Vous êtes sur la page 1sur 127

Product ID: SSDAC-G36

Single Section Digital Axle Counter

2DP1S Installation Manual


(SSDAC-2DP1S-IM)

Document ID: SSDAC-2DP1S-IM


Version 1.0, Revision 4

G.G.Tronics India Private Limited, Plot No : 10, 3rd Phase, 6th Main, Peenya Industrial Area, Bangalore – 560058, INDIA
Phone : +91-80-28372449, 28372450, 28372451 Fax : +91-80-28372387
Mail : info@ggtronics.com Website : www.ggtronics.com

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - I


About this Document

Document Title 2DP1S Installation Manual


Version 1.0, Rev 4
Submission
Distribution list R&D

Copyright © 2014 All Rights Reserved

This Document is confidential and may be privileged. Using it partially or wholly for
any purpose or copying or storage in any medium without written permission of
G.G.Tronics is strictly prohibited.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - I


Dear Customer,

Thank you for your decision on choosing the SSDAC-G36 that adds
value in your venture for modernization of safety signaling system in Railways. It is
our privilege that the SSDAC-G36 will be integrated into the family of signaling
system for effortless management of block and station section proving. The 2 / 2
Microcontroller voting with CENELEC SIL-4 level safety validation makes the system
most safe and reliable under stringent working environment.

We ensure at the end of the day the customer is satisfied and look at other versions of
3DP-1S for point zones, 3D-2S for IBS and AS for Auto Section signaling solutions at
various section layouts.

We look forward to serving you with commissioning and technical support round the
clock for years to come.

We thank you once again for choosing our product for your signaling needs.

Yours Sincerely,

Shamantha K.S.,
Director,
G.G.Tronics India Private Limited,
Bangalore, India

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - II


Revision History

Date Ver Rev Modification / Description Author


G. Hair Krishna
28-12-2005 1 0 Initial Draft
M. Ravi Kumar
03-03-2006 1 0 Quality Check N.Vinutha
20-05-2006 1 0 Approval N. Mohan Rao
14-07-2007 1 1 Initial Draft S. Venkat Krishna
26-07-2007 1 1 Approval N. Mohan Rao
Maintenance log sheet FTB
08-01-2009 1 1 N. Mohan Rao
Numbers Modification
10-09-2009 1 2 TX & RX Coil DRG Modification S. Venkat Krishna
26-08-2011 1 3 Address & Logo Modified Amulya
Logo & Director Name
28-11-2014 1 4 Modified ,Drawings added Karthikeyan.S
from Page.No.96
29-11-2014 1 4 Approval S Rajkumar

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - III


Table of Contents

1 Introduction 1
1.1 Overview ............................................................................................................. 1
1.2 Configurations of System .................................................................................... 1
1.3 Specifications ...................................................................................................... 2
1.4 System Design ..................................................................................................... 2
1.5 Physical Description ............................................................................................ 3
1.6 Construction Details ............................................................................................ 3
2 System Overview 4
2.1 SSDAC- 2DP1S system in brief .......................................................................... 4
2.2 Configuration of SSDAC- 2DP1S ....................................................................... 5
2.3 System working principle .................................................................................... 5
2.4 SSDAC- 2DP1S (2DP1S Configuration Setting) ................................................ 7
2.4.1 SSDAC- 2DP1S SF (Start Fed Configuration Setting) ....................................... 7
2.4.2 SSDAC- 2DP1S EF (End Fed Configuration Setting) ........................................ 8
3 System Wiring Details 11
3.1 Introduction: ...................................................................................................... 11
3.2 Transmitter Coil 1 Connection (MS-5): ............................................................ 11
3.3 Transmitter Coil 2 Connection (MS-4) ............................................................. 12
3.4 Receiver Coil 1 Connection (MS-17) ................................................................ 13
3.5 Receiver Coil 2 Connection (MS-16) ................................................................ 14
3.6 Modem-A Communication (FSK) Connection (MS-6) .................................... 15
3.7 Modem-B (COM2) Communication (FSK) Connection (MS-11) .................... 16
3.8 SM/Event Logger Connection (MS-15) ............................................................ 17
3.9 RESET- A (MS-12) ........................................................................................... 18
3.10 RESET- B (MS-13) ........................................................................................... 19
3.11 Vital Relay A (MS-2) ........................................................................................ 20
3.12 Vital Relay B (MS-3) ........................................................................................ 21
3.13 Preparatory Relay A (MS-7) ............................................................................. 22
3.14 Preparatory Relay B (MS-8).............................................................................. 23
3.15 Train Simulator (MS - 9) ................................................................................... 24
3.16 DC-DC Converter (MS - 14) ............................................................................. 25
3.17 LCD Display (MS - 10) ..................................................................................... 26
3.18 Relay Box .......................................................................................................... 27
3.19 System Level Connections ................................................................................ 30
4 Installation Procedure 32
4.1 Pre Requisites for Installing SSDAC Systems .................................................. 32
4.2 Unpacking the systems ...................................................................................... 33
4.3 Steps for Installation .......................................................................................... 34
4.3.1 Location of Axle Detectors ............................................................................... 35
4.3.2 Marking & Drilling holes on the Rail ............................................................... 36
4.3.3 Fixing of Axle Detectors (Transmitter and Receiver Coil) ............................... 37
4.3.4 Fixing of Rail Deflector .................................................................................... 37
4.4 Installation of Location Box (Full size) ............................................................ 38
4.4.1 Power Supply Arrangement .............................................................................. 38

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - IV


4.4.2 Batteries ............................................................................................................. 38
4.4.3 Battery Charger ................................................................................................. 39
4.4.4 Cable .................................................................................................................. 39
4.4.5 Axle Detector coils ............................................................................................ 39
4.4.6 SSDAC Unit ...................................................................................................... 40
4.4.7 Display Unit ...................................................................................................... 41
4.4.8 Relay Box .......................................................................................................... 41
4.4.9 Reset Box .......................................................................................................... 42
4.4.9.1 Controls ............................................................................................................. 42
4.5 System Wiring ................................................................................................... 43
4.5.1 Fused Tag Block (FTB) ..................................................................................... 43
4.6 Tests before power ON...................................................................................... 43
4.7 Tests after power ON ........................................................................................ 44
5 LCD Display and LED Indications 45
5.1 LED Indications ................................................................................................ 45
5.2 LCD Display of SSDAC ................................................................................... 47
5.3 Trouble Shooting Chart ..................................................................................... 53
6 Resetting Procedure 66
6.1 Reset Procedure for 2DP1S ............................................................................... 66
7 Maintenance 68
7.1 Maintenance of the SSDAC system .................................................................. 69
7.2 Tools and Spares ............................................................................................... 69
7.2.1 Tool kit .............................................................................................................. 69
7.2.2 Recommended Spares ....................................................................................... 70
8 Do’s and Don’ts 71
8.1 Do’s ................................................................................................................... 71
8.2 Don’ts ................................................................................................................ 72
ANNEXURE 73
Annexure-I 87
Annexure-II 88
Annexure-III 89
DRAWINGS 94

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - V


List of Figures

Figure 2-1 Single Section Digital Axle Counter 2DP1S Configuration .......................... 5
Figure 2-2 SF of 2DP1S Configuration Setting ............................................................... 7
Figure 2-3 EF of 2DP1S Configuration Setting ............................................................... 8
Figure 3-1 System level Connection of 2DP1S Configuration ...................................... 31
Figure 3-2 MS Coupler connection diagram for 2DP1S Configuration ........................ 31
Figure 4-1 Reset Box ...................................................................................................... 42

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - VI


List of Tables

Table 2-1 Jumper Settings for Configuration SF of 2DP1S ............................................. 7


Table 2-2 CPU addressing for SF of 2DP1S configuration ............................................. 8
Table 2-3 Jumper Settings for Configuration EF of 2DP1S ............................................ 8
Table 2-4 Jumper Settings for setting CPU address EF of 2DP1S Configuration ........... 9
Table 2-5 Addressing Scheme for 2DP1S ...................................................................... 10
Table 3-1 TX1 MS Coupler (MS-5): .............................................................................. 11
Table 3-2 TX2 MS Coupler (MS-4) ............................................................................... 12
Table 3-3 RX1 MS Coupler (MS-17)............................................................................. 13
Table 3-4 RX2 MS Coupler (MS-16)............................................................................. 15
Table 3-5 Modem -A (COM1) Coupler (MS-6) ............................................................ 16
Table 3-6 Modem-B (COM2) Coupler (MS-11) ............................................................ 17
Table 3-7 SM / Event Logger Coupler (For remote communication) (MS-15) ............. 18
Table 3-8 Reset-A Coupler (MS-12) .............................................................................. 18
Table 3-9 Reset-B Coupler (MS-13) .............................................................................. 20
Table 3-10 Vital Relay A Coupler (MS-2) ..................................................................... 21
Table 3-11 Vital Relay B Coupler (MS-3) ..................................................................... 22
Table 3-12 Preparatory Relay A Coupler (MS-7) .......................................................... 23
Table 3-13 Preparatory Relay B Coupler (MS-8) .......................................................... 24
Table 3-14 Train Simulator Coupler (MS 9) .................................................................. 25
Table 3-15 DC-DC Converter Coupler .......................................................................... 26
Table 3-16 LCD Display Coupler .................................................................................. 26
Table 3-17 Vital Relay ................................................................................................... 28
Table 3-18 Preparatory Relay......................................................................................... 29
Table 4-1 Pre- requisites for installation of 2DP-1S Configuration ............................... 32
Table 4-2 Relay Boxes ................................................................................................... 41
Table 5-1 LED Indications of the 2DP1S Configuration of Start Fed ........................... 45
Table 5-2 LED Indications of the 2DP1S Configuration of End Fed ............................ 46
Table 5-3 LCD Display for Start Fed of 2DP1S ............................................................ 47
Table 5-4 LCD Display for End Fed of 2DP1S ............................................................ 50
Table 5-5 Trouble Shooting Chart.................................................................................. 56
Table 7-1 Monitoring points of SSDAC ........................................................................ 68
Table 7-2 Maintenance table .......................................................................................... 69
Table 7-3 Tool Kit .......................................................................................................... 69
Table 7-4 Recommended Spares .................................................................................... 70
Table 8-1 Table of DO’s ................................................................................................ 71
Table 8-2 Table of Don’ts .............................................................................................. 72

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - VII


Mechanical Drawings

DRG- 1 Start Fed of 2DP1S (G36SF2D00) Configuration ............................................ 94


DRG- 2 End Fed of 2DP1S (G36EF2D00) Configuration............................................. 95
DRG- 3 Rear View of SSDAC-SF Unit ......................................................................... 96
DRG- 4 Rear View of SSDAC-EF Unit ......................................................................... 98
DRG- 5 Display Unit (G36DSPL00) ........................................................................... 988
DRG- 6 Dual Relay Box used for SF/EF of 2DP1S (G36RLP1V1) ............................ 999
DRG- 7 Reset unit (G36RSBX00) ............................................................................... 100
DRG- 8 Reset Filter Unit (G36RSFL00) ................................................................... 1011
DRG- 9 Mechanical Drawing of TX coil housing ..................................................... 1022
DRG- 10 Mechanical Drawing of RX coil housing ................................................. 10203
DRG- 11 Cable Requirement for 2DP1S Single Line Block Section ........................ 1054
DRG- 12 Earthing Arrangement ................................................................................ 1065
DRG- 13 Cable requirement in D-L block Section .................................................... 1076
DRG- 14 Dummy wheel............................................................................................. 1077
DRG- 15 Trolley Wheel ............................................................................................. 1088
DRG- 16 Tag block for 2DP1S configuration Start Fed & End Fed ....................... 10909
DRG- 17 Typical assembled view of TX & RX coils in Track ............................... 11010
DRG- 18 Typical assembled view of TX & RX coils with Deflectors ...................... 1111
DRG- 19 Train simulator ........................................................................................... 1122
DRG- 20 Power supply & reset circuit-wiring diagram............................................ 1133
DRG- 21 Reset Box Indications Wiring Chart ........................................................... 1144
DRG- 22 Selection of rails for fixing TX & RX Coils............................................... 1155
DRG- 23 Test Jig for drilling holes on the different Rails (52 Kg, 60 Kg & 90 R) ... 1166

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - VIII


WARRANTY

G.G.Tronics gives warranty for this product for 12 months from date of purchase by the
user against manufacturing defects in material and workmanship. After expiry of this
period, the customer can still avail repair facility at extra cost. The warranty is subject
to the following conditions

1. To provide the details of date of purchase and order number to G.G.Tronics.

2. The defective Card / Unit must be delivered at the user’s cost to service center
in G.G.Tronics.

3. The guarantee is not valid for the damages resulting from accidents,
mishandling, negligence, unauthorized repairs, tampering, loss of components /
accessories, exposure to extensive heat and temperature, damped due to rain or
any other chemical such as acid etc.

4. G.G.Tronics liability for damage is restricted to repair / replacement of the


defective parts.

Serial Number :

Date of Dispatch :

Configuration : 2DP-1S Ver: 2

Authorized Signature

G.G.Tronics India Private Limited.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - IX


COMMITED TO SERVE BETTER

G.G.Tronics India Private Limited for the last decade has harnessed the power of
intellectual signaling professionals to design and produce fail-safe and reliable products
for Railway Signaling Application. Our products meet the CENELEC standard with
SIL-4 Level. These include Block proving by Digital Axle Counter for 2DP 1Section,
3DP 1Section, 3DP 2Section and Auto Section, Train Actuated Warning Device with
Station Master Console, Fail Safety Flasher, Fail Safety Timer and DC-DC Converter
Card etc.

We are working on introduction of cost-effective and innovative products based on


Real Time Embedded System technology involving with software and Microcontroller
hardware for various applications in Railways.

G.G.Tronics India Private Limited has highly motivated professionals and specialists
trained on the above technologies. We reiterate and extend our commitment for
modernization of signaling systems in Railways.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page - X


1 Introduction
1.1 Overview

Single Section Digital Axle Counter (SSDAC) is Train detection


equipment used in Railways for monitoring a defined track section to provide
occupancy/clear status. The system detects the presence of a train in a specified
track section. It is a safety critical system for ensuring utmost safety to the
passengers, goods and saving of national property. This system prevents allowing
of a train in an already occupied track section by giving Track Occupied status to
further control systems.

The fail safety feature is built into the system by means of 2 out of 2
architecture. Two computing elements are built in system to check the arrival and
clearance of the train in the track section. The equipment is of continuously self
checking type and is having separate indication to show track Clear / Occupied
conditions, Vital contacts given through Vital Relays. Any disturbance or failure
in the equipment, including power supply failure results in withdrawal of clear
indication and shows occupied status along with Vital Relay outputs. Any defect
occurring in the equipment will not result in a condition that will lead to an unsafe
situation. The SSDAC unit is independent and totally self-contained product.

1.2 Configurations of System

SSDAC units can be configured to work in the following various


configurations:

• Two detection points Single section: In straight line [2DP1S].

• Three detection points Single section: In point zone [3DP1S].

• Three-detection points for two consecutive sections in a straight line


[3DP2S].

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 1


1.3 Specifications

The SSDAC equipment is an embedded micro controller based system


designed and developed as per the RDSO Specification No. RDSO / SPN / 177 /
2012 Version. 3.

1.4 System Design

Each unit of SSDAC contains the following hardware modules, which are
necessary for effective functioning of the system and to establish, fail safe
operation of 2 out of 2 voting. The system salient features are computation by
Dual CPUs, Failsafe AND Gate for both CPUs to cast their individual decisions to
drive vital safety relay. The units employ safety hardware and safety validated real
time software.

The hardware and software for all the configurations are same. The
different PCB modules for the units are listed below

 Central Processing Unit Module

 Communication Module

 Relay Drive Module

 Phase Detector Module

 SM-CPU /Event Logger Module

 DC-DC converter Module

 Reset box

 Voltage Window Module

 Axle Detectors

 LCD display Module

 7 Segment Display Module

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 2


1.5 Physical Description

The SSDAC Unit of the Digital Axle Counter system is manufactured in a


6U height and 68T width desktop enclosure. The system comprises of ten plug-in
modules. Three modules are of Full Euro size (220mm x 200mm) and the other
seven modules are of Half Euro size (220mm x 100mm) that plugs into a
motherboard in the sub rack. DRG No 1 and DRG No 2 show the front view of
the system and the position of modules. DRG No 3 shows the rear view of the
system. The various dimensions of the Unit are as follows.

• Width: 404.32mm. (68 T)

• Height: 266 mm (6 U)

• Depth: 320 mm

1.6 Construction Details

1. Web mounted axle detectors.

2. Sub rack for SSDAC.

3. Modular design of modules.

• Inter module shielding.

• Motherboard for Inter module Connections.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 3


2 System Overview

2.1 SSDAC- 2DP1S system in brief

1. In SSDAC-2DP1S configuration, there will be two SSDAC units i.e. Start Fed –
SF and End Fed – EF Units.

2. These units will be interfaced through FSK Modem communication using separate
½ quad cables.

3. The system will communicate at baud rate of 1200bps.

4. It will be connected with the station-reset and repeater relay signal using 6-core
signalling cable of 1.5 Sq mm.

5. 2-core aluminium cable of 25 Sq mm will be used to provide power supply to the


unit.

6. It can be interfaced with intelligent station reset box through FSK communication
of 1200 bps using separate ½ quad cable.

7. More than 14,000 events stored in SM-CPU / Event Logger module of the system
will be downloaded through RS232 communication port available on the module.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 4


2.2 Configuration of SSDAC- 2DP1S

STATION STATION
A B

2 core cable 2 core cable 6 core cable


6 core cable 25 Sq mm 25 Sq mm 1.5 Sq mm 1/2 quad
1/2 quad cable
cable 1.5 Sq mm power power Reset and
Reset and Repeat station
station master
master Repeat Relay
Relay Signal communica
communica tion
tion Signal

MODEM COMMUNICATION
1/2 quad cable
END FED
START FED

APPROACH APPROACH
DETECTORS DETECTORS
UP DIRECTION DOWN
DIRECTION
21KHZ 25KHZ MAXIMUM 25 KM's,Up to -30db 21KHZ 25KHZ
TX1 TX2 TX1 TX2

RX1 RX2 RX1 RX2


21KHZ 25KHZ 21KHZ
25KHZ

Figure 2-1 Single Section Digital Axle Counter 2DP1S Configuration

2.3 System working principle

1. Once the system is powered ON, it will boot and enter the reset state. A
dedicated unit called a reset box will be used to reset the SSDAC.

2. In this configuration two reset boxes will reset two SSDAC placed at each
station.

3. There will be two relays namely preparatory and vital relays provided in the
system, which remains in the de-energized state.

4. The system will wait for the stationmaster to actuate the SM Key and reset
button to enter the preparatory state.

5. The SM Key and reset button of both the units of the particular section will
be actuated and then system will enter preparatory state.

6. However, the stationmaster has to make sure that there are no trains in that
section only then he can actuate the reset button.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 5


7. The stationmaster can now allow a pilot train to be run. In this mode, the
system will wait for pilot train to enter and exit the section with a minimum
of two wheels as In-count and Out-count.

8. After counting all the wheels at both entry and exit points, the respective
preparatory relay A (EF) and preparatory relay B (SF) will get de-energized.

9. The system enters clear mode after In-count and Out-count of the pilot train
matches and vital relay A (EF) and vital relay B (SF) will get energized.

10. Whenever any train enters the section, on counting the first wheel system
shall enter occupied mode and the In-counts will be incremented till the last
wheel of the train.

11. When the train that has already entered the station, exits the station, Out-
count will start incrementing.

12. When both In-counts and Out-counts match, the section will enter the clear
mode and the vital relay A (EF) and vital relay B (SF) will get energized.

13. Communication between two units will be through FSK communication.


Axle counts as both In-counts and Out-counts will be displayed on the LCD
pane.

14. The System Status, Checksum & Version No, Counts and error code are
displayed in the Reset Box LCD display through FSK Communication using
½ Quad Cable.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 6


2.4 SSDAC- 2DP1S (2DP1S Configuration Setting)

The SSDAC system is configurable to different configurations based on


the requirements. The polarizing is also used to identify and make sure that the
right configured CPU insertion in the CPU module slot designated. The jumper
“0” indicates no jumper to be done and “1” indicates jumper to be soldered. The
Polarizing connector “1” indicate break and “0” indicate no break.

The SSDAC- 2DP1S system consists of SF (Start Fed) and EF (End Fed)
Systems.

2.4.1 SSDAC- 2DP1S SF (Start Fed Configuration Setting)

SSDAC - 2D SF Start Fed Configuration ( CPU Card Top View Component Side )

Up 12

LK LK
17 10 25 18
0

Down 1 Address Set t ing Refer Configurat ion Set t ing


Address set ting t able
Polarizing
connector

Figure 2-2 SF of 2DP1S Configuration Setting


Table 2-1 Jumper Settings for Configuration SF of 2DP1S

Jumper Settings for SSDAC – 2DP1S SF Start Fed configuration


LK25 LK24 LK23 LK22 LK21 LK20 LK19 LK18
0 0 0 0 0 0 0 1

Next step is to set the address of the CPU in each of the units for
proper communication between the units. In order to identify the CPUs in each

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 7


of the units, 1 to 252 unique addresses are provided which can be set with the
help of jumpers from LK10 to LK17 as per table below.

Table 2-2 CPU addressing for SF of 2DP1S configuration

Jumper Settings
Address
LK10 LK11 LK12 LK13 LK14 LK15 LK16 LK17
Assigned
LSB MSB
1 0 0 0 0 0 0 0 1
0 1 0 0 0 0 0 0 2
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 0 1 1 1 1 1 1 252

2.4.2 SSDAC- 2DP1S EF (End Fed Configuration Setting)

SSDAC - 2D EF End Fed Configuration ( CPU Card Top View Component Side )

Up 12

LK LK
17 10 25 18
0

Down 1 Address Set ting Refer Configurat ion Setting


Address set ting table
Polarizing
connector

Figure 2-3 EF of 2DP1S Configuration Setting

Table 2-3 Jumper Settings for Configuration EF of 2DP1S

Jumper Settings for SSDAC – 2DP1S EF End Fed configuration


LK25 LK24 LK23 LK22 LK21 LK20 LK19 LK18
0 0 0 0 0 0 1 0

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 8


Next step is to set the address of the CPU in each of the units for proper
communication between the units. In order to identify the CPUs in each of the
units, 3 to 254 unique addresses are provided which can be set with the help of
jumpers from LK10 to LK17 as per table below.

Table 2-4 Jumper Settings for setting CPU address EF of 2DP1S Configuration

Jumper Settings
Address
LK10 LK11 LK12 LK13 LK14 LK15 LK16 LK17
Assigned
LSB MSB
1 1 0 0 0 0 0 0 3
0 0 1 0 0 0 0 0 4
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 1 1 1 1 1 1 1 254

The below table indicates possible addresses of different SSDAC –


2DP1S configurations. The addressing method is same for either Start Fed or
End Fed system. Ensure that Group Local Addresses of individual SSDAC
equipments are configured through CPU module as below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 9


Table 2-5 Addressing Scheme for 2DP1S

Group Group
SSDAC Unit SF - Start Fed EF – End Fed
Local Address Local Address
SSDAC CPU-1 001 CPU-1 003
1-2 CPU-2 002 CPU-2 004
SSDAC CPU-1 005 CPU-1 007
3-4 CPU-2 006 CPU-2 008
SSDAC CPU-1 009 CPU-1 011
5-6 CPU-2 010 CPU-2 012

▼ ▼ ▼ ▼ ▼

▼ ▼ ▼ ▼ ▼

▼ ▼ ▼ ▼ ▼
SSDAC CPU-1 251 CPU-1 253
‘n’ CPU-2 252 CPU-2 254

Note: Any deviation from the above configuration, the SSDAC – 2DP1S system does
not boot and enters wrong configuration status with error message displayed.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 10


3 System Wiring Details
3.1 Introduction:

This chapter provides the details for interconnection to be made between


SSDAC units, TX / RX axle detectors, Modem, Power Supply, Train Simulator,
Reset and other details. This includes the details of MS Coupler connectors
provided on SSDAC units for external connections. System Level connections are
also given in this chapter.

3.2 Transmitter Coil 1 Connection (MS-5):

The TX coil1 (21 KHz) axle detector is connected to PD1 through MS


Coupler 5 (3 pin, refer DRG: 3). From the MS Coupler pins the signals are
connected to a (4-pin) Phoenix connector J14 on the Motherboard. These are
finally connected to PD1. The pin configuration of J14 (4-pin) connector is given
in table below.

Table 3-1 TX1 MS Coupler (MS-5):

A
C

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 11


MS coupler
(MS-5), refer Description
Sl. No DRG no: 3 Wiring Details Of TX1 Coil Axle Detector
of Signal
Pin Cable
Blue 23 / 0.2mm, 2 core shielded PVC
cable with gray sheath 15m
1 A RED TX1a 21 KHz
connected to the MS coupler MS-5
of the system
White 23 / 0.2mm, 2 core shielded PVC
cable with gray sheath 15m
2 B BLACK TX1b 21 KHz
connected to the MS coupler MS-5
of the system
3 C NC NC NC No Connection

3.3 Transmitter Coil 2 Connection (MS-4)

The TX coil2 (25 KHz) axle detector is connected to PD2 through MS


Coupler 4 (3 pin, refer DRG: 3). From the MS Coupler pins the signals are
connected to a (4-pin) Phoenix connector J16 on the Motherboard. These are
finally connected to PD2. The pin configuration of J16 (4-pin) connector is given
in table below.

Table 3-2 TX2 MS Coupler (MS-4)

A
C

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 12


MS coupler
(MS-4), refer Description Wiring Details Of TX2 Coil Axle
Sl.No DRG no: 3 of Signal Detector
Pin Cable
23 / 0.2mm, 2 core
Blue shielded PVC cable with
blue sheath 15m
1 A RED TX2a 25 KHz
connected to the MS
coupler MS-4 of the
system
23 / 0.2mm, 2 core
White shielded PVC cable with
blue sheath 15m
2 B BLACK TX2b 25 KHz
connected to the MS
coupler MS-4 of the
system
3 C NC NC NC No Connection

3.4 Receiver Coil 1 Connection (MS-17)

The RX coil1 (21 KHz) axle detector receives the induced signals and
these are fed to PD1 for processing the information through MS Coupler 17 (5
pin, refer DRG: 3). From the MS Coupler pins, the signals are connected to a (6-
pin) Phoenix connector J15 on the Motherboard. These are finally connected to
PD1. The pin configuration of J15 (6-pin) connector is given in table below.

Table 3-3 RX1 MS Coupler (MS-17)

E
B

D C

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 13


MS coupler
Sl. (MS-17), refer Description Wiring Details Of RX1 Coil Axle
No DRG no: 3 Of Signal Detector
Pin Cable
23 / 0.2mm, 2 core
Blue shielded PVC cable
with Blue sheath 15m
1 A RED RX1b 21 KHz
connected to the MS
coupler MS-17 of the
system
23 / 0.2mm, 2 core
White shielded PVC cable
with Blue sheath 15m
2 B BLACK RX1a 21 KHz
connected to the MS
coupler MS-17 of the
system
Input from Trolley
3 C RED TP IN + RED
protection relay
Input from Trolley
4 D BLACK TP IN - BLACK
protection relay
5 E NC NC NC No Connection

3.5 Receiver Coil 2 Connection (MS-16)

The RX coil2 (25 KHz) axle detector receives the induced signals and
these are fed to PD2 for processing the information through MS Coupler 16 (5
pin, refer DRG: 3). From the MS Coupler pins, the signals are connected to a (6-
pin) Phoenix connector J17 on the Motherboard. These are finally connected to
PD2. The pin configuration of J17 6-pin connector is given in table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 14


Table 3-4 RX2 MS Coupler (MS-16)

E
B

D C

MS coupler
Sl. (MS-16), refer Description Wiring Details Of RX2 Coil Axle
No DRG no: 3 Of Signal Detector
Pin Cable
23 / 0.2mm, 2 core
Blue shielded PVC cable with
blue sheath 15m
1 A RED RX2b 25 KHz
connected to the MS
coupler MS-16 of the
system
23 / 0.2mm, 2 core
White shielded PVC cable with
blue sheath 15m
2 B BLACK RX2a 25 KHz
connected to the MS
coupler MS-16 of the
system
Input to Trolley
3 C RED TP OUT + RED
protection
Input to Trolley
4 D BLACK TP OUT - BLACK
protection
5 E NC NC NC No Connection

3.6 Modem-A Communication (FSK) Connection (MS-6)

The two CPU modules send the digital packet information to the COM1
module through the motherboard. The analog signal from modem module through
Euro Connector is available at (4-Pin) connector J21 on motherboard and then
connected to MS coupler 6 (3-Pin, refer DRG: 3) on the back plate. The COM1 is

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 15


connected with remote SSDAC unit for communication by means of 2 Wire,
0.9mm dia Quad cable. The pin configuration of (3-pin) MS Coupler 6 is given in
table below

Note: Modem A (COM1) is used in EF, CF and 3DP1S unit types of SSDAC

Table 3-5 Modem -A (COM1) Coupler (MS-6)

A
C

MS coupler
(MS-6), refer
Sl.No DRG no: 3 Description of Signal Cable to be used

Pin Cable
1 A RED A-MODEM-INOUT+ ½ Quad 0.9 mm
2 B BLACK A-MODEM-INOUT-
3 C NC NC No Connection

3.7 Modem-B (COM2) Communication (FSK) Connection (MS-11)

The two CPU modules send the digital packet information to the COM2
module through the motherboard. The analog signal from modem module through
Euro Connector is available at (4-Pin) connector J22 on motherboard and then
connected to MS coupler 11 (3-pin, refer DRG: 3) on the back plate. The COM2
is connected with remote SSDAC unit for communication by means of 2Wire,
0.9mm dia Quad cable. The pin configuration of (3-pin) MS Coupler 11 is given
in table below.

Note: Modem B (COM2) is used in SF, CF and 3DP1S unit types of SSDAC

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 16


Table 3-6 Modem-B (COM2) Coupler (MS-11)

A
C

MS coupler (MS-11),
Sl. No refer DRG no: 3 Description of Signal Cable to be used
Pin Cable
1 A RED B-MODEM-INOUT+
½ Quad 0.9 mm
2 B BLACK B-MODEM-INOUT-
3 C NC NC No Connection

3.8 SM/Event Logger Connection (MS-15)

The two CPU modules send the digital packet information to the
SM/Event Logger module through the motherboard. The analog signal from
modem module through Euro Connector is available at AMP connectors J24 (4-
Pin) and J25 (6-pin) respectively on motherboard and then connected to MS
coupler 15 (5-pin, refer DRG: 3) on the back plate. This module also consists of
EEPROM’s, which stores the events of SSDAC. Stored events can be down
loaded to PC/Laptop locally through RS-232 Port (Baud Rate-9600bps). This
module sends the system information through FSK of 1200 baud rate to reset box
by establishing the connection between the A&B of MS coupler 15 and T5&T6 of
reset box FSK connector. The pin configuration of (5-pin) MS coupler 15 is given
in table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 17


Table 3-7 SM / Event Logger Coupler (For remote communication) (MS-15)

E
B

D C

MS coupler
(MS-15), refer Description of
Sl. No DRG no: 3 Cable to be used
Signal
Pin Cable
SM-MODEM-
1. A RED
INOUT+ ½ Quad 0.9 mm up to
SM-MODEM- station
2. B BLACK
INOUT-
3. C RED RTC-BAT
2 Core coil cable
4. D BLACK DIG- GND
5 E NC NC No Connection

3.9 RESET- A (MS-12)

The connection from Reset box to SSDAC Unit is provided through MS


Coupler 12 (3-pin, refer DRG: 3). From the MS Coupler pins the signals are
connected to a (2-pin) Phoenix connector J20 on the Motherboard. The 48V DC is
available at RESET1 + and RESET1- pin when Reset is applied. The pin
configuration of (3-pin) MS Coupler 12 is given in table below.

Note: Reset A is used in EF

Table 3-8 Reset-A Coupler (MS-12)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 18


A
C

MS coupler
(MS-12), refer Description of
Sl. No DRG no: 3 Cable to be used
Signal
Pin Cable
1. A RED RESET1+ 1.5mm Signaling
cable or 1/2 Quad
2. B BLACK RESET1- 0.9mm (refer note)
3 C NC NC No Connection

3.10 RESET- B (MS-13)

The connection from Reset box to SSDAC Unit is provided through MS


Coupler 13 (3-pin, refer DRG: 3). From the MS Coupler pins the signals are
connected to a (2-pin) Phoenix connector J37 on the Motherboard. The 48V DC is
available at RESET2+ and RESET2- pin when Reset is applied .The pin
configuration of (3-pin) MS Coupler 13 is given in table below.

Note: Reset B is used in SF

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 19


Table 3-9 Reset-B Coupler (MS-13)

A
C

MS coupler (MS-13),
refer DRG no: 3 Description of
Sl. No Cable to be used
Signal
Pin Cable
1. A RED RESET2+ 1.5mm Signaling
cable or 1/2 Quad
2. B BLACK RESET2 - 0.9mm(refer note)
3 C NC NC No Connection

Note:

SF Unit- Reset B-1.5mm Signaling cable


EF Unit- Reset A-1.5mm Signaling cable
3D Units- Reset B-1.5mm Signaling cable
CF Unit- Reset A & B-1/2 Quad 0.9mm
3.11 Vital Relay A (MS-2)

The SSDAC is connected by means of MS coupler MS2 (7-pin, refer


DRG: 3) to Vital Relay A in Relay Box. The (7-pin) MS coupler is connected to
relay drive-A module through (6-pin) AMP connector J27 on motherboard. The
input / output pin detail of (7-pin) circular connector is given in table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 20


Table 3-10 Vital Relay A Coupler (MS-2)

A
F B
G
E C
D

MS coupler
MS coupler (MS-1) on
Sl. (MS-2), refer
Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
No
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED VR-A+ (+24V DC) C,D RED
3. F,E BLACK VR-A- (-24V DC) F,E BLACK
4. G BLUE RLYUV1-FB (-5V DC) G BLACK

3.12 Vital Relay B (MS-3)

The SSDAC is connected by means of MS coupler MS-3 (7-pin, refer


DRG: 3) to Vital Relay B in Relay Box. The (7-pin) MS coupler is connected
to relay drive-B module through (9-pin) AMP connector J28 on motherboard.
The input / output pin detail of (7-pin) circular connector is given in table
below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 21


Table 3-11 Vital Relay B Coupler (MS-3)

A
F B
G
E C
D

MS coupler
MS coupler (MS-1) on
Sl. (MS-3), refer
Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
No
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED VR-B+ (+24V DC) C,D RED
3. F,E BLACK VR-B- (-24V DC) F,E BLACK
4. G BLUE RLYUV2-FB (-5V DC) G BLACK

3.13 Preparatory Relay A (MS-7)

The SSDAC is connected by means of MS coupler MS-7 (7-pin, refer


DRG: 3) to Preparatory Relay A in Relay Box. The (7-pin) MS coupler is
connected to relay drive-A module through (6-pin) AMP connector J33 on
motherboard. The input / output pin detail of (7-pin) circular connector is given in
table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 22


Table 3-12 Preparatory Relay A Coupler (MS-7)

A
F B
G
E C
D

MS coupler
MS coupler (MS-2) on
(MS-7), refer
Sl. No Description of Signal Relay Box, refer DRG no: 5
DRG no: 3
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED PREP1+ (+24V DC) C,D RED
3. F,E BLACK PREP1 - (-24V DC) F,E BLACK
4. G BLUE PREP1-FB (-5V DC) G BLACK

3.14 Preparatory Relay B (MS-8)

The SSDAC is connected by means of MS coupler MS8 (7-pin, refer


DRG: 3) to Preparatory Relay B in Relay Box. The (7-pin) MS coupler is
connected to relay drive-B module through (9-pin) AMP connector J38 on
motherboard. The input / output pin detail of (7-pin) circular connector is given in
table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 23


Table 3-13 Preparatory Relay B Coupler (MS-8)

A
F B
G
E C
D

MS coupler
MS coupler (MS-2) on Relay
Sl. (MS-8), refer
Description of Signal Box, refer DRG no: 5
No DRG no: 3
Pin Cable Pin Cable
1. A,B RED +5V DC A,B RED
2. C,D RED PREP2+ (+24V DC) C,D RED
3. F,E BLACK PREP2 - (-24V DC) F,E BLACK
4. G BLUE PREP2-FB (-5V DC) G BLACK

3.15 Train Simulator (MS - 9)

The wheel signals for simulating SSDAC unit are provided on to a MS


Coupler MS9 (7-pin, refer DRG: 3) on the back plate of the SSDAC. These
signals are extended through (8-pin) connector J35, J36 on motherboard to both
the CPU’s. The details of (7 pins) MS Coupler are given in the table below

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 24


Table 3-14 Train Simulator Coupler (MS 9)

A
F B
G
E C
D

MS coupler
MS coupler (MS-2) on Train
(MS-9), refer Description of
Sl.No. Simulator Box, refer DRG no: 19
DRG no: 3 Signal
Pin Cable Pin Cable
2 Core Coil wire -
1. A RED WHEEL-M1 A
Red
2 Core Coil wire -
2. B BLACK WHEEL-S1 B
Black
2 Core Coil wire -
3 C GREEN WHEEL-SUP1 C
Red
2 Core Coil wire -
4 D RED WHEEL-M2 D
Black
2 Core Coil wire -
5 E BLACK WHEEL-S2 E
Red
2 Core Coil wire -
6 F GREEN WHEEL-SUP2 F
Black
2 Core Coil wire -
7 G BLACK DIG- GND G
Green

3.16 DC-DC Converter (MS - 14)

The power supply 24V connection is made to the system through MS


Connector MS14 (2-pin, refer DRG: 3). This is extended to the DC-DC converter
module through motherboard and is given in table below.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 25


Table 3-15 DC-DC Converter Coupler

A
C

MS coupler (MS-14),
refer DRG no: 3 Connection from
Sl.No Power Supply
battery / IPS
Pin Cable
1. A RED + 24V DC
2. B BLACK - 24V DC 2 Core cable Coil Wire
3. C NC No Connection

3.17 LCD Display (MS - 10)

The LCD Display connection is made to the system through MS Coupler


MS10 (14-pin, refer DRG: 3). This is extended to the CPU 1 and CPU2 modules
through motherboard and is given in table below.

Table 3-16 LCD Display Coupler

MS coupler (MS-10), MS coupler (MS-1) on LCD,


refer DRG no: 3 LCD refer DRG no: 4
Sl.No
Display
Pin Cable Pin Cable
3 Core Coil wire - 3 Core Coil wire -
1. A LCD1-RS A
Red Red
3 Core Coil wire - 3 Core Coil wire -
2. B LCD1-DET B
Black Black
3 Core Coil wire - 3 Core Coil wire -
3 C LCD1-D-E C
Yellow- Green Yellow- Green
3 Core Coil wire - 3 Core Coil wire -
4 D LCD1-STR D
Red Red

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 26


3 Core Coil wire - 3 Core Coil wire -
5 E LCD1-D E
Black Black
3 Core Coil wire - 3 Core Coil wire -
6 F LCD1-CLK F
Yellow- Green Yellow- Green
3 Core Coil wire - 3 Core Coil wire -
7 G LCD2-RS G
Red Red
3 Core Coil wire - 3 Core Coil wire -
8 H LCD2-DET H
Black Black
3 Core Coil wire - 3 Core Coil wire -
9 J LCD2-D-E J
Yellow- Green Yellow- Green
3 Core Coil wire - 3 Core Coil wire -
10 K LCD2-STR K
Red Red
3 Core Coil wire - 3 Core Coil wire -
11 L LCD2-D L
Black Black
3 Core Coil wire - 3 Core Coil wire -
12 M LCD2-CLK M
Yellow- Green Yellow- Green
2 Core Coil wire - 2 Core Coil wire -
13 N 5VDC N
Red Red
2 Core Coil wire - 2 Core Coil wire -
14 P DIG- GND P
Black Black

3.18 Relay Box

The Vital relay and Preparatory relay are housed in the Relay box. The
relay coil and its contacts of vital and preparatory relays are terminated on to the
two separate MS coupler MS-1 and MS-2 (10-pin, refer DRG: 5) fixed at the back
of the Relay box. The wiring is as shown in table below. The Relay Drive output
from SSDAC is connected to Vital Relay through coupler MS-1 and preparatory
relay through MS-2.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 27


Table 3-17 Vital Relay

H A

I B
G C

F J
D
E

MS coupler (MS-1),
refer DRG no: 5 Description of signal to vital
Sl.No. Connection to be made
relay
Pin Cable
1. A RED Coil R1 (VR +) (+24V DC)
2. B RED Coil R2 (VR -) (-24V DC)
3. C BLUE A1 (+5 VDC)
4. D BLUE A2 (VR – FB) (-5V DC) Direct connections should be
made between the coupler of
5. E BROWN C1 (+24V)
Relay Box (MS-1, refer DRG:
6. F BROWN C2 (+VPR) (+24V DC) 5) and coupler of SSDAC
7. G GREEN B3 (- 24V) (MS-2 / 3, refer DRG: 3)
8. H GREEN B4 (- VPR) (-24V DC)
9 I NC No Connection
10 J NC No Connection
RELAY TYPE: Q type 24V, 1000Ω
Ω 6F, 6B for Vital Relay

A B C D
1 (+5 VDC) (+24V) 1
2 (VR – FB) (-5V DC) (+VPR) (+24V DC) 2
3 (- 24V) 3
4 (- VPR) (-24V DC) 4
5 5
6 6
7 7
8 8
R1 (VR +) (+24V DC) (VR -) (-24V DC) R2
R3 R4

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 28


Table 3-18 Preparatory Relay

H A

I B
G C

F J
D
E

MS coupler (MS-2),
refer DRG no: 5 Description of signal to
Sl.No Connection to be made
Preparatory relay
Pin Cable
1. A RED Coil R1 (PR +) (+24V DC)
2. B RED Coil R2 (PR -) (-24V DC)
3. C BLUE A1 (+5 VDC)
4. D BLUE A2 (PR – FB) (-5 VDC) Direct connections should be
made between the coupler of
5. E BROWN C1 (+24V)
Relay Box (MS-2, refer DRG: 5)
6. F BROWN C2 (+PPR) (+24V DC) and coupler of SSDAC
7. G GREEN B3 (- 24V) (MS-7 / 8, refer DRG: 3)
8. H GREEN B4 (- PPR) (-24V DC)
9 I NC No Connection
10 J NC No Connection
RELAY TYPE: Q type 24V, 1000Ω
Ω 6F, 6B for Preparatory Relay

A B C D
1 (+5 VDC) (+24V) 1
2 (PR – FB) (-5V DC) (+PPR) (+24V DC) 2
3 (- 24V) 3
4 (- PPR) (-24V DC) 4
5 5
6 6
7 7
8 8
R1 (PR +) (+24V DC) (PR -) (-24V DC) R2
R3 R4

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 29


3.19 System Level Connections

Railway Track

21 KHz 25 KHz
21 KHz 25KHz
RX RX
TX Axle Detectors TX Ax le Detectors

Display Unit Display Unit

Relay Box

SPARE

SPARE
SPARE
FSK

RD1
RD2
COM2
Vital Relay B Relay Box
Communication

DC-DC Converter

DC-DC Converter
Prep Relay B Vital Relay A
PD1 PD2 PD1 PD2 Prep Relay A

SM SM
SPARE

COM1
CPU CPU CPU / CPU CPU CPU /
1 2 Event 1 2 Event
Logger Logger

24VDC
SSDAC SF

24VDC
SSDAC EF
SSDAC Status
SSDAC Status
in LC D Display RS 232/ FSK
in LC D Display
To SSDAC To SSDAC C ommunication
RS 232/ FSK
SF Unit C ommunication EF Unit

Reset Box Reset Box

Power supply Power supply

Station A 21 KHz RX 25 KHz RX


Station B
21 KHz TX 25 KHz TX

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 30


Figure 3-1 System level Connection of 2DP1S
Configuration
LCD Display LCD Display

MS 1
MS 1

START FED END FED

MS 3 MS 2
MS 4 MS 5 MS 4 MS 5
MS 1 MS 2 Vital Relay MS 1 Vital Relay MS 3
25 TX 21 TX 25 TX 21 TX
B A

STATIONB
STATION A

MS 8 MS 6 MS 7
MS 6 MS 7 Preparatory Preparatory MS 8
Modem A
Relay B Relay A

DB25

DB25
MS 9 MS 9

MS 11 MS 13 MS 12
MS 12 MS 11 MS 13
Modem B Reset B Reset A

MS 14 MS 15
MS 14 MS 15 24 I/P SM COM
MS 16 MS 17
24 I/P MS 16 MS 17
SM COM 25 RX 21 RX
25 RX 21 RX

24V SM 25 25 21 21 24V SM Reset 25 25 21 21


VR PR Reset COM VR PR COM
DC COM TX RX TX RX DC COM TX RX TX RX

MS 1 MS 2
MS 1 MS 2
VR PR
VR PR

Reset Reset
Box with QUAD Cable QUAD Cable QUAD Cable Box with
Error Error
Display Display

Figure 3-2 MS Coupler connection diagram for 2DP1S Configuration

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 31


4 Installation Procedure
4.1 Pre Requisites for Installing SSDAC Systems

The supportive equipment and accessories required for SSDAC are


provided in table below. Other accessories are:

1. Web Type Transmitter Coils (TX coil)

2. Web Type Receiver Coils (RX coil)

Table 4-1 Pre- requisites for installation of 2DP-1S Configuration

Quantity

Block Section (S- Block Section


Sl. Supportive equipment and Station Area L) (D-L)
No. accessories (1 set of SSDAC) (1 set of SSDAC) 2 sets of SSDAC

24V, 120 AH low


maintenance battery or 24V, 5
1. 1 No. 2 Nos. 2 Nos.
Amp output from one module
of IPS
24V, 5A Axle counter type
2. 1 No. 2 Nos. 2 Nos.
Battery Charger
0.9 mm 0.9 mm 0.9 mm
3. 4/6 Quad cable
(1 Pair) (1 Pair) (2 Pair)
Apparatus case (Full) with
4. 2 Nos. 2 Nos. 4 Nos.
termination board
25 sq mm ‘AL’ Power Cable, Length as Length as
5. Length as required
2 core required required
1.5 Sq. mm, Signaling cable
Length as Length as
6. (6 Core required + 4 spare for Length as required
required required
D/L)
Earthing of Apparatus case
7. 2 Nos. 2 Nos. 4 Nos.
(Locations)
8. Deflectors for Axle detectors 4 Nos. 4 Nos. 8 Nos.

Note: Separate Earth for equipment and Cables

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page32


4.2 Unpacking the systems

The SSDAC units are supplied after RDSO inspection and are dispatched
in a kit form for easy installation and commissioning. The kit consists of

 Equipments of required configurations

 Display Box

 Cable with MS Couplers

 Fuse tag block assembly along with surge protector

 Relay box with relays.

 Reset box

 Axle detector assemblies

 Filter Box

 Fixing items

 Installation Manual

All the equipments are identified, serially numbered and matched


wherever applicable.

• The equipments are packed in bubble sheet packing and provided with
Thermo Cole spaces for shock absorption and finally despatched in
corrugated cardboard cartons that are again covered with polythene
covers to make them moisture proof.

• A packing list accompanying the package indicates the items packed


and same have to be checked for their correctness and any deviations
must be reported immediately to M/s G.G.Tronics India Pvt. Ltd. at
Bangalore.

• The SSDAC unit consisting of, system, display module, relay box,
filter box and the fused tag blocks are to be housed in a full GRS
Location Box adjacent to the track.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page33


• The Axle detection units of web mounting type are to be mounted on
to one of the rails of the track (refer DRG No: 22).

• The Reset box / boxes are to be provided in the station master cabin.

• 24V DC power is to be provided from the station.

• The wiring between all these units is to be carried out as per Railway
standards.

4.3 Steps for Installation

The schematic of the installation of 2DP1S Configurations are shown in


Figure 3-2(2DP1S).

The installation can be taken up with the following parallel activities.

• Laying foundation as per Railway standards for the location box,


fixing the location box.

• Trenching for running the required cable.

• Drilling of rail for fixing TX/RX coils with the jig.

• Fixing of TX/RX coils on the rail.

• Lay of power, signalling cables and cables coming from TX/RX coils.

• Painting and fixing of required planks and the fuse terminal block.

• Terminating the cables as per drawings DRG No: 15 & DRG No: 16
(2DP1S SF and EF Configuration) on the Fuse Terminal Block.

• Placing of the unit with all the PCB modules, display module and the
Relay box on the plank provided in the location box.

• Fixing of the MS Coupler cable assemblies on to the designated mating


Couplers on the rear panel of the systems as per the drawing DRG No:
03.

• Continuity, insulation resistance between cables should be checked.


Also the insulation resistance between the chassis and the cables must
be checked.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page34


• Connecting earth terminal of the unit chassis to the main chassis
through copper cables.

• All the shields and the screen wires shall also be connected to the
earth.

• Fix the reset box in a convenient location in the station.

• Connect the wires coming from the system to the reset box as per
drawing DRG No: 20 and DRG No: 21

• Connect 24V DC to power supply.

• Connect the power cables coming from the system to the source of
power supply of 24V DC at the station, keeping the FTB (DRG No: 15
& DRG No: 16) connector open.

4.3.1 Location of Axle Detectors

• As per Railway standard practice the Axle detectors should be installed


after Advance starter (LSS) signal post and Home signal (HS) post on
UP and DN lines of Double line section for use in BPAC.

• The Axle detectors should be installed after Advance Starter Signal


(LSS) Post for direction of Single Line Section for use in BPACs.

• In main Lines, loop lines, yard area the Axle detectors can be fixed just
after the Starter Signal post of each line under monitoring of SSDAC.

• The Axle detector separation between two sets of different SSDAC


systems should be at least 2 meters away so as to avoid mutual
interference.

• The detectors have to be fixed on the clear spacing between two


sleepers.

• It should be ensured that the rail is not badly worn causing the wheel
flanges to graze over the fittings according to RDSO Specification
RDSO/SPN/177/2005 Clause No: 4.0.7.

• The design of the detector is suitable for 90R, 52Kg and 60Kg rails.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page35


• The transmitter and Receiver coils are provided with 23/0.2mm, 2 core
shielded PVC cable with gray sheath 15m and have to be taken to
location box directly without any loops

• For easy identification of the cables, the colors of the sheath of the
cables are made as Grey for 21 KHz and Blue for 25 KHz. For further
identification of TX and RX coils, both ends of the cables are provided
with colored sticky tapes as follows 21KHz TX-RED, 21KHz RX-
YELLOW, 25KHz TX- BLUE, 25KHz RX- BLACK

• Transmitter and Receiver cables should run separately at a minimum


separation of 400mm in different HDPE pipes. The cables have to be
laid in the 40mm HDPE pipe for safety and buried underground below
ballast at the depth of approx. 0.3mts.

4.3.2 Marking & Drilling holes on the Rail

• The marking jig is to be fixed from bottom of the rail and tightened to
the rail with bolts.

• The marking for 3 holes with punch is to be made on the Web of rail
using marking jig refer DRG No: 23

• The 3 Holes required for fixing web mounted TX / RX coils are to be


drilled at each location with spacing of 183mm.

• From bottom of the rail drill the holes at 68 mm for 52 KG, 84 mm for
60 KG and 57 mm for 90 R as per DRG No: 23

• The drilling is to be carried out on the web of rail at marked places by


using drill machine ratchet drill method. 3 Nos. of holes of 13 mm dia
are made on the web as per the markings at each location.

• The burr is to be removed from the holes after drilling.

Important: The marking and drilling of holes on the web to the given
dimensions are very important for proper working of the system.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page36


4.3.3 Fixing of Axle Detectors (Transmitter and Receiver Coil)

• The Axle detectors are to be fixed on web of the rail at the drilled holes
by means of M12 bolts & nuts with spring washers and check nuts.
(NOTE: the torque wrench, specified in the checklist, should be used
for tightening of nuts and bots.)

• M12 x 100mm – 3 Nos. bolts & nuts are used for fixing the axle
detectors. 2nd nut is with Nylon washer and is to be used on each bolt.

• Transmitter coil assembly (21 KHz & 25 KHz) should be fixed on the
outer side of rail. The transmitter assembly should sit properly on the
web of rail.

• Receiver coil assembly (21 KHz & 25 KHz) should be fixed on the
inner side of rail. The receiver assembly should be placed properly on
the web of rail.

• It should be ensured that transmitter coil assembly and receiver coil


assembly are facing opposite to each other (21 KHz TX to 21 KHz RX
and 25 KHz TX to 25 KHz RX) on either side of rail with centerline of
coils matching with each other.

• The TX coil cables of 21 KHz & 25 KHz are taken together in one
HDPE pipe to the location Box. Similarly both 21 KHz & 25 KHz RX
coil cables are taken together but separately from TX coil cables to the
location box.

4.3.4 Fixing of Rail Deflector

• To protect axle detectors against the damage from hanging parts of


train, rail deflector plates (protectors) should be mounted on both sides
of the axle detectors. These should be installed in the sleeper space
(approx 30 cm to 40 cm next to the axle detectors). The deflector
clamps are first fixed to bottom of rail. These deflector plates are fitted
to deflector clamp with bolts and nuts on each side.(Refer DRG No.18)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page37


• While fixing deflector plate, it should be ensured that the deflector
plates are positioned in front of transmitter and receiver coils.

4.4 Installation of Location Box (Full size)

• The location box should be installed as close as possible to detection


point so that the length of Axle detector cable should not exceed 15m

• The location box foundation should be cast at rail level and as per
scheduled dimensions of Railways. (Standard practice in railways).

• One Shelf made out of teak wood should be provided in the location
box for keeping SSDAC Counting Unit & Relay Box.

• Cable grounding should be provided.

4.4.1 Power Supply Arrangement

The SSDAC system works off 24V DC supply. This has to be provided
by the respective station through power cables. The continuous current drain,
depends upon the configuration employed at that station and the requirement
of battery and charger are as indicated below

Continuous Battery Charger


Sl. No. Description
Current Drain Capacity Capacity
24V / 40AH 5 Amps – 2
1. 2DP1S Version < 2A
– 1 No’s No’s

The power supply and its connections are indicated in DRG No: 20.

• The same battery can be used for supplying all the systems of a
particular configuration.

• No other load should be connected to this battery / charger.

4.4.2 Batteries

Low Maintenance Battery Bank may be used for powering of the SSDAC.
The batteries are to be procured as per latest RDSO specification.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page38


• The batteries are kept on teak wood/ hard wood shelf on MS angles
and are to install in the battery room.

• Insulators are to be provided below the batteries.

• The charging of batteries has to be done as per manufacturer’s manual.

4.4.3 Battery Charger

• The Axle counter type Battery Charger as per latest specification is to


be procured and installed in the equipment room. The battery chargers
are usually kept on teak wood shelf fixed on MS Angles.

• The 24V, 5A battery charger has to be installed and connected to


battery on auto mode. The current consumption of each SSDAC unit is
<1A @ 24V. For complete system (2 SSDAC units) it is <2A @ 24V.

4.4.4 Cable

The connecting cable from Battery / IPS to SSDAC units at the site
should be as given below:

• 2 core, 25 sq. mm aluminum power cables.

4.4.5 Axle Detector coils

The Digital Axle Counter depends heavily on the axle detector coils that
are responsible for detecting the wheels of a train. The Axle detectors design,
mounting and connection to the system are very important for the proper operation
of the SSDAC. For wheel recognition, counting, ignoring the trolley wheels, etc.
the output from the coil is essential. In order to meet the above requirements, the
following procedure is adopted while installing the axle detector coils.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page39


The axle detector coils are supplied in pairs of TX and RX assemblies of
web mountable type. The RX coils are factory tuned to 21 KHz and 25 KHz.
These coil assemblies are supplied with two core-shielded cables, of 15mts length
for both TX and RX. The shield of the cables is to be earthed.

While installing care should be taken that, the TX coils are on the outer
side of the rail and RX coils are on the inner side and are mounted as per drawing
DRG No: 16, with surface ‘A’ of the RX coil at a depth of 55mm from the top
surface of the rail.

The leads of individual, TX and RX coils have to be taken from the track
to the system in separate HDPE pipes to avoid interference. Hence a set of 2 pipes
will be required for one pair of TX and RX coils.

These cables are to be terminated on to the FTB as per drawing DRG No:
15 (2DP1S Configuration) on the FTB.

4.4.6 SSDAC Unit

The SSDAC is installed on the wooden/ Hylam/NFTC plank inside the


location box. This is firmly fixed using clamps, nuts & bolts.

The system along with the associated display box, filter box and the Relay
box are to install in location boxes of full GRS type. The chassis of the systems
with its motherboard and all PCB modules mounted in the position are supplied as
indicated modules after testing and passing by RDSO. All the modules are fixed
rigidly to the chassis for which not be loosened. The chassis is to be fixed rigidly
in the location box with the help of screws provided for the same. Similarly the
relay box and the display unit should also have to be fixed rigidly on the plank.
The front view of the system chassis is shown for the different configurations in
the drawings DRG No: 1 and DRG No: 2.The rear view of the system chassis is
shown for the different configurations in the figures DRG No: 3.

A universal rear plate has been designed with MS Couplers for easy
connection, with clear identification of their usage and purpose for different
configurations. The Couplers have been chosen with different pin numbers for
different functions. Also male and female couplers are used to make foolproof

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page40


connections. Also dummy plates are used wherever the MS Couplers are not
required for particular configurations to avoid confusion.

Along with the chassis MS Couplers assemblies with cables with clear
marking are supplied for connection and wiring on the FTB.

4.4.7 Display Unit

An LCD, hexadecimal display unit is provided along with system for


monitoring the status, error codes and their explanations etc. The display unit
has a capacity of displaying four lines simultaneously with each line of 20
characters. This unit is mounted on the chassis through suitable fixing and
hence becomes an integral part of the system.

4.4.8 Relay Box

The Relay box is consists of 2 Relays.

Table 4-2 Relay Boxes


Units Vital Relay Preparatory Relay

2D-SF 1 1

2D-EF 1 1

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page41


4.4.9 Reset Box

Figure 4-1 Reset Box


A standard Reset Box has been designed as per RDSO drawing No.
RDSO / S / 20003 for executing the reset operations for all the configurations,
which has the following controls and displays.

4.4.9.1 Controls

• SM Key – This has a facility of locking to prevent unauthorized


operations. For executing a reset command, this key has to be kept
pressed after unlocking it.

• Reset Push Button – This switch is meant for sending the reset
command to the system. For sending the reset command, both the SM
Key and the reset push button are to be held pressed simultaneously
and momentarily.

The reset box required may be one per unit or two per unit depending
upon the configurations. Process of resetting required for a particular
configuration also differs. For example a single stationmaster or two separate
stationmasters can do reset.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page42


4.5 System Wiring

The systems are internally wired and terminated at the MS Coupler on


the rear panels and all the MS Couplers are identified for their purpose.

A set of cables with MS Couplers with labelling is also sent with the
system. After the placement of the system in location box, cables from MS
Couplers and cables from the external equipments are to be terminated at the
FTB as per the DRG No: 15 (2DP1S SF Configuration) and DRG No: 16
(2DP1S EF Configuration). The power supply, communication and reset
cables are to be passed through the surge protectors as per the DRG No: 20.

4.5.1 Fused Tag Block (FTB)

The fused tag block assembly act as interface between the internal
wiring and the external wiring of both power and signals of the SSDAC. The
fused tag blocks are mounted on DIN rail along with surge protector and end
blocks. Each fused tag blocks are equipped with required number of fuses
depending up on the circuit to which it is wired to, as per the details in
drawings DRG No: 15 (2DP1S SF Configuration) and DRG No: 16 (2DP1S
EF Configuration). The surge protectors are rated for 24 V main supplies and
48 V for reset box. The wiring diagram takes for the proper routing of the
cables through the surge protectors. The metallic frame of the surge protector
should be connected to the main earth rigidly achieved proper earth protection.

4.6 Tests before power ON

After fixing the axle detector coils, system, relay box, reset box etc it is
essential that preliminary checks are to be made for the continuity of the
wiring, insulation, resistance between different wires and connecting terminals
in order to satisfy the correct terminations and avoiding unnecessary shorts.
The drawing DRG No: 15 (2DP1S SF Configuration) and DRG No: 16
(2DP1S EF Configuration) may be referred for this purposes

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page43


4.7 Tests after power ON

The preliminary tests to be carried out after installation and before


commissioning are indicated in the Table 7.1.The systems would have been
tested thoroughly in the factory before dispatching.

However, before conducting functional tests of the system installed,


certain measurements have to be taken and adjustments to be made (if
necessary) to ensure the proper working of the system after commissioning.
To ensure proper working of PD Module on No wheel/wheel conditions are
tested. It is also preferred that a trolley wheel test should be conducted on
detection points to ensure non-detection of trolley wheel.

Before making any adjustments, observe that the WHEEL-M and


WHEEL-S (Amber LED) LEDs are OFF on each of the PD modules (21 KHz
and 25 KHz). This ensures that the termination of the coil connections of TX
and RX are correct up to the Phase Detector module. In case the WHEEL-M
and WHEEL-S (Amber LED) LEDs glows on any of the PD modules as soon
as power is ON, the corresponding module termination on FTB to be reversed
which will put-off the LED’s.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page44


5 LCD Display and LED Indications
5.1 LED Indications

The various LED indications are tabulated below for power on, clear
and occupied mode conditions, when the system is healthy.

Table 5-1 LED Indications of the 2DP1S Configuration of Start Fed

Power On Preparatory Occupied


Module LED Clear Mode
Mode Mode Mode
TX ON ON ON ON
SUP-OK ON ON ON ON
PHASE DETECTOR
SUP-FAIL OFF OFF OFF OFF
PD 1 & PD 2
WHEEL-M OFF OFF OFF OFF
WHEEL-S OFF OFF OFF OFF
TX2 Flashing Flashing Flashing Flashing
RX2 Flashing Flashing Flashing Flashing
COM 2 CD2 Flashing Flashing Flashing Flashing
CS2 Flashing Flashing Flashing Flashing
RS2 Flashing Flashing Flashing Flashing
TXIA Flashing OFF OFF OFF
RLYV1-FB OFF OFF OFF OFF
RX1A Flashing OFF OFF OFF
RLYV2-FB OFF OFF ON ON
DAC CPU 1 TX1B OFF Flashing Flashing Flashing
RX1B OFF Flashing Flashing Flashing
EN1A OFF OFF OFF OFF
EN1B OFF OFF ON OFF
STATUS CODE -b and –r -p CL OC
TX2A Flashing OFF OFF OFF
RLYV1-FB OFF OFF OFF OFF
RX2A Flashing OFF OFF OFF
RLYV2-FB OFF OFF ON ON
DAC CPU 2 TX2B OFF Flashing Flashing Flashing
RX2B OFF Flashing Flashing Flashing
EN2A OFF OFF OFF OFF
EN2B OFF OFF ON OFF
STATUS CODE -b and –r -p CL OC
PREP/SBY OFF ON OFF ON
RELAY DRIVE 2
VITAL-RLYA OFF OFF ON OFF
TX Flashing Flashing Flashing Flashing
RX OFF OFF OFF OFF
SM CPU CD OFF OFF OFF OFF
CS Flashing Flashing Flashing Flashing
RS Flashing Flashing Flashing Flashing
ON ON ON ON ON
REVERSE OFF OFF OFF OFF
NORMAL ON ON ON ON
UNDER VOLTAGE OFF OFF OFF OFF
OVER VOLTAGE OFF OFF OFF OFF
DC-DC
POWER SHUTDOWN OFF OFF OFF OFF
CONVERTER
+5VDC ON ON ON ON
+18VDC ON ON ON ON
+12VDC ON ON ON ON
-12VDC ON ON ON ON
+5VDC OVERLOAD OFF OFF OFF OFF

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page45


Table 5-2 LED Indications of the 2DP1S Configuration of End Fed

Power On Preparatory Occupied


Module LED Mode Clear Mode
Mode Mode
TX ON ON ON ON
SUP-OK ON ON ON ON
PHASE DETECTOR
PD 1 & PD 2 SUP-FAIL OFF OFF OFF OFF
WHEEL-M OFF OFF OFF OFF
WHEEL-S OFF OFF OFF OFF
TX1 Flashing Flashing Flashing Flashing
RX1 Flashing Flashing Flashing Flashing
COM 1 CD1 Flashing Flashing Flashing Flashing
CS1 Flashing Flashing Flashing Flashing
RS1 Flashing Flashing Flashing Flashing
TXIA Flashing Flashing Flashing Flashing
RLYV1-FB OFF OFF ON ON
RX1A Flashing Flashing Flashing Flashing
RLYV2-FB OFF OFF OFF OFF
DAC CPU 1 TX1B OFF OFF OFF OFF
RX1B OFF OFF OFF OFF
EN1A OFF OFF ON OFF
EN1B OFF OFF OFF OFF
STATUS CODE -b and –r -p CL OC
TX2A Flashing Flashing Flashing Flashing
RLYV1-FB OFF OFF ON ON
RX2A Flashing Flashing Flashing Flashing
RLYV2-FB OFF OFF OFF OFF
DAC CPU 2 TX2B OFF OFF OFF OFF
RX2B OFF OFF OFF OFF
EN2A OFF OFF ON OFF
EN2B OFF OFF OFF OFF
STATUS CODE -b and –r -p CL OC
PREP/SBY OFF ON OFF OFF
RELAY DRIVE 1
VITAL-RLYA OFF OFF ON OFF
TX Flashing Flashing Flashing Flashing
RX OFF OFF OFF OFF
SM CPU CD OFF OFF OFF OFF
CS Flashing Flashing Flashing Flashing
RS Flashing Flashing Flashing Flashing
ON ON ON ON ON
REVERSE OFF OFF OFF OFF
NORMAL ON ON ON ON
UNDER VOLTAGE OFF OFF OFF OFF
OVER VOLTAGE OFF OFF OFF OFF
DC-DC
POWER SHUTDOWN OFF OFF OFF OFF
CONVERTER
+5VDC ON ON ON ON
+18VDC ON ON ON ON
+12VDC ON ON ON ON
-12VDC ON ON ON ON
+5VDC OVERLOAD OFF OFF OFF OFF

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page46


5.2 LCD Display of SSDAC

LCD displays for SSDAC system are given below.

LCD Display for 2DP1S Configuration


LCD Display for 2DP1S-Start Fed
Table 5-3 LCD Display for Start Fed of 2DP1S

Column 1 Column 10 Column 13


Line 1 Address Unit Type Checksum
Column 2 Column 7 Column 12 Column 17
Line 2 LU1_DS_FWD_ RU1_DS_FWD_C LU1_DS_REV_C RU1_DS_REV_
COUNT OUNT OUNT COUNT
Column 2 Column 7 Column 12 Column 17
Line 3 LU2_DS_FWD_ RU2_DS_FWD_C LU2_DS_REV_C RU2_DS_REV_
COUNT OUNT OUNT COUNT
Column 1
Line 4 Status / Error messages

The above information corresponds to the different aspects of the system as follows

Address : Is the address of CPU of SSDAC Unit


Unit Type : Is the type of Configuration of SSDAC Unit
Checksum : Checksum of Code Memory
LU1_DS_FWD_COUNT : Local Unit 1 Down Stream Forward Count
RU1_DS_FWD_COUNT : Remote Unit 1 Down Stream Forward Count
LU1_DS_REV_COUNT : Local Unit 1 Down Stream Reverse Count
RU1_DS_REV_COUNT : Remote Unit 1 Down Stream Reverse Count
LU2_DS_FWD_COUNT : Local Unit 2 Down Stream Forward Count
RU2_DS_FWD_COUNT : Remote Unit 2 Down Stream Forward Count
LU2_DS_REV_COUNT : Local Unit 2 Down Stream Reverse Count
RU2_DS_REV_COUNT : Remote Unit 2 Down Stream Reverse Count

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page47


When train enters from SF side
E.g. Power ON Condition

SF
A d r 0 0 2 S F D B 7 B B 6 7 7

S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T

EF
A d r 0 0 4 E F D B 7 B B 6 7 7

S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T

E.g. Preparatory condition

SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n

EF
A d 4 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page48


E.g. Occupied condition

SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0

EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0

E.g. Clear condition

SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0

EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page49


LCD Display for 2DP1S-End Fed
Table 5-4 LCD Display for End Fed of 2DP1S

Column 1 Column 10 Column 13

Line 0 Address Unit Type Checksum

Column 2 Column 7 Column12 Column 17


Line 1
LU1_US_FWD_C RU1_US_FWD_C LU1_US_REV_CO RU1_US_REV_C
OUNT OUNT UNT OUNT

Column 2 Column 7 Column 12 Column 17


Line 2
LU2_US_FWD_C RU2_US_FWD_C LU2_US_REV_CO RU2_US_REV_C
OUNT OUNT UNT OUNT

Column 1
Line 4 Status/ Error messages

The above information corresponds to the different aspects of the system as follows

Address : Is the address of CPU of SSDAC Unit


Unit Type : Is the type of Configuration of SSDAC Unit
Checksum : Checksum of Code Memory
LU1_US_FWD_COUNT : Local Unit 1 Up Stream Forward Count
RU1_US_FWD_COUNT : Remote Unit 1 Up Stream Forward Count
LU1_US_REV_COUNT : Local Unit 1 Up Stream Reverse Count
RU1_US_REV_COUNT : Remote Unit 1 Up Stream Reverse Count
LU2_US_FWD_COUNT : Local Unit 2 Up Stream Forward Count
RU2_US_FWD_COUNT : Remote Unit 2 Up Stream Forward Count
LU2_US_REV_COUNT : Local Unit 2 Up Stream Reverse Count
RU2_US_REV_COUNT : Remote Unit 2 Up Stream Reverse Count

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page50


When train enters from EF side

E.g. Power ON Condition

SF
A d r 0 0 2 S F D B 7 B B 6 7 7

S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T

EF
A d r 0 0 4 E F D B 7 B B 6 7 7

S / W V e r s i o n - S 0 0 2
W A I T I N G F O R R E S E T

E.g. Preparatory condition


SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n

EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
W a i t F o r P i l o t T r a i n

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page51


E.g. Occupied condition
SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2

EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0

E.g. Clear condition


SF
A d r 0 0 2 S F D B 7 B B 6 7 7
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0
0 0 0 2 0 0 0 2 0 0 0 0 0 0 0 0

EF
A d r 0 0 4 E F D B 7 B B 6 7 7
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2
0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page52


5.3 LCD Display of Reset Box for 2DP1S

Local DP Checksum / Count


Remote DP 4 Row by 20 Character LCD Display Checksum / Count
Local DP (Status)
Remote DP (Status)

1. Reset Box Powered up first and SSDAC – Not Powered UP still

S S D A C R e s e t B o x V 0 0 1

C o m m u n i c a t i n g w i t h
S S D A C

2. SSDAC is Powered UP first and Reset Box is Powered next, communication is


established

C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2

Since SSDAC system is in Powered UP condition and Reset Box is powered UP next,
it communicates with SSDAC and show the Checksum and S/W Version of SSDAC
and continue with the current status of SSDAC.

If Reset Box is powered UP first and then SSDAC system is Powered UP next, the
following display will be shown.

2DP-1S (2 DP 1 Section)

1. Power up condition:

C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2
W a i t i n g f o r R E S E T
W a i t i n g f o r R E S E T

2. Reset Applied at Local Unit:

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page53


C H E C K S U M S / W V e r 0 0 2
C H E C K S U M S / W V e r 0 0 2
R e s e t A p p l i e d
W a i t i n g f o r R E S E T

3. Reset Applied at Remote Unit:

C h e c k s u m S / W V e r 0 0 2
C h e c k s u m S / W V e r 0 0 2
W a i t i n g f o r R E S E T
R e s e t A p p l i e d

4. Preparatory condition:

0 0 0
0 0 0
W a i t f o r P i l o t T r a i n
W a i t f o r P i l o t T r a i n

4.1 Pilot Train at Local

0 0 2
0 0 0
P i l o t i n g i n P r o g r e s s
W a i t f o r P i l o t T r a i n

4.2 Pilot Train at Remote

0 0 0
0 0 2
W a i t f o r P i l o t T r a i n
P i l o t i n g i n P r o g r e s s

5. Clear condition:

0 0 0
0 0 0
S e c t i o n C L E A R
S e c t i o n C L E A R

6. Occupied condition:

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page54


0 4 0
0 3 8
S e c t i o n O C C U P I E D
S e c t i o n O C C U P I E D

7. Error Condition:

0 4 0
0 4 2
D i r e c t - O U T C O U N T 4 5
S Y S T E M I N E R R O R

8. Error Condition: Reset Applied at Local Unit

C h e c k s u m S / W V e r 0 0 2
0 4 2
R e s e t A p p l i e d
S Y S T E M I N E R R O R

9. Error Condition: Reset Applied at Remote Unit:

40 0
C h e c k s u m S / W V e r 0 0 2
D i r e c t - O U T C O U N T 4 5
R e s e t A p p l i e d

10. Preparatory condition after Error and Reset applied at both the DP:

0 0 0
0 0 0
W a i t f o r P i l o t T r a i n
W a i t f o r P i l o t T r a i n

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page55


5.4 Trouble Shooting Chart

There are different types of errors. The errors listed below are handled by
software. Each error is identified with one error code. The analysis of all these errors
and the corrective measures to be taken are tabulated in table of below.

Table 5-5 Trouble Shooting Chart

Error
Code on Corrective
Errors Analysis
display measure
of CPU
Error occurred due to
Place the PD1
missing of the Phase
module in the slot
01 PD1_BOARD_MISSING detector 1 module (PD1-
and reset the
21KHz) during run time
system
and boot time diagnosis.
Error occurred due to
Place the PD2
missing of the Phase
module in the slot
02 PD2_BOARD_MISSING detector 2 module (PD2-
and reset the
25KHz) during run time
system
and boot time diagnosis.
Error occurred due to Place the SM-CPU
missing of the SM-CPU module in the slot
03 SM_CPU_MISSING
module during run time and reset the
and boot time diagnosis. system
Error occurred due to Place the
missing of the Communication A
04 MODEM_MODULE_A_MISSING Communication A module in the slot
module during run time and reset the
and boot time diagnosis. system
Error occurred due to Place the
missing of the Communication B
05 MODEM_MODULE_B_MISSING Communication B module in the slot
module during run time and reset the
and boot time diagnosis system
Error occurred due to
Place the Relay
missing of the Relay
Drive A module in
06 RELAY_DRIVE_A_MISSING Drive A module during
the slot and reset
run time and boot time
the system
diagnosis
Error occurred due to
Place the Relay
missing of the Relay
Drive B module in
07 RELAY_DRIVE_B_MISSING Drive B module during
the slot and reset
run time and boot time
the system
diagnosis

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page56


Error occurred due to
Place the CPU
missing of the any one of
module missing in
PEER_CPU_MISSING the CPU module during
08 the slot and reset the
run time and boot time
system
diagnosis
When EF CPU1 could
not transmit to remote 1. Make the
unit (CF or SF) CPU1 connection
Cause 1: Check the Properly
communication links 2. Replace CPU1
09 COMM_LU1_TO_US1_FAILURE (MS Coupler) and of EF Unit
Reset the system 3. Replace
Cause 2: CPU 1 of EF COMM1 of EF
Unit Bad Unit
Cause 3: COMM1 of
EF Unit bad
When EF CPU1 could
not transmit to remote 1. Make the
unit (SF or CF) CPU2 connection
Cause 1:Check the Properly
communication links 2. Replace CPU1
10 COMM_LU1_TO_US2_FAILURE (MS Coupler) and of EF Unit
Reset the system 3. Replace
Cause 2: CPU1 of EF COMM1 of EF
bad Unit
Cause 3: COMM1 of
EF Unit bad
When SF CPU1 could
not transmit to remote 1. Make the
unit (CF or EF) CPU1 connection
Cause 1:Check the Properly
communication links 2. Replace CPU1
11 COMM_LU1_TO_DS1_FAILURE (MS Coupler) and of SF Unit
Reset the system 3. Replace
Cause 2: CPU1 of SF COMM2 of SF
bad Unit
Cause 3: COMM2 of
SF Unit bad
When SF CPU1 could 1.Make the
connection
not transmit to remote
unit (CF or EF) CPU2 Properly
Cause 1:Check the 2. Replace CPU1
12 COMM_LU1_TO_DS2_FAILURE communication links of SF Unit
(MS Coupler) and 3. Replace
Reset the system COMM2 of SF
Cause 2: CPU1 of SF Unit
bad

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page57


Cause 3: COMM2 of
SF Unit bad
When EF CPU1 could
not receive any response
1. Make the
from the remote unit (SF
or CF) CPU1 connection
Cause 1:Check the Properly
communication links 2. Replace CPU1
13 COMM_US1_TO_LU1_FAILURE (MS Coupler) and of EF Unit
Reset the system 3. Replace
COMM1 of EF
Cause 2: CPU1 of EF Unit
bad
Cause 3: COMM1 of
EF Unit bad
When EF CPU2 could
not receive any
response from the 1. Make the
remote unit (SF or CF) connection
CPU1 Properly
Cause 1:Check the 2. Replace CPU2
14 COMM_US2_TO_LU1_FAILURE communication links of EF Unit
(MS Coupler) and 3. Replace
Reset the system COMM1 of EF
Cause 2: CPU2 of EF Unit
bad
Cause 3: COMM1 of
EF Unit bad
When SF CPU1 could
not receive any
response from the 1. Make the
remote unit (CF or EF) connection
CPU1 Properly
Cause 1:Check the 2. Replace CPU1
15 COMM_DS1_TO_LU1_FAILURE communication links of SF Unit
(MS Coupler) and 3. Replace
Reset the system COMM2 of SF
Cause 2: CPU1 of SF Unit
bad
Cause 3: COMM2 of
SF Unit bad

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page58


When SF CPU2 could
not receive any response 1. Make the
from the remote unit (CF connection
or EF) CPU1 Properly
Cause 1:Check the 2. Replace
communication links CPU2 of SF
16 COMM_DS2_TO_LU1_FAILURE (MS Coupler) and Unit
Reset the system 3. Replace
Cause 2: CPU2 of SF COMM2 of
bad SF Unit
Cause 3: COMM2 of
SF Unit bad
When EF CPU2 could
1. Make the
not transmit to remote
unit (SF or CF) CPU1
connection
Cause 1:Check the Properly
communication links 2. Replace
(MS Coupler) and CPU2 of EF
17 COMM_LU2_TO_US1_FAILURE Unit
Reset the system
3. Replace
Cause 2: CPU2 of EF COMM1 of
bad EF Unit
Cause 3: COMM1 of
EF Unit bad
When EF CPU2 could
1. Make the
not transmit to remote
unit (SF or CF) CPU2
connection
Cause 1:Check the Properly
communication links 2. Replace
(MS Coupler) and CPU2 of EF
18 COMM_LU2_TO_US2_FAILURE Unit
Reset the system
3. Replace
Cause 2: CPU2 of EF COMM1 of
bad EF Unit
Cause 3: COMM1 of
EF Unit bad
When SF CPU2 could 1. Make the
not transmit to remote connection
unit (CF or EF) CPU1
Properly
Cause 1:Check the
2. Replace
communication links
CPU2 of SF
19 COMM_LU2_TO_DS1_FAILURE (MS Coupler) and
Unit
Reset the system
3. Replace
Cause 2: CPU2 of SF COMM2 of
bad SF Unit
Cause 3: COMM2 of SF
Unit bad
20 When SF CPU2 could 1. Make the
COMM_LU2_TO_DS2_FAILURE
not transmit to remote connection

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page59


unit (CF or EF) CPU2 Properly
Cause 1:Check the 2. Replace
communication links CPU2 of SF
(MS Coupler) and Unit
Reset the system 3. Replace
Cause 2: CPU2 of SF COMM2 of
bad SF Unit
Cause 3: COMM2 of
SF Unit bad
When EF CPU1 could
not receive any response 1. Make the
from the remote unit (SF connection
or CF) CPU2 Properly
Cause 1:Check the 2. Replace
communication links CPU1 of EF
21 COMM_US1_TO_LU2_FAILURE (MS Coupler) and Unit
Reset the system 3. Replace
Cause 2: CPU1 of EF COMM1 of
bad EF Unit
Cause 3: COMM1 of
EF Unit bad
When EF CPU2 could
not receive any response 1. Make the
from the remote unit (SF connection
or CF) CPU2 Properly
Cause 1:Check the 2. Replace
communication links CPU2 of EF
22 COMM_US2_TO_LU2_FAILURE (MS Coupler) and Unit
Reset the system 3. Replace
Cause 2: CPU2 of EF COMM1 of
bad EF Unit
Cause 3: COMM1 of
EF Unit bad
When SF CPU1 could
not receive any response 1. Make the
from the remote unit (CF connection
or EF) CPU2 Properly
Cause 1:Check the 2. Replace
communication links CPU1 of EF
23 COMM_DS1_TO_LU2_FAILURE (MS Coupler) and Unit
Reset the system 3. Replace
Cause 2: CPU1 of SF COMM1 of
bad EF Unit
Cause 3: COMM2 of SF
Unit bad

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page60


When SF CPU2 does
not receive any
1. Make the
response from the
connection
remote unit (CF or EF)
Properly
CPU2
2. Replace
Cause 1:Check the
CPU2 of SF
24 COMM_DS2_TO_LU2_FAILURE communication links
Unit
(MS Coupler) and
3. Replace
Reset the system
COMM2 of
Cause 2: CPU2 of SF SF Unit
bad
Cause 3: COMM2 of
SF Unit bad
Carrier signal is being
blocked by modem 1. Replace
25 MODEM_ERROR_NO_CARRIER Cause 1: COMM1 /
COMM1/COMM2 gone COMM2
Bad
Cause 1: SM- 1. Replace SM-
CPU/Event Logger CPU/Event
26 PEER_CPU_LINK_FAILURE gone bad Logger
Cause 2: CPU1/CPU2 2. Replace
gone bad CPU1/CPU2
Check the error
Error at Down stream at remote unit,
unit rectify the error
27 FAILURE_AT_DS
Cause 1: Failure in the and reset the
remote unit system

Error at Up stream unit Check the error at


28 remote unit, rectify
FAILURE_AT_US Cause 1: Failure in the
the error and reset
remote unit the system
PD Wheel Detection
during Power On
Condition.
30 BOOTUP_PD_FAIL Cause 1: Train moving Reset the System
in the Section on TX /
RX coils, power OFF &
ON in fraction of
seconds.
PD1 module supervisory 1. Make the
is low for 3 seconds connection
Cause 1: TX1/RX1 coils Properly
not connected properly
33 PD1_SUP_LOW 2. Replace
Cause2: TX1/RX1 coil
gone bad TX1/RX1
Cause 3: CPU1/CPU2 coil
gone bad 3. Replace

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page61


Cause 4: PD1 module CPU1/CPU2
gone bad 4. Replace PD1
module

PD2 module
1. Make the
supervisory is low for
connection
6 seconds
Properly
Cause 1: TX2/RX2
2. Replace
coils not connected
TX1/RX1
properly
34 PD2_SUP_LOW coil
Cause2: TX2/RX2
3. Replace
coil gone bad
CPU1/CPU2
Cause 3: CPU1/CPU2
4. Replace PD2
gone bad
module
Cause 4: PD2 module
gone bad
Error occurs when any 1. Make the
one sensor is connection
influenced two or more Properly
times. 2. Replace
35 PD1_PULSING Cause 1: Loose TX1/RX1
contacts of TX1/RX1 coil
connections 3. Replace PD2
Cause 2: PD2 module module
gone bad
Error occurs when any 1. Make the
one sensor is connection
influenced two or more Properly
times. 2. Replace
36 PD2_PULSING Cause 1: Loose TX2/RX2
contacts of TX1/RX1 coil
connections 3. Replace PD1
Cause 2: PD1 module module
gone bad
1. Make the
Error occurs when connection
double sensor is Properly
influence in the sequence 2. Replace
Cause 1: Loose TX1/RX1,
37 PD_STATE_MISSING
contacts of TX1/RX1, TX2/RX2
TX2/RX2 connections coil
Cause 2: PD1, PD2 3. Replace PD1,
module gone bad PD2 module

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page62


If supervisory signals
1. Make the
pulsates more than 4
times connection
Cause 1: TX1/RX1 or Properly
TX2/RX2 coils not 2. Replace
connected properly TX1/RX1,
Cause2: TX1/RX1, TX2/RX2
38 PD_SUP_PULSATING
TX2/RX2 coil gone coil
bad 3. Replace
Cause 3: CPU1/CPU2 CPU1/CPU2
gone bad 4. Replace PD1,
Cause 4: PD1, PD2 PD2 module
module gone bad
Error occurs when any
1. Make the
wheel counting state
sequence is missing connection
Cause 1: TX1/RX1 or Properly
TX2/RX2 coils not 2. Replace
connected properly TX1/RX1,
Cause2: TX1/RX1, TX2/RX2
39 PD_STATE_FAIL
TX2/RX2 coil gone coil
bad 3. Replace
Cause 3: CPU1/CPU2 CPU1/CPU2
gone bad 4. Replace PD1,
Cause 4: PD1, PD2 PD2 module
module gone bad
Error occurs when both
the PD modules doesn’t
1. Make the
sense the wheel for more
than 3 times connection
Cause 1: TX1/RX1 or Properly
TX2/RX2 coils not 2. Replace
connected properly TX1/RX1,
40 PD_NOT_SENSING
Cause2: TX1/RX1, TX2/RX2
TX2/RX2 coil gone coil
bad 3. Replace PD1,
Cause 4: PD1, PD2 PD2 module
module gone bad

No/Improper feedback 1. Make the


from Preparatory A relay connection
Cause 1: Loose Properly
contacts of Preparatory 2. Replace
41 PREPARATORY_RELAY_A_FAILURE relay connections Relay Driver
Cause2: Relay Drive 1 1 module
module gone bad 3. Replace
Cause 4: CPU1/CPU2 CPU1/CPU2
module gone bad module

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page63


No/Improper feedback
from Preparatory B relay 1. Make the
Cause 1: Loose connection
contacts of Preparatory Properly
relay connections 2. Replace
42 PREPARATORY_RELAY_B_FAILURE
Cause2: Relay Drive 2 Relay Driver
module gone bad 2 module
Cause 3: CPU1/CPU2 3. Replace
module gone bad CPU1/CPU2

No/Improper feedback
from Vital Relay A relay
1. Make the
Cause 1: Loose
connection
contacts of Vital relay
Properly
connections
2. Replace
43 VITAL_RELAY_A_FAILURE Cause2: Relay Drive 1
Relay Driver
module gone bad
1 module
Cause 3: CPU1/CPU2
3. Replace
module gone bad
CPU1/CPU2

No/Improper feedback
from Vital Relay B relay 1. Make the
Cause 1: Loose connection
contacts of Vital relay Properly
connections 2. Replace
44 VITAL_RELAY_B_FAILURE
Cause2: Relay Drive 2 Relay Driver
module gone bad 2 module
Cause 3: CPU1/CPU2 3. Replace
module gone bad CPU1/CPU2

Without IN COUNT,
45 DIRECT_OUT_COUNT Reset the system
OUT COUNT registered
Power failure at Down Make the
stream CPU1
49 TRANSIENT_POWER_FAILURE_DS1 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Down Make the
50 stream CPU2
TRANSIENT_POWER_FAILURE_DS2 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Up Make the
stream CPU1
51 TRANSIENT_POWER_FAILURE_US1 connection
Cause 1: Loose contacts
of power connections Properly
Power failure at Up Make the
stream CPU2
52 TRANSIENT_POWER_FAILURE_US2 connection
Cause 1: Loose contacts
of power connections Properly

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page64


Change the
address settings by
When CPU address
57 INVALID_NETWORK_ADDRESS using LK10 to
range wrong
LK17 links and
reset the system
This is a Boot Up error.
Re-program the
When CRC of the code
58 INCORRECT_CODE_CRC processor and code
mismatches with the
memory checksum
stored CRC
Change the
address and
When unit type and configuration
59 INVALID_CONFIGURATION
address of CPU is wrong settings as per the
requirement and
reset the system
60 INVALID_COUNTS Train with 10,000 wheels Reset the system
This is an Boot up error
when RAM (In- built Replace the Micro
61 RAM_TEST_FAILED
memory of Micro Controller
controller) is failed

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page65


6 Resetting Procedure
It is essential that the systems have to be initialised properly after
initial power ON and restored to normal mode of working. Similarly,
whenever the system goes to faulty / error mode, the system has to be reset
after correcting the errors to bring it to the normal working mode. The
procedure for reset for the different configurations is described in the
following paragraphs.

The reset for all the configurations of SSDAC have to be executed


through the reset box provided for this purpose, located in the station master
room. The reset box is wired to SSDAC system through a pair of repeater
relays named as PPR and VPR. The repeater relays in the relay room repeat
the status of the vital and preparatory relays of the SSDAC system. For all
SSDAC system configurations the same reset circuit can be used.

6.1 Reset Procedure for 2DP1S

The SSDAC-2DP1S system allows reset from stationmaster whenever


system is powered on or system/section enter error mode or unbalanced with
occupied LED glowing. The system reset is possible only if the system is in
unbalanced mode but no hardware failures.

SSDAC-SF and SSDAC-EF needs reset from station A and station B.


Under this condition, reset is possible only if preparatory and vital relay are
de-energize/drop state.

Reset Procedure

• Stationmaster A inserts and turns the SM key and press the reset button
simultaneously.

• Preparatory LED start blinking and LCD display’s “Reset Applied“ in the
position of remote DP status indicating that reset is pressed.

• Stationmaster B inserts and turns the SM key and presses the reset button
simultaneously.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page66


• After SSDAC-SF and SSDAC-EF communication is successful both the
systems enter the preparatory mode with preparatory LED glowing in the
reset box at station A and station B and the counter gets incremented by 1.
The LCD display’s “Wait For Pilot Train” in both Local and remote DP
status position.

• Now the pilot train is allowed in the section to balance the section. On
successful piloting of train with minimum of two axles and matching of In-
counts and Out-counts section gets balanced.

• SSDAC–2DP1S system cover the section goes through reset operation and
vital relays of SSDAC-SF and SSDAC–EF energize/pickups. Occupied
LEDs goes off and clear LEDs glow at both station A and station B.

• Reset procedure is now completed and SSDAC-2DP1S section is ready for


train movements.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page67


7 Maintenance

SSDAC has various monitoring points. These different points are being
tabulated below.

Table 7-1 Monitoring points of SSDAC

Measured values range


Module Monitoring point name
RX-SIG and GND 900 mV to 1.2 V AC
PHASE SUP-OUT and GND 4V to 5V DC
DETECTOR WHEEL-M-OUT and GND 4.5V to 5V DC
WHEEL-S-OUT and GND 4.5V to 5V DC
(PD1 and PD2) RX-PH-SIG and GND 10 V to 12V DC
SUP-ADJ and GND 4V to 5V DC
+5VDC and GND 4.75 to 5.25V DC
DC-DC +18VDC and GND 17.75 to 18.25V DC
Converter +12VDC and GND 11.75 to 12.25V DC
-12VDC and GND 11.75 to 12.25V DC
+24VDC and GND 22V to 26V DC
EN1B O/P and GND (for SF, CF, 3DP1S units) 11.5V to 12.5V DC
CPU 1
EN1A O/P and GND (for EF, CF) 11.5V to 12.5V DC

EN2B O/P and GND (for SF, CF, 3DP1S units) 11.5V to 12.5V DC
CPU 2
EN2A O/P and GND (for EF, CF) 11.5V to 12.5V DC

RELAY DRIVE VITAL RLY A O/P (+)


> 20V DC
1 (for EF, CF) VITAL RLY A O/P (-)
RELAY DRIVE
VITAL RLY B O/P (+)
2 (for SF, CF, > 20V DC
VITAL RLY B O/P (-)
3D units)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page68


7.1 Maintenance of the SSDAC system

Table 7-2 Maintenance table

Time Maintenance
Daily NIL
Weekly NIL
Check and record the readings of
Power supply module and PD
Monthly
module and check the TX / RX Coil
Voltages as per Table 8-1
Half yearly Replace if any parts broken

7.2 Tools and Spares

The following toolkit and spares must be procured separately for


installation and maintenance.

7.2.1 Tool kit

Note: 1 set of tool kit to be purchased separately for every 10 sets of SSDAC
systems

Table 7-3 Tool Kit

Sl.No Tools Quantity


Portable Data logger for downloading event
1 1
logger data for analysis and report generation
Pure sine wave Digital Multimeter (Fluke make
2 1
187 or Rishab make 28S or similar)
3 Train simulator 1
4 Extender module 1
5 Dummy wheel 1
6 Ring spanner 17-19,24-26 1
7 Open end spanner 17-19, 24-26 1
8 Socket spanner with handle 1
Torque wrench, Jaicom make JPR65 or
9 1
Equivalent - 88 Nm.
10 Screw Driver No. 902 1
11 Screw Driver No. 935 1
12 Marking jig for drilling 1

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page69


7.2.2 Recommended Spares

The following spares are to be procured separately for 5 nos. of Single


Section Digital Axle Counter working in field

Table 7-4 Recommended Spares

Sl.No Spares Part No Quantity


1 Phase Detector modules 1 H001M01R1 2
Phase Detector modules 2
2 H001M02R1 2
3 CPU1 Module of SF H001M09R1 1
4 CPU2 Module of SF H001M10R1 1
5 CPU1 Module of EF H001M11R1 1
6 CPU2 Module of EF H001M12R1 1
7 Communication Module 1 H001M04R1 1
8 Communication Module 2 H001M05R1 1
9 Relay drive Module 1 H001M07R1 1
10 Relay drive Module 2 H001M06R1 1
Event Logger / SM-CPU
11 H001M03R1 2
Module
12 DC-DC converter Module H001M08R1 2
Axle detectors 21 KHz /
13 G36-T212500 2
25KHz (TX coil)
Axle detectors 21 KHz / 25
14 G36-R212500 2
KHz (RX coil)
Hardware for mounting axle
15 1
detectors
MS circular connectors (6
16 2
No.)
SSDAC – Reset box with
17 G36-RSBX01 2
Error Display
SSDAC –SF unit (housing
18 with mother board, without H001M21R1 1
modules)
SSDAC –EF unit (housing
19 with mother board, without H001M21R1 1
modules)
20 Relay Box G36-RB2R00 2

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page70


8 Do’s and Don’ts
8.1 Do’s

Table 8-1 Table of DO’s

Sl.No DO’s
The interconnection drawings are to be followed for connecting the
1 Transmitter and Receiver Coils. Tx1 is 21 KHz, Tx2 is 25 KHz & Rx1
and RX2 coils are 21 KHz & 25 KHz, respectively.
Ensure that Receiver and Transmitter coil cables have been laid in
2
different pipes.
Ensure that both the TX coils & RX coils are having proper alignment
3
on Rail.
Ensure that packing of sleepers with ballast on both sides of Axle
4
detector is proper.
Check that metal sheaths of the outdoor cable are connected to earth at
5
both ends.
The recommended cables for wiring of the system at site should be
6
used.
7 The steady battery voltage 24 V should be maintained.
8 The cable connections should not be connected loosely.
The MS Coupler connectors of SSDAC System are checked and
9
maintained firmly.
Preparatory Resetting should be done only after ensuring that there is no
10
train in the Section.
It is recommended that heat resisting paint to be used on the apparatus
11 case so that the temperature inside apparatus case is maintained lower in
comparison to other normal paints.

Caution Board has to be placed near the SSDAC Axle Detectors to


12
avoid damaging of coils from packing machines.

Deflector Plates must be mounted near the SSDAC Axle Detectors to


13
avoid damaging of coils.

Usage of Spokes Trolley wheel reduces the SSDAC system entering the
Error mode and increases the Availability. The straight movements or
14
passing of Motor Trolley or Push Trolley with solid mass wheel does
not effect the SSDAC system.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page71


8.2 Don’ts

Table 8-2 Table of Don’ts

Sl.No DON’Ts
Don’t cut or join the Transmitter / Receiver cables supplied along with the coil.
1
It would result in change of input Receiver signal.
Don’t remove the modules from SSDAC System under Power ON condition.
2 Remove the modules if necessary after switching OFF the power to the SSDAC
System.
Local Address of the CPU – 1, CPU – 2 and Configuration settings of the
3
SSDAC System should not be changed at the field.
The Hardware of Communication module and Relay Drive module are similar
for all systems. However their position of mounting is different in different unit
4
types. These modules have to be equipped correctly after verifying the drawings
(DRG No: 1 & DRG No: 2), which indicates their positions.
When Section is in Occupied / Preparatory Mode, Motor Trolley wheel, Push
5 Trolley with solid mass wheel and Material Trolley wheel must not be allowed
to Enter / Exit the Section to avoid SSDAC System going to Error condition.
The SSDAC System does not support Entry / Exit of Motor Trolley wheel
whether fixed to Motor Trolley or Push Trolley in Occupied Sections, Back to
6 Back movement within a period of 6 seconds, Shunting operations. The
SSDAC system may enter into Error mode if the Motor Trolley or Push Trolley
with solid mass wheel movement on the track is Wobbling.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page72


ANNEXURE
SSDAC Unit Sl. No (SF UNIT) ---------------- (EF UNIT) --------------

0 General Information:

0.1 Station/Section Name


0.2 Division/Zonal Railway
0.3 Contact Details of Railways at site
0.4 Contact Details of Railways at HQr/Division
0.5 Total No of detection point/Section
0.6 Contact no.
0.7 Date of Pre commissioning inspection
0.8 Name of firm’s authorized Rep

Note: 1. System should be installed and commissioned by authorized


technical staff of manufacturer only.
2. Installation practices of SSDAC model SSDAC-G36 for Phase Reversal
should be strictly adhered to and checked before commissioning covering all
points in the following document

1. Out door (Location Box)

Observed
OK / Not
Sl. No. Item Required SF EF OK
UNIT UNIT
Relay used in Relay Q type, 24V, 1000 Ohm
1.1 (Printed Sticker of VR/PR either on front
Box VR & PR cover or inside bottom of the relay box)
Diode across each
Should be provided with BY127 /
1.2 relay coil in reverse
IN4007 / IN5408
bias.
1.3 Unused Quad pair To be terminated on terminals.
Dressing of Quad To be properly dressed with
1.4
pair insulated tape.
Spiral before No individual conductor to be
1.5
termination. made spiral

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page73


2.Outdoor (track device)

Observed
OK /Not
Sl. No. Item Required SF EF OK
UNIT UNIT
Wiring of TX / RX
Wired on approved ARA / PBT
2.1 coils & MS coupler
terminal strips
cables
Condition of worn Should be within vertical limit of
out of Rail worn out
2.2 60 Kg - 13 mm 159-172 mm
52 Kg - 8 mm 148-156 mm
90 R - 5 mm 138-143 mm
GGT Jig as per drawing no.DRG-
23 of Installation manual version
Marking of holes on 1.0 Revision 1 to be used as per
rail rail section.
2.3
(From bottom of the 60 Kg 84 mm
rail) 52 Kg 68 mm
90 R 57 mm
from the bottom of the rail.
Should be of 14mm dia Should be
Drilling of holes in
2.4 square (perpendicular), should not
the web of rail
be oblong.
Torque applied to
fix track device Jaicom make JPR65 or
2.5
using Torque Equivalent - 88 Nm.
wrench
2.6 Fixing of TX Outside the rail
2.7 Fixing of RX Inside the rail
Fixing of axle On the same rail as per drawing
2.8 detectors at entry & no. DRG-12 of installation manual
exit end Version 1.0,Revision 1
Laying of axle
2.9 In corrugated / HDPE pipe
detector cable
Screen of axle
2.10 Should be earthed
detector cable
Fixing of deflector As per drawing given to
2.11 Installation Manual Version 1.0
plates Revision 1 DRG-18

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page74


Observed OK /
Sl. No. Item Required SF EF NOT
UNIT UNIT OK
2.13 Rail section 60 Kg / 52 Kg / 90 R
Nuts, bolts
Insertion of bolt from Rx coil side
2.14 &washers for fixing
i.e. inside of the rail
rail contacts
30 cm away from TX / RX coils in
2.15 Position of deflector
the next sleeper
Should not be higher than the rail
2.16 Height of deflector
top
Clearance between
2.17 400 mm between sleepers
sleepers
Should not be covered by Track
2.18 Embossing on rail
device

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page75


3. Outdoor Quad Cable

3. Outdoor (Quad Cable/PIJF twisted pairs telecom cable for Axle counter system
working in station area, As per RDSO letter no. STS/E/SSDAC/SPN/177
dated-28/30.08.2006)

3.1 Test format for testing of QUAD cable/PIJF twisted pair telecom cable
before commissioning of SSDAC in Station area

Sl No. Item Expected Measured/ Remarks


Observed (OK/Not OK)
Only Quad cable / PIJF twisted
Communication pair telecom cable is to be used
3.1.1 a Media between field units.
Type of Cable No Signaling Cable is to be used
in totality/parts.
Proper pair of wires to be used for
connectivity.
3.1.2 b Use of pair
Annex-1 for Quad cable may be
referred
Duplication of No wires to be paralleled for
3.1.3 c
Wires reducing conductor resistance.
Insulation
Shall be greater than /equal to 10
3.1.4 d resistance of
M ohm.
Quad cable
Not to exceed 56 ohm/Kms for
Quad Cable at 200 C & ____*
Loop resistance ohms/Kms for PIJF telecom
3.1.5 e
of designated pair cable.
See Annexure -2 for correction
factor.
Attenuation loss
Shall not be greater than 30.0 dB
3.1.6 f measured at 2
for full length of the cable used.
KHz
Continuity of
3.1.7 g Continuity shall be there
cable armour

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page76


Remarks
Measured /
Sl No. Item Expected (OK / Not
Observed
OK)
Separate Earth of
3.1.8 h quad/PIJF Shall be less than One ohm
telecom cable
Cable allocation
3.1.9 i Shall be filled up & attached
table
Unused Quad
3.1.10 j To be terminated on terminals.
pair
Dressing of Quad To be properly dressed with
3.1.11 k
pair insulated tape.
Spiral before No individual conductor to be
3.1.12 l
termination. made spiral
3.2 Test format for testing of QUAD cable before commissioning of SSDAC /
BPAC / SSBPAC (D) used in between Station to station

Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
Block section
3.2.1 a ≤ 12 Km.
length limit
Only Quad cable is to be
Communication
used between field units.
3.2.2 b Media
No Signaling Cable is to
Type of Cable
be used in totality/parts.
Proper pair of wires to be
3.2.3 c Use of pair used for connectivity.
Annex-1 may be referred
No wires to be paralleled
Duplication of
3.2.4 d for reducing conductor
Wires
resistance.
Insulation
Shall be greater than
3.2.5 e resistance of Quad
/equal to 10 M ohm.
cable

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page77


Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
Not to exceed 56 ohm/Kms at
Loop resistance 200 C.
3.2.6 f
of designated pair See Annexure -2 for
correction factor.
Attenuation loss Shall not be greater than 30.0
3.2.7 g measured at 2 dB for full length of the cable
KHz used.
Near End Cross
3.2.8 h Shall be better than 55 dB.
Talk (NEXT)
Far End Cross Talk
3.2.9 i Shall be better than 55 dB.
(FEXT)
Continuity of
3.2.10 j Continuity shall be there
cable armour
Separate Earth of
3.2.11 k Shall be less than One ohm
quad cable
Cable allocation
3.2.12 l Shall be filled up & attached
table
Unused Quad
3.2.13 m To be terminated on terminals.
pair
Dressing of Quad To be properly dressed with
3.2.14 n
pair insulated tape.
Spiral before No individual conductor to be
3.2.15 o
termination. made spiral

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page78


3.2.2 Test format for testing of local QUAD / PIJF twisted pair telecom cable &
OFC before commissioning of SSDAC / BPAC / SSBPAC (D) on OFC in between
station to station.

Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
3.2.2 QUAD/PIJF
Jelly filled telecom cable/
Quad cable to be used
Communication
between field units &
3.2.2.1 a Media
OFC Equipment room.
Type of Cable
Signaling Cable shall not
be used at all.
Proper pair of wires to be
3.2.2.2 b Use of pair used for connectivity.
Annex-1 may be referred
No wires to be paralleled
Duplication of
3.2.2.3 c for reducing conductor
Wires
resistance.
Insulation
Shall be greater than
3.2.2.4 d resistance of
/equal to 10 M ohm.
Quad cable
Not to exceed 56
ohm/Kms at 200 C for
Loop resistance quad cable &
3.2.2.5 e of designated * ohm/Kms for PIJF
pair telecom cable.
See Annexure -2 for
correction factor.
Earth of quad Shall be less than One
3.2.2.6 f
cable ohm
Cable Shall be filled up &
3.2.2.7 g
allocation table attached
Unused Quad To be terminated on
3.2.2.8 h
pair terminals.
Dressing of To be properly dressed
3.2.2.9 i
Quad pair with insulated tape.
Spiral before No individual conductor
3.2.2.10 j
termination. to be made spiral

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page79


Measured / Remarks
Sl No. Item Expected
Observed (OK / Not OK)
3.2.3 OFC
For 0 dB Trans signal
level, the received signal
3.2.3.1 Channel line up level at other end shall
not be more than
-15.0 dB.

3.3 Test format for testing of QUAD cable/PIJF twisted pair telecom cable in
between SSDAC Unit and Station before commissioning of SSDAC

Sl No. Item Expected Measured/ Remarks


Observed (OK/Not OK)
Only Quad cable / PIJF twisted
Communication pair telecom cable is to be used
3.3.1 a Media between field units.
Type of Cable No Signaling Cable is to be used
in totality/parts.
Proper pair of wires to be used for
connectivity.
3.3.2 b Use of pair
Annex-1 for Quad cable may be
referred
Duplication of No wires to be paralleled for
3.3.3 c
Wires reducing conductor resistance.
Insulation
Shall be greater than /equal to 10
3.3.4 d resistance of
M ohm.
Quad cable
Not to exceed 56 ohm/Kms for
Quad Cable at 200 C & ____*
Loop resistance ohms/Kms for PIJF telecom
3.3.5 e
of designated pair cable.
See Annexure -2 for correction
factor.
Attenuation loss
Shall not be greater than 30.0 dB
3.3.6 f measured at 2
for full length of the cable used.
KHz
Continuity of
3.3.7 g Continuity shall be there
cable armour

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page80


Remarks
Measured /
Sl No. Item Expected (OK / Not
Observed
OK)
Separate Earth of
3.3.8 h quad/PIJF Shall be less than One ohm
telecom cable
Cable allocation
3.3.9 i Shall be filled up & attached
table
Unused Quad To be terminated on
3.3.10 j
pair terminals.
Dressing of Quad To be properly dressed with
3.3.11 k
pair insulated tape.
Spiral before No individual conductor to be
3.3.12 l
termination. made spiral
* PIJF telecom cable is available with three types of Conductor dia-

Condr Dia used in PIJF


Sl. No Resce at 200 C Loop Resce /KM
cable
1 0.50 mm 86 ohm +/- 6 172 ohm / Kms
2 0.63 mm 58 ohm +/- 4 116 ohm / Kms
3 0.90 mm 28 ohm +/- 2 56 ohm / Kms

Note: Procedure for test-

Attenuation Loss: The output/Input impedance of signal generator/dB meter shall be 600
ohm.
Near End Crosstalk: Test tone of 150 KHz to be fed in the adjacent pair of the same quad &
NEXT to be measured at the same end on the other pair of the same
quad.
Far End Cross talk: Test tone of 150 KHz to be fed in the adjacent pair of the same quad &
FEXT to be measured at the far end on the other pair of the same quad.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page81


4. Outdoor electronics

Observed OK /Not
Sl. No Item Required
SF UNIT EF UNIT OK
4.1 a. Sl. No. of SSDAC Same serial number pairs.
units Example – 001 (SF UNIT),
001 (EF UNIT)
b. Details of Track Track circuit No.
circuit
4.2 Placement of Should be in proper position
Cards/modules
4.3 Firmness of Should be tightened with screw /clip
card/Modules provided
4.4 MS Couplers Installed and tightened properly

4.5 MS coupler cables Wired properly as per color / label


code
4.6 Earthing of SSDAC Should be provided firmly through
units copper strips or other standard
copper cable.
Value < 1 Ohms
4.7 Earthing of Relay Should be provided firmly through
Box copper strips or other standard
copper cable.
Value < 1 Ohms
4.8 Fixing of SSDAC Should be firmly fixed using clamp
unit
4.9 Fixing of Relay Box Should be firmly fixed using clamp
4.10 Cable for taking 24v 2 X 25 sq. mm Al.
D.C. from central
location to SSDAC
unit.
4.11 External Surge Indicative type, plug able or easy to
Protection Devices on install on a DIN rail. Non plug able
input, output and shall be connected in parallel.
power supply lines
4.12 Address of SSDAC Address pair should be different
from any SSDAC system working
on the same station / section.
4.13 Fuse 2A
4.14 Software version no. S 002
4.15 Input voltage with
Charger ON 22 V to 30 V DC

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page82


Observed OK /Not
Sl. No Item Required SF UNIT EF UNIT OK
4.16 Input voltage with
Charger OFF.(Keep 22 V to 30 V DC
charger OFF for 15
minutes before taking
reading )

4.17 Ripple of Input Less than 10 mV rms / 50


Power Supply mV peak to peak.
4.18 Relay drive output to
the Vital Relay.
(This may be checked
across R1 & R2 of
coil of vital relay in
relay box).
4.18 a Section Unoccupied >20V
4.18 b Section Occupied < 2V
4.19 Relay drive output to
the Preparatory
Relay. (This may be
checked across R1 &
R2 of coil of
Preparatory relay in
relay box).
4.19 a Section Clear > 20V
4.19 b Section Occupied < 2V
4.20 Drive voltage of
repeater relays in
picked up condition,
when charger is OFF
for 15 minutes.
4.21 VPR > 22V
4.22 PPR > 22V

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page83


5.0 INDOOR POWER SUPPLY/CT RACK

Observed
Sl. Remarks
Item Required SF EF
No OK / Not OK
UNIT UNIT
Shall be of Q type 24 V ,
5.1 PPR & VPR Relays
1000 ohms
5.2 Fuse ratings 2.0 Amps
a) Charger should be fit for
axle counter use.
5.3 b) There should not be any
Power supply for axle other load on the power
counter supply except axle counter.
c) Class B & C types surge
protection must be provided
on 230 V mains line.
Ripple of Input Power Less than 10 mV rms / 50 mV
5.4
Supply peak to peak.
Glitch in Input Power
5.5 Supply by putting No glitch should be there
ON/OFF the charger
Drive voltage of the VPR.
(This may be checked
5.6 >22V
across R1 & R2 of coil of
relay).
Drive voltage of the PPR.
(This may be checked
5.7 >22V
across R1 & R2 of coil of
relay).

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page84


6.0 INDOOR (Reset Box Location)

Observed
Sl. Remarks
Item Required SF EF
No. OK / Not OK
UNIT UNIT
Wired as per drg no. DRG-
6.1Box Reset Box
Reset 18 OF Installation Manual
6.2 Reset Box Connected to earth
Earthing. properly.
6.3 a) Reset not possible when
Axle Counter section is
clear and healthy.
Reset function b) Reset not possible when
Axle counter section is in
Preparatory reset mode.
6.4 24 V D. C.
level at Reset 22V DC to 30 V DC
box input.
6.5 Level of reset
signal from 48 V ± 4 V DC
reset box.
6.6 Level of reset
signal at 38 V to 50V DC ± 2V DC
SSDAC unit
input.

7.0 COMMISSIONING

Sl. Measured / Remarks (OK /


Item Required Not OK)
No. Observed
7.1 Commissioning System should be installed &
commissioned by personal trained by
the manufacturer.
7.2 Training Railway personnel should be trained
before commissioning.
7.3 Verification of System to be monitored for 72 hours for
working trouble free operation before
commissioning. During this period,
effect of various trolley wheels used in
the section should be checked as per
Annexure ‘III’

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page85


Commissioning Log sheet of SSDAC [Phase reversal detection Type]
Model : SSDAC-G36, Software version : S001

The following card version should be checked:

Remarks
SF EF
Sl.No. Type of Card Part No. Version OK / Not
UNIT UNIT
OK
1 Phase Detector Card 1 H001M01R1 00
2 Phase Detector Card 2 H001M02R1 00
3 CPU Card 1 of SF H001M09R1 00 * NA *
4 CPU Card 2 of SF H001M10R1 00 * NA *
5 CPU Card 1 of EF H001M11R1 00 * NA *
6 CPU Card 2 of EF H001M12R1 00 * NA *
7 SM CPU/Event Logger
H001M03R1 00
Card
8 Communication Card 1 H001M04R1 00 * NA *
9 Communication Card 2 H001M05R1 00 * NA *
10 Relay Driver Card 1 H001M07R1 00 * NA *
11 Relay Driver Card 2 H001M06R1 00 * NA *
12 DC-DC Converter Card H001M08R1 00
13 LCD Display Box H001M24R1 00
14 Relay Box with Q-type;
24 V ; 1000 Ohm relay- G36-RB2R00 00
6F/6B
15 Filter Box G36-RSFL00 00
16 Axle detectors
G36-T212500 00
(Web type TX Coils)
17 Axle detectors
G36-R212500
(Web type RX coils)
18 Reset Box G36-RSBX01 00
19 Surge Voltage Protection
G36-LTDU00 00
device

* NA *: Not applicable

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page86


Annexure-I
Precautions to be taken care during the wiring/connections are to be done at the time of commissioning
of SSDAC/BPAC/SSBPAC (D)

Position of One Quad in Quad cable:

White
(A)
X

Red (C) X X (D) Grey

X
(B)
Quad color

1st pair = White & Quad colour i.e A & B Wires


2nd pair= Red & Grey colour i.e C & D Wires of designated colour of Quad.

Each Quad is binded by the respective Quad colour binder

Table-1
Colour scheme of PE insulated Quads
Quad Colour
Quad No Pair A - Wire B -Wire Pair No. C- Wire D - Wire
No.
Orange 1 1A White Orange 1B Red Grey
Blue 2 2A White Blue 2B Red Grey
Brown 3 3A White Brown 3B Red Grey
Green 4 4A White Green 4B Red Grey
Yellow 5 5A White Yellow 5B Red Grey
Black 6 6A White Black 6B Red Grey

Precautions to be taken for using QUAD Cable:

 Designated pair of wire of the same quad (mentioned in Table -1) should be used.

 Do not use one wire from one quad and another wire from some other quad.

 If any wire of a pair of the quad is broken/Non functional, then use fresh pair of wire.

 Do not parallel wires of quad cable.

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page87


Annexure-II
TEMPERATURE CORRECTION FACTOR FOR CONDUCTOR RESISTANCE FOR
ANNEALED HIGH CONDUCTIVITY COPPER

Temp. Corre. Temp. Corre. Temp Corre. Temp. Corre. Temp. Corre.
Deg C factor deg C Factor deg C factor deg C factor deg C Factor
1. 2. 1. 2. 1. 2. 1. 2. 1. 2

5. 1.0638 17 1.0122 29 0.9653 41 0.9225 53 0.8834


5.5 1.0618 17.5 1.0101 29.5 0.9634 41.5 0.9208 53.5 0.8818
6. 1.0593 18 1.0081 30 0.9615 42 0.9191 54 0.8803
6.5 1.0571 18.5 1.0060 30.5 0.9597 42.5 0.9174 54.5 0.8787
7. 1.0549 19. 1.0040 31. 0.9579 43. 0.9158 55. 0.8772
7.5 1.0526 19.5 1.0020 31.5 0.9560 43.5 0.9141 55.5 0.8757
8. 1.0504 20. 1.0000 32. 0.9542 44.. 0.9124 56. 0.8741
8.5 1.0482 20.5 0.9980 32.5 0.9524 44.5 0.9107 56.5 0.8726
9. 1.0460 21. 0.9960 33. 0.9506 45. 0.9091 57. 0.8711
9.5 1.0438 21.5 0.9940 33.5 0.9488 45.5 0.9074 57.5 0.8696
10. 1.0417 22. 0.9920 34. 0.9470 46. 0.9058 58. 0.8681
10.5 1.0395 22.5 0.9900 34.5 0.9452 46.5 0.9048 58.5 0.8667
11. 1.0373 23. 0.9881 35. 0.9434 47. 0.9025 59. 0.8651
11.5 1.0352 23.5 0.9862 35.5 0.9416 47.5 0.9009 59.5 0.8636
12. 1.0331 24. 0.9843 36. 0.9398 48. 0.8993 60. 0.8621
12.5 1.0309 24.5 0.9823 36.5 0.9380 48.5 0.8977 60.5 0.8606
13. 1.0288 25. 0.9804 37. 0.9363 49. 0.8961 61. 0.8591
13.5 1.0267 25.5 0.9785 37.5 0.9346 49.5 0.8945 61.5 0.8576
14. 1.0246 26. 0.9766 38. 0.9328 50. 0.8929 62. 0.8562
14.5 1.0223 26.5 0.9747 38.5 0.9311 50.5 0.8913 62.5 0.8547
15. 1.0204 27. 0.9728 39. 0.9294 51. 0.8897 63. 0.8532
15.5 1.0183 27.5 0.9709 39.5 0.9276 51.5 0.8881 63.5 0.8518
16. 1.0163 28. 0.9690 40. 0.9259 52. 0.8863 64. 0.8503
16.5 1.0142 28.5 0.9671 40.5 0.9242 52.5 0.8850 64.5 0.8489

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page88


Annexure-III
Response test of digital Axle Counter with different type of Trolley Wheels done jointly
with railways

Observed Result( No
S.No. Type of Trolley wheel influence / Goes to error / Remarks
Counted / other)
4 spoke wheel
Wheel Dia with flange –
550 mm
1 Wheel base – 110 mm
Flange thickness – 9 mm
Wheel Flange – 20 mm
Spoke width –
6 spoke wheel
Wheel Dia with flange –
Wheel Width –
2
Flange width –
Flange depth –
Spoke width –
Solid Wheel with 6 holes
Wheel Dia with flange –
3 Wheel Width –
Flange width –
Flange depth –
8 spoke wheel
Wheel Dia with flange –
530 mm
4 Wheel base – 100 mm
Flange thickness – 15 mm
Wheel Flange – 15 mm
Spoke width – 63 mm

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page89


Observed Result( No
S.No. Type of Trolley wheel influence / Goes to error / Remarks
Counted / other)
8 spoke with slots
Wheel Dia with flange –
Wheel Width –
5
Flange width –
Flange depth –
Spoke width –
Perforated
No. of perforation with
dia.
Wheel Dia with flange –
6 Wheel Width –
Flange width –
Flange depth –
Spoke width –
Solid wheel
Wheel Dia with flange –
7 Wheel Width –
Flange width –
Flange depth –
Motor trolley wheel , Solid
Wheel Dia with flange –
8 Wheel Width –
Flange width –
Flange depth –
Rail Dolly Wheel solid
Wheel Dia with flange –
9 Wheel Width –
Flange width –
Flange depth –

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page90


Observed Result( No
S.No. Type of Trolley wheel influence / Goes to error / Remarks
Counted / other)
Material Trolley solid
wheel
Wheel Dia with flange –
Wheel Width –
10
Flange width –
Flange depth –
Motor Trolley
Wheel Dia with flange –
450 mm
11 Wheel base –120 mm
Wheel Flange – 45 mm
Flange thickness – 40 mm
Tower Wagon
Wheel Dia with flange –
12 Wheel Width –
Flange width –
Flange depth –

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page91


Maintenance log sheet for SSDAC (SF UNIT)

DC – DC Converter
Battery (24V)
Description

With Push Trolley


Phase Detector 1 Phase Detector 2
Tx1 Tx2 Rx1 Rx2 on axle detectors
DC Volts DC Volts DC Volts
Vrms / Vrms / Vrms Vrms (4 spokes /
freq freq 8 spokes)
5V 12 V -12 V +18V 24 V

RX PH-SIG & GND RX PH-SIG & GND RX PH-SIG &


Points

Socket Socket GND Socket


Test

FTB FTB FTB FTB FTB


Monitoring Sockets on DC-DC converter card
1&2 51 & 52 55 & 56 53 & 54 57& 58 Dummy Dummy
Normal Normal PD1 PD2
wheel wheel

300mV 300mV
to 1.2V to 1.2V
Date

(AC) (AC)
4.75
to
5.25
V 17.75
-11.75 V
40 to 11.75
40 to V to
70 V RX 10 V V
Phase
(Limit)

70 V RX SIG 10 V to to 18.25
for

SIG & to 12 to
& GND 12 V -12.25 V
GND V 12.25
24.750 to Socket 10 V to 10 V to V 22V to
22-30 V 20.802 to Socket <1V <1V V
25.250 12 V 12 V 26V
21.302
KHz 750
KHz 750 to
to 1200
1200
MV
MV

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page92


Maintenance log sheet for SSDAC (EF UNIT)

DC – DC Converter
Battery (24V)
Description

With Push Trolley


Phase Detector 1 Phase Detector 2
Tx1 Tx2 Rx1 Rx2 on axle detectors
DC Volts DC Volts DC Volts
Vrms / Vrms / Vrms Vrms (4 spokes /
freq freq 8 spokes)
5V 12 V -12 V +18V 24 V

RX PH-SIG & GND RX PH-SIG & GND RX PH-SIG &


Points

Socket Socket GND Socket


Test

FTB FTB FTB FTB FTB


Monitoring Sockets on DC-DC converter card
1&2 51 & 52 55 & 56 53 & 54 57& 58 Dummy Dummy
Normal Normal PD1 PD2
wheel wheel

300mV 300mV
to 1.2V to 1.2V
Date

(AC) (AC)
4.75
to
5.25
V 17.75
-11.75 V
40 to 11.75
40 to V to
70 V RX 10 V V
Phase
(Limit)

70 V RX SIG 10 V to to 18.25
for

SIG & to 12 to
& GND 12 V -12.25 V
GND V 12.25
24.750 to Socket 10 V to 10 V to V 22V to
22-30 V 20.802 to Socket <1V <1V V
25.250 12 V 12 V 26V
21.302
KHz 750
KHz 750 to
to 1200
1200
MV
MV

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page93


DRAWINGS

DRG- 1 Start Fed of 2DP1S (G36SF2D00) Configuration

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page94


DRG- 2 End Fed of 2DP1S (G36EF2D00) Configuration

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page95


DRG- 3 Rear View of SSDAC-SF Unit

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page96


DRG- 4 Rear View of SSDAC-EF Unit

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page97


DRG- 5 Display Unit (G36DSPL00)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page98


DRG- 6 Dual Relay Box used for SF/EF of 2DP1S (G36RLP1V1)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page99


DRG- 7 Reset unit (G36RSBX00)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page100


DRG- 8 Reset Filter Unit (G36RSFL00)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 101


DRG- 9 Mechanical Drawing of TX coil housing

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 102


DRG-10 Mechanical Drawing of RX Coil housing

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 103


©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 104
DRG- 11 Cable Requirement for 2DP1S Single Line Block Section

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 105


DRG- 124 Earthing Arrangement

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 106


DRG- 53 Cable requirement in D-L block Section

DRG- 64 Dummy wheel

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 107


DRG- 75 Trolley Wheel

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 108


DRG- 86 Tag block for 2DP1S configuration Start Fed & End Fed

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 109


DRG- 97 Typical assembled view of TX & RX coils in Track

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 110


DRG- 108 Typical assembled view of TX & RX coils with Deflectors

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 111


DRG- 119 Train simulator

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 112


DRG- 20 Power supply & reset circuit-wiring diagram

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 113


SM's ROOM RELAY ROOM LOCATION BOX

PPR
B2 B1
B24
1.5 Sq.mm Signaling cable PR
C2 C1
N24
COUNTER

Reset T3 PPR A2 A1
RESET CIRCUIT

1.5 Sq.mm Signaling cable


VR
VPR B2 B1 R2 R1
Reset T5 +24V

MS3 Second Pair


-24V

Reset T 12 VPR A2 A1
PR
R2 R1
VPR +24V
Reset T 13 A4 A3
MS7 Second Pair
+24V -24V
VPR C2 C1
B24
OCCUPIED LED

POWER LED
PREP LED

CLEAR LED

Vital Relay Contacts For Railway Purpose

VPR D2 D1
N24

VPR
B2 B1
B24
1.5 Sq.mm Signaling cable VR
C2 C1
N24

-24Vdc

DRG- 21 Reset Box Indications Wiring Chart

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 114


DRG- 122 Selection of rails for fixing TX & RX Coils

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 115


DRG- 133 Test Jig for drilling holes on the different Rails (52 Kg, 60 Kg & 90 R)

©2014 G.G.Tronics SSDAC-2DP1S-IM Ver 1.0 Rev 4 Page 116