESET RELAY

Section D
Logic low <4V

RSTSD- RSTZD2
X8:5 X8:9
RSTRD1
COMMON RESET

X8:10
DIGITAL INPUT

RSTTD+
(SECTION D)

Section D
X8:6 RSTRD2
Reset Relay
Logic high >14V X8:2
Logic low <4V
RSTMD1
RSTTD- X8:4
Section D
X5:7 RSTMD2
Reset Relay
X8:3
SINGLE RESET

Section E Section E
DIGITAL INPUT

RSTSE+
(SECTION E)

X4:1 Occupied Relay Reset Relay RSTZE1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Logic high >14V Section E X4:4

Free Relay

SECTION E RESET RELAY

Section E
Logic low <4V

RSTSE- RSTZE2
X3:1 X3:6
RSTRE1
COMMON RESET

X3:3
DIGITAL INPUT

RSTTE+ Section E
(SECTION E)

X4:2 RSTRE2
Reset Relay
Logic high >14V X4:3
Logic low <4V
RSTME1
RSTTE- X4:5
Section E
X3:2 RSTME2
Reset Relay
X3:4
SINGLE RESET

Section F Section F
DIGITAL INPUT

RSTSF+
(SECTION F)

X7:5 Occupied Relay Reset Relay RSTZF1

Reset Relay

AUXILIARY OUTPUT CONTACTS

Section F

Logic high >14V X6:3

Free Relay

SECTION F RESET RELAY

Section F

Logic low <4V

RSTSF- RSTZF2
X6:5 X7:7
RSTRF1
COMMON RESET

X7:8
DIGITAL INPUT

RSTTF+
Section F
(SECTION F)

X6:4 RSTRF2
Reset Relay
Logic high >14V X6:8
Logic low <4V
RSTMF1
RSTTF- X6:6
Section F
X7:4 RSTMF2
Reset Relay
X6:7

AXLE COUNTER BO23-UNUR

Connector Plate KP (rear side)

Figure 24: Digital inputs for reset of sections D, E and F on BO23-UNUR indoor unit

Nevertheless, it is recommended for each reset input to always be active in period shorter
than 5s, because in the operating software there is a safety action for cases when there is a
failure in station interlocking or automatic block system and >14V appears continuously on
certain reset input. In these cases, the possibility of accidental section reset is much higher

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because accidental pressing of only one pushbutton (instead of two) can reset the section.
Because of that, in cases when only one reset input is active the axle counter BO23 runs the
following safety actions:

- If RSTS is not active and only RSTT is activated for longer than 5s: section remains clear if
it was clear, but further clearing once it is occupied or it was occupied is disabled
- If RSTT is not active and only RSTS is activated (longer than 100ms): the section remains
clear if it was clear, but further clearing once it is occupied or it was occupied is disabled

The common reset input RSTT of each section can be connected in parallel to one
common reset output from the station interlocking, while the single reset input RSTS must
always be controlled by the separate reset output for each section from the station interlocking.
Activation of single reset input RSTS on relay output module RE activates the safety relay
SECTION RESET (figures 23 and 24) that has a yellow state indication LED on the front panel
of the RE module. Auxiliary outputs of the SECTION RESET relay, combined with auxiliary
outputs of SECTION FREE and SECTION OCCUPIED relays can be used in safety circuit for
section reset by station interlocking.
Figure 25 shows the example of connecting section reset digital outputs of a high safety
level microprocessor signalling system to the axle counter BO23. This type of signalling system
continuously monitors status of its digital outputs and there is no possibility to have
simultaneous activation of two single reset outputs for different sections. Therefore, a
connection schematic diagram is rather simple; common reset output is connected in parallel
to all inputs for common reset RSTT on axle counters and single reset output for each section
is connected to single reset input RSTS of the section on the axle counter. In case a
preparatory reset is required for the station or automatic block, it is not necessary to connect a
common reset output, but only single reset output to single reset input RSTS of the proper
section on the axle counter (as on figure 25) and the common reset input RSTT is for each
section connected in parallel to single reset input RSTS (for example for section A: RSTSA+ is
connected to RSTTA+ and RSTSA- is connected to RSTTA-).
Figure 26 shows an example of fail-safe connection of reset pushbuttons form the control
table in station. Relay station interlocking systems mostly use common and single pushbutton
for section reset. Sometimes relay interlocking systems have a special relay group for reset by
pushbuttons, mostly designed for particular type of axle counter, i.e. for defined impedance on
the reset input of the axle counter. The logic of such relay group is similar to logic in schematic
diagram on figure 26. The main purpose of such connection is to disable the reset by
accidental pressing of only one push button, to disable accidental reset of two sections when
two single reset buttons and common reset button are pressed simultaneously, and to disable
reset of any section in case of permanent short-connection (failure) on each push button.

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Fail-safe control of
the digital output

SAFETY DIGITAL OUTPUTS OF MICROPROCESSOR INTERLOCKING FOR RESETTING THE SECTIONS

RSTTA+
X2:19
Common reset DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION A
Fail-safe control of RSTTA-
the digital output X2:8
RSTSA+
X2:20
Single reset of the DIGITAL INPUT FOR
certain section (A) SINGLE RESET OF
THE SECTION A
RSTSA-
X2:7

RSTTB+
X9:11
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION B
Fail-safe control of RSTTB-
the digital output X5:21
RSTSB+
X5:20
Single reset of the DIGITAL INPUT FOR
certain section (B) SINGLE RESET OF
THE SECTION B
RSTSB-
X9:10

RSTTC+
X2:6
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION C
Fail-safe control of RSTTC-
the digital output X1:1
RSTSC+
X2:5
Single reset of the DIGITAL INPUT FOR
certain section(C) SINGLE RESET OF
THE SECTION C
RSTSC-
X1:2

INDOOR EQUIPMENT UNUR

OF AXLE COUNTER BO23
+ -
Internal DC power 14V...80V Connector plate KP

Figure 25: Example of connection of reset outputs from microprocessor interlocking

The axle counter BO23 in its operating software already has safety action (section clearing
disable) in case of permanent voltage on any reset input, so there is no need for additional
(external) protection in case of permanent short-connection on the common reset pushbutton.
The R1 and R2 (figure 26) can be calculated with regards to power supply voltage, input
resistance of digital inputs for single reset and the fact that the digital input is activated in case
of voltage >14V and deactivated in case of voltage <4V.

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Electromechanical counter
of the reset pulses Common RSTTA+
+ reset X2:19
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION A
Common
push button Minus pole RSTTA-
for section of power supply X2:8
DIGITAL INPUT FOR SINGLE RESET
reset Single RSTSA+ OF THE SECTION A
reset (A) X2:20

Reset Relay
OPERATOR'S CONTROL DESK IN THE STATION (MAY BE PART OF THE RELAY INTERLOCKING)

Section A
Single push
button for
certain
section RSTSA-
reset (A) X2:7
Section A Section A
Reset Relay Occupied Relay
RSTZA1
X2:17

Free Relay
Section A
RSTZA2
X2:12
Plus pole RSTMA1
of power X2:16 Section A
R1 Reset Relay
RSTMA2
X2:10
R2
RSTTB+
X9:11
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION B
RSTTB-
X5:21
DIGITAL INPUT FOR SINGLE RESET
Single RSTSB+ OF THE SECTION B
reset (B) X5:20

Reset Relay
Section B
Single push
button for
certain
section RSTSB-
reset (B) X9:10
Section B Section B
Reset Relay Occupied Relay
RSTZB1
X9:12 Free Relay
Section B

RSTZB2
X9:14
RSTMB1
X9:9 Section B
RSTMB2 Reset Relay
X9:8
+ -
INDOOR EQUIPMENT UNUR
Main DC
power supply
OF AXLE COUNTER BO23
+ -
Connector plate KP

Figure 26: Example of safety connection of reset push buttons on the control desk

Calculated values of the R1 and R2 resistors are for example in case of 60V DC power
supply +20% / -10%:

- For power supply 60V DC +20% / -10%: R1=39kΩ, 0.25W R2=11kΩ, 0.25W

For application of connection as on figure 26 with some other DC power supply voltages
contact manufacturer for calculation of R1 and R2 resistor values.

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2.2.15 CONNECTING SEVERAL INDOOR UNITS IN RELAY ROOM FOR STATION

SECTIONS CONTROL

In case the BO23-UNUR indoor units for controlling the whole station (or part of a
station / automatic block) are located in the same relay room (if possible on the same
chassis/rack), connection to outdoor devices can be optimised to use less telecommunication
pairs and minimal number of UP modules. Sometimes number of power supply DC12 module
can also be reduced. The number of receiving UP modules should not be greater than the
number of counting points, as shown on figure 27. Each counting point (control unit BO23-VUR
with ZK24-2 rail wheel sensor) is connected to relay room using only one 2-wire twisted pair,
no matter if it belongs to only one section (terminal counting point) or two neighbouring
sections.
VUR ZK
2 VUR
K3 4-
2 4
4
2
2 4-
ZK

K2A S1 S2 K2 S3 S4 K2B
ZK24-2 ZK24-2 ZK24-2 ZK24-2 ZK24-2 ZK24-2 ZK24-2 ZK24-2
4 4 4 ZK 4 4 ZK24-2 4 4 4
2 4-
VUR VUR VUR 2 VUR VUR 4 VUR VUR VUR
K1 VUR K1B
4
VUR
ZK24-2 S5 ZK24-2
4 4
VUR VUR

2 2 2 2 2 2 2 2 2 2 2 2 2 2

BT1 BT3 BT4 BT5 BT6 BT7 BT8 BT3 BT5 BT7 BT8 BT2 BT3 BT8
GLAVNO DC
NAPAJANJE

U+ U+
+ NAP+ BO23-UNUR FOR CONTROL OF NAP+ BO23-UNUR FOR CONTROL OF U- U- BO23-UNUR FOR CONTROL OF
SECTIONS K2A,S1,S2,K1 SECTIONS K2,S3,S4,K2B +12V +12V SECTIONS S5,K1B,K3
- NAP- CONFIGURATION: 5 (BO23-3A3B3C2D) 0V NAP- CONFIGURATION: 5 (BO23-3A3B3C2D) 0V 0V CONFIGURATION: 3 (BO23-3A-3B-2C)
H4 L4 H6 L6 H8 L8 H1 L1 H4 L4 H6 L6 -12V -12V H1 L1 H2 L2 H3 L3 H4 L4 H7 L7 H8 L8

2
2
2 2
2

STATION RELAY ROOM

Figure 27: Example of optimal connection of axle counters BO23 for small station control

When counting point (ZK24-2 + BO23-VUR) belongs to two neighbouring sections there
are three possible cases: when the indoor unit BO23-UNUR is set to one of the configurations
for controlling consecutive sections and both neighbouring sections are controlled by the same
indoor unit BO23-UNUR (for example K2A and S1), when one section belongs to one indoor
unit and the other section to another indoor unit (such as S2 and K2), and the case when the
indoor unit is set to one of the configurations for controlling independent sections and both
neighbouring sections are controlled by the same indoor unit (such as S5 and K1B). In last two
cases it is necessary to connect auxiliary outputs H and L from receiving UP module of certain
counting point to auxiliary inputs H and L of counting point that belongs to neighbouring section
on the same or different indoor unit (figure 27) and not to insert the UP module of this counting
point. Length of wires used for this interconnection should not be more than 15m.
Terminals of the auxiliary inputs/outputs H and L on connection plate KP on the rear side of the
indoor unit are shown on figure 28. In case input module UP is inserted into position for certain
counting point (for example UP3), belonging terminals H and L (H3, L3) on connector plate KP
are used exclusively as output (for sending signal to neighbouring section) and in case when
input module UP is not inserted into position, belonging terminals H and L (H3, L3) on
connector plate KP are used exclusively as inputs (for receiving signal from neighbouring
section). In case signals H and L are connected from one indoor unit to another, 0V potential of
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their internal power supplies must also be connected together (terminals X11:5 on connector
plates KP) as on figure 27.
In case the rack of the BO23-UNUR indoor unit contains relatively small number of
inserted UP and RE modules, the internal system power supply can be connected from
another indoor unit with also relatively small number of modules. Internal system power supply
±12V (X11:3, X11:4, X11:5 on KP) and filtered main power supply U+, U- (X11:2, X11:1 on KP)
should be connected in this case (figure 27). In this case module DC12 is not inserted in one of
these two subracks. Total number of all UP and RE modules should not be greater than 11
when connecting the internal system power supply from one subrack to another.

2.2.16 AUXILIARY INPUTS/OUTPUTS OF BO23-UNUR INDOOR UNIT

Terminal list on the connector plate KP of outputs H1…H8 and L1…L8 from receiving
UP modules, that are also inputs for the MPU microprocessor module when the UP module of
a certain counting point is not inserted, is shown on figure 28. Terminals for internal system
power supply ±12V and filtered main DC power supply U+, U- that can be used for
interconnection to another indoor unit BO23-UNUR are also shown. Some terminals on the
X11 and X2 connectors of the connector plate KP are short-connected together (figure 28) and
can be used as auxiliary terminals for the interconnecting purposes.
Each counting point has one auxiliary optocoupler digital output that gives a 3 seconds
pulse only in one direction of the train passage over the counting point (outputs DIR1+, DIR1-,
DIR2+, DIR2-, … DIR8+, DIR8- on figure 28). Output transistor of the optocoupler on these
outputs is in the basic state open (switched-off). The transistor is switching-on (closing /
saturation) only when the wheel is exiting the section over the counting point and remains
closed for 3 seconds, i.e. it gives the 3-seconds pulse when the wheel is moving out from the
section. When the wheel is moving into the section (opposite direction, entering the section)
the optocoupler output DIRx will remain in the basic state (output transistor open), i.e. will not
give the 3-seconds pulse, as shown on the figure 28. When more than one wheel/axle is
exiting the section in less than 3 seconds between two axle passage the optocoupler output
DIRx will be activated (closed) during the exit of the whole train plus 3 seconds after the last
axle. On counting points that are common for two neighbouring sections, this rule applies to
section in which the counting direction is correct according to table 2. The maximal current on
optocoupler transistor is 50mA DC and overvoltage protection elements must be used
(such as reverse diode in parallel to relay coil) when inductive loads are connected to
direction outputs DIR1…DIR8.
Figure 28 also shows 6 auxiliary optocoupler digital inputs ENFRA*…ENFRF*, one per
each section (A…F), that are used to disable picking-up of the SECTION FREE relay. When
there is no voltage on the input ENFR* (<5V) the relay output SECTION FREE operates
normally. When the voltage on ENFR* is 18V…32V DC towards ENFR-, relay SECTION FREE
is disabled to pick-up. The maximal voltage permanently connected to ENFRA*…ENFRF*
inputs is 32V DC.

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RECEIVED SIGNALS H, L FROM THE COUNTING POINT

X10:1 H1 Counting DIR1+

PASSAGE (3 SEC. PULSE ONLY AT EXIT FROM SECTION)

INPUTS/OUTPUTS FOR THE INTERCONNECTION OF
Direction on X10:32
X10:2 L1 point 1 counting DIR1-

OUTPUTS FOR MOVEMENT DIRECTION OF TRAIN

point 1 X10:31

X10:3 H2 Counting DIR2+

Direction on X10:30
X10:4 L2 point 2 counting DIR2-
point 2 X10:29

X10:5 H3 Counting DIR3+

Direction on X10:28
X10:6 L3 point 3 counting DIR3-
point 3 X10:27

X10:7 H4 Counting DIR4+

Direction on X10:26
X10:8 L4 point 4 counting DIR4-
point 4 X10:25

X10:9 H5 Counting DIR5+

Direction on X10:24
X10:10 L5 point 5 counting DIR5-
point 5 X10:23

X10:11 H6 Counting DIR6+

Direction on X10:22
X10:12 L6 point 6 counting DIR6-
point 6 X10:21

X10:13 H7 Counting DIR7+

Direction on X10:20
X10:14 L7 point 7 counting DIR7-
point 7 X10:19

X10:15 H8 Counting DIR8+

Direction on X10:18
X10:16 L8 point 8 counting DIR8-
point 8 X10:17
(activation: min. 18V, max. 32V DC towards ENFR-)

ENFRA*
AUXILIARY INPUTS FOR TRACK CLEARANCE

X10:39 U+ X11:2
FILTERED MAIN
Section A
clearance DC POWER
U- X11:1
SUPPLY
disabling
ENFRB*
X10:38 Section B +12V X11:3 INTERNAL
clearance SYSTEM
0V X11:5
disabling POWER
ENFRC* -12V X11:4 SUPPLY
X10:37 Section C
DISABLING

clearance X11:6

TERMINALS FOR AUXILIARY

disabling
ENFRD* X11:7

SHORT-CONNECTED

INTERCONNECTION
X10:36 Section D X11:8
clearance X12:1
disabling
ENFRE* X12:2
X10:35 Section E X12:3
clearance X12:4
disabling
ENFRF* X12:5
X10:34 Section F X12:6
clearance X12:7
ENFR- disabling
X10:33 X12:8

AXLE COUNTER BO23-UNUR

Connector plate KP (rear side)

WHEEL EXITING WHEEL ENTERING

WHEEL WHEEL
THE SECTION OVER THE SECTION OVER
COUNTING POINT X COUNTING POINT X
SECTION SECTION

H L H L

+12V +12V
Output Hx SEVERAL Output Hx SEVERAL
towards X11:5 MILLISEC. towards X11:5 MILLISEC.
0V 0V
+12V +12V
Output Lx SEVERAL Output Lx SEVERAL
towards X11:5 MILLISEC. towards X11:5 MILLISEC.
0V 0V

CLOSED CLOSED
Optocoupler Optocoupler
3 SECONDS
output DIRx output DIRx
OPEN OPEN

Figure 28: Auxiliary inputs/outputs of the BO23-UNUR indoor unit

2.2.17 INDICATORS ON THE BO23-UNUR FRONT PANELS

Figure 4 is a front view of the BO23-UNUR indoor unit that shows all indicators (display,
LEDs) on front panels of modules with matching indication colours. Table 3 explains the
meaning of each LED indication.

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Table 3: Meaning of each LED indication on the BO23-UNUR indoor unit

LED Meaning of indication
Module designation /
colour ON OFF Blinking
SECTION Direction of the last train movement over Direction of the last train
ENTRANCE / the counting point was entrance (toward movement over the counting point -
yellow the section). was exit (from the section).
Pulses on at least one of the sensors or
DISTURBANCE transmission lines on the section that are No disturbance on the outdoor
-
/ red not evaluated as a wheel (such as pulse units of certain section.
on only one sensor sensing system).
Error in axle counting on the section
MPU ERROR / red (negative axle number or >999). LED is No error in axle counting. -
off only after section reset.
Different status on one of three vital Communication with distant
microcontrollers in stationary state or indoor unit disconnected
error on one of microcontrollers. If all All three vital microcontrollers work (MPU LINK – cable
FAILURE / red microcontrollers are correct and one has properly and have the same data disconnected, error on
different data status LED goes off after status in stationary state. modem…).
reset of section(s) with different data Indication possible only on
status. configuration 9.
Sensor sensing system H or L activated Rectified input signal of sensing
Train passing over the H or
ACTIVE (H, L) by the wheel, or has dropped-away, or systems H and L from the counting
L sensing system on the
/ red rectified input signal is <3.3V or >8V, or point is >3.3V (with hysteresis
counting point.
outdoor unit / UP module failure. >1.8V) and <8V DC.
UP Rectified input signal of sensing
Rectified input signal of sensing systems Train passing over the H or
READY (H, L) systems H or L from the counting
H or L from the counting point is within L sensing system on the
/ green point is out of the range 4V…6V
allowed range 4V…6V DC. counting point.
DC.
Output safety relay SECTION CLEAR of
SECTION (1 the section 1 or 2 on relay module is Output safety relay SECTION
or 2) CLEAR / picked-up (section A or B on RE1, CLEAR of the section 1 or 2 on
green section C or D on RE2, section E or F on relay module is dropped.
RE3).
SECTION (1 Output safety relay SECTION
RE or 2) OCCUPIED of the section 1 or 2 on Output safety relay SECTION
relay module is picked-up (section A or OCCUPIED of the section 1 or 2
OCCUPIED / B on RE1, section C or D on RE2, on relay module is dropped.
red section E or F on RE3).
Safety relay RESET on single
RESET (1 or Safety relay RESET on single reset input
reset input for section 1 or 2 is
2) / yellow for section 1 or 2 is picked-up.
dropped.
POWER / Main DC power supply within normal Main DC power supply outside
yellow range 18V…80V DC. normal range 18V…80V DC.
ZANAP Internal system power supply +12V DC Failure on internal system power
+12V / yellow within normal range supply +12V DC.
Internal system power supply -12V DC Failure on internal system power
-12V / yellow within normal range supply -12V DC.
DC/DC converter main-to-internal power Failure on BO23-UNUR power
DC12 ON / yellow supply (module DC12) works properly. supply or no power supply.

The MPU module display shows current number of axles on section chosen with the
SECTION push button (default: section A). By pressing the SECTION button, the display
shows letter (A…F) of the section currently being displayed on the display and LEDs SECTION
ENTRANCE, DISTURBANCE and ERROR. If the SECTION button is pressed and hold longer
than 2 seconds, indication switches to next section alphabetically (after section F comes
section A), depending on configuration set by the SW1 switch on the main board (for example
on configuration BO23-4A-4B only sections A and B can be displayed). Pressing the
COUNTING POINT push button, the display shows counting point of the section that was last
passed by the train. Pressing the LED TEST, all LED segments of the display and all LEDs on
the MPU module turn on.

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3. INSTALLATION MANUAL
3.1 MOUNTING OF THE WHEEL SENSOR ZK24-2 ON THE TRACK

3.1.1 SENSOR MOUNTING LOCATION

Wheel sensor ZK24-2 positioned on the curved part of the track should always be
mounted on the inner rail of the curve. On the straight part of the track, sensor can be
mounted on any of the rails.
Following instruction is valid for all types of clamp mounting brackets (depending on the
type of the track on which the wheel sensor is mounted).
3.1.2 TOOLS
- Torque wrench [100 Nm] with 24mm socket
- 30mm socket for torque wrench (if shields are also mounted)
- Plastic template for sensor position setting
- Vernier caliper

3.1.3 MOUNTING, SETTING THE HEIGHT AND SIDE DISTANCE OF THE SENSOR WITH
CLAMP BRACKET
1. Release the nut pos. 1 (figure 29) that comes to the outer side of rail (the opposite side
from sensor) and put the clamp on the rail foot in the way that sensor comes on the inner
side of the rail.
Pull the clamp bracket with sensor along the rail to get it in a symmetrical position between
two sleepers, make sure that sensor is parallel to the rail and tighten the nut pos. 1 using
the 24mm socket up to the torque of 100 Nm. If the sensor has to be mounted on the rail
profile smaller than UIC60 (i.e. UIC54, S49, etc.), 24mm spacer has to be put before the
nut and spring washer. If the sensor has to be mounted on the rail type UIC60 or similar
profile, 24mm spacer has to be removed.

Figure 29: Position of sensor on the rail

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2. Release the nut pos. 2 on the bracket and move the sensor vertically until the upper plate
of the plastic template touches the rail top or is less than 1mm away from the rail top.
Surface of the T-profile console for vertical positioning has 1mm step teeth so the optimal
teeth position has to be found; the plastic template has to touch the rail top or to be less
than 1mm away from the rail top, but the template also has to fit on the sensor with its
complete surface (figure 30). Make sure that teeth on the T-profile console fit correctly
among the teeth on the clamp.
3. Using vernier caliper, check whether the distance between the upper plate of the template
and the rail top is less than 1mm. After that, tighten the nut pos. 2 on the bracket using the
torque wrench, 24mm socket up to the torque of 100 Nm; the height between the rail top
and the sensor top is then adjusted.

If the passage of a train is expected very soon, plastic template has to be

removed from the sensor. Leaving the template on sensor during the passage
of a train can result in death or serious injury of people!

Figure 30: Setting the sensor’s side distance

4. Release the nut pos. 3, set the plastic template for the sensor position setting on the wheel
sensor and move the sensor towards the rail until the 2mm wide tooth on the plastic
template touches the side of the rail head (it can be visually checked from above through
the hole on the template) with one side, and the side of the sensor with the other side
(figure 30). Sensor must not fit the template too tight (over the plastic template tooth); the
template should be easily removed and placed back on the sensor.
5. Tighten the nut pos. 3 using the torque wrench, 24mm socket up to the torque of 100 Nm;
the sensor's side distance from the rail head is then adjusted to 2mm with tolerance +1/-
0.5mm.
6. After position adjustment of the sensor, it is necessary to visually check the position of the
sensor once again. Take a side and a top look at the sensor to check without template
whether the sensor is parallel to the rail and whether the distance between sensor and the
rail head is approximately 2mm on each part of the sensor. Once again, check the tightness
of all four nuts using the torque wrench, 24mm socket to the following torque values:
 The nut pos. 3 for sensor horizontal (side) position adjustment: 100 Nm,
 The nut pos. 2 for sensor vertical position adjustment: 100 Nm,
 The nut pos. 1 for main fixing of clamp to the rail foot: 100 Nm.
Torque values have to be checked in three circles of tightness check.
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Figure 31: Correct position of sensor mounted on the rail type UIC60

3.2 INSTALLATION OF THE OUTDOOR UNIT BO23-VUR

3.2.1 TOOLS
- Open-end spanner 13, 17, 24, 30 and 32mm
- Flat-head screwdriver 2,5mm
- Flat-head screwdriver 6mm
- Flat-head screwdriver 8mm
- Crimp tool for bigger terminals (25 to 50mm²)
- Wire strippers
- Wire cutter
- Cable ties, approx. 20cm
- Insulating tape
- Scalpel or knife
- Wire cable for dragging the sensor cable through the protecting tube, at least 11m
- Pick axe, shovel

3.2.2 ASSEMBLY PARTS PER ONE COUNTING POINT

- Trackside control unit BO23-VUR in the box on the column
- Protecting tube with inner diameter Ø13mm for sensor cable
- Fastening rings for fastening the protecting tube on the cable gland – 2 pieces to protect
sensor cable (this doesn’t include possible protection of power supply or
telecommunication cable)
- Crimp terminals M16, 25 to 50mm²
- Earth bonding strap or cable, 25mm², 35mm² or 50mm²
- Welding tool for connection of earth bonding strap or cable to the rail

3.2.3 BURYING THE BO23-VUR

The trackside control unit BO23-VUR on a column should be buried in the ballast with at
least 200mm of column above the ballast. The distance between the closer rail and BO23-VUR
can be from 1m up to 3.5m, depending on the circumstances and railway regulations (figure
32).

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Figure 32: Location of the control unit BO23-VUR beside the track

The control circuitry BO23-VUR should be turned that way so the cable gland of the
sensor cable (contacts H+, H-, L+, L-) is faced toward the track. If it is possible, make sure that
the housing of the BO23-VUR is not beneath the level of the rail.

3.2.4 PROTECTION OF SENSOR CABLE AND PLACING THE CABLE INTO THE BO23-
VUR HOUSING

Sensor cable is mechanically protected with a special protecting tube. Cut a piece of
protecting tube long enough to cover the distance between the cable gland on the sensor and
the cable gland on the BO23-VUR box beneath the H+, H-, L+, L- contacts. Place the sensor
cable through the tube and plug the tube end on the cable gland on sensor. Put two fastening
rings (worm drives) on the tube and fasten the one on the sensor end using a spanner 8mm.
Now, drag the cable through the cable gland on the BO23-VUR housing under the H+, H-, L+,
L- terminals till the protecting tube fits into its place on the cable gland. While pulling the sensor
cable to fit the protecting tube as good as possible on the cable gland, tighten the cable gland
using a spanner 22mm to fix the sensor cable on its position. Pull the protecting tube over the
cable gland and fasten the remaining fastening ring on the tube using a spanner 8mm. In the
box, connect the sensor cable on H+, H-, L+, L- terminals as described in 2.1.
The telecommunication cables (that transmit the information to the indoor unit BO23-
UNUR) can also be protected the same way as sensor cable. Length of protecting tube on
telecommunication cable depends on the circumstances on the field.

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3.2.5 OUTDOOR EQUIPMENT GROUNDING

Grounding terminal of the outdoor unit BO23-VUR has to be connected to the rail on
which the wheel sensor ZK24-2 is mounted using cable with cross section at least 25mm². It is
preferred that the rail on which the sensor ZK24-2 is mounted is grounded. If a track circuit is
overlapping with the axle counter section on the certain counting point, and the sensor ZK24-2
for some reason can be mounted only on the isolated rail (e.g. because it is the inner rail in the
curve), and the railway signalling department doesn’t allow the connection of the outdoor unit
BO23-VUR with isolated rail because of possible decrease of track resistance, the grounding
terminal of the outside unit BO23-VUR can be exceptionally connected to the other rail (on
which the sensor is not mounted), but only in case the rail is grounded.
On not-electrified lines where neither rail is grounded, it is highly recommended to
connect the ground terminal of the outdoor unit BO23-VUR to the rail on which the sensor
ZK24-2 is mounted. However, if the railway authority doesn’t allow this connection, the ground
terminal of the outside unit BO23-VUR has to be grounded to the earth by buried metal rod, or
FeZn bar etc., but in this case there is a higher probability of wheel sensor damage by the
lightning strike and it is possible to have a degradation of performance. It is also possible to
connect the outdoor unit BO23-VUR ground terminal both to the rail and to the earth grounding
metal rod

3.3 INSTALLATION OF THE INDOOR UNIT BO23-UNUR

3.3.1 PREPARING THE INDOOR UNIT BO23-UNUR

It is advised to make preparations of the indoor unit BO23-UNUR in the workshop to

reduce the quantity of work that needs to be done on the field. First of all, plug in the module
set depending on the use of the axle counter system (see 2.2). If the exact location of every
ZK24-2 sensor is already known or at least there is a precise schematic diagram, so the exact
location of each ZK24-2 sensor is known, counting direction jumpers (J17…J24) and counting
points power supply jumpers (J1…J16) can be set on the main board beneath the lightning
protection module ZAG2Z, on the rear side of the BO23-UNUR. Also, the SW1 switch for
configuration selection as well as J25 for reset mode can be set (see 2.2.).

3.3.2 MOUNTING THE INDOOR UNIT BO23-UNUR SUBRACK

The case of the indoor unit BO23-UNUR is a standard 19˝ Eurocard subrack with the
height of 3U (U=44.5mm) with possibility of installing into a standard 19˝ (482.6mm) rack cases
and fastening with 4 M6 screws. For installing into a different type of a railway case, it is
necessary to fix the corresponding adjusting console on each side of the indoor unit BO23-
UNUR. The area of at least 5mm beneath and above the case should be clear to enable the
airflow and cooling of the indoor unit (figure 33).

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Figure 33: Mounting the indoor unit BO23-UNUR into a standard 19˝ rack

Fasten the indoor unit BO23-UNUR with adjusting consoles on it using four M8×20mm
on each side. Each screw should have two washers M8, one spring washer M8 and one nut
M8. To tighten them use two spanners 13mm.

3.3.3 GROUNDING

On the rear side of the BO23-UNUR indoor unit, there are two lightning protection
modules ZAG2Z. Each lightning protection module has terminals X4:1, X4:2 provided for
grounding (figure 17). For better protection from lightning overvoltage, on each ZAG2Z module
one of the terminals X4:1 or X4:2 should be grounded to the nearest ground using isolated
1mm² wire. If the chassis (rack) is grounded, this connector can be connected to the closest
suitable place on the chassis, or even on the subrack if there is a good galvanic connection to
chassis. If the chassis (rack) is not grounded and local regulations prohibit ground connections
to the equipment on chassis using isolated wire, the grounding terminal on ZAG2Z can also be
connected to the closest place on chassis or a BO23-UNUR indoor unit subrack, but this kind
of connection doesn't guarantee the same level of protection against lightning as when ZAG2Z
is connected to proper ground.

3.3.4 WIRING THE INDOOR UNIT BO23-UNUR

If counting direction jumpers (J17…J24), counting point power supply jumpers

(J1…J16), reset mode jumper (J25) and SW1 switch for configuration selection are already set,
after mounting the subrack, telecommunication pairs from outdoor equipment can be
connected (according to 2.2). The main power supply should be connected last. In case that it
is necessary to connect the main power supply wires under voltage, remove both fuses on the

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ZANAP module and return them after connecting. After the main power has been connected it
is necessary to reset the system (before that make sure that no train is on the section!)
and check the equipment function and counting direction.

3.3.5 FUNCTION AND COUNTING DIRECTION CHECK

The quick check of indoor unit BO23-UNUR function while there is no train on the
section can be made using two short cables with Ø2mm plugs. One side of each cable plug
together into the black GND socket on the UP module. The other end of the cable should be
plugged into the red H and L sockets. With proper order, depending on the location of sensors
on the track, it is possible to count in and count out an axle (it is necessary in one moment to
have both cables plugged in to simulate the pulse overlap). It is good to do this kind of a check
with every UP module (for each counting point).
The proper function of the whole axle counter system can only be checked by going on
every single counting point and passing over the sensor with metal template. The template is
made to simulate the wheel flange of the smallest wheel (Ø330mm) with the lowest wheel
flange height (25mm) and thickness (20mm). Using a mobile communication contact the
person near the indoor unit BO23-UNUR and check if the counting and counting direction are
accurate. The negative number on the display indicates that the counting direction is not
properly set. In that case, only resetting the system can clear the section. The wheel passage
simulation using the template is performed only in case of low railway traffic density on the
section; correct function of the axle counter section can be checked by observing the axle
counter function during the passage of the first following train.

3.4 DISMOUNTING AND REMOUNTING THE SENSOR DURING THE TRACK

RECONSTRUCTION

3.4.1 TOOLS
- Torque wrench [100 Nm] with 24mm socket
- Open-end spanner 30mm (if the sensor shields are mounted)
- Open-end spanner 24mm
- Hammer
- Plastic template for sensor position setting
- Vernier caliper
- Ballast removing tool (small shovel or pick axe)

3.4.2 WITH SENSOR MOUNTED ON THE CLOSER RAIL

Remove the ballast under the mounting bracket and clear approximately 250mm of
space under the rail. Release the nut on the outer side of the rail (spanner 24mm), loose the
claw using a hammer and remove the whole mounting bracket with sensor on it from the
bottom part of the rail. Other two nuts on the bracket do not need releasing. Slip the
mounting bracket with sensor on it beneath the rail. During the reconstruction, sensor can be
put aside the track together with its protecting tube. Also, using a spanner 30mm remove the
sensor shields from the rail (if mounted).
After the track has been serviced, mount the shields and the wheel sensor back on the
rail according the instructions in the chapter 3.1.3.

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3.4.3 WITH SENSOR MOUNTED ON THE MORE DISTANT RAIL

The procedure is the same as in 3.4.2 except that the ballast needs to be removed
under the closer rail (not the distant one with sensor mounted on it). After removing the ballast,
slip the bracket with sensor under the closer rail toward the trackside control unit BO23-VUR.

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4. MAINTENANCE MANUAL

4.1 SIX-MONTHS PERIOD MAINTENANCE PROPOSAL – OUTDOOR EQUIPMENT

4.1.1 MECHANICAL MEASURING AND JOINT TIGHTENING

On each counting point a plastic template should be placed over the sensor to check the
height of the sensor from the top of the rail (as in 3.1.2.), and side distance of the sensor. The
template is plastic and it does not influence the sensor, so this check can be done with axle
counter in function. In the most cases the template fits gently between the sensor and the rail
head, so it is not necessary to change the side distance of the sensor. Because of the rail
exploitation wear, sometimes it is necessary to reposition the sensor.
All three nuts on the mounting bracket and nuts on the shields should be tightened
according the instructions in the chapter 3.1.3.

Take care not to pass with a metal objects (spanners, screwdrivers ) in the
area 40mm above the sensor to avoid sensor activation.

4.1.2 ELECTRICAL MEASURING

Remove the top cover of the outdoor unit BO23-VUR and check if both green LED's light
(READY H and READY L) with no wheel above the sensor (figure 5). Check the DC voltage
between sensor terminals H-, U- and L-, U- and between power supply terminals U+, U-
(sensor side) and VOD1+, VOD1- (indoor unit BO23-UNUR side). Check the AC voltage on
terminals VOD1+, VOD1- and VOD2+, VOD2-. For reference list with tolerance for these
values check the six-month checklist in Appendix C.

Figure 34: LED indication of a non-active state of the wheel sensor ZK24-2 on the trackside
control unit BO23-VUR

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Figure 35: LED indication of an active state of both sensing systems (H and L) of the wheel
sensor ZK24-2 on the trackside control unit BO23-VUR

Using an ohmmeter check the connection of every terminal with the box (ground). This
needs to be done because every terminal is over-voltage protected with 3-stage lightning
protection to the ground. If in last six months any element of lightning protection was burnt
because of the close lightning strike, the resistance will be less than 1 MΩ between the
terminal and the box. In that case, the front panel VUR-P that contains the lightning protection
(beneath the panel) should be replaced.
The front panel VUR-P of the trackside unit contains 4 ultra-rapid fuses 20×5mm for
protection of sensor ZK24-2 against lightning (one fuse for each wire of the sensor cable) with
the following value:

- FF500mA (10 pcs pack), 4 pcs per trackside unit.

After each replacement of any fuse on the front panel VUR-P or the whole front
panel VUR-P or electronic module BO23-VUR (after failure caused by lightning strike)
the wheel sensor ZK24-2 should be functionally tested, i.e. passed by the rail wheel
simulator or similar metal object (e.g. hammer) while observing the operation of LEDs
on the front panel VUR-P, to confirm that the sensor was not damaged by lightning.

4.2 SIX-MONTHS PERIOD MAINTENANCE PROPOSAL – INDOOR UNIT BO23-UNUR

4.2.1 VISUAL CHECK

On the MPU module, when the indication is set to a certain section (see 2.2.17), no red
LED should light (DISTURBANCE, ERROR, FAILURE) and the display should indicate right
number of axles (000 if the section is clear). On part of one of the RE modules belonging to the
selected section, there green LED SECTION CLEAR should light if there is no train, or red
LED SECTION OCCUPIED should light if there is a train on the section. Such visual check
should be carried out for each section in configuration of indoor unit BO23-UNUR (by setting
the indicated section with push button SECTION, see 2.2.17).
On all UP modules, there green LEDs H and L READY should light, and ZANAP and
DC12 should have yellow LEDs POWER, +12V, -12V and ON turned on (figure 4). The system
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works properly only if combination of LEDs lights as described in case of clearance or

occupancy or clearance of section (the transition phase during entrance or exit of the train is
not considered).
If the red LED FAILURE lights on microprocessor module MPU, there is a possibility that
one of the three vital microprocessors doesn't have the same data. In this case, reset sections
one by one on the indoor unit until the red LED FAILURE turns off. If the LED is still on, turn
the main power supply of the indoor unit off and on. If red LED FAILURE remains lighting, the
MPU module should be replaced with a proper one.
During each periodical check, press the LED-TEST on the MPU module to check if all
LEDs and display segments work properly.

4.2.2 ELECTRICAL MEASUREMENT

On each UP module a negative pole of the voltmeter should be plugged in the black
socket (GND). Plug the positive pole into red socket H to measure the rectified DC voltage
from the counting point that sends the status of H system of the sensor. After that, plug the
positive pole into red socket L to measure the rectified DC voltage from the counting point that
sends the status of L system of the sensor. Referent values with tolerances are given in
measuring list for six-month period check in the appendix C.
Using the ohmmeter on the rear side of each of the lightning protection modules ZAG2Z,
measure resistance towards the ground (figure 17) on each of 8 terminals of inputs (+, -) for 4
counting points and each of 2 terminals of the main power supply (NAP+, NAP-). If the
resistance is less than 1 MΩ towards the ground, some of protection elements on ZAG2Z
module have burned out and the ZAG2Z module should be replaced.

4.2.3 FUSE VALUES ON THE INDOOR UNIT BO23-UNUR

On the indoor unit BO23-UNUR of the BO23 axle counter, quick blow 20×5mm fuses are
used. Value of each fuse is marked on the front panel near the fuse housing. Exception from
this are ZAG2Z lightning protection modules on the rear side of indoor unit; on each ZAG2Z
module there are 10 quick blow ceramic 20×5mm fuses; value of each fuse is marked on figure
17 (F2A and F6.3A). There are two quick blow fuses on the power supply protection module
ZANAP. In total, three types of fuses are used:
- FF1.6A (10 pcs pack), 2 pcs per unit
- F2A (10 pcs pack), 16 pcs per unit
- F6.3A (10 pcs pack), 4 pcs per unit.

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5. TROUBLESHOOTING AND DIAGNOSTICS MANUAL

This chapter only explains failure detection without checking the MPU microprocessor
module memory. For a full check of the MPU module memory, it is necessary to use the BO23
diagnostics software. Document number D215617-0214010102 (PC/Windows diagnostic
software for axle counter BO23) explains in detail how to use the BO23 diagnostics software.
Failure detection on the BO23 axle counter is much simpler if the BO23-UNUR indoor
unit is remotely connected (Ethernet network achieved by the SEC module / GSM modem to a
personal computer in the local maintenance center.

5.1 FAILURE DETECTION ON THE OUTDOOR EQUIPMENT

After coming on the failed counting point, remove the top cover of the BO23-VUR and
check if both green LEDs READY H and READY L light.

5.1.1 POWER FAILURE – THE FAILURE AFTER CLOSE LIGHTNING STRIKE

If none of the LEDs lights (neither green nor red) there is a possibility of a power failure.
Check the DC voltage between VOD1+ and VOD1-. It should be between 40V DC and 98V
DC. If there is no such voltage, the short circuit check between each terminal and the box
(ground) should be made as described in 4.1.2. If any of lightning protection elements was
burnt during the lightning there will be the short circuit between the terminal and the ground
(box) and the front panel VUR-P should be replaced.
If no terminal has the connection towards the box and BO23-VUR doesn’t get the power
supply voltage, the twisted pair to indoor unit BO23-UNUR on VOD1+, VOD1- is probably
interrupted.

5.1.2 FAILURE IN THE SENSOR CIRCUIT

If the BO23-VUR have the power supply 40V…98V DC between VOD1+ and VOD1-, and
one of the green LEDs doesn't light, check for any kind of metal objects on the sensor and
whether its position on the rail is proper. Then, check the DC voltage between U+, U-
terminals. If the voltage is not within 24V DC ±5%, disconnect the sensor cable and check the
voltage again. If the voltage is still not within the mentioned range and the BO23-VUR power
supply is proper 40V…98V DC measured between VOD1+, VOD1- terminals, the BO23-VUR
should be replaced. If the voltage is within 24V DC ±5%, the sensor should be replaced. If the
sensor power supply is proper 24V DC ±5%, check the DC voltage between sensor terminals
H-, U- and L-, U-. If the voltage is not within 4V DC ±10% and the sensor is properly mounted
on the rail, the ZK24-2 sensor should be replaced.

5.1.3 FAILURE IN OUTPUT CIRCUITRY OF BO23-VUR

If the voltage between the H+, H- and L+, L- terminals are within the proper range, check
the AC voltage on the output signals on the VOD1+, VOD1- and the VOD2+, VOD2- terminals.
In both cases the voltage should be within 1.1V AC ±15%. If not, the failure is in the electronic
module BO23-VUR and it should be replaced.

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5.2 FAILURE DETECTION ON THE INDOOR UNIT BO23-UNUR

5.2.1 FAILURES CAUSED BY ATMOSPHERE DISCHARGES

Atmosphere discharges (lightning strikes) up to 500m in circle from the system can cause
high voltage in the transmission lines that could damage over-voltage protection on the ZAG2Z
module of the indoor unit BO23-UNUR , or over-voltage protection placed beneath the front
panel VUR-P of the outdoor unit BO23-VUR. In both cases, failure is manifested as
impossibility to clear the axle counter by resetting. On the lightning protection module ZAG2Z
there is a quick blow ceramic fuse F2A per each wire of the transmission line for each counting
point, as well as one F6.3A for each wire of the main power supply. If some of the fuses
towards the twisted pairs for counting points has blown, there will be no receiving signal on the
respective UP module, neither the power supply for the counting point 98V DC (if the counting
point is power supplied from the indoor unit BO23-UNUR) on its twisted pair. In this case, only
the blown fuse is replaced and over-voltage protection elements on module ZAG2Z are
checked according to 4.2.2.
If no fuse has blown, but over-voltage protection elements have been burnt on module
ZAG2Z or beneath the front panel of the trackside control unit BO23-VUR, it is possible that
there is no 98V DC power supply to counting point, because transmission line towards the
counting point can be short-connected on the ZAG2Z module or on BO23-VUR control unit.
Counting point power supply circuitry on module UP is trying to set power supply voltage for
that counting point at value of 98V DC but it continuously fails because somewhere on the
transmission line is a short circuit. By measuring the resistance between the connection pins
and ground (earth), detection of over-voltage protection failure on the indoor unit BO23-UNUR
on the ZAG2Z module according instructions 4.2.2, or detection of over-voltage protection
failure of the outdoor unit BO23-VUR of the counting point with no signal (detection of lightning
protection failure according to 4.1.2) should be obtained. Extreme damaging of protection
elements on the ZAG2Z module of indoor unit BO23-UNUR can cause that the main fuse of
the axle counter DC power supply in the relay room blows. By replacement of the ZAG2Z
module, axle counter should work properly if over-voltage protection beneath the front panel of
the trackside control unit BO23-VUR on some counting point is not damaged.

5.2.2 FAILURE ON THE INPUT AMPLIFIER MODULE UP

If any of the green LEDs (H or L) on the UP module doesn't light, DC voltage check on
the related red socket toward black one GND should be performed; the voltage should be in
range +4V DC to +6V DC. If the voltage is out of that range, AC signal from the outdoor unit
should be checked. For each counting point, the voltage on the ZAG2Z module (on the rear
side) between pins BT+ and BT- (figure 17) should be in range of 12 mV AC to 1100mV AC. If
received AC signal is in that range for certain counting point and voltage on the related socket
H, L (red toward black) is out of range (+4V DC to +6V DC) and cannot be adjusted to that
range, UP module is faulty and should be replaced. If the voltage on the H and L sockets is in
range, outputs H and L of the UP module (on the KP connection plate, figure 28) toward the
MPU module should be checked. The voltage on each H or L output toward the 0V (X11:5)
should be 12V DC ±10%. If one of the above mentioned UP module outputs is not in the range
of 12V DC ±10% (while voltage on the front sockets is in range), replacement of the UP
module should be considered.
On the UP module, there is also a converter for counting point power supply (98V DC). If
the counting point is supplied by the indoor unit and there is no 98V DC on the transmission
line terminals on the ZAG2Z module (also check with transmission pair disconnected), and if
the ZAG2Z module (according to 4.2.2.) is working properly, the UP module should be
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replaced because of possible failure on its counting point power supply circuit.

5.2.3 MPU MICROPROCESSOR MODULE FAILURE

Failure states on the microprocessor MPU module are indicated by permanent or blinking
FAILURE LED, or blinking ERROR LED (see 2.2.17). Table 4 shows all the necessary actions
in case of some failure indication; in most cases, resetting all sections should help. If not,
BO23-UNUR main power supply should be switched off and on again. If there is still failure
indication, MPU module should be replaced.
In case of individual failure detection, certain error code can be displayed on the MPU
module display. In this case, error code is displayed every 3 seconds in a half a second
duration, so that the current axle number on the section can be monitored. Explanation of each
error code (E01…E08) is shown in table 4.

Table 4: MPU module error codes explanation

Error code Explanation
E01 Failure on the diagnostics NVRAM memory
E02 Low voltage of the diagnostics memory maintenance battery
E03 Failure on the RTC (real time clock) set for generation of exact time
E04 Date and time are not set
E05 Failure of a vital micro controller uC1
E06 Failure of a vital micro controller uC2
E07 Failure of a vital micro controller uC3
E08 Wrong track configuration is set. Current configuration is not used

5.2.4 POWER SUPPLY FAILURE

On power supply protection module ZANAP three yellow LEDs should light: POWER,
+12V and –12V. If just one of those doesn't light, the certain fuse beside that LED should be
checked and replaced if necessary. If still one or more yellow LEDs don't light, yellow DC12
LED "ON" on main power supply module DC12 should be checked if it lights. If yellow LED
POWER doesn't light on the ZANAP module, main DC power supply between NAP+ and NAP-
on ZAG2Z should be checked if within 18V…80V DC. If the main power supply is proper and
yellow LED POWER on ZANAP lights and yellow LED ON doesn't light on DC12 module,
DC12 module should be replaced.
After system power supply failure, or after the main power supply is switched off and on
again, yellow LED POWER on the ZANAP module and yellow LED "ON" on DC12 module will
light, but for the first 10 seconds all other modules will not have the power supply. After 10
seconds, if there is no failure (such as short-connection), internal system power supply ±12V
will start and indications on other modules will light. After each time of switching the power
supply on, all sections are occupied and should be reset. If internal system supply tries to start
±12V each 10 seconds but fails every time, there is a short-circuit on one of the modules, and
one by one should be removed and after 10 seconds checked if the system manages to start
internal power supply ±12V. This way, the module with a short-circuit can be detected.

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5.2.5 RELAY OUTPUT MODULE RE FAILURE

If any of safety relays SECTION CLEAR, SECTION OCCUPIED or RESET for some of
the sections is not picked-up (respective LED on the RE module doesn't light) when all
conditions are met for picking-up of the relay, RE module should be replaced. If both SECTION
CLEAR and SECTION OCCUPIED relays are picked-up at the same time, RE module should
also be replaced.

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6. TECHNICAL SPECIFICATIONS

6.1 OUTDOOR EQUIPMENT (BO23-VUR + sensor ZK24-2)

Power supply (VOD1+, VOD1-): 40V DC to 98V DC

Sensor power supply (U+, U-): 24V DC ±5%

Power dissipation (BO23-VUR + ZK24-2): max. 2.5W

Total power dissipation with

telecommunication cable losses: max. 5W

Output current of basic state of

sensor ZK24-2: sensing system H: 16mA DC ±8%
sensing system L: 16mA DC ±8%

Output current of active state of

sensor ZK24-2: sensing system H: 10mA DC ±8%
sensing system L: 10mA DC ±8%

Side distance of drop-away from rail

detection of sensor ZK24-2: 5 to 15mm on the whole temperature range, for all rail
types

Operating temperature range: -40°C to +80°C

Relative humidity: up to 100%

Water and dust protection: IP68 for sensor ZK24-2

IP65 for trackside control unit BO23-VUR
(higher IP on demand)

Vibration and shocks resistance: according to EN 50125-3

- Sensor ZK24-2 - vertical axis: vibrations 5… 2000Hz, 28g r.m.s., shocks 250g / 6ms
- Sensor ZK24-2 - transversal axis: vibrations 5… 2000Hz, 14g r.m.s., shocks 120g / 6ms
- Sensor ZK24-2 - longitudinal axis: vibrations 5… 2000Hz, 5g r.m.s., shocks 50g / 6ms

Electrical connection: signal – screwdriver terminal blocks

rail ground – M16 screw, crimp terminal for 35 to
50mm² wire

Minimal rail wheel diameter: 300mm

Wheel flange height: according to UIC 510-2 (table 5)

Wheel flange thickness: according to UIC 510-2 (table 6)

Rail profile: all types of tracks

Dimensions of BO23-VUR
box (D × W × H): 203 × 233 × 151mm
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Dimensions of BO23-VUR box on column

(D × W × H): 203 × 233 × 600mm

BO23-VUR weight with column: 8.5kg

Sensor ZK24-2 weight (without cable): 1.72kg

Weight of the sensor mounting

bracket (depending on the rail type): 4 - 6kg

Sensor shield weight: 14kg

Table 5: Wheel flange height (according to UIC 510-2)

Wheel diameter 330mm to 630mm 630mm to 760mm >760mm
Min. 32mm Min. 30mm Min. 28mm
Wheel flange height
Max. 36mm Max. 36mm Max. 36mm

Table 6: Wheel flange thickness (according to UIC 510-2)

Wheel diameter 330mm to 840mm >840mm
Min. 27.5mm Min. 22mm
Wheel flange thickness
Max. 33mm Max. 33mm

6.2 INDOOR UNIT BO23-UNUR BO23-UNUR

Power supply: 18V to 80V DC

Stabilized counting point power supply: 98V DC ±4%, 8W, galvanically isolated

Total power dissipation (8 counting

points, power supplied): at 24V DC: 66W
at 48V DC: 66W
at 60V DC: 66W
at 80V DC: 72W

Operating temperature range: -30°C do +70°C, up to 100% RH

Axle counting capacity: 999 axles with indication on the display;

1000 - 3000 axles internally without indication;
3001 and more axles, system reports error.

Microprocessor module configuration: 2-out-of-3

Maximal number of counting points: 8 local + 1 remote via remote indoor unit (RS232)

Maximal number of track sections: 6 sections

Output signals: relay – safety relay contacts

serial interface – RS232
direction output
cross connection signals
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Maximal current switching on safety

relay output contacts: 2A DC

Maximal voltage switching on safety

relay output contacts: 150V DC

Maximal current on optocoupler

output transistors: 50mA

Maximal collector-emitter voltage

on optocoupler outputs: 75V

Maximal saturation voltage

on optocoupler outputs: 1V

Reset inputs voltage: reset activation: 14…80V DC

reset deactivation: <4V DC

ENFRA…ENFRF inputs voltage: activation: 18…32V DC

deactivation: <5V DC

Maximal train speed: for wheel diameter >840mm: 250km/h

for wheel diameter 630 to 840mm: 220km/h
for wheel diameter <630mm: 150km/h

Train passage memory: last 10000 passages (date, time, number of axles,
occupation, direction, location, disturbances, errors,
failures) – inerasable with power off

Subrack dimensions (W × D × H): 483 × 240 × 133mm (Eurocard 19˝, 3U height)

6.3 SIGNAL TRANSMISSION FROM OUTDOOR TO INDOOR UNIT BO23-UNUR

Maximal loop resistance: 500 Ω

Maximal permitted
signal rejection up to 5 kHz: 40dB

Cable type: Screened/unscreened signalling/telecommunication cable;

with twisted pairs / star quads or with untwisted wires
(screened cable with twisted pairs is recommended)

Number of conductors per

counting point: 2 wires

Table 7: Maximal cable length from outdoor to indoor unit BO23-UNUR

Conductor diameter (mm) 0.8 0.9 1.2 1.4
Loop resistance of typical signalling cable (Ω/km) 73 56 32 23
Signal rejection at 5kHz of typical signalling cable (dB/km) 1.89 1.44 0.94 0.81
Cable length with BO23-VUR power supplied from indoor
6.8 8.9 15.6 21.7
unit BO23-UNUR (km)
Cable length with BO23-VUR power supplied locally (km) 21 27 42 49
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APPENDIX A – DIMENSION DRAWINGS

Figure 36: Dimension drawing – sensor ZK24-2

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Figure 37: Dimension drawing – trackside control unit BO23-VUR

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Figure 38: Dimension drawing – indoor unit BO23-UNUR

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APPENDIX B – MOUNTING DRAWINGS

Figure 39: Mounting the sensor ZK24-2 on mounting bracket on the rail – cross section

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Figure 40: Mounting of the wheel sensor ZK24-2 on the mounting bracket with shields on the rail
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APPENDIX C – MEASURING LIST PROPOSAL FOR SIX-MONTH

MAINTENANCE
MEASURING LIST FOR SIX-MONTHS CHECK OF THE OUTDOOR EQUIPMENT OF AXLE
COUNTER BO23

DATE _________________________

COUNTING POINT __________________________________________________

Reference value with Measured

Measured signal Terminals
tolerance value
Internal power supply of
U+, U- 24V DC ±5%
electronic module BO23-VUR
Signal voltage of sensor ZK24-2
system H (sensor current over H-, U- 4V DC ±10%
BO23-VUR input resistance)
Signal voltage of sensor ZK24-2
system L (sensor current over L-, U- 4V DC ±10%
BO23-VUR input resistance)
DC power supply voltage VOD1+, VOD1- 40V…98V DC
AC signal for the first
VOD1+, VOD1- 1100mV AC ±15%
transmission line*
AC signal for the second
VOD2+, VOD2- 1100mV AC ±15%
transmission line*
VOD1+, box No connection, >1 MΩ
VOD1-, box No connection, >1 MΩ
LOCAL
No connection, >1 MΩ
POWER+, box
LOCAL POWER-,
No connection, >1 MΩ
Short circuit from terminal to box
ground (box) check** VOD2+, box No connection, >1 MΩ
VOD2-, box No connection, >1 MΩ
H+, box No connection, >1 MΩ
H-, box No connection, >1 MΩ
L+, box No connection, >1 MΩ
L-, box No connection, >1 MΩ

* Measure with AC voltmeter with min. 2% accuracy for 5 kHz AC signal

** Measure with ohmmeter or with multimeter in diode-check mode

Sensor’s vertical position from the top of the rail (according the corresponding plastic template
±1mm): _____________mm
Sensor’s horizontal position from the side edge of the rail head (according the corresponding
plastic template +1/-0.5mm): __________mm

 mechanical parameters check visually using the plastic template

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MEASURING LIST FOR SIX-MONTHS CHECK OF THE INDOOR UNIT BO23-UNUR OF

AXLE COUNTER BO23

DATE ________________

SECTION A ______________ SECTION B ______________ SECTION C ____________

SECTION D ______________ SECTION E ______________ SECTION F ____________

Reference value with Measured

Measured signal Terminals
tolerance value
H, GND on UP1 4V…6V DC
L, GND on UP1 4V…6V DC
H, GND on UP2 4V…6V DC
L, GND on UP2 4V…6V DC
H, GND on UP3 4V…6V DC
Rectified input signals, L, GND on UP3 4V…6V DC
sensing system H and H, GND on UP4 4V…6V DC
sensing system L of the L, GND on UP4 4V…6V DC
sensor on counting points H, GND on UP5 4V…6V DC
1…8 L, GND on UP5 4V…6V DC
H, GND on UP6 4V…6V DC
L, GND on UP6 4V…6V DC
H, GND on UP7 4V…6V DC
L, GND on UP7 4V…6V DC
H, GND on UP8 4V…6V DC
L, GND on UP8 4V…6V DC
BT1+, ground No connection, >1 MΩ
BT1-, ground No connection, >1 MΩ
BT2+, ground No connection, >1 MΩ
Lightning protection module BT2-, ground No connection, >1 MΩ
ZAG2Z terminal connection
BT3+, ground No connection, >1 MΩ
to the ground for counting
BT3-, ground No connection, >1 MΩ
points 1…4*
BT4+, ground No connection, >1 MΩ
BT4-, ground No connection, >1 MΩ
NAP+, ground No connection, >1 MΩ
NAP-, ground No connection, >1 MΩ
BT5+, ground No connection, >1 MΩ
BT5-, ground No connection, >1 MΩ
BT6+, ground No connection, >1 MΩ
Lightning protection module BT6-, ground No connection, >1 MΩ
ZAG2Z terminal connection BT7+, ground No connection, >1 MΩ
to the ground for counting BT7-, ground No connection, >1 MΩ
points 5…8* BT8+, ground No connection, >1 MΩ
BT8-, ground No connection, >1 MΩ
NAP+, ground No connection, >1 MΩ
NAP-, ground No connection, >1 MΩ

* Measure with ohmmeter or with multimeter in diode-check mode

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APPENDIX D – LIST OF SPARE PARTS AND TOOLS FOR INSTALLATION

AND MAINTENANCE
In table 8 listed are assemble parts of one counting point of the axle counter BO23 and
required number of each component.
Table 8: One counting point’s assemble parts of the axle counter BO23
ASSEMBLE PARTS FOR ONE BO23 COUNTING
Quantity per one
POINT (OUTDOOR EQUIPMENT COMPLETE SET Order code
counting point
AP215501)
Outdoor equipment Outdoor equipment electronic
1 piece AP215502
trackside control unit module (BO23-VUR)
BO23-VUR – set BO23-VUR box 1 piece AP215510
AP215512
1 piece BO23-VUR column 1 piece AP215511
Sensor cable protection tube 5 meters AP215508
Sensor mounting bracket (different types) 1 piece AP2158xx
Wheel sensor ZK24-2 1 piece AP215595
Sensor shield (left and right, different types) 1 pair AP215xxx

Table 9 shows all modules that one indoor BO23-UNUR unit contains. Each indoor unit
BO23-UNUR can contain frame BO23-RACK with main board and basic modules MPU,
ZANAP, DC12, ZAG2Z and KP. Depending on specific application in frame can be added
specific number of UP modules used for receiving signal from counting point, specific number
of relay outputs RE, and communication module SEC (depending on the configuration).

Table 9: Parts for BO23 indoor unit BO23-UNUR

Quantity per one
PARTS OF INDOOR UNIT BO23-UNUR Order code
BO23-UNUR
Frame BO23-RACK 1 AP215621
Rack with main board Main board MP 1 AP215630
and basic modules Microprocessor module MPU 1 AP215623
MPU, ZANAP, DC12, Module ZANAP 1 AP215625
ZAG2Z, KP; order Module DC12 1 AP215624
code AP215620, 1 Lightning protection module
piece 2 AP215633
ZAG2Z
Module KP (connector board) 1 AP215640
Module UP 0…8 AP215629
Module RE 0…3 AP215613
Module SEC for Ethernet communication interface 0…1 AP215646
Adjusting console (different types) pair AP215622.xx

Table 10 shows other parts which can be delivered within the BO23 axle counter, and
which are mentioned in this document, diagnostics software, fastnening material for outdoor
unit BO23-VUR and VUR-P front panel which is an integral part of the outdoor unit BO23-VUR.

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Table 10: Other parts

Number of pieces in
OTHER PARTS Order code
one package
Plastic template for sensor position adjustment on rail 1 AP215516
Fuse FF500mA 10 AT215724
Fuse FF1.6A 10 AT215744
Fuse F2A 10 AT215745
Fuse F6.3A 10 AT215746
Diagnostic software BO23-Diagnostics for diagnosis
1 AP215617
on a personal computer
Fastening material for protection tube 2 AP215506
Front panel VUR-P with lightning protection 1 AP215503
Rail wheel simulator 1 AP215999

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APPENDIX E – RECOMMENDATION FOR SPARE PART QUANTITIES TO

BE KEPT DURING THE EXPLOITATION
The following list of spare parts (table 11) with quantities (expressed in percentage of used
modules) is based on usage experience of axle counters BO23 and is recommended for one-
year planning.

Table 11: Spare parts recommendation

Order Spare quantity as a
Module/Part
Code percentage of used modules
Wheel sensor ZK24-2 AP215595 2.5%
Electronic module BO23-VUR of the trackside
AP215502 1%
unit
Front panel VUR-P of the trackside unit with
AP215503 5%
lightning protection
Lightning protection ZAG2Z for indoor unit AP215633 10%
Module MPU AP215623 0.5%
Module UP AP215629 0.5%
Module RE AP215613 0.5%
Module ZANAP AP215625 0.5%
Module DC12 AP215624 0.5%

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