Maintenance Handbook on FRAUSCHER ACS2000 Multi Section ... · Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page ii %ॉशर ए सी एस 2000 मट सेÈशन

भारतभारतभारतभारत सरकारसरकारसरकारसरकार GOVERNMENT OF INDIA

रेलरेलरेलरेल मंऽालयमंऽालयमंऽालयमंऽालय MINISTRY OF RAILWAYS

(केवलकेवलकेवलकेवल काया�लयीनकाया�लयीनकाया�लयीनकाया�लयीन ूयोगूयोगूयोगूयोग हेतुहेतुहेतुहेतु ) (For official use only)

ृृृृॉॉॉॉशशशशरररर एएएए ससससीीीी एएएएसससस 2000

मममम��टटटटीीीी ससससेेेे��शशशशनननन ििििडडडडििििजजजजटटटटलललल एएएए��""""लललल ककककााााउउउउ$$$$टटटटरररर परअअअअननननुुुुरररर''''णणणण हहहहःःःःततततपुिस्तका

Maintenance Handbook on

FRAUSCHER ACS2000

Multi Section Digital Axle Counter

कैमटेक/एएएएसससस////ूूूूोोोजजोजज////2222000011115555 – 11116666////एएएएममममएएएएचचचचबबबबीीीी-एफ__ एमएएएएससससडडडडीीीीएएएएससससीीीी////1111....0000

माचर् 2222000011116666CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0

March 2016

MAHARAJPUR, GWALIOR – 474 020

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page ii

ॉशर ए सी एस 2000म ट से शन डिजटल ए ल काउ टर

परअनरु ण ह तपिु तका

Maintenance Handbook on

FRAUSCHER ACS2000 Multi Section Digital Axle Counter

कैमटेक/एस/ ोज/2015–16/एमएचबी-एफ__ एमएसडीएसी/1. 0 माच 2016

CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0 March 2016

Table of Contents

ा कथन

ेक स कट गाड़ी क उपि थती क जाँच करने म मह वपूण भू मका नभात ेह ,िजनके वारा गा ड़यो के संचालन म संर ा सु नि चत होती है । डिजटल ए सल काउ टर ेक स कट का एक उ नत प है, िजसके अपने लाभ तथा संर ा स बंधी अ त र त वशषेताय ह। तकनीक उ नयन के साथ भारतीय रेलवे म नवीन ा प का आगमन हुआ है।

वतमान वकास के साथ कदम मलात ेहु ये कैमटेक न ेइस ह तपुि तका को तैयार कया है, िजसम नवीनतम अनुमो दत ॉशर एसीएस 2000 डिजटल ए सल काउ टर क जानकार सि म लत है । मुझे इस ह तपुि तका को स नल क मक हेतु तुत करते हु ये हष होता है और मुझ ेआशा है, क इसके वारा उ ह अपने से शन म उपरो त ए सल काउंटर के अनुर ण म सहायता मलेगी ।

कैमटेक वा लयर ए. आर. तुपे दनाँक: 10.03.2016 कायकार नदेशक

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page iii Table of Contents

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page iv

FOREWORD

Track circuits play a vital role in train operation by detecting the presence of train

vehicle, thereby ensuring safety in train operation. Digital axle counter is the

advanced form of track circuit which has its own advantages and additional

safety features. With technological advancements, new versions are being

introduced in Indian Railways.

To keep pace with latest developments, CAMTECH has prepared this handbook

consisting information on newly approved Frauscher ACS 2000 Digital Axle

Counter. It gives me pleasure in presenting this handbook to Signal personnel

and I hope that this will help them in maintaining the subject Digital Axle

Counters in their section.

CAMTECH Gwalior Date: 10.03.2016

A.R.Tupe Executive Director

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भू मका

वतमान मे डिजटल ए सल काउ टर स न लगं णाल का एक मह वपूण अवयव है। म ट

से शन डिजटल ए सल काउंटर का सीध े से शन म, टेशन े के वाइंट जोन म तथा

लॉक से शन म अनु योग है । टेशन अथवा लॉक से शन म ए सल काउ टर क खराबी

गा ड़य के संचालन को बा धत करती है तथा उनक समय ब ता को भा वत करती है।

टे नॉलॉजी म सुधार के कारण नये नमाताओ का ए सल काउंटरो के उ नत सं करण के

साथ आगमन हो रहा है । ॉशर से सर टे नॉलॉजी उनमे से एक फम है जो क भारतीय

रे वे म ए सी एस 2000 म ट से शन डिजटल ए सल काउंटरो को उपल ध करान ेतथा

सं थापन हेत ुअनुमो दत है।

इस ह तपुि तका को फ ड का मको को अपने से शन मे ॉशर ए सी एस 2000 डिजटल

ए सल काउ टर के ु ट वह न काय हेतु अनुर ण करने म सहायता करन े के लए तैयार

कया गया है। ह तपुि तका व श ट भाग म वभािजत है िजसम णाल के सहंावलोकन,

सं थापन, अनुर ण, ु ट नवारण तथा सावधा नय को सि म लत कया गया है।

हम ी पी के वमा, नदेशक/संकेत/VII/आर. डी. एस. ओ./लखनऊ, ी जनादन सहं, व र ठ

संकेत एवं दरूसंचार अ भय ता (सम वय)/सीएसट मु बई/म य रेल, मै. ॉशर से सर

टे नोलॉजी बगलु के ी पी. वी. के. सु हम णयन/ नदेशक/इंजी नय रंग एवं उनके सहयोगी

तथा मु बई डवीजन/म य रेल एव ंआगरा डवीज़न/उ तर म य रेल के फ ड का मक के

अ यंत आभार ह िज ह न ेहम इस ह तपुि तका को तैयार करन ेम सहायता क ।

चू ं क तकनीक उ नयन एवं श ण एक मक या है, अतः इस ह तपुि तका म आप

कुछ जोड़न ेया सुधारने क आव यकता महसूस कर सकत ेह | य द ऐसा है तो कृपया अपने

सुझाव हम ईमेल [email protected] पर भेज अथवा इस पत े पर लख भेज :

भारतीय रेल, उ च अनुर ण ो यो गक क , होटल आ द याज़ के सामने, महाराजपुर,

वा लयर (म ) 474020

कैमटेक वा लयर दनेश कुमार यादव द.: 10.03.2016 नदेशक (संकेत एव ंदरूसंचार)

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page v Table of Contents

mailto:[email protected]

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page vi

PREFACE

At present Digital Axle counter is an important part of the signalling system. Multi Section Digital Axle Counters have applications in straight sections and point zones of Station area as well as in proving of Block section. Failure of axle counters in a station or block section paralyses the movement of trains thereby affecting their punctuality. Due to improvement in technology, new vendors are coming with enhanced versions of axle counters. Frauscher Sensor Technology is one such firm who is approved for supply and installation of ACS 2000 Multi Section Digital Axle Counters on Indian Railways.

This handbook has been prepared to help the field personnel in maintaining Frauscher ACS 2000 Digital Axle Counters in their section for trouble-freeperformance. The handbook has been divided into specific sections; containing overview, installation, maintenance, troubleshooting and precautions for the above system.

We are sincerely thankful to Shri P.K.Verma/Director Signal/VII/RDSO/ Lucknow, Shri Janardan Singh, Senior Divisional Signal & Telecom. Engineer (Co)/CST Mumbai/Central Railway, Shri P.V.K.Subramanian, Director Engineering of M/s Frauscher Sensor Technology India Pvt. Ltd. Bangalore and his team and field personnel of Mumbai division, CentralRailway and Agra division, North Central Railway who helped us in preparation of the handbook.

Since technological upgradation and learning is a continuous process, you may feel the need for some addition/modification in this handbook. If so, please give your comments on email address [email protected] or write to us at Indian Railways Centre for Advanced Maintenance Technology (in front of Adityaz Hotel), Maharajpur, Gwalior (M.P.) 474020.

D.K.M.Yadav CAMTECH Gwalior Date: 10.03.2016 Director (S&T)

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Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page vii

वषय सूची Table of Contents

ा कथन Foreword....................................................................................iii/ivभू मका Preface ...........................................................................................v/viवषय सूची Table of Contents ....................................................................... viiसुधार पच Correction slip .............................................................................. xड लेमर तथा हमारा उ े य Disclaimer & Our objective............................ xi

सं त श दावल Abbreviations ....................................................................xiii

1 ॉशर ए सी एस 2000 म ट से शन डिजटल ए सल काउ टर Frauscher ACS2000 Multi Section Digital Axle Counter ….……….....1

1.1 प रचय Introduction.....................................................................................11.2 ए सी एस 2000 णाल के घटक

Components of Axle counting system ACS2000 .....................................1 1.3 सहायक द तावेज Supporting documents ...................................................11.4 णाल का ववरण System description........................................................21.5 संचालन क े कार Modes of operation..........................................................31.6 घटक का ववरण Description of components............................................51.7 केबल बछाने क योजना Cabling scheme...................................................11

2 ह ल से सर आर एस आर 180 का सं थापन Installation of Wheel sensor RSR180 .........................................................12

2.1 घटक तथा अ य अवयव Components and fixing elements...................122.2 आलंबन हेतु सामा य नदश General mounting instructions......................122.3 रेल लॉ का आलंबन Rail claw mounting..................................................132.4 ह ल से सर क ेआलंबन हेतु आव यक औजार

Tools required for mounting of Wheel sensor.............................................13 2.5 लगाना एवं समायोजन Fixing and adjustments.......................................142.6 केबल का संयोजन Connection of cable....................................................152.7 धुरा गणना क दशा का प रवतन

Changing the direction of axle counting....................................................16

कैमटेक प्रकाशन CAMTECH Publications..................................................xii

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page viii

2.8 पी बी 200 क सहायता से आर एस आर 180 क ऑकु पे सी डटे शन

of RSR180 using PB200………….…………………………………… 16 2.9 पी बी 200 क सहायता से ह ल ससर आर एस आर 180 पर ेवर सगं

का स यलेुशन करना Simulation of traversing over Wheel sensor RSR180 using PB200 ...............................................................................17

2.10 ह ल ससर तथा ट एलजेबी के सं थापन हेतु जांच सूची Checklist for installation of Wheel sensor and TLJB.............................18

3 समायोजन एवं मापन Adjustments and measurements…..................... 203.1 पावर स लाई Power supply…....................................................................203.2 एव युएशन बोड पर मापन एवं समायोजन

Measurements and adjustments at the Evaluation board.........................20

3.3 एबीपी क डप ि वच सै टंग DIP-switch settings of ABP.......................213.4 रसेट बॉ स पर मापन Measurements at the Reset box ..........................253.5 र सेट बॉ स म ज पर सै टंग Jumper settings in the Reset box...............25

4 काया मक पर ण Functional testing…………….................................. 264.1 काया मक पर ण के कार Types of functional tests..............................264.2 काउं टंग हेड नधारण प र ण Counting head assignment test .................264.3 आइसोलेटेड मोड म गणना क दशा का स यापन

Verification of counting direction in isolated mode .................................26 4.4 ांस मशन मोड म गणना क दशा का स यापन

Verification of counting direction in transmission mode…......................274.5 र सेट ऑपरेशन का स यापन Verification of reset operation.. ...................27

5 अनुर ण Maintenance................................................................................ 295.1 पर ण /जांच Tests/Checks........................................................................295.2 औजार तथा मापन उपकरण Tools and measuring equipment...................295.3 एवलु एशन बोड के टे ट सॉकेट पर मापन

Measurements at the test sockets of the Evaluation board........................29 5.4 ह ल से सर , रेल डफले टर तथा लाइन वे र फकेशन बॉ स का

प र ण /जाँच Testing/checking of Wheel sensor, Rail deflector andLine verification box .................................................................................29

क� �मता क� जांच करना Checking occupancy detection capability

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page ix

5.5 एसीबी का पर ण Testing of ACB...........................................................305.6 डीआईओबी का पर ण Testing of DIOB...............................................305.7 रसेट बॉ स का पर ण Testing of Reset box ........................................31

6 नदान एवं ु ट नवारण Diagnostics & Troubleshooting ..................... 326.1 नदान एवं ु ट नवारण हेतु सामा य नदश

General instructions for diagnostics and troubleshooting.........................32 6.2 ु ट कोड का दशन Display of error codes ............................................326.3 एसीबी का पॉवर अप Power-up of ACB ....................................................326.4 ु ट कोड को पढना Reading of error codes..............................................336.5 ु ट कोड, कारण एवं नवारण Error codes, causes and remedies…......346.6 ु ट नवारण Troubleshooting.....................................................................426.7 ॉशर नदान णाल Frauscher diagnostic system...................................45

7 सावधा नयां एवं या कर व या न कर Precautions and Do’s & Don’ts…………………….............................. 46

7.1 बोड/मॉ यू स का बंधन Handling of boards/modules...............................467.2 बोड/मॉ यू स को बदलना Replacement of boards/modules....................467.3 ु ट नवारण म सावधा नयां Precautions while troubleshooting................477.4 या कर व या न कर Do’s & Don’ts.....................................................47

अनुल नक AnnexuresI ए सी एस 2000 नदान एवं ु ट नवारण हेतु लो चाट 1 ACS 2000 Diagnostics & Trouble shooting Flowchart 1…………….…..….49

III दोहरा उपयोग Double usage...........................................................................51

IV ट्रॉल� प्रोटेक्शन Trolley protection.................................................................52

II ए सी एस 2000 �नदान एवं त्र�ुट �नवारण फ्लो चाटर् 2 ACS 2000 Diagnostics & Troubleshooting Flowchart 2.................................50

सुधार प चय को जार करना

ISSUE OF CORRECTION SLIPS

इस ह तपुि तका के लए भ व य म जार क जाने वाल सुधार प चय के मांक इस कार से

रहगे:

The correction slips to be issued in future for this handbook will be numbered as follows:

केमटेक/एस/ ोज/2015 – 16/एमएचबी –एफ_ एमएसडीएसी/1.0 # XX द .................

CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC /1.0# XX date .......

जहां “XX” स बं धत सुधार पच क म सं या है (01 से शु होकर)Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

सुधार पच याँ जार क गयीं CORRECTION SLIPS ISSUED

सुधार पच क म सं या

Sr. No. of Correction

Slip

जार करने क तार ख Date of

issue

संशो धत पृ ठ मांक एवं मद

सं या Page no. and Item

No. modified

ट प णयाँ Remarks

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page x Table of Contents

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page xi

�डस्क्लेमर यह स्पष्ट ि कया जाता है ि क इस हःतपुिःतका म; दी गयी जानकारी िस>नल इंजीिनयिरंग मै$युअल,रेलवे बोड� ूकाशन@ तथा आर डी एस ओ ू काशन@ के ि कसी भी वत�मान आलेख@ को िवःथािपत नही ंकरतीं है | यह दःतावेज वैधािनक नही ंहै वरन इसम; िदए गए िनदGश केवल माग� दश�न हेतु हH | य�द �कसी िब$दु पर िवरोधाभास I9ीगोचर होता है, तब िस>नल इंजीिनयिरंग मै$युअल, रेलवे बोड� ूकाशन@, आरडी एस ओ माग�दश�न अथवा जोनल रेलवे के िनदGश@ का प ालन कर; |

Disclaimer It is clarified that the information given in this handbook does not supersede any existing provisions

laid down in the Signal Engineering Manual, Railway Board and RDSO publications. This document

is not statuary and instructions given in it are for the purpose of guidance only. If at any point contradiction is observed, then SEM, Railway Board/RDSO guidelines may be referred or prevalent

Zonal Railways instructions may be followed.

हमारा उद्देश्य

अनुर'ण ूौMोिगकी और काय�ूणाली का उ$नयन करना तथा उPपादकता और रेलवे की प िरसQपिR एवं जनशिS के िनंपादन म; सुधार करना िजससे अंतिव�षय@ म; िवVसनीयता, उपयोिगता और द'ताूाX की जा स के

Our objectiveTo upgrade Maintenance Technologies and Methodologies and achieve improvement in Productivity

and Performance of all Railway assets and manpower which inter-alia would cover Reliability,

Availability and Utilisation.

य�द आप इस स$दभ� म; कोई िवचार और सुझाव देना चाहते हH तो कपया हम; इस पते पर िलख;:

संपकर् सतू्र: िनदेशक (सकेंत एवं दरूसचंार)भारतीय रेल उ]च अनुर'ण ूौMोिगकी क; िपत्राचार का पता :

टेलीफ़ोन:

फैक्स:ई2मेल:

महाराजप ुर, >वािलयर (म. ू.) �पन कोड – 474 0200751-2470185

0751-2470841

[email protected] If you have any suggestion & any specific comments, please write to us: Contact person: Director (Signal & Telecommunication)

Postal address: Centre for Advanced Maintenance Technology, Maharajpur Gwalior (M.P.) Pin Code – 474 020

Phone:

Fax:

Email:

07512 2470185

07512 2470841

[email protected]

Table of Contents

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page xiiTable of Contents

कैमटेक प्रकाशन CAMTECH Publications

CAMTECH is continuing its efforts in the documentation and up-gradation of information on maintenance practices of Signalling & Telecom assets. Over the years a large number of publications on Signalling & Telecom subjects have been prepared in the form of handbooks, pocket books, pamphlets and video films. These publications have been uploaded on the internet as well as railnet.

For downloading these publicationsOn Internet:Visit www.rdso.indianrailways.gov.inGo to Directorates → CAMTECH → Publications for download → S&T Engineering

On Railnet:Visit RDSO website at 10.100.2.19Go to Directorates → CAMTECH → Publications → S&T Engineering

A limited number of publications in hard copy are also available in CAMTECH library which can be got issued by deputing staff with official letter from controllong officer. The letter should be addressed to Director (S&T), CAMTECH, Gwalior.

For any further information regarding publications please contact:Director (S&T) – 0751-2470185 (O)(BSNL)SSE/Signal - 7024141046 (CUG)

Or

Email at [email protected]

Or

FAX to 0751-2470841 (BSNL)

Or

Write atDirector (S&T)Indian Railways Centre for Advanced Maintenance Technology,In front of Hotel Adityaz, Airport Road, Maharajpur,Gwalior (M.P.) 474020

Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page xiii

सं��प्त शब्दावल� AbbreviationsIn this document the following abbreviations are used: ABP AC ACB ACS AXR BBK BGT BSI004 CTR DC DEACT DIOB DIP DIR/DIR’ DN/DN’ DP EB EMC FDS Fm FRA FRD GND GS IMC LB LVB MSDAC P PB200 RDSO RSR180 RSTBOX SCI SIC SEM SK140 SRC SSDAC Sys1/Sys2 TLJB TS

Axle counting backplane Alternating current Axle counting board Axle counting system Axle counter rack Clamping bolt Board rack Overvoltage protection board, type 004 Cable termination rack Direct current Deactivation inputs/outputs used for counting head control Digital input/output board Dual in - line package (DIP - switch) Direction inversion and/or addressing DIP-switch for channels 1 and 2 DN - DIP switch for channel 1 and 2 (for double usage) Detection point Evaluation board Electro magnetic compatibility Frauscher diagnostic system Track section clear indication relay contact (= status of track section ‘unoccupied’) Frauscher Reset acknowledgement pcb Frauscher Rail deflector Ground Equipment version Evaluation board with microcontroller (integrated microcontroller evaluation board) Soldering jumper Line verification box Multi section digital axle counter Test relay contact (= status of track section ‘occupied’) Testing plate, type PB200 Research Designs and Standards Organization Wheel sensor, type 180 Reset box Serial communication interrupted Fuse board with crowbar driver Signal engineering manual Rail claw, type 140 Strain relief clamp Single section digital axle Counter Sensor systems of a wheel sensor Track lead junction box Track section

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Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page 1

Figure 1.1: Front view of ACS2000 system

The Frauscher Axle counting system ACS2000 is a microcontroller based system developed by M/s Frauscher GmbH, Austria and manufactured in India by M/s Frauscher Sensor Technology India Pvt. Ltd., Bangalore. The system comprises two mutually independent channels with identical hardware. The channels are fed in parallel with the same input data. Track clear indication is obtained only when results from two mutually independent comparators coincide.

1.2 एसीएस 2000 धरुा गणक के घटक Components of Axle counting system ACS2000

Figure 1.2: Wheel sensor RSR180

Figure 1.3: ACS2000 System rack

Trackside equipment • Wheel sensor RSR180 with moulded cable and protection tube• Rail claw with clamping bolts• Rail deflector FRD• Strain relief clamp SRC• Track lead junction box TLJB• Line verification box LVB (for ‘conditional hard reset’ application

only)

Indoor installation • Overvoltage protection board BSI• Board rack BGT• Axle counting backplane ABP• Fuse board SIC• Evaluation board IMC (EB)• Axle counting board ACB• Digital input/output board DIOB (optional for transmission mode)• Reset box RSTBOX (for ‘preparatory or conditional hard reset’

applications)• Frauscher Reset acknowledgement pcb FRA (for ‘preparatory reset’

application only)

1.3 सहायक दस्तावेज Supporting documentsFor more detailed description and information on the axle counting system ACS2000, refer to documentation “D10043 Part 01 to 13 of the axle counting system ACS2000” and “D1414-3 Mounting and commissioning of wheel sensor type RSR180” supplied by M/s Frauscher.

The axle counting system ACS2000 is a modular system and, when fully configured, comprises the following components/boards:

CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0

1 फ्रॉशर ए सी एस 2000 मल्ट� सेक्शन �डिजटल एक्सल काउन्टर Frauscher ACS2000 Multi Section Digital Axle Counter 1.1 प�रचय Introduction

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1.4 प्रणाल� का िववरण System descriptionWheel sensors are provided at the beginning and end of each track section. Wheel sensor, together with the evaluation board, operates as the counting head. The counting head detects all train wheels traversing this section as well as their driving direction. Each wheel sensor is connected to an evaluation board by means of a four-wire signalling cable (typically star-quad cable). This cable carries the power for the wheel sensor and the axle detection data for the evaluation board.

The axle counting system ACS2000 works on power supply voltage from +19 V DC to +72 V DC. The axle counting board ACB is capable of evaluating the information, supplied byevaluation boards, of up to 6 independent counting heads.

In case of adjacent track sections, double usage (same wheel sensor is shared between two track sections) of the counting head at the separation joint is possible depending on the configuration. For a track section with more than 6 counting heads (up to 12 counting heads maximum), two ACBs can be interconnected with a null modem cable to evaluate and provide track clear indication (Please refer Annexure III, Page 51).

The evaluation board IMC provides counting head control functionality. The track section ‘clear/occupied’ status output from the axle counting board ACB is fed to the evaluation board IMC for counting head control purposes using the RJ45 sockets on the backplane ABP. The counting head control outputs (track section “clear” status and referred to as DEACT OUT) from an ACB must be connected to the corresponding counting head control inputs (DEACT IN) using the patch cables. When counting head control is wired, the counting head remains fully functional and activated, however, no occupied status output is delivered in the event of a mistimed occupancy. This increases the availability, as no faults will occur from maintenance work (e.g. metal of tools temporarily above a wheel sensor). The principle of counting head control is that individual connected counting heads are desensitised as long as all adjacent track sections are ‘clear’ (unoccupied). If an adjacent track section is occupied or its system enters fault mode, the counting head is sensitised. This counting head control feature of the evaluation board IMC is used for trolley suppression by axle counting system in Indian Railway applications (Please refer Annexure IV Page 52 & 53).

The axle counting board ACB of the axle counting system compiles the axle detection data received from all counting heads connected. It generates “track clear” or “track occupied” indication for the corresponding track section as an overall result. The output of this result is given to direct relays (potential-free). The front panel of the axle counting board ACB features two toggle switches for “pre-Reset”. The axle counting board ACB also provides inputs for “Reset” of the axle counting system and the reset inputs are wired from the reset box.

The reset box allows carrying out of ‘preparatory reset’ or ‘conditional hard reset’ of the axle counting system by the authorised operating personnel depending on the respective track section’s requirement. In ‘preparatory reset’, after the reset has been applied and accepted by the ACS2000, the track section clear status will occur only after the track section has been correctly traversed by a sweep train. In case of ‘conditional hard reset’, the line verification box is used to communicate to the ACS2000 system that the track section is clear after physical verification. Once the ACB has accepted the ‘conditional hard reset input’, the resetting of the ACS2000 will occur immediately with no need for traversing of the track section by a train.

The Frauscher Reset acknowledgement PCB FRA transmits the “reset acknowledgement” status from the ACB to the reset box when the ‘preparatory reset’ command is applied and accepted by the system.

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Advantages:

• No drilling of holes is required for mounting wheel sensors to the rail.• No electronic components (e.g. EJB) are installed at site.• No earthing is required at site.• No frequent adjustments are required at site. However, inspection and adjustments of indoor and

outdoor equipment shall be carried out according to the schedules specified in section 5“Maintenance”.

1.5 संचालन के प्रकार Modes of operationThe axle counting system ACS2000 can be configured to work in following modes:

• Isolated mode (this is generally used for track sections within the station area)• Transmission mode (in this mode, an optional Digital input/output module (DIOB) can be used)

When the ACS2000 system is used in transmission mode with DIOB, additional 16 digital arguments (e.g. information, messages, commands) can be transmitted bi-directionally via modem. Arguments are read in by optocouplers and output by direct relays (potential- free).

Generally, the ACS2000 system is used in transmission mode for block applications (e.g. absolute block, automatic signalling etc.). The axle counting system ACS2000 can be configured for SSDAC and MSDAC applications.

Figure 1.4: ACS2000 block diagram in isolated mode


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Figure 1.5: ACS2000 block diagram in transmission mode

Figure 1.6: ACS2000 block diagram in transmission mode with DIOB


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TS1 TS1

TS1 TS1


1.6 घटक� का िववरण Description of components1.6.1 Evaluation board IMC The evaluation board IMC is used to power and evaluate a wheel sensor with two sensor systems (System 1 and System 2). The output switching signals are transmitted to the axle counting board ACB via the axle counting backplane ABP. Description of IMC front panel illuminated LED and control elements are shown in activated state in Figure 1.7:

Figure 1.7: Front panel of IMC

Serial Interface .......................... serial interface IMC GS03: Diagnostic connection

PWR ......................................... supply voltage channel 1 present

Sys1 .......................................... system 1 occupied (illuminated) or faulty (flashes)

A1 ............................................. output direction 1

B1 ............................................. output system 1

Adjust ....................................... required for IMC adjustment

Test ........................................... required to adjust IMC/simulate an occupancy of system 1

V+, GND .................................. 2 mm test sockets, voltage corresponds to the analogue wheel sensor current via a 100 Ω shunt

PWR ......................................... supply voltage channel 2 present

Sys2 .......................................... system 2 occupied (illuminated) or faulty (flashes)

A2 ............................................. output direction 2

B2 ............................................. output system 2

Adjust ....................................... required for IMC adjustment

Test ........................................... required to adjust IMC/simulate an occupancy of system 2

V+, GND .................................. 2 mm test sockets, voltage corresponds to the analogue wheel sensor current via a 100 Ω shunt

Type key: nnn ............................................ board identification code beginning with 001

xx..yy ........................................ operating voltage range

zz ...............................................version beginning with 01

1.6.2 Fuse board SIC

Figure 1.8: Front panel of Fuse board SIC

The fuse board SIC is used as supply voltage protection for ACS2000.

Si1............................. fuse for the supply voltage of channel 1

Si2............................. fuse for the supply voltage of channel 2

Type key: nnn............................ board identification code beginning with 001 xx...yy........................ operating voltage range zz............................... version beginning with 01


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Figure 1.9:Front panel of ACB

5 V............................. voltage supply channel 1 present

Occupied................... track section occupied (LED illuminated)/faulty (LED flashes)

Display...................... number of axles / information on status (error)

pre - Reset.................. elimination of the reset restriction (actuated: causes the same function as HIGH level at the "pre- Reset" inputs)

5 V............................. voltage supply channel 2 present

Serial Interface.......... D - SUB socket / RJ45 socket

Type key: nnn............................ board identification code beginning with 001 xx...yy........................ operating voltage range zz .............................. version beginning with 01

1.6.4 Digital input/output board DIOB

The digital input/output board DIOB is an optional board used for the transmission of digital data via modem. The DIOB is not necessary for implementing axle counting track section applications. It shall be used only where there is a need for transmitting digital information between two locations.

In the case of non safety - relevant applications, up to 16 arguments (bits or functions) can be transmitted. When applications are safety - relevant, transmission of up to 8 arguments is possible. The DIOB can only be used in transmission mode and will only operate in combination with an ACB. The data (switching status) is read in by optocouplers, serially transmitted and output at the partner device by direct output relays (potential - free).

Description of DIOB front panel elements is given in Figure 1.10 (Display illuminated):


1.6.3 Axle counting board ACBThe axle counting board ACB processes the counting head data supplied by the evaluation boards. Based on the data of the evaluation boards, the clear or occupied status of the track section being monitored is determined. The track status output (“clear/occupied”) is delivered using potential - free relay contacts on the ACB. The maximum number of wheels that can be counted per track section by the ACB is 8191. Description of ACB front panel illuminated LED and control elements are shown in activated state in Figure 1.9:

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5V.............................. voltage supply channel 1 present SCI............................ serial connection present IN............................... HIGH signal present at the relevant input OUT........................... relay contact closed at the relevant output

5V.............................. voltage supply channel 2 present SCI............................ serial connection present IN.............................. HIGH signal present at the relevant input OUT........................... relay contact closed at the relevant output

Serial Interface.......... D - SUB socket

Type key: nnn............................ board identification code beginning with 001 xx...yy........................ operating voltage range zz............................... version beginning with 01

Figure 1.10: Front panel of DIOB

1.6.5 Axle counting backplane ABPEach track section requires one axle counting backplane ABP. The axle counting backplane ABP comprises two backplanes (back side & inside of board rack) and is used to connect up to 6 evaluation boards IMC, one axle counting board ACB, one fuse board SIC and one digital input/output board DIOB (optional).

A 9 pin D- SUB plug is available on the ABP for connection of a modem for configuring the system in transmission mode.

The axle counting backplanes ABP are available in the following versions depending on the combination of boards required for a track section.

• Backplanes with slots for 1 ACB + 1 SIC + 2/3/4/5/6 evaluation boards IMC (5 combinations)• Backplanes with slots for 1 ACB + 1 SIC + 1 DIOB + 2/3/4/5/6 evaluation boards IMC (5

combinations)The minimum configuration of backplane is with slots for 1 ACB + 1 SIC + 2 evaluation boards IMC.


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Figure 1.11: Front view (inside face) of ABP002- 6 backplane (1 ACB + 1 SIC + 6 IMC + 1 DIOB)

`

Figure 1.12: Rear view (backside of housing) of ABP002- 6 backplane (1 ACB + 1 SIC + 6 IMC + 1 DIOB)

DIR, Mode & DIP - switch (Channel 1)

DN - DIP switch

(Channel 1)

Screw-type terminal for19 to 72 V

DC input(Channel 1)

ST4 (Channel 1),

ST5 (Channel 2)connectors for DIOB

RJ45 Counting head control I/P1/J7,2/J10,3/J13,4/J16,5/J19,6/J22

1’/J8,2’/J11,3’/J14,4’/J17,5’/J20,6’/J23

ST6 connector Clear, Occupied, pre - Reset, Reset interface

RJ45 Double usage I/P

3/J1,4/J2,5/J3,6/J4

ST1 connectorRSR180 interface

RJ45 Counting head control output

1/J5, 2/J6

DIR, Mode DIP - switch (Channel 2)

DN -DIP switch

(Channel 2)

9 pinD- SUB plugRS232C for

Modem interface

RJ45 Double usage outputs1/J9, 2/J12, 3/J15, 4/J18, 5/J21,

6/J24

Screw type terminal for 19 to

72 V DC input (Channel 2)


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Figure 1.14: Rear view (backside of housing) of ABP002 - 2 backplane with 1 ACB + 1 SIC + 2 IMC

Figure 1.13: Front view (inside face) of ABP002 - 2 backplane with 1 ACB + 1 SIC + 2 IMC

1.6.6 Board rack BGT

Figure 1.15: Board rack BGT

The boards of the axle counting system ACS2000 require a board rack BGT. The board rack houses the boards and provides mechanical protection. The board rack is an aluminium frame with a labelling bar.

1.6.7 Overvoltage protection board BSI

Figure 1.16: BSI

1.6.8 Reset box RSTBOX

Figure 1.17: Reset box

The over-voltage protection board BSI protects the indoor installation against interference voltages that may be induced into the cable between wheel sensor and cable termination rack (or BSI) due to lightning or overhead line short- circuit. The over-voltage protection board BSI is connected between the evaluation board and the wheel sensor and mounted on a DIN rail in the indoor installation.

The reset box RSTBOX comprises reset push button, reset counter and LED indicators. It is used by the operating personnel to carry out ‘preparatory reset’ or ‘conditional hard reset’ of the axle counting system. The reset box interfaces with the axle counting board ACB and transmits the reset command. A plug- in berg jumper on the pcb inside the reset box is used to set the reset configuration. If the reset box is configured for ‘conditional hard reset’, it will also be connected to the line verification box LVB for ‘line verified’ input.


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Figure 1.18: FRA pcb

1.6.10 Wheel sensor RSR180

Figure 1.19: Wheel sensor RSR180

1.6.11 Rail deflector FRD

Figure 1.20: Rail deflector

The reset acknowledgement pcb FRA is required for the ‘preparatory reset’ configuration. It is used to transmit the “reset acknowledgement” status (“waiting for clearing of track”) from the ACB to the reset box via potential - free relay contacts.

The wheel sensor comprises two sensor systems. System 1 (Sys1) is located on the left side and System 2 (Sys2) is located on the right side. Configuration of Sys1 and Sys2 is symmetrical. The wheel sensor has a moulded four- wire cable with a standard length of 5 m (10 m and 15 m cable lengths are also available). One wire of each sensor system is assigned to transmit the sensor system signal to the evaluation board. The other two wires are used for the voltage supply of the wheel sensor. Together with an evaluation board, wheel sensor RSR180 acts as a counting head. The wheel sensor is mounted to the rail using the rail claw. Exceptionally, the wheel sensor may be mounted directly to the web of the rail.

The rail deflectors FRD protect the wheel sensors against any mechanical damage from hanging parts of train. The rail deflectors are fixed inside the rail (wheel flange side) and mounted adjacent to either side of the wheel sensor. The distance between the centre of the wheel sensor and rail deflectors on either side in the longitudinal direction should be at least 350 mm.

The rail deflectors consist of two profiles with mounting bolts and nuts, one each for right hand and left hand side of the wheel sensor systems. The rail deflectors FRD are suitable for both 52 Kg and 60 Kg rail profiles.

1.6.12 Track lead junction box TLJB

Figure 1.21: TLJB

In the track lead junction box TLJB, the wheel sensor cable (standard length = 5 m) and the star quad cable from the indoor installation (cable termination rack/BSI) are terminated. Typically, each wheel sensor requires one track lead junction box. There are no electronic components inside the TLJB and the TLJB is installed on a concrete foundation.


1.6.9 Reset acknowledgement pcb FRA

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Figure 1.22: LVB

1.6.14 Strain relief clamp SRC

Figure 1.23: SRC

1.6.15 Testing plate PB200

The line verification box LVB is used for axle counting section that is configured for ‘conditional hard reset’. The LVB has a key actuated push button switch inside the box and is provided with a key/lock mechanism to prevent unauthorized access. It is typically mounted inside the location box closer to the track section.

The strain relief clamp SRC protects the wheel sensor cable from strain and stress created by ballast packing. The strain relief clamp allows the cable to move along with the wheel sensor and avoids stress when the train traverses over the wheel sensor. Different sizes of strain relief clamps are used for 52 Kg and 60 Kg rail profiles. One strain relief clamp is required for each wheel sensor installation.

The Testing plate PB200 is used to check occupancy detection capability of the wheel sensor and simulate traversing of a train wheel (axle). During the simulation of traversing, the PB200 touches the rail head like a real wheel.

Figure 1.24: Testing plate PB200

1.6.16 ModemTransmission mode of the ACS2000 system requires an RS2 32 compatible modem link. The type of modem shall depend upon the communication medium (copper or optic fiber cable) between the two locations. The modem shall be of any reputed make meeting the technical requirements of the axle counting system ACS2000. M/s Frauscher Sensor Technology shall be consulted for selection of modem.

1.7 केबल �बछाने क� योजना Cabling schemeThe axle counting system ACS2000 is connected to the wheel sensor via TLJB. A star- quad outdoor signalling cable is used between the indoor and outdoor equipments. See Figure 1.25 for the cabling scheme:

Figure 1.25: ACS2000 Indoor- outdoor interface cabling scheme


1.6.13 Line verification box LVB

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2 व्ह�ल सेन्सर आर एस आर 180 का ससं्थापन Installation of Wheel sensor RSR180

2.1 घटक तथा अनय अवयव Components and fixing elementsThe arrangement, mounting and commissioning of the wheel sensor RSR180 with rail claw must be carried out according to documentation “D1414 - 3 Mounting and commissioning of wheel sensor type RSR180” supplied by M/s Frauscher.Correct mounting in compliance with instructions is the basis for a long service life of the sensor. For mounting of wheel sensor RSR180 with rail claw and connecting it to the indoor installation, the following components and fixing elements are required:

Figure 2.1: Wheel sensor & Rail claw

• Wheel Sensor RSR180 with moulded connecting cable,standard length of 5 m (10 m and 15 m cable lengths are alsoavailable), consisting of 4 wires – brown (System 1), yellow(System 2), green (Vcc) and white (GND). A protection tubesuitable for the connecting cable length is clamped to thewheel sensor.

• Rail claw type SK140 with fixing bolts according to the railprofile.

• Track lead junction box.• Outdoor star quad cable.

Figure 2.2: Track lead junction box

2.2 आलंबन हेत ुसामान्य �नद�श General mounting instructions

Figure 2.3: Installation of Wheel sensor & TLJB

• Wheel sensor RSR180 is to be mounted at the insideface of the rail (wheel flange side).

• In curves, the wheel sensor RSR180 is to bemounted at the inside face of the curve.

• In point areas, the minimum admissible spacebetween rails is 100 mm (inside width betweenheads of rail).

• Minimum spacing between two wheel sensors on thesame rail is two sleeper spaces.

• Minimum spacing between a wheel sensor and the next rail joint or the next rail-weld is 1.5 m to 2.5 m.• The wheel sensor must be mounted concentrically between two sleepers.• Mounting of the wheel sensor RSR180 in the short pitch corrugation area is to be avoided where possible• The wheel sensor housing must not touch the head of rail.In case of possible need to deviate from mounting instructions, please consult the manufacturer.


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min. width of foot of rail 110 mm

max. width of foot of rail 155 mm

min. height of rail 130 mm

max. height of rail 180 mm

height (vertical) between the top of the railhead and the top of the sensor (Measurement A, see Figure 2.4)

40 to 45 mm

depth (horizontal width) between the side of the railhead and the inner face of the sensor (Measurement B, see Figure2.4)

0 to 8 mm

Figure 2.4: Wheel sensor measurement of A and B

In case of variation in the above guiding values, please consult the manufacturer. Following are the type of rail claw and clamping bolts according to the rail profiles:

Rail profile Claw type Bolt type

60 Kg rail SK140-011 BBK 22

52 Kg rail SK140-012 BBK 17.5

90 lb rail SK140-013 BBK 22

2.4 व्ह�ल सेन्सर के आलंबन हेत ुआवश्यक औजार Tools required for mounting of Wheel sensor

Steel wire brush and WD40 spray used to clean the rail surface area for easy fixing of rail claw.

Torque wrench (range 15 2 60 Nm) used to fasten the bolts at specified torque.

Socket spanner SW19 and SW17 & screw drivers

Fixed spanner SW36/Friction type ratchet – used to fix rail claw in the rail. Steel tape measure* Plumb bob for level measurement (2 m length)

Figure 2.5: Wheel sensor mounting tools


2.3 रेल क्लॉ का आलंबन Rail claw mountingThe following parameters and guiding values are to be considered for rail claw mounting of wheel sensor RSR180 to the rail:

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*Note: In RE area Fibre/wooden tape measure may be used instead of steel tape measure.


• Mount wheel sensor with respective fixing bolt to rail claw, if not already mounted. Cleanmounting area at foot of rail from coarse dirt using steel wire brush and WD40 spray.

• Place rail claw pos.2 on the foot of rail from the inside of the rail.• Clip tie- rod pos.2.2 and spring washer pos.2.7 on the outside face of rail.• Tighten nut pos.2.3 until the rail claw pos.2 touches the foot of rail on both sides (ensure

parallelism with foot of rail).

Note: The housing must not touch the head of rail. Ensure correct position of strain washer pos.3.4and pos.3.5 (bulge of washer outside). The hexagon socket head screw pos.2.6 must not be changed.

• Determine measurement “B” with tape measure.Rated range: 0 to 8 mm.If measurement “B” is outside of rated range, see “Horizontal position correction”.

• Determine measurement “A” with steel tape measure.Rated range: 40 to 45 mm.If measurement “A” is outside of rated range, see “Height correction”.

2.5.2 Horizontal position correction Note: If for the purpose of height correction, strain washers pos.3.4 (pos. 3.5) are removed, ensurecorrect position when placed again (bulge of washer outside).

If measurement “B” is not within rated range.

a) Place washer pos. 3.3 (dash lined) on the inside face of support pos. 2.1 and/or

b) Replace the fixing bolt.• Tighten nut pos.3.1 with 15 Nm.• Tighten nut pos.3.2 (pos.2.4) with 40 Nm.

2.5.3 Height correction • Loosen nut pos.2.4.• Shift support pos.2.1 until measurement “A” is between 40 mm and 45 mm.Note: If for the purpose of height correction strain washer pos.2.5 is removed, ensure correct positionwhen placed again (bulge of washer outside).

• Tighten nuts pos.2.4 with 40 Nm.


2.5 लगाना एवं समायोजन Fixing and adjustmentsThe following mounting instructions apply to rail claw mounting of wheel sensor RSR180 (see Figure 2.6).

2.5.1 Fixing

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Figure 2.6: Rail claw mounting of Wheel sensor RSR180

2.6 केबल का संयोजनConnection of cable

The moulded 4 wire wheel sensor cable together with protection tube shall be inserted through the cable gland in the track lead junction box. The 4 wires of the wheel sensor cable and of the star- quad cable from the indoor equipment shall be connected to the cage- clamp terminal block in the TLJB and each pair of diametrically opposed wires in the star quad cable from cable termination rack shall be used for wheel sensor according to Figure 2.7.

Figure 2.7: Cabling in the TLJB

Note: Prior to connection of wheel sensor cable check, isolation from earth of earthing cable wires.

4-Quad cable

from Loc Box Wheel sensor

cable


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• Method 1By setting DIR - DIP switches (located on the backplane ABP) ON or OFF in isolated mode. In case of transmission mode, these switches have different functions and either Method 2 or 3 will have to be used. See section 3.3 for more details on setting of DIP - switches.• Method 2By interchanging the wheel sensor systems cable wiring as shown in Figure 2.8.

Figure 2.8: Wheel sensor systems RSR180 reversed wiring connection

• Method 3By changing the mounting place of the wheel sensor to the other rail as shown in Figure 2.9.

2.8 पी बी 200 क� सहायता से आरएसआर 180 क� ऑकुपेन्सी �डटेक्शन क� �मता क� जाँच करना Checking occupancy detection capability of RSR180 using PB200

The occupancy detection capability of wheel sensor RSR180 can be checked by simulation using the testing plate PB200.

Figure 2.10: Check occupancy detection capability using PB200

1. Place PB200 on the left edge of the wheel sensor. When placingthe PB200 to the left edge of the wheel sensor for checkingSys1, the corresponding evaluation board IMC connected toSys1 will output an occupancy (i.e. track section status willchange from “clear to occupied”). The LED Sys1 on the frontpanel of the associated evaluation board IMC will light up.

2. Place PB200 on the right edge of the wheel sensor. Whenplacing the PB200 to the right edge of the wheel sensor forchecking Sys2, the corresponding evaluation board IMCconnected to Sys2 will output an occupancy (i.e. track sectionstatus will change from “clear to occupied”). The LED Sys2 onthe front panel of the associated evaluation board IMC will lightup.

ABP TLJB

RSR systems

BSI004RSR CTR ST.1

reversed

e.g.:Terminal


2.7 धरुा गणना क� �दशा का प�रवतर्न Changing the direction of axle countingThere are three methods for changing the direction (count in or out) of axle counting:

Figure 2.9: Changing wheel sensor mounting side on rail

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Figure 2.11: Methods of using Testing plate PB200

1. During the simulation of traversing, place the Testing plate PB200 such that ittouches the rail head like a real wheel.

2. Initial position: Wheel sensor is not occupied.3. Position PB200 on left of sensor Sys1, laterally to the head of rail, and move (pull) it

evenly in the direction of arrow over the sensor Sys1: Sensor Sys1 is occupied.4. Move (pull) PB200 evenly in the direction of arrow in to the centre of the two sensor

systems (Sys1 & Sys2): Sensors Sys1 and Sys2 are occupied.5. Move (pull) PB200 evenly in the direction of arrow over the sensor Sys2: Sensor

Sys2 is occupied.

Note that one wheel count is counted at the end of step 5.6. End position: Both sensors are not occupied.

Similarly, move PB200 from Sys2 to Sys1 for simulation of traversing in opposite direction.


2.9 पी बी 200 क� सहायता से वह�ल स�सर आर एस आर 180 पर टे्रवर�सगं का �सम्यलेुशन करना

Simulation of traversing over Wheel sensor RSR180 using PB200 The traversing of a train over the wheel sensor RSR180 can be simulated with the help of testing plate PB200 as shown in Figure 2.11 and described below:

1 2 3

4 5 6.

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Station: Line Up / Down: Date:

Wheel sensor part #: Wheel sensor serial #: Wheel sensor (DP) ID: TLJB ID:

S.No. Check description Unit Expected result

Check result

Notes

1 Specify the rail profile in which the wheel sensor is mounted. - 60 Kg / 52 Kg/ 90 lb

2

Specify the side of rail in which the wheel sensor (DP=Detection Point) is mounted:

3 Specify the wheel sensor cable length used: Mtr 5/10/15

4

Check that correct rail claw is used and configured according to rail profile. 60 Kg = BBK22 52 Kg = BBK17.5 90 lb = BBK22

�� / ��

5 Torque value (wheel sensor to BBK) [Nm] 15 Nm 6 Torque value (BBK/front plate to rail claw) [Nm] 40 Nm

7 Check that the wheel sensor is mounted at the inside face of the rail (wheel flange side). �� / ��

8 In curves, check that the wheel sensor is mounted at the inside face of the curve. �� / ��

9

Check that the minimum spacing between a wheel sensor and the next rail joint or the next rail weld is 1.5 m to 2.5 m.Note: The minimum spacing between two wheel sensors on the same rail is two sleeper spaces.

�� / ��

10 Check that the wheel sensor is mounted concentrically between two sleepers. �� / ��

11 Check that the wheel sensor housing does not touch the head of rail. �� / ��

12 Check that there is no gap between the rail claw and foot of the rail. �� / ��

13 Check that the wheel sensor is not mounted on the welded part of the rail. �� / ��

14 Check that the wheel sensor surface is in parallel with the head of rail in longitudinal direction of the rail.

�� / ��

15

Check that the wheel sensor is mounted 1 m away from centre of S-bond towards direction of train movement in non- rope portion of loop provided for AFTC (see Figure 2.12)

�� / ��

16 Check that the wheel sensor is mounted 1 m away from tuning unit in case of Alpha bond provided for AFTC (see Figure 2.13)

�� / ��

17 Check that the spring washers (pos.2.5, pos. 3.4 &pos.3.5) used for rail claw mounting are positionedcorrectly with the bulge of washer outside.

�� / ��

18 Check of measurement A (vertical spacingbetween the wheel sensor and head of the rail) [mm] 40 to 45 mm

19 Check of measurement B (horizontal spacingbetween the wheel sensor and head of the rail) [mm] 0 to 8 mm

20 Check that correct strain relief clamp is used �� / ��


2.10 व्ह�ल स�सर तथा ट�एलजेबी के संस्थापन हेत ुजांच सचूीChecklist for installation of Wheel sensor and TLJB

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according to the rail profile and it is securely mounted to the rail base for protecting the wheel sensor cable.

21 Check that rail deflectors are mounted adjacent to either side of the wheel sensors and on the inside face of the rail (wheel flange side).

�� / ��

22 Check that the top edge of the rail deflector is not in contact with the rail head. �� / ��

23 Check that the rail deflectors are mounted at least 350 mm away from the wheel sensor on either side. �� / ��

24

Installation of TLJB: Check that it is firmly erected, straight, within permissible height and away from the permissible distance from the nearest rail as per the Railway’s Schedule of Dimensions (SOD). It should not infringe with the Railway’s SOD.

�� / ��

25 Check that the opening of TLJB is preferably away from trackside. �� / ��

26 Check that the wheel sensor cable to the TLJB is provided with protection tube. �� / ��

27 Check that the wheel sensor cable is laid 400 mmbelow sleeper level. �� / ��

28 Check that the wheel sensor cable to the TLJB is laid through double wall corrugated pipe. �� / ��

29 Check that only star quad cable is used between the BSI in equipment room and the TLJB (no signalling cable is to be used).

�� / ��

30 Check of the insulation resistance for the quad cable used between the wheel sensor and the BSI in the equipment room.

≥ 10 MΩ MΩ

31 Check of the earth resistance for the quad cable used between the wheel sensor and the BSI in the equipment room.

≤ 1Ω Ω

32

Check of the loop resistance for the star quad cable (0.9 mm wire diameter) between the wheel sensor and the BSI in the equipment room.

Resistance between SYS1 wire and GND wire < 56.6 Ωper km Ω

Resistance between SYS2 wire and GND wire < 56.6Ωper km Ω

Resistance between VCC wire and GND wire < 56.6Ωper km Ω

33 Check that the length of star quad cable between the wheel sensor and the BSI in the equipment room is < 4 km (for 0.9 mm wire diameter).

�� / ��

34 Check that the unused cores/pairs of star quad cable in the TLJB are cut such that none of the conductors remain exposed.

�� / ��

35 Check that no wires are paralleled to reduce conductor resistance. �� / ��

Figure 2.12: Installation of Wheel sensor in AFTC with S Bond Figure 2.13: Installation of Wheel sensor in AFTC with Alpha bond

Train direction 1 mtr Train direction

TU

1 mtr


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3 समायोजन एवं मापन Adjustments and measurements

3.1 पावर सप्लाई Power supplyThe axle counting system ACS2000 requires stable power supply. It is recommended to derive the power from the IPS (Integrated Power Supply)/regulated power supply. Apply and measure the supply voltage:

Voltage supply range +19 V to +72 V DC

Typically 24 V DC power supply is used for installations on Indian Railway.

3.2 एवल्यएुशन बोडर् पर मापन एवं समायोजन Measurements and adjustments at the Evaluation board The test sockets are provided on the front panel of the evaluation board. Measurement of a voltage that is proportional to the sensor current can be done on these test sockets.

3.2.1 Tools and measuring equipment mV-Meter: Range 1000 mV DC, precision ± 0.5 %

Two probes with 2 mm male connectors (for connection of evaluation board with mV meter)

3.2.2 Measurement of Wheel sensor current

Wheel sensor currents are measured as proportional voltages at the test sockets across an internal 100 Ohm shunt resistance. Thus 100 mV corresponds to a sensor system current of 1 mA. The sensor current in system 1 and system 2 must have a value between 2.8 mA and 5.0 mA, which corresponds to 280 mV and 500 mV DC at the test sockets. System 1 measured voltage must not differ from system 2 measured voltage by more than 20 mV DC (0.2 mA or 5% maximum of the sensor current). If multimeter is used for measurement of sensor current, the multimeter shall be set to measure DC voltages.

Figure 3.1: Measurement of Wheel sensor current

1) If a measured value exceeds the rated range, wheel sensor RSR180 must not be operated undersuch condition.

2) System currents of wheel sensor depend mainly on:• Rail profile and mounting of rail claw.• Mounting position (measurement “A”, measurement “B”, concentrically between sleepers).• Metal parts in direct proximity of the RSR (e.g. earthing connectors).• Cable loop resistance of the star quad cable between the indoor and outdoor equipment.

3.2.3 Adjustment of the Evaluation board IMC Apart from commissioning of new installation, adjustment of the IMC board is also required after replacement of the IMC board, replacement of the wheel sensor or dismounting and mounting of the wheel sensor due to repair, cleaning or track work or in case of changes in the cable run (changes in loop resistance).


Note:

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Figure 3.2: Push switches on thefront panel of Evaluation board IMC

• At the IMC to be adjusted, push the switches (TA1 and TA2)simultaneously to the left in direction “Adjust“ (simultaneousmeaning within 500 ms).

• Both switches must remain in this position for at least 500 ms.• Release both switches simultaneously within 500 ms.• Switches must not remain in normal position for more than 2

seconds.• Push both switches simultaneously within 500 ms to the right

in direction “Test“.• Both switches must remain in this position for at least 500 ms.• Release both switches simultaneously within 500 ms.

Successful adjustments are signalled by LEDs Sys1 and Sys2, which light up for approximately 2 seconds.

Failed adjustments are signalled by fast flashing (10 times per second) of LEDs Sys1 and Sys2 for 4 seconds. In that case, the operating sequence described above must be repeated.

3.3 एबीपी क� �डप िस्वच स�ैटगं DIP-switch settings of ABPThe functioning of the axle counting system ACS2000 depends upon the configuration settings of the DIR-, MODE- and DN - DIP switches on the ABP. The DIR-, MODE- and DN - DIP switches can be accessed from the back of the board rack and are located above and below of plug connector ST6.

• In isolated mode, the DIR-, MODE- and DN - DIP switch settings of channel 1 must not differ from channel 2.

• In transmission mode, the MODE and DN DIP switch settings of channel 1 must not differ from channel 2 of the same ACS2000 system. In transmission mode, the DIR - DIP switch settings have an addressing function.

• The DIP switches DIP1 -7, DIP2 -7 and DIP2- 8 of channel 1 and DIP1’- 7, DIP2’ -7 and DIP2’ -8 of channel 2 have no function.

See Figure 3.3 for configuration of DIP- switches for channel 1 and channel 2.


Prior to adjustment, it is necessary to verify that the wheel sensor connected to the IMC board was correctly mounted and that there is no train in the track section.

During the adjustment procedure, the wheel sensor connected to the IMC board must not be damped (no metal parts or testing plate in direct proximity of the sensor), as adjustment under such conditions is not completed or will be faulty.

Prior to adjustment, measure system currents as in section 3.2.2 above.

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Figure 3.3: Configuration of DIP-switches for Channel 1 and Channel 2 on ABP

3.3.1 MODE DIP- switches The MODE DIP- switches (DIP1/DIP1’ - Switch 8) are used to set the operating mode of the ACS2000 system (Isolated mode or Transmission mode).

3.3.2 DN - DIP - switches

The DN- DIP- switches (DIP2/DIP2’ - Switches 1 to 6) indicate the ACS2000 as to which input of the ACB is used for double usage of counting head. In case of double usage, one counting head input is shared and evaluated by two ACBs of adjacent track sections.

3.3.3 DIR- DIP switches in Isolated mode The DIR- DIP- switches (DIP1/DIP1’ - Switches 1 to 6) are used to configure the counting direction of each counting head in isolated mode.

3.3.4 DIR - DIP switches in Transmission mode

In transmission mode, the DIR- DIP- switches cannot be used (as in isolated mode) to configure the counting direction. In transmission mode these switches are used for defining the following configurations of ACB: -DIP1/DIP1’ - Switch 1 is used to define an ACB as MASTER or SLAVE (one of the two ACBs that are connected shall be defined as Master and the other as Slave). The ACB that is defined as Master will start the serial communication in transmission mode.

If two ACBs are connected in transmission mode, one of the ACBs is defined as Master by placing the DIP1/DIP1’ - Switch 1 (of both channel 1 and channel 2) in ON position. The other ACB is


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Sys1 to Sys2 Figure 3.4: Traversing directions over Wheel sensor

Sys2 to Sys1

Isolated mode Traversing

from DIR - DIP

- switch Counting process

Sys1 to Sys2 OFF Count in Sys1 to Sys2 ON Count out Sys2 to Sys1 OFF Count out Sys2 to Sys1 ON Count in

Table 3(a): Counting direction in Isolated mode

Transmission mode Traversing

from RSR system

wiring Counting process

Sys1 to Sys2 Not reversed Count in Sys1 to Sys2 Reversed Count out Sys2 to Sys1 Not reversed Count out Sys2 to Sys1 Reversed Count in

Table 3(b): Counting direction in Transmission mode


defined as Slave by setting the corresponding DIP1/DIP1’ Switch 1 (of both channel 1 and channel 2) in OFF position.

DIP1/DIP1’ – Switches 2 to 6 are used to set an internal 10- bit address for serial data communication between the two ACS2000 systems. The 10 - bit internal address and corresponding switch setting must be identical for those two systems that communicate with each other. For a bit value of 1, the switch is set in ON position and, for a bit value of 0 it is set in OFF position.

If several ACS2000 systems are used in an installation (for example, UP line and DN line), unique serial addresses shall be set for UP line and DN line axle counting systems to detect / prevent accidental wrong connection of the modem line.

In transmission mode, the counting direction can be changed by interchanging the wheel sensor systems cable wiring as shown in Figure 2.8. See Figure 3.4 for traversing directions over wheel sensor, Table 3(a) for counting direction in isolated mode and Table 3(b) for counting direction in transmission mode.

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DIP- switches (in Isolated mode) Switch Position Function Channel 1 Channel 2

DIP1- Switch 1 to 6

DIP1’- Switch 1 to 6

OFF Count in (When traversing from Sys1 to Sys2) ON Count out (When traversing from Sys1 to Sys2) OFF Count out (When traversing from Sys2 to Sys1) ON Count in (When traversing from Sys2 to Sys1)

DIP1 - Switch 7 DIP1’- Switch 7 OFF or ON No function

DIP1- Switch 8 DIP1’- Switch 8 OFF Isolated mode ON Transmission mode

DIP2- Switch 1 to 6

DIP2’-Switch 1 to 6

OFF Counting head double usage at respective input (1 to 6)

ON No counting head double usage at respective input (1 to 6) DIP2- Switch 7 & 8

DIP2’-Switch 7 & 8

OFF or ON No function

Table 3(c): Setting of DIP switches in Isolated mode

DIP switches (in Transmission mode) Switch Position Function Channel 1 Channel 2

DIP1- Switch 1 DIP1’- Switch 1 OFF Axle counting board is defined as SLAVE ON Axle counting board is defined as MASTER DIP1 – Switch 2 to 6

DIP1’ –Switch 2 to 6

OFF Respective serial address bit set to “0”

ON Respective serial address bit set to “1”

DIP1- Switch 7 DIP1’- Switch 7 OFF or ON No function

DIP1- Switch 8 DIP1’- Switch 8 OFF Isolated mode ON Transmission mode

DIP2- Switch 1 to 6

DIP2’-Switch 1 to 6

OFF Counting head double usage at respective input (1 to 6)

ON No counting head double usage at respective input (1 to 6) DIP2- Switch 7 & 8

DIP2’-Switch 7 & 8

OFF or ON No function

Table 3(d): Setting of DIP - switches in Transmission mode


See Tables 3(c) and 3(d) for setting of DIP - switches according to the configuration and requirement.

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Note: In the event of double usage of a counting head, the counting direction must be configured for both axle counting systems using the corresponding DIR/DIR’ - DIP switches on the ABP. If an input of the ACB is not used, the associated DIR/DIR’ - DIP switch will have no function. However both channels must have same setting (both OFF or both ON).

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• Input power supply voltage range +19.2 V to +30 V DC

When reset is applied: • Switched reset output voltage at RST+/RST = reset input voltage at RV+/RV.• Check the duration of switched reset output voltage pulse length > 3 to 5 seconds without

interruption.• Check the count increments in the non - resettable counter.

3.5 र�सेट बॉक्स म� जम्पर सै�टंग Jumper settings in the Reset boxThe plug - in berg jumper on the pcb inside the reset box is used to configure the reset type.

• Set jumper to position “P” for ‘preparatory reset’.• Set jumper to position “H” for ‘conditional hard reset’. (This reset will require “line verified”

input from line verification box).


3.4 �रसेट बॉक्स पर मापन Measurements at the Reset boxApply and measure the power supply voltage:

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• Counting head assignment test• Verification of counting direction in isolated mode• Verification of counting direction in transmission mode• Verification of reset operation

4.2 काउं�टगं हेड �नधार्रण पर��ण Counting head assignment testUpon initial commissioning of the ACS2000 system, it is necessary to verify the assignment of the counting heads.

The assignment of the wheel sensors is to be checked for each wheel sensor that is assigned to a track section.• Damp (traverse) wheel sensor RSR using a testing plate PB200.• LEDs for Sys1 and Sys 2 of respective evaluation board must turn on.• Assigned axle counting boards ACB must detect occupancy (including double usage) and turn on

“occupied” status LED.

4.3 आइसोलेटेड मोड म� गणना क� �दशा का सत्यापन Verification of counting direction in isolated mode

Counting direction of the axle counting system in isolated mode is verified as follows: • Enter one or more wheels into the track section (wheels may also be simulated using the testing

plate PB200):The axle counting system turns on “occupied” status LED and the number of wheels counted areshown in the display of the ACB.

• Exit the wheel(s) from the track section:The axle counting system turns off “occupied” status LED and the ACB display shows “0”.

• Repeat this procedure with each wheel sensor assigned to a track section.• If counting direction is incorrect, switch both the DIR and DIR’ DIP switches to ON or OFF for

the associated wheel sensor. Thereby the counting direction is reversed.

Note: The following factors determine whether the axle counting board ACB will count IN or countOUT of the wheels during traversing the wheel sensor: • Trackside, where counting head is mounted.• Direction, in which wheels traverse the counting head.• DIR- DIP switches ON or OFF.

• Wiring of wheel sensor systems.

Note: Reversal of direction is possible by:


4 कायार्त्मक पर��ण Functional testing

4.1 कायार्त्मक पर��ण के प्रकार Types of functional testsFunctional tests are required upon initial commissioning and after modifications made to the installation. If necessary, a reset may be performed between the functional tests. After a reset, response of the assigned ACB is to be checked. The following functional tests are required to be performed:

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• DIR - DIP switches ON or OFF.• Changing the mounting side (if not contrary to mounting and commissioning instructions of

wheel sensor). In case of double usage, this method does not apply.

4.4 ट्रांस�मशन मोड म� गणना क� �दशा का सत्यापनVerification of counting direction in transmission mode

Counting direction of the axle counting system in transmission mode is verified as follows: • Enter one or more wheels into the track section (wheels may also be simulated using the testing

plate PB200):The two axle counting systems operating in transmission mode turn on “occupied” status LEDand the number of axles counted is shown in the displays of both ACBs.

• Exit the wheel(s) from the track section:The two axle counting systems operating in transmission mode turn off “occupied” status LEDand “0” is shown on the displays of both ACBs.

• Repeat this procedure for each wheel sensor assigned to a track section.• If counting direction is incorrect, reverse wheel sensor systems wiring at respective input (Sys1 ��Sys2).The DIR DIP switch settings have a different functionality in transmission mode than in isolatedmode.

Note: The following factors determine whether the axle counting board ACB will count in or countout of the wheels during traversing the wheel sensor:

• Trackside, where counting head is mounted.• Direction, in which wheels traverse the counting head.• Wiring of wheel sensor systems.

Note: Reversal of direction is possible by:

• Reversing the two sensor systems wiring (Sys1 ��Sys2).• Changing the mounting side (if not contrary to mounting and commissioning Instructions of

wheel sensor). In case of double usage, this method does not apply.

4.5 र�सेट ऑपरेशन का सत्यापन Verification of reset operationThe reset procedure is dependent upon the type of ACB, reset box and reset configuration (‘preparatory reset’ or ‘conditional hard reset’).

The verification of the reset box functionality requires the respective axle counting section in the “failed” status.

Preparatory reset: • Simulate incorrect wheel counts in or out using the testing plate PB200.• Apply reset command from the reset box. The count increments in the reset counter.• Once the reset command is accepted by the ACB, the axle counting system will be reset and an

LED “PREP RESET” on the reset box is turned on.• Simulate correct passage of train through counting head(s) assigned to the respective track

section (enter one or more wheel(s) in to and exit the wheel(s) from the track section using thetesting plate PB200).


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• After correct traversing by a train, the axle counting system will turn off “occupied” status LEDand display ‘0’ on the ACB front panel.

Conditional hard reset: • Simulate incorrect wheel counts in or out using the testing plate PB200.• Provide “line verified” input from the line verification box.• Apply reset command from the reset box. The count increments in the reset counter.• Once the reset command is accepted by the ACB, the axle counting system will be reset. The axle

counting system will turn off “occupied” status LED and display ‘0’ on the ACB front panel.

Note: The verification of reset operation may only be carried out when there are no trains on the associated track section(s). After completion of the reset verification, it must be ensured that the axle counting system is restored to normal working condition.


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• mV Meter range 1000 mV DC, precision +/- 0.5 %• 2 measuring strips with 2 mm connector• 2 measuring strips with testing tips• Testing plate PB200

5.3 एवल्यएुशन बोडर् के टेस्ट सॉकेट पर मापन Measurements at the test sockets of the Evaluation board Cycle: < 2 years

Tests: Perform measurements as given in section 3.2.2 and, if necessary, adjust the evaluation board. The wheel sensor current of wheel sensor RSR180 is set at 2.8 to 5 mA. The wheel sensor system currents must be measured in the undamped status, with the sensor correctly mounted. It is recommended to record the measured values.

5.4 वह�ल सेनसर , रेल �डफलेकटर तथा लाइन वे�र�फकशेन बॉकस का पर��ण/जाँच Testing/checking of Wheel sensor, Rail deflector and Line verification box

5.4.1 Testing of Wheel sensor RSR180 Cycle: < 2 yearsTest: Perform visual inspection and mechanical checks of wheel sensor RSR180.

• Traverse wheel sensor with a train or• Damp (occupy) the wheel sensor using the testing plate PB200.The wheel sensor‘s occupancy detection capability must be tested once in two years by means of traversing or by damping with the testing plate PB200. This is done by means of traversing (both system 1 and system 2) of at least one axle, which must be counted in and out correctly by the corresponding ACB. Compliance with standards of mounting, commissioning and maintenance is required.

5.4.2 Checking of Rail deflector Cycle: < 2 yearsCheck 1: Perform visual inspection and mechanical checks of rail deflectors mounted on both sides

of a wheel sensor.

Check 2: Measure the distance between the centre of the wheel sensor and rail deflectors on either

side in the longitudinal rail direction; it should be at least 350 mm away from the wh

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Maintenance Handbook on FRAUSCHER ACS2000 Multi Section ... · Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page ii %ॉशर ए सी एस 2000 मट सेÈशन