Digital Axle Counter PDF

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Handbook on
Troubleshooting
of
DIGITAL AXLE COUNTERS
CAMTECH/S/PROJ/2013-14/HB- DAC (T)

SEPTEMBER 2013
MAHARAJPUR, GWALIOR – 474 005
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FOREWORD
Diagnostics and troubleshooting procedures of any equipment help the engineers
and technicians in rectifying their failures quickly and in correct manner thereby
minimizing the failure time. As Digital Axle Counters have been installed in station yards
as well as in Block sections and Automatic Signalling sections of Indian Railways, there
is always a need for the availability of troubleshooting guidelines for quick reference.
CAMTECH has made an effort in this direction by preparing this handbook for Signal
maintenance personnel.
I hope that this handbook will help the signal maintenance personal in efficiently
rectifying the failures of Digital Axle Counters. Any suggestions for further improvement
are welcome.
CAMTECH Gwalior A.R.Tupe

Date: 30.09.2013 Executive Director
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PREFACE
Digital Axle Counters are microcontroller and software based systems.
These are manufactured by different firms and hence the troubleshooting procedures
are accordingly different. This handbook has been prepared to help the signal personnel
in effectively rectifying the faults in the Digital Axle Counters installed in their section.
This handbook is the sequel to the handbook on “Maintenance of Digital Axle Counters”
earlier prepared by CAMTECH, hence for better understanding of the subject, this
handbook may be also be referred along with the troubleshooting.
It is clarified that this handbook does not supersede any existing provisions laid
down in Signal Engineering Manual, Railway Board publications and RDSO
publications. This handbook is not statutory and instructions given in it are for the
purpose of guidance only.
We are sincerely thankful to Shri S. Bandopahyay, Sr.D.S.T.E./ Bhopal/WCR, Shri

M.Uppal, Sr D.S.T.E./Kota/WCR, M/s Eldyne Electro-systems, M/s Siemens, M/s
Central Electronics Ltd, M/s G.G.Tronics and field personnel who helped us in
preparation of the handbook.
Since technological upgradation and learning is a continuous process, you may feel
the need for some addition/modification in this handbook. If so, please feel free to give
your comments on email address dirsntcamtech@gmail.com or write to us at Indian
Railways Centre for Advanced Maintenance Technology, In front of Adityaz Hotel,
Airport Road, Maharajpur, Gwalior (M.P.) 474005.
CAMTECH Gwalior D.K.M.Yadav

Date: 30.09.2013 Jt .Director (S&T)
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Contents
of
Handbook on Troubleshooting of Digital Axle Counters
Section Description Pages
Foreword IV
Preface VI
Contents VIII
Correction Slip X
Disclaimer XII
About Troubleshooting of Digital Axle Counters 1
I Troubleshooting – Eldyne AzLS Digital Axle Counter 1-9
II Troubleshooting – Eldyne AzLM Digital Axle Counter 1-24
III Troubleshooting- Siemens Az S 350 U Multi Section Digital 1-16

Axle Counter
IV Troubleshooting - DACF 710 A & DACF 710 P CEL SSADC 1-27
V Troubleshooting of SSDAC-G36 G.G.Tronics Single Section 1-5

Digital Axle Counter
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ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be numbered as follows:
CAMTECH/S/PROJ/2013-14/HB-DAC(T)/2.0# XX date .......
Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. of Date of Page no. and Item No. Remarks

Correction issue modified
Slip
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DISCLAIMER
It is clarified that the information given in this handbook does not supersede any
existing provisions laid down in the Signal Engineering Manual, Railway Board and
RDSO publications. This document is not statuary and instructions given are for
the purpose of guidance only. If at any point contradiction is observed, then SEM,
Railway Board/RDSO guidelines may be referred or prevalent Zonal Railways
instructions may be followed.
----------------------------------------------------------------------------------------------------
OUR OBJECTIVE
To upgrade Maintenance Technologies and Methodologies and achieve improvement in Productivity
and Performance of all Railway assets and manpower which inter-alia would cover Reliability,
Availability and Utilisation.
If you have any suggestion & any specific comments, please write to us:
Contact person: Director (Signal & Telecommunication)
Postal Address: Centre for Advanced Maintenance Technology, Maharajpur,

Gwalior (M.P.) Pin Code – 474 005
Phone : 0751 - 2470185
Fax : 0751 – 2470841
Email : dirsntcamtech@gmail.com
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Section I
Troubleshooting of
Eldyne AzLS
Single Section Digital Axle Counter

September 2013
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Contents
Section I - Troubleshooting – Eldyne AzLS Digital Axle Counter
Clause No. Description Page No.
1.1 Introduction 1
1.2 LED indications on Analog card 1
1.3 Sequence of LED indications on Analog card with wheel 1

movement over Sk1 & Sk2
1.4 LED indications on Digital Card 3
1.5 LED diagnostics after restart 4
1.6 Diagnostics through LED indications on Digital Card 5
1.7 Troubleshooting chart for analog card of AzLS 7
1.8 Troubleshooting chart for digital card of AzLS 9
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CAMTECH/S/PROJ/13-14/HB-DAC (T) 1
Section I
Troubleshooting
Az LS
Eldyne Single Section Digital Axle Counter
1.1 Introduction
Troubleshooting in AzLS can be done with the help of LEDs provided on the Analog and
Evaluator/Digital cards of the Trackside Electronic Unit (EAK) which indicate the status
of the system. Diagnostics LED indications conforming to AzLS version V1.1 are given
in the following paragraphs.
1.2 LED indications on Analog card
Fig. 1.1 : LED indications on Analog card (As viewed from top)
LED Colour Indication

H1 - 1 Red On: Wheel on rail contact 1(Sk1); Off: No wheel on rail contact 1(Sk1)
H1 - 2 Green Off: Wheel approaching; Flashing: Sensor voltage (MESSAB1) within
tolerance no wheel approaching.
H2 - 1 Red On: Wheel on rail contact 2 (Sk2); Off: No wheel on rail contact 2 (Sk2)
H3 - 1 Red On: Voltage H24V out of tolerance; Off: Voltage H24V within tolerance.
H3 - 2 Green On: Voltage H5V O.K.; Off: Voltage H5V not O.K.
1.3 Sequence of LED indications on Analog card with wheel movement over
Sk1 & Sk2
(i)
→ LED ON (Steady)
☼ ☼ → LED ON (Blinking)
Ο Ο → LED OFF (Blank)
Fig. 1.2(a) : Sequence of LED indications on Analog board with wheel movement over
Sk1 & Sk2
Section I: Troubleshooting Eldyne AzLS September 2013
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(ii)
(iii)
(iv)
(v)
(vi)
Fig. 1.2(b) : Sequence of LED indications on Analog board with wheel movement over
Sk1 & Sk2
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(vii)
(viii)
(ix)
Fig. 1.2(c) : Sequence of LED indications on Analog board with wheel movement over
Sk1 & Sk2
1.4 LED indications on Digital card
Fig.1.3: LED indications on Digital Card (As viewed from top)

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LED Colour Indication if permanently Indication if Flashing

ON permanently OFF
H1/H5 - 1 Green Preparatory reset is input Preparatory reset is
not input
H1/H5 – 2 Green Voltage on relay coil (Section No voltage on relay
Clear) coil (Section
Occupied/Disturbed/
Defect)
H2/H6 – 1 Green Telegrams from all other Telegram
detection point received missing/Communicati
on loss
H2/H6 – 2 Green No transmission of Transmission of telegram
telegram is taking place.
H3/H7 – 1 Red Negative axles in section After accepting reset After restart and after test
phase.
H3/H7 – 2 Green Single point reset: No reset active or Sweeping in progress
Reset command accepted . rejected. (only for preparatory
Co-operative reset: reset)
Reset command accepted at
one detection point.
H4/H8 – 1 Red Disturbance^ of own No disturbance Disturbance of other
detection point computer. detection point received.
H4/H8 – 2 Red Defect* of own detection No defect Defect of other detection
point computer point received.
^ Disturbance indicates an error in the system due to any problem in communication medium
and/or power. System is re-settable after rectifying the problem and without putting the power
off.
* Defect indicates an error in the system due to any problem in analog card and/or digital card
and/or motherboard. Power to be made OFF and then ON for resetting the system after
rectifying the problem.
1.5 LED diagnostics after restart

LED Colour ON State OFF State Blinking
State
H1/1 & H5/1 Green N.A. No function N.A.
H1/2 & H5/2 Green N.A. No function N.A.
H2/1 & H6/1 Green CPU test started CPU test completed successfully N.A.
(after approx. 10 sec.)
H2/2 & H6/2 Green RAM test RAM test completed successfully N.A.
started (after approx. 1 sec.)
H3/1 & H7/1 Red ROM test ROM test completed successfully N.A.
H3/2 & H7/2 Green ROM test ROM test completed successfully N.A.
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1.6 Diagnostics through LED indications on Digital Board

Status of a track section can be ascertained through pattern of lit LEDs during various
stages.
→ LED ON (Steady), ☼ ☼ → LED ON (Blinking), Ο Ο → LED OFF (Blank)

Fig.1.4 (i) Pattern of lit LEDs on Digital Card during various stages of track section
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→ LED ON (Steady)
☼ ☼ → LED ON (Blinking)
Ο Ο → LED OFF (Blank)
Fig.1.4 (ii) Pattern of lit LEDs on Digital Card during various stages of track section
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1.7 Troubleshooting charts for Analog Card of AzLS
Fig.1.5 (i): Troubleshooting chart for Analog Card of AzLS
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Fig.1.5 (ii): Troubleshooting chart for Analog Card of AzLS
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1.8 Troubleshooting chart for Digital Card AzLS
Fig.1.6 : Troubleshooting chart for Digital Card of AzLS
If the AzLS system experiences frequent loss of telegram (due to fault in communication
media or power supply), the system performs a safe act by halting the CPUs on the
Digital Card. If the Digital card halts, the EAK is to be powered OFF and then ON to
make it functional.
To prevent the occurrence of Digital Card halt phenomena, the possibility of
electromagnetic induction in the communication media is to be reduced. Following
preventive measures are to be taken to arrest EMC/EMI problem and ensure trouble-free
operation of the system:
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 The cross pair conductors in quad cable (used for axle counter communication)
when exposed from the protective jacket of the quad cable, must be twisted to the
points of termination of the conductors.
 Unused quad pairs inside location box must be earthed.
 All cable segments to be earthed at one end only.
 The ripple content of the power supply must be less than 20 mV AC.
 A free wheeling diode (IN4007) must be connected across the coil of each Vital
and Reset relay.
LED indication Digital Card in halt state:
Case 1 Case 2 Case 3
H2-1 H2-2 H2-2 H3-2 H4-2 H-1 H3-2

(GREEN)- (GREEN)- (GREEN) - (GREEN) - (RED) - (RED)- (GREEN)-
ON ON ON ON ON ON ON
H3-1 H3-2 H6-2 H7-2 H8-2 H4-1 H4-2
(RED)- (GREEN)- (GREEN) - (GREEN) - (RED) - (RED)- (RED)-
ON ON ON ON ON ON ON
H4-1 H4-2 H7-1 H7-2
(RED)- (GREEN)- (RED)- (GREEN)-
ON ON ON ON
H6-1 H6-2 H8-1 H8-2
(GREEN)- (GREEN)- (RED)- (RED)-
ON ON ON ON
H7-1 H7-2
(RED)- (GREEN)-
ON ON
H8-1 H8-2
(RED)- (RED)-
ON ON
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Go to index  Go to Chapter index
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Section II
Troubleshooting of
Eldyne AzLM
Multi Section Digital Axle Counter

September 2013
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Contents
Section II - Troubleshooting – Eldyne AzLM Digital Axle Counter
2.1 Introduction 1
2.2 Diagnostics through LED indications on EAK 1
2.3 Diagnostics through LED indications on Axle Counter Evaluator (ACE) 2
2.4 System Diagnosis by Computer 6
2.5 Graphical Diagnostic Interface (GDI) – AzLM 9
2.6 Do’s & Don’ts 17
2.7 Troubleshooting Flowchart for Analog Card of AzLM 18
2.8 Troubleshooting Flowchart for Digital Card of AzLM 20
2.9 Troubleshooting Flowchart for serial I/O Card of AzLM 22
2.10 Troubleshooting Flowchart for section disturb/defect 24
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Section II
Troubleshooting
Az LM
Eldyne Multi Section Digital Axle Counter
2.1 Introduction
Troubleshooting in AzLM can be done with the help of LED indications provided on the
Analog and Evaluator/Digital cards of the Trackside Electronic Unit (EAK) as well as on
the front panel of boards in Axle Counter Evaluator (ACE). A Diagnostic Interface
Software is also provided as an additional tool which interrogates the system to determine
its status.
2.2 Diagnostics through LED indications on EAK
LED indications on Analog board
Fig.2.1 :LED indications on Analog card (As viewed from top)
LED Colour Indication

H1 - 1 Red On: Wheel on rail contact 1(Sk1); Off: No wheel on rail contact 1(Sk1)
H2 - 1 Red On: Wheel on rail contact 2 (Sk2); Off: No wheel on rail contact 2 (Sk2)
H3 - 1 Red On: Voltage H24V out of tolerance; Off: Voltage H24V within tolerance.
H3 - 2 Green On: Voltage H5V O.K.; Off: Voltage H5V not O.K.
Note: The Sequence of LED indications on Analog Board with wheel movement over Sk1 &
Sk2 is same as that of AzLS.
Section II - Trouble shooting– Eldyne AzLM September 2013

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LED indications on Digital board
Fig.2.2: LED indications on Digital Card
LED Colour Indication Normal operation

H1 - 1 Green Transmitting data Flashing
H1 – 2 Green CPU1 indicates a fault during OFF
self-test of Analog part
H2 – 1 Green Transmitting data Flashing
H2 – 2 Green CPU2 indicates a fault during OFF
self-test of Analog part
2.3 Diagnostics through LED indications on Axle Counter Evaluator (ACE)

All the cards in ACE have their own LED indications which are useful for diagnostic
purpose.
2.3.1 Indications of Power Supply Card
LED1 LED2 LED 3 Meaning

ON ON ON Normal operation
ON OFF ON Temperature too high, overload, over-
voltage output1, under-voltage output1
ON ON OFF Temperature too high, overload, over-
voltage output2, under-voltage output2
ON OFF OFF Input voltage too low, input voltage too high
OFF ON ON Not possible, or “LED in” is broken
OFF ON OFF Not applicable
OFF ON ON Not applicable
OFF OFF OFF No input voltage, input voltage too low,
.
input open, input voltage too high
Fig.2.3: Front panel of Power Supply card
The three Green LEDs are ON if all voltages are OK

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2.3.2 Indications on CPU Card
1. Ethernet interface
2. Reset Button
3. LED 1…4
LED1: The flashing LED shows the communication
on the Ethernet interface.
LED2 & 3: Flashing LEDs show the communication
between the processors. In normal condition, both
LEDs flash.
LED4: Not used.
4. Alphanumeric display
The display shows a rotating bar if the CPU is
operational
5. Diagnostic interface
The serial interface socket to which the serial
interface of the diagnostic PC is connected.
Fig. 2.4.: Front panel of CPU card
The alphanumeric display on the CPU Card shows the following indications:
Start up:
Initially the display is illuminated for a short while, then the screen goes blank for a short
period. After that a ’_’ sign appers and stays for approximately 2.5 minutes. Then the normal
operation begins.
Normal operation: Rotating bar

Faults:
Axle counter application stopped, diagnostic still available: Alternating x and X
Axle counter application and diagnostic stopped: Standing bar in any orientation
LED 1 The flashing LED shows the communication on the Ethernet interface
LED 2 & 3 The flashing LEDs show the communication between the processors. In
normal operation both LEDs flash.
LED 4 Not used

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2.3.3 Indications of Serial I/O Card
The serial I/O interface consists of two independent ISDN transmission paths and one I/O
board is used for maximum two detection points.
LED ISDN-link channel 1
LED ISDN-link channel 2
• ON for link state “connected”(if the ISDN link to the associated
detection point is operational)
• otherwise OFF
LED ISDN-telegram channel 2
LED ISDN-telegram channel 1
• flashes while receiving an ISDN-telegram(if a valid ISDN telegram
was received from the associated detection point)
• otherwise OFF
Fig.2.5: Front panel of Serial I/O card
2.3.4 LED Diagnostics of Serial I/O Card
The status of Detection Point

Detection Point computer not
●●
is OK working;
computer halted
Loss of
Detection Point
communication
computer not
between
working;
Detection Point
computer halted
and ACE
LEDON (Steady) ● LED ON (Flashing) LED OFF (Blank)
Fig.2.6: LED indications on Serial I/O card during different stages

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2.3.5 Parallel I/O Card: LED Diagnostics (AzLM)
Vital Input 1: Preparatory Reset without

Acknowledgement
Vital Input 2: Unconditional Reset
Non-vital Output 1: Waiting for Operation

(Train Movement)
Non-vital Output 2: Technical Defect
Non-vital Output 3: Not applicable
Non-vital Output 4: Not applicable
Fig.3.14: Details of Inputs and Outputs of

Parallel I/O Card
Fig.2.7: LED diagnostics with Parallel I/O card
2.3.6 Indications of Parallel I/O Card
LED Channel Colour Function (When ON)

row
1 1&2 Green Vital input 1 activated
2 1& 2 Green Vital input 2 activated
3 1&2 Green Section Clear, Relay
picked up (Voltage on
Relay)
4 1 Yellow Non-vital output 1
activated
Key Switch 2 Yellow Non-vital output 2
activated
5 1 Yellow Non-vital output 3
Push button activated
2 Yellow Non-vital output 4
activated
6 1&2 Green Polling
Fig.2.8: Front panel of Parallel card

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2.4 System Diagnosis by Computer

The diagnostic data are stored in the Computer Board as
Historical data
Element status
The data is stored together with the associated internal system time of the ACE. The
internal system time is converted to real time and displayed it together with the data.
The historical data may be used to reconstruct the sequential occurrence of events.
The element status indicates the momentary status of the following elements
Sections
Detection points
Interfaces
Computers
Software Versions
System diagnostics for AzLM can be done with the help of a PC loaded with diagnostic
software. The diagnostic PC must be a Pentium PC having a serial interface RS-232
(19200 bps) port with Windows operating system. The serial interface has to be
connected to the serial interface port on the CPU Card 1 of ACE by a Null-modem cable
having female DB9 connector at both ends. After running the diagnostic software, the
system data (viz. Elements current data and Historical data) can be downloaded and
analyzed on the PC.
The elements data includes status of section, detection point, interfaces, versions etc. The
status of elements is displayed on the PC screen in a coded message format with date &
time of occurrence.
Note:
The null-modem cable should always be kept connected at the CPU card end as well at
the diagnostic PC end. In case the null-modem cable needs to get disconnected, it should
be disconnected from both ends.
Diagnostic Messages
The following format of diagnostic messages is used in the history files and element data
files generated by the diagnostic tool.
RNr Replica Date/Time Element Element Diagnostic Parameter

Type Number Event
Where
RNr - CPU number from where the diagnostic messages are read out.
Replica
0 - Message from all running CPUs
1 - Message from CPU1 (that is, CPU Card on left side of ACE subrack)
2 - Message from CPU2 (that is, CPU Card on right side of ACE subrack)
3 - Message from CPU1 and CPU2

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Date/Time
Date and time of occurrence of diagnostic event.
Element Type
There are several element types, e.g., section, detection point, parallel I/O card, serial I/O
card etc.
Element Number
Each element has its own number (e.g., n = 1, 2, …) which is specified in the site specific
data. These element numbers are listed in the element window of the diagnostic tool together
with the names which are used in the layout plan.
Diagnostic Event
There are five types of diagnostic events, namely, operational name, site specific data, state,
version and axles.
Parameter
Information about different events.
Following is the example of display of a diagnostic message on the PC screen
RNr Replica Date/Time Element Element Diagnostic Parameter Explanation

Type Number Event
1 3 yy:mm:dd Detection n DP VERSATZ x (y) Counting fault of x
hh:mm:ss:sss Point information axles in DP n. The
new difference
between the CPUs is
y axles.
Information:
CPU 1 and 2 are
sending a different
number of counted
axles. This may be
caused by a miscount
in one CPU due to
non-standard small
wheels
Some coded messages and there interpretations useful for diagnostic purposes are given
below:
Sr. Diagnostic Parameter Explanation

No. Event (Message)
1. DP information WLP ZPR 1+0+1 Wheel pulse longer than 3 seconds detected at
DP n.
2. DP information VERSTAZI(1) Counting fault in DP n.
3. DP information STA 01 011 Self test of analog circuits failed in DP n
message received from SK1
4. DP information DRW AS11,1 Drift warning from DP n. CPU1 & 2 send a

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Sr. Diagnostic Parameter Explanation

No. Event (Message)
AS20,0 drift warning to rail contact SK1.

5. DP information DFW 11 Defect warning from DP n received from CPU1
& 2.
6. DP information DFM 11 Defect message from DP n received from CPU1
& 2.
7. DP information AR 11 Restart of CPU1 & 2 in the detection point.
8. DP information AKT 00 Detection point n is not communicating.
9. DP information REIH (1) NN The ACE did not received the detection point
54724….54726 telegram with the telegram no. 54725.
10. STATE OK dfw The status of DP n is OK but a defect warning
was sent.
11. STATE OK da The status of DP n is OK but one of the rail
contacts indicates a permanent wheel pulse. If
no train is present, this indicates a faulty rail
contact or analog board.
12. STATE DEF st The status of DP n is defect due to an
unsuccessful self test.
13. STATE DEF komm The status of DP n is defect due to loss of
communication.
14. STATE DEF dfm The status of DP n is defect due to a defect
message (dfm).
15. Command Kdo abgew Reset for section n cannot be carried out due to
AZEGR ANFORD a technical defect.
Grund
TECHNISCH.
16. Command Kdo abgew Conditional reset not carried out for section n
AZEGR ANFORD because the last count was accounted into the
Grund Einschr = section ( Section occupied).
Einzaehlen bei
BELEGET
17. Command Kdo abgew Reset not carried out for section n because
AZEGR ANFORD section is already clear.
Grund
BETRIEDLICH
18. Command Kdo empf AZEGR Conditional reset command for section n.
ANFORD
01030000
19. STATE OK fre Section n is clear
20. STATE OK bel Section n occupied
21. STATE DEF ges Section n disturbed. A reset is possible.
22. STATE DEF def Section n disturbed due to a defect. Reset not
possible.

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2.5 Graphical Diagnostic Interface (GDI) – AzLM

GDI is a newly developed tool for diagnostics purposes in AzLM with a user friendly
menu. Unlike in older version of Diagnostic software, the user need not refer to the list of
coded messages (parameters) for failure diagnostics. The required information can be
obtained simply by clicking on the menu available on the screen.
Troubleshooting using GDI

For troubleshooting with the help of GDI, following steps are to be performed:
 Connect the diagnostic PC with the diagnostic interface of ACE.
 Start the diagnostic PC
 Start the diagnostic program via icon
 Identify disturbed sections
 Identify disturbed detection points
GDI Menu
Fig.2.9: Screen showing GDI Menu
Following is the description of the GDI Menu items:
New - Creates new ACE data

Open - Opens existing ACE data
Close - Closes ACE data
Exit - Exits Graphical Diagnostic Interface program
Open Diagnostic Printout - Opens saved Diagnostic files (*.diag).
Terminal - Opens a console window used by development engineers for text-base input and
output
Refresh - If checked, the display on the GDI screen gets refreshed cyclically.

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GDI - To Create a new ACE Data

If the Diagnostic PC is connected to the ACE for the first time, ACE to be created by
selecting ‘ACE’  ‘New’.
Choose the type of ACE and interface.
Fig.2.10:Selecting the type of ACE and Interface
Save ACE data in the Diagnostic PC. The name of the data file should be as same as the
name of project site so that the data file can be easily identified later.
Fig.2.11: Assigning File Name and saving data in Diagnostic PC

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GDI - To Open an ACE

Select ‘ACE’  ‘Open’ to get the Open window
Choose the required data file and open it.
Fig.2.12: Selecting the required data file for opening
When an ACE is opened for the first time, it takes some time to get opened. Later the same
ACE can be opened much faster.
Fig.2.13: Display on screen after opening ACE data file

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Graphical Diagnostic Interface (GDI)
Fig.2.14: Front end screen of GDI
Graphical Diagnostic Interface (GDI) – Serial I/O
Fig.2.15: Display of Preprocessor1 state of Serial I/O Card

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Fig.2.16: Display of Preprocessor 1 history of Serial I/O Card
Graphical Diagnostic Interface (GDI) – Parallel I/O
Fig.2.17: Display of state of Parallel I/O 1 Card

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Fig.2.18: Display of Parallel I/O 1 Card history
Fig.2.19: Display of site specific data of Parallel I/O 1 Card

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Graphical Diagnostic Interface (GDI) – CPU
Fig.2.20: Display of state of ACE in chronological order
Fig.2.21: Display of history of ACE

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Fig.2.22: Display of site specific data of ACE
Fig 2.23.: Display of messages of operating system

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Fig.2.24: Display of versions of DPs and preprocessors
2.6 Do’s & Don’ts

Connect serial interface of diagnostic PC to the left-side CPU.
Connect Ethernet interface of diagnostic PC to the right-side CPU.
Left side CPU – connector for Right side CPU – connector for
serial interface of diagnostic PC Ethernet interface of diagnostic PC
Fig.2.25: Diagnostic interfaces of ACE
Never connect the diagnostic PC to the serial interface as well as Ethernet interface in the
ACE at same time.
Never connect the diagnostic PC to more than one ACE at same time.

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2.7 Troubleshooting Flowchart for Analog Card of AzLM
Fig.2.26 (i): Troubleshooting Flowchart for Analog Card of AzLM

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Fig.2.26 (ii): Troubleshooting Flowchart for Analog Card of AzLM

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2.8 Troubleshooting Flowchart for Digital Card of AzLM
Fig.2.27: Troubleshooting Flowchart for Digital Card of AzLM

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If the AzLM system experiences frequent loss of telegram (due to fault in communication
media or power supply), the system performs a safe act by halting the CPUs on the Digital
Card. If the Digital card halts, the EAK is to be powered OFF and then ON to make it
functional.
To prevent the occurrence of Digital Card halt phenomena, the possibility of electromagnetic
induction in the communication media is to be reduced. Following preventive measures are
to be taken to arrest EMC/EMI problem and ensure trouble-free operation of the system:
 The cross pair conductors in quad cable (used for axle counter communication) when
exposed from the protective jacket of the quad cable, must be twisted to the points of
termination of the conductors.
 Unused quad pairs inside location box must be earthed.
 All cable segments to be earthed at one end only.
 The ripple content of the power supply must be less than 20 mV AC.
 A free wheeling diode (IN4007) must be connected across the coil of each Vital and
Reset relay.
LED indication Digital Card in halt state:
H1-1 (GREEN)-ON H1-2 (GREEN)-ON
H2-1 (GREEN)- ON H2-2 (GREEN)- ON

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2.9 Troubleshooting Flowchart for serial I/O Card of AzLM
Upper LED of Serial I/O Card hangs
Fig.3.28 (i): Troubleshooting Flowchart for Serial I/O Card of AzLM

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Lower LED of Serial I/O Card is not blinking
Fig.2.28 (ii): Troubleshooting Flowchart for Serial I/O Card of AzLM

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2.10 Troubleshooting Flowchart for section disturb/defect in AzLM
Fig. 2.29 : Troubleshooting Flowchart for Section disturb/defect in AzLM


Go to index Click for Contents Go to Chapter index
Section III
Troubleshooting
of
Siemens Az S 350 U
Multi Section Digital Axle Counter
CAMTECH/S/PROJ/2013-14/HB- DAC(T)
September 2013
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Contents
Section III - Troubleshooting- Siemens Az S 350 U Multi Section Digital Axle
Counter
3.1 Introduction 1
3.2 Outdoor equipment 1
3.3 Indoor Equipment 3
3.4 Fault finding and troubleshooting (Outdoor equipment) 4
3.5 Fault finding and troubleshooting (Indoor equipment) 5
3.6 Fault finding and troubleshooting - Indoor equipment 10
3.7 Rectifying failure of Evaluation Computer boards 10
3.8 Rectifying failure of Evaluation Computer boards after Emergency 13

Shutdown
3.9 AzGrT Button Operation Error 14
3.10 Switching the Evaluation Computer On and Off 14
3.11 Replacing Boards 15
3.12 Restarting an Evaluation Computer 16
3.13 Special Board Replacement Conditions 16
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Section III
Troubleshooting
Az S 350 U
SIEMENS MULTI SECTION DIGITAL AXLE COUNTER
3.1 Introduction
Az S 350 U consists of two main components:
 Outdoor equipment
 Indoor equipment
The outdoor equipment is the ZP 43 wheel detection equipment (counting head)

comprising a double wheel detector and a trackside connection box. Counting heads are
installed at the limits of a track vacancy detection section. The indoor equipment
consists of the evaluation computer. The counting head is connected to the Az S 350 U
via a two-core cable
Power Supply
Following power supplies are required for functioning of the Axle Counter equipment:
 5 V DC for internal operation
 70 V DC for external operation of max. five counting heads
3.2 Outdoor equipment

ZP 43 Wheel Detection Equipment
Fig.3.1: ZP43 Wheel Detection Equipment at site
Section III Troubleshooting Siemens Az S 350 U September 2013

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3.2.1 Tools and Test Equipment required for adjustment

Open-end, ring or box spanner, width across flats 13
Screwdriver 0.6 x 2.8 as per DIN 7437
Screwdriver 0.6 x 3.5 as per DIN 7437
Test equipment is Probe adapter board and multi-meter (Fluke-189 or equivalent) with
measuring ranges.
The probe adapter board SCN S25552-B43-D1 can be used during commissioning and
maintenance for testing and adjusting work on the ZP 43 V Wheel Detection Equipment.
Adjusting work (voltage and frequency measurements) can be performed using a
commercially available multi-meter. Measuring sockets arranged in pairs are provided on
the front. The multi-meter is connected to them.
Fig. 3.2: (i) ZP 43 V Wheel Detection Equipment with Probe Adapter Board (ii) Front
panel of the Probe Adapter Board
Electrical parameters of ZP 43 V Wheel Detection Equipment

Parameter Description Standard value Tolerance range
U60 WDE voltage 60 V DC 30 V to 72 V
U24 Operating voltage 24 V DC 21.3 V to 22.4 V
FS Transmitter frequency of 43 kHz 42.8 kHz to 43.2
the double wheel detector kHz
F1 Signal frequency 1 3.50 kHz 3.47 kHz to 3.53
kHz
F2 Signal frequency 2 6.37 kHz 6.31 kHz to 6.43
kHz
Ur1 Standard voltage 1 3.55 V DC 3.45 V to 3.65 V
Ur2 Standard voltage 2 3.35 V DC 3.25 V to 3.45 V
uE 1 Receiver voltage 1 AC 60 mV to 150 mV
uE 2 Receiver voltage 2 AC 60 mV to 150 mV

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3.3 Indoor Equipment

Evaluation Computer
The Evaluation Computer consists of plug-in circuit boards which are accommodated in a
single-tier mounting frame with wiring backplane. Dummy boards are inserted in free
slots for optional boards.
Fig. 3.3 : Front view of Az S 350 U Evaluation computer (including slot numbers)
3.3.1 Adjustments and measurements at Evaluation Computer

On the front panel of each VESBA board, there are measuring sockets for fault
diagnostics as well as LEDs for displaying the state of passage and a potentiometer for
adapting to different cable lengths and setting the transmission level.
Sr. Observed Values

Parameter Acceptable Range
No. CH1 CH2 CH3 CH4 CH5 CH6
1 Signal F1 2.9 to 3.1 V DC
2 Signal F2 2.9 to 3.1 V DC
Fig.3.4: VESBA board front panel view

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3.4 Fault finding and troubleshooting (Outdoor equipment)
ZP43 Wheel detection equipment
WDE Supply Voltage U60

Fault : The WDE Supply voltage is below 30V DC.
Cause of fault Measure

Break in signalling cable Check signalling cable
WDE connected with reverse polarity Check polarity
Short circuit or interruption in the Replace lightning protection or jumper
lightening protection or jumper board board
Voltage controller defective Replace band pass filter board .
Generator board defective Replace generator board.
No supply voltage from the indoor Locate Fault in the indoor equipment:
equipment Defective fuse: Check the signalling
cable and interface boards in the
evaluation unit for short circuit of the
WDE supply voltage.
WDE Supply Voltage U24

Fault : The internal WDE voltage is lower than 21.3 V DC or higher
than 22.4 V DC.
Voltage controller defective Replace band pass filter board
Fuse on the band pass filter board Replace fuse.
defective
Transmitter frequency fs
Fault: Transmitter frequency is out of the tolerance range. Frequency
adjustment is not possible.
Generator defective Replace generator board
Lightning protection elements defective Replace lightning protection board
Frequency tuning board defective Replace mounting frame
Double wheel detector (transmitter) Replace double wheel detector
defective (transmitter)
Signal frequencies f1 and f2

Fault: Signal frequency f1 and f2 is out of the tolerance range.
Double wheel detector loose Firmly tighten the fastening bolts.
Readjust transmitter frequency fs and
signal frequencies f1 and f2.
Double wheel detector is installed Install double wheel detector correctly.
incorrectly

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Receiver voltage UE1 and UE2

Fault: Receiver voltages are less than 60 mV.
Double wheel detector is defective or Firmly tighten the fastening bolts or
loose replace double wheel detector
The Double wheel detector is installed Check the double wheel detector for
on a very high rail section correct installation (drilling dimensions,
secure fit of the screws, no stray metal
parts in the vicinity). If UE1 and UE2
are at the least 54 mV and it is possible
to adjust the signal frequencies to the set
point no further measures are required.
3.5 Diagnostics through LED indications

SVK2150 (Power Supply) board
The SVK2150 power supply board provides 5 V for the evaluation computer and 70 V or
the counting heads.
The SVK2150 board transforms the interlocking voltage into controlled voltages (5 V DC
for computers, 12 V DC (used for predecessor systems only) and 70 V DC for counting
heads). All voltages are monitored by voltage controllers. Input and output voltages are
electrically isolated.
Fig.3.5: Front view of SVK2150 board
The SVK2150 board is ready for operation when voltage is applied to the switching
input. This is indicated by the yellow LED "Vin". When the switch on the front panel is
set to "I", the yellow LEDs "5 V" and "70 V" ("12 V" is not used) indicate the presence
of the voltages.
In case of under-voltage, the output voltage is switched off. When the output voltage is
missing, the control-circuit fuse (fuse 0.2 A; fast) on the front panel blows. The unit
cannot go back into operation until this fuse has been replaced.
If there is no voltage at all, the input fuse on the printed circuit board (fuse 8 A; slow-
acting) has to be checked.

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VAU board
The VAU processing and monitoring board, a CPU board, constitutes

the failsafe microcomputer system (SIMIS C computer core). It
provides monitoring and comparator functions for synchronous dual-
channel microcomputer operation.
Indication Description
VGL(Yellow LED) Comparator
SPW (Red LED) Voltage Controller
PAB (Red LED) Program-controlled shutdown
ANL (Red LED) Start-up
Red button System reset
Fig.3.6 : Indications of VAU board
STEU board - Normal display

Display of operating states of the four track vacancy detection sections (TVDS) (during
operation; operating state display). The display is shown in fig. below and the details are
given on pages
Fig. 3.7: Front view

of STEU board;
display of operating
states for TVDS 1 to 4
Note
The meaning of LED 4
(reset restriction) is
only applicable to the
AzGrT mode. In the
vAzGrT mode LED 4
is permanently off.

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3.5.1 Meaning of LEDS on STEU board –Normal display
LED display Meaning/Fault Cause Effect Remedy

*-Steady
o-Flashing
LED 0-* System reset  Hardware reset Reset EC in permanently  Obtain track
buttons on VAU boards occupied state. clear indication
have been pressed. via visual
 Power supply switched inspection.
on  Press AzGrT
button after
reset
LED 0-o Program  EC fault resulting in  Program  Remove cause
controlled asynchronous operation controlled of fault.
emergency shut of the two channels. shutdown of EC  Carry out
down  AzGrT button has been results in hardware
pressed on one or both permanently reset.
channels during occupied state.  Obtain track
hardware reset.  Program is caught clear
 Asynchronism of block in an endless loop. indication via
information.  On both VAU visual
 For further possible boards the LEDs inspection.
causes refer operating VGL are switched  Reset EC by
manual. off and the LEDS pressing the
PAB are switched AzGrT button.
on.
LED 1-* Minus axle  At least one axle more  Permanently  Obtain track
blocking counted out than has occupied state clear
effective been counted in. caused by minus indication via
axle blocking. visual
inspection.
 Reset EC by
pressing
AzGrT button.
Counting  Incorrect programming  Permanently  Remove cause
capacity or counting direction of occupied state of fault.
exceeded (max. a counting head.  Obtain track
32.767 axles)  Counting head counting clear
out is faulty. indication via
 Counting head visual
maladjusted. inspection
 Reset EC by
pressing
AzGrT button.

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*-Steady
o-Flashing
Undefined  Inexplicable pulse  Permanently  Obtain track
counted pulse detection by counting occupied state clear
head indication via
visual
inspection
reset EC by
pressing
AzGrT button.
LED 2-* Count  --  Permanently  --
monitoring occupied state
double wheel without counting.
detector  Occupied state and
traversed on display are
one channel maintained until
only (e.g. next complete
shunting traversal of double
movement) wheel detector or
next AzGrT
operation.
Count  Double wheel detector,  Counting error  Check
monitoring after complete traversal, leading to a counting head
counting head detected pulses on one permanently concerned
fault due to channel only (more than occupied state including
spurious pulse 4ms.)  No counting error, cable.
 Double wheel detector at least one axle  Obtain track
during a traversal follows after the clear
detected pulse due to cause the track indication via
spurious pulses (more clear indication visual
than 4ms) will be given after inspection
 Double wheel detector the train has  Reset EC by
without a traversal passed display is pressing
detected pulses due to switched off. AzGrT button.
spurious pulse (more  Occupied state
than 4ms) without a train,
occupied state and
display are
maintained until
next traversal with
track clear
indication or until
next AzGrT
operation.
LED 3 -* Telegram  Data transmission  As long as the  Check
transmis-sion between Ecs is fully connection is connection
faulty or faulty. interrupted or faulty between Ecs
switched off  Second EC has been data is received the  Check whether
switched off. TVDS with remote second EC has

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*-Steady
o-Flashing
 Second EC is in counting heads been switched
emergency shutdown remain in the off or is in an
state. occupied state. emergency shut
 Data transmission  Occupied state and down state
between Ecs was faulty display are (restart).
(DIP switch TELFM is maintained until  Reset EC by
set to off and double next complete pressing
wheel detector detected traversal of double AzGrT button.
no pulses). wheel detector or  Wait for train
next AzGrT run. If TVDS
operation (DIP remain
switch TELFM set occupied
to off). perform the
measures
above.
ED 4-* Reset  One counting head of the  RR effective and  Cancel RR via
restriction (RR) TVDS detected pulses. section is AzGrT button
 There are axles in the occupied. after section
TVDS. clear proving
 Time frame for (according to
simultaneous AzGrT station
operation exceeded working
(single channel rules).
operation).  If time frame
was exceeded
restart EC
(after
consultation
with SM).
Reset  Issue of track clear  RR effective and --
restriction (RR) indication for TVDS via the section is clear.
AzGrT operation
LED 5-* Section  There is train in the --  Obtain track
occupied section which has not yet clear
been counted out (axle indication via
count = 0) visual
inspection
 Reset EC by
pressing
AzGrT button
Section  Axle count =0 e.g. due to --  Reset EC by
remains counting error pressing
occupied AzGrT button
LED 6-* to Meaning as for As above As above As above
LED 11-* LED 0 to LED
5

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3.6 Fault finding and troubleshooting - Indoor equipment

 Troubleshooting should start in the indoor equipment (evaluation computer).
 Record and evaluate the current operating state displays.
 If the fault could not be eliminated by means of an axle count reset operation by
the authorized person press the AzGrH button on one channel in order to activate
the statistics functions and record and evaluate the statistical data.
 To pinpoint the causes of counting errors, re-measure the signal frequencies f1 of

3.50 kHz (tolerance range from 3.47 kHz to 3.53 kHz) and f2 of 6.37 kHz
(tolerance range from 6.31 kHz to 6.43 kHz) at the measuring sockets "f1" for
3.50 kHz and "f2" for 6.37 kHz. In addition, re-measure the output voltages V1
(3.0 V DC) and V2 (3.0 V DC) at the measuring sockets "U" of the VESBA
board. The values must lie within the admissible tolerance range (2.90 V to 3.10
V).
 If the signal frequencies f1, f2 and the voltages V1, V2 are within the admissible
tolerance range, the cause of fault is most probably to be found in the evaluation
computer.
 If the voltages or signal frequencies f1 and/or f2 are outside the admissible

tolerance range, check the counting head. If the counting head proves fault-free,
check the transmission path (cable).
 Before checking the outdoor equipment, check whether the fuse on the VESBA
board (0.2 A) in the evaluation computer is fault-free and if there is WDE supply
voltage present in the indoor equipment. The tests are carried out with the test
adapter board for ZP 43 WDE in conjunction with a multi-meter and by
comparison with the values given in the table on page. Faulty boards must be
replaced.
 Only the boards of a failed computer channel may be replaced with spare boards.
It is not allowed to insert boards of intact computer channels into a faulty
computer channel. If a board of the evaluation computer has failed, the cause of
the fault may be the failure of a peripheral board.
3.7 Rectifying failure of Evaluation Computer boards

Boards from a faulty computer channel may be replaced with spare boards only.
If fault occurs without an emergency shutdown, carry out corrective maintenance to
replace the boards and restart the evaluation computer, as given below:
 First check the LEDs of the boards to identify the faulty board.
 The VAU board might be faulty if the LEDs "VGL" or "SPW" are permanently on.
 The STEU board might be faulty if the LED "0" is flashing (emergency shutdown).
 The BLEA12 and SIRIUS2 boards show no external signs of being faulty.
 Note down the LED display (fault record) and interpret it for diagnostics.

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 Set the switch of the power supply board to "0".

 Replace the board(s) recognised as faulty with spare board(s).
 Observe "Special Board Replacement Conditions" of the manufacturer’s manual -
Maintenance Instructions for AzS 350 U.
 Make sure that the front connectors of the connecting cables are mounted correctly.
 Proceed as described in Section 3.10 "Switching On", page 14.
3.7.1 Failure of VESBA Board

In normal operation, when the yellow LEDs on the front panel light up, they indicate that
a train is traversing or occupying the track-installed wheel detector. These LEDs light up
shortly depending on the speed of the train.
Fig.3.8: Front view of VESBA board
If one of the LEDs is permanently on, there is probably a wheel at the position where the
wheel detector is mounted. If this is not the case, a fault can be assumed.
The LEDs light up if no counting head is connected or if the voltage supply for the
counting head is not present, interchanged or maladjusted (V < 1.3 V or counting head
connected incorrectly).
Approx. 60/70 V DC must be measured at the terminals for the counting heads. If no
voltage is measured, the fuses must be checked. The counting heads are protected via
fuse Si 1, which is mounted directly on the front panel, and another fuse on the printed
circuit board.

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Fault: Yellow LED of the VESBA card is continuously lit (i.e. no wheel on the
detection point)

There is a fault at the counting head
Check the counting head for loose
nut. Check if the frequencies f1 and
f2 are in the given range. Check the
fuse on the junction box.
The VESBA voltage is not adjusted Adjust the VESBA voltage to 3V.
to 3V. Check the fuse on the VESBA
module.
3.7.2 Failure of SVK2150 (Power Supply) board

Probable cause: The fuse on the front panel (0.1 A) or on the printed circuit board (8
AT) of the SVK2150 power supply board may be faulty.
Procedure
Set the switch of the failed power supply board to "0".
Replace the fuse(s) if faulty, or replace the failed power supply board with a spare board.
Ensure that the power supply board is replaced with a board of the same type.
Set the switches of the power supply boards to "I".
On the front panel of the SVK2150 board, the LEDs "5 V" (computer supply voltage) and
"70 V" (WDE supply voltage) must be on.
If LED "5 V" is not on:

Set the switch of the power supply board to "0" and check the fuse(s) of the power supply
board.
If one of them or both are faulty, it is likely that one of the boards is also faulty. Identify
the faulty board by removing the boards.
Replace the power supply fuse(s).
Set the switch of the power supply board to "I" and check LEDs "5 V" and "70 V" again.
If the LEDs are still not on, also replace the remaining boards of the channel with spare
boards. If this is not successful, then notify the firm.
If LED "70 V" is not on:
Check the WDE cable (for short circuits).
Check the WDE connection (wrong polarity).
If power supply was faulty, continue maintenance work as described in Section 3.12
"Restarting an Evaluation Computer" on page 16.
The SVK2150 board is ready for operation when voltage is applied to the switching
input. This is indicated by the yellow LED "Vin". When the switch on the front panel is
set to "I", the yellow LEDs "5 V" and "70 V" ("12 V" is not used) indicate the presence
of the voltages.

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In case of under-voltage, the output voltage is switched off. When the output voltage is
missing, the control-circuit fuse (fuse 0.2 A; fast) on the front panel blows. The unit
cannot go back into operation until this fuse has been replaced.
If there is no voltage at all, the input fuse on the printed circuit board (fuse 8 A; slow-
acting) has to be checked.
3.8 Rectifying failure of Evaluation Computer boards after Emergency Shutdown

A board failure can also result in an emergency shutdown.
If, in addition to the indication, an emergency shutdown occurs, carry out corrective
maintenance, please follow the instructions given under section 3.12 "Restarting an
Evaluation Computer" on page no.16.
3.8.1 Precautions after Emergency Shutdown

The following precautions must be observed after an emergency shutdown:
After an emergency shutdown corrective maintenance (evaluation computer
disconnected) must be carried out within 8 days.
If the evaluation computer is disconnected after an emergency shutdown for a longer
time, the permissible out-of-service period is 5.5 months (only if supply voltage is
switched off immediately after channel failure).
If these times are exceeded, special safety measures must be performed. The evaluation
computer may only be put into operation again by Siemens specialist staff.
Fig. 3.9 : Front view of STEU board, display for emergency shutdown (TVDS 1 to 4)

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3.9 AzGrT Button Operation Error

If the reset buttons for a track vacancy detection section have not been operated on two
channels within the defined period of time (timeout), the operation will be blocked. The
blocking can only be cancelled by restarting the evaluation computer.
3.9.1Detection of AzGrT operation error

Symptom - Axle Count Reset for the track vacancy detection section (TVDS) affected
not possible by pressing of AzGrT button due to Reset Restriction (RR)
A lit LED 4 or LED 10 of the STEU board indicates the RR for the TVDS affected.
Remedy - Restart the evaluation computer. (Refer section 3.12 on page 16).
Reset restriction
Depending on the configuration, the reset restriction is set according to different
parameters. There might be a reset restriction, if one of the following is true:
 Pulse detection by a counting head belonging to the TVDS:
 There is an axle on or oscillating over the double wheel detector.
 The power supply of the counting heads is faulty.
 The double wheel detector or double wheel detector cable connections are faulty.
 Counting heads of the TVDS have been traversed within the last six seconds.
 The last test of switching capability (internal software test – SOPP) of the data
channels on the VAU board has not been successful.
 The axle last recorded by the evaluation computer in a track vacancy detection
section is an axle counted in.
3.9.2Cancelling a Reset Restriction

There a two AzGrH buttons for each track vacancy detection section, i.e. one per channel.
By pressing the two AzGrH buttons (dual channel operation), by an authorised person,
the reset restriction is cancelled for the relevant track vacancy detection section.
LED 4 or LED 10 of the TVDS affected goes OFF.

Axle count reset is possible again for the affected track vacancy detection section.
Note
After AzGrH operation, the authorized person can, after verifying that track section is
clear actuate the AzGrT button for an axle count reset. No train movements should be
carried out during this operation.

3.10 Switching the Evaluation Computer On and Off
Switching ON
 Restarting an evaluation computer means switching on all computer channels either
for the first time or after a fault.
 Set the switches of the power supply boards to "I".
 Simultaneously press the red buttons (system reset) on both VAU boards of both
computer channels for approx. 1 sec.

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 After pressing the red buttons (system reset), the LED "ANL" must light up on both
VAU boards for approx. 3 sec.
 After the LED "ANL" on the VAU boards has gone off, the LED "VGL" will light
up.
 During computer start-up, all LEDs 0 to 11 on the STEU boards light up for max. 10
sec. As soon as the LEDs change to normal display (see Section "Normal Display"),
the evaluation computer is operable (LED 0 shows steady light).
 When an evaluation computer is restarted, it is guaranteed that all track vacancy
detection sections are first indicated as being "occupied" and displayed accordingly.
In accordance with the configured reset type (AzGrT or vAzGrT) and the railway
regulations the authorised person must then perform the axle count reset. No train
movement should be carried out during this procedure.
Switching OFF
 The evaluation computer may only be switched off in consultation with the SM/
authorised person.
 For switching OFF a computer for corrective maintenance or long-term shutdown
purposes:
 Set the switch of the power supply board to "0".
 In case of long-term computer shutdown, the supply voltage must be switched off. Do
not exceed the admissible out-of-service period as given in 4.8.1 on page 13.
3.11 Replacing Boards

Only remove or insert boards and front connectors when the computer is in the de-
energised state. Removing and inserting boards in the energised state may damage or
destroy boards or computer.
3.11.1 Removing Boards

To remove boards, proceed as follows:
 Loosen the knurled screws at the upper and lower locking bars of the mounting
frame (if present).
 Remove both locking bars.
Fig. 3.10 : Extraction tool for boards

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 Loosen front connectors (if present).

 If the board is supplied with a handle, pull at the handle to remove the board.
Remove boards without a handle using the extraction tool. Pull out the board
completely.
3.11.2 Inserting Boards

To insert boards, proceed as follows:
 Slightly press up the upper locking bar and insert the board into the mounting
frame according to the location diagram.
 Plug in front connectors (if present) previously prepared and tighten them.
 Tighten the knurled screws of the locking bars.
Note: The VAU board must always be replaced in pairs
3.12 Restarting an Evaluation Computer

Proceed as follows:
 First check all LEDs of the computer channels.
 If all LEDs of the evaluation computer are off.
 Check that whether the power supply been switched off, or
 Whether the power supply cable to the evaluation computer is faulty, or
 Whether the fuses of the power supply are faulty.
Observe that
 The LED "PAB" on the VAU board is on.
 The LED "0" is flashing (emergency shutdown).
 Note down the LED display (fault record) and interpret it for diagnostics.
 If the failure of a board is identified, continue maintenance as described in Section

3.7 - "Rectifying failure of Evaluation Computer boards" on page 10.
 Set the switches of all power supply boards to "0" (wait until all LEDs are off).
 Proceed as described in Section 4.10 "Switching On", page 14.

3.13 Special Board Replacement Conditions
Special Board replacement conditions must be observed while replacing boards.
3.13.1 Special Conditions for VAU Board

The program revision level of the spare board must be the same as that of the faulty VAU
board.
Determine the program revision level of the VAU board by means of the Siemens code
number
For example for VAU board with code no.S25552 – B600U1-4/P-4/VAU-2, the program
revision level is P-4.
Replace the faulty VAU board with a spare board with the same program revision level.
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3.13.2 Special Conditions for BLEA12 Board

Before replacing a BLEA12 board, note down the position of the DIP switches and
jumpers of the faulty board. The DIP switches and jumpers of the spare board must be set
identically.
Before replacing the faulty BLEA12 board, observe the following:
The slot assignment and DIP switch positions of the BLEA12 board are different in the
Az S 350 U. The program revision level of the VAU board determines the special
conditions for the settings on the BLEA12 board.
Determine the program revision level of the VAU board by means of the Siemens code
number.
Depending on the program revision level of the VAU board, the slot assignment is given
in sections (A), (B) & (C).
Fig. 3.11 : DIP switches and jumpers on the BLEA12 board

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(A) Slot Assignment for VAU Program Revision Level <4

In this level, the BLEA 12 boards are paired as shown in figure below:
Fig.3.12.:Pairing of BLEA 12 Boards for

The slot assignment and DIP switch positions must be as follows:
DIP switch position

(DIP switches 1 and 2 of switch bank 2) Slot assignment
1 2 3 4 5 6 7 8 BLEA12 board in channel 1 (slot 11) 1st pair of
ON BLEA12
OFF boards
1 2 3 4 5 6 7 8 BLEA12 board in channel 2 (slot 63)

ON
OFF
1 2 3 4 5 6 7 8 BLEA12 board in channel 1 (slot 19) 2nd pair of

ON BLEA12
OFF boards

ON
OFF
Remove the faulty BLEA12 board.

Set all DIP switches and jumpers on the spare board as on the faulty board
The Fig on page shows all DIP switches and jumpers to be checked on the BLEA12
board.
Insert the BLEA12 spare board in accordance with the slot assignment above.

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(B) Slot Assignment for VAU Program Revision Level 4

In this level, the BLEA 12 boards are paired as shown in figure below:
The slot assignment and DIP switch positions must be as follows:
DIP switch position

(DIP switches 1 and 2 of switch bank 2) Slot assignment
1 2 3 4 5 6 7 8 BLEA12 board in channel 1 (slot 11) 1st pair of
ON BLEA12
OFF boards

ON
OFF
1 2 3 4 5 6 7 8 BLEA12 board in channel 1 (slot 19) 2nd pair of

ON BLEA12
OFF boards

ON
OFF

Set all DIP switches and jumpers on the spare board as on the faulty board
The Fig on page shows all DIP switches and jumpers to be checked on the BLEA12
board.
Insert the BLEA12 spare board in accordance with the slot assignment above.

Click for Contents
(C) DIP Switch Positions for VAU Program Revision Level 5
When replacing the BLEA12 board, the DIP switch positions on switch bank 1 and
switch bank 12 must be checked. This refers to the BLEA12 board in slot 11 and the
BLEA12 board in slot 71 only.

Set DIP switch 6 of switch bank 1 of the spare board as indicated in the table below (Fig.
on page shows switch bank 1 on the board).
VAU program revision level ≤4 VAU program revision level ≥5

Possible DIP switch positions of the faulty BLEA12 DIP switch positions of the BLEA12 spare board
board
BLEA12 board in BLEA12 board in channel BLEA12 board in channel BLEA12 board in channel
channel 1 (slot 11) 2 (slot 71) 1 (slot 11) 2 (slot 71)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Use the same DIP switch
ON positions
ON
OFF OFF
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
ON ON ON ON
OFF OFF OFF OFF
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Set the switches as shown Set the switches as shown
ON ON
OFF OFF
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
ON ON Use the same DIP switch positions
OFF OFF
Set DIP switches 1 to 6 of switch bank 12 of the spare board as indicated in the table
below (Fig. on page shows switch bank 12 on the board).
VAU program revision level ≤4 VAU program revision level ≥5

BLEA12 board in BLEA12 board in channel BLEA12 board in BLEA12 board in
channel 1 (slot 11) 2 (slot 71) channel channel
1 (slot 11) 2 (slot 71)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Use the same DIP switch positions as on
the faulty board
ON ON
OFF OFF
Set the switches as shown Set the switches as shown
Insert the spare board.

Click for Contents
3.13.3 Special Conditions for VESBA Board

When commissioning or replacing the VESBA board, the rectified voltages V1, V2
(which can be measured and adjusted on the front panel) must be adjusted to 3.0 V DC.
Use a voltmeter with an internal resistance of ≥ 50 k_ for this purpose.
Before switching on the evaluation computer, set the potentiometers (for V1, V2) as far
to the left as they will go.
After having replaced or moved the VESBA board to another slot, its proper operation
must be checked by carrying out or simulating a train movement over the counting heads
connected.
3.13.4 Special Conditions for DIGIDO Board

The outputs of the DIGIDO board may be loaded with max. 10 mA/output. The voltage
at the opto-coupler outputs may be 0 V to 5 V.
3.13.5 Special Conditions for SVK2150 Board

A faulty SVK2150 power supply board may be replaced without switching off the supply
voltage (interlocking power supply).


Go to index Go to Chapter index

Click for Contents
Section IV
Troubleshooting of
CEL
DACF 710 A & DACF 710 P
Single Section Digital Axle Counter
CAMTECH/S/PROJ/2013-14/HB- DAC(T)
SEPTEMBER 2013
Click for Contents

Contents
Section IV -Troubleshooting - DACF 710 A & DACF 710 P CEL SSADC
4.1 Introduction 1
4.2 LED indications on SSDAC unit 1
4.3 Recording of parameters 2
4.4 Troubleshooting through LED indications 5
4.5 System Error Codes 7
4.6 Reset box functions 17
4.7 Troubleshooting through Event Logger 20
4.8 Status chart of SSDAC for various conditions 29
Go to Chapter index
Click for Contents

Section IV
Troubleshooting
DACF 710 A & DACF 710 P
CEL SINGLE SECTION DIGITAL AXLE COUNTER
4.1 Introduction
The LED indications are provided on the facial plate i.e. on front side of different modules of
SSDAC viz. SCC cards, MLB Cards, Modem Card, Relay Driver, DC-DC Converter and
Event Logger to indicate OK or Error condition. These indications are helpful in the
troubleshooting of DACF 710A & 710 P SSDAC.
4.2 LED indications on SSDAC unit

SCC Cards
Sr. No. LED Colour Information
1. OSC OK GREEN ON when TX coil & Oscillator are working normally.
OFF when these becomes faulty.
2. LD OK GREEN ON when signal from RX coils are normal and above
certain level, OFF when fault in RX coil or disconnection
3. PULSE OK GREEN ON when signal from RX coil normal and pulse level in
Card OK. OFF when RX coil faulty, wrongly connected
or disconnected
4. TP CON GREEN Permanently OFF as trolley suppression track circuit is
not required in phase reversal type system.
MLB Cards
1. 8 LED BLOCK All RED Normally OFF, ON when error appears
2. CLEAR GREEN ON for clear condition
3. OCCUPIED RED ON for occupied condition
Modem Card
1. Tx GREEN Transmitting the signal when LED is flashing.
2. RX GREEN Receiving the signal when LED is flashing
3. MODEM GREEN Normally OFF, Glows and again goes low when system is reset.
4. CD GREEN Carrier is detected when LED is flashing
Relay Driver
1. MLB 1 CLEAR GREEN ON when section clear, OFF when section occupied
2. MLB 1 CLOCK GREEN LED flashes when section is clear.
3. MLB 2 CLEAR GREEN ON when section clear, OFF when section occupied
4. MLB 2 CLOCK GREEN LED flashes when section is clear
5. RELAY DRIVE GREEN ON when section clear, OFF when section occupied.
Section IV - Troubleshooting - DACF 710 A & DACF 710 P CEL SSADC

September 2013 Click for Contents
Fig.5.1: Front view of SSDAC unit
DC-DC Converter
1. +5V RED ON when +5V supply available
4. +15V ISO RED ON when +15V ISO supply available
Event Logger
1. RUN GREEN Blinks continuously indicating normal working of Event
Logger Card
2. LOG GREEN Blinks whenever data is being logged into the flash memory
(approx. after every 2 minutes)
3. DNLD GREEN ON when data is being downloaded from the flash memory of
the card, OFF when download is complete.
4.3 Recording of parameters

For trouble-free performance of Single Section Digital Axle Counter various parameters are
to be checked periodically. The various signal input and output levels and its limits which are
to be recorded and adjusted to correct levels wherever necessary are given in following
tables:
24 V DC Supply (Battery)
Measure the DC 24 V input to the system with charger ON, charger OFF condition with all
the units connected (i.e. on load) or using dummy load.
S.No. Input Range near SSDAC unit Actual measured value

(In DC Volts) With Charger ON Charger OFF
1. 19.2 V to 28.8 V
Note: Keep Charger OFF for 15 minutes before taking measurements.

Oscillator Output (TX Coils)

Measure the oscillator output, frequency of TX coil of Axle detectors.
S.No. Parameter Limit TX coil 1 TX coil 2
(21 KHz) (23 KHz)
1. Oscillator output 30V to 40V rms
2. Oscillator frequency (i) 20.80 to21.20 KHZ
(ii) 22.80 to 23.20 KHz
Receiver Coil Output

Measure the RX coil signal output with and without dummy wheel.
Fig 5.2: Adjustment of Receiver coil with the help of dummy wheel
Fig 5.3 : Dummy wheel setting = 44 mm for 90 R, 52 kg and 60- kg rails

For Amplitude Modulation type Digital Axle Counter

S.No. Parameter Signal Limit Signal Dip 15% of Dip
mV rms Measured signal (mV measured
Value rms) value
1. RX Coil 1 (21 KHz) 750 - 1200
2. RX Coil 2 (23 KHz) 750 - 1200
For Phase Reversal type Digital Axle Counter

S.No. Parameter Limit mV rms Measured Value
1. RX Coil 1 (21 KHz) 275 - 600
2. RX Coil 2 (23 KHz) 275 - 600
SCC Cards (Cards 1 & 2)

Measure the DC voltages at monitoring sockets of SCC cards 1 & 2 with respect to ground.
S. Card Measured output voltage (DC volts)

No. Without dummy With dummy With push
wheel wheel trolley (4/8
spokes) on axle
detectors
Limit Meas- Limi Meas- Limit Meas-
ured t ured ured
value value value
1. SCC1 2.0 <0.7 >1.7 V
to
2.5 V
2. SCC2 2.0 <0.7 >1.7 V
to
2.5 V
Fig 5.4.: Front view of SCC 1 Card
Modem Output (Card 6)

Check and record the modem signal output of SSDAC during normal working condition of
the system.
S.No. Measuring Limit (mV rms) Measured Output (mV rms)

1. >400 mV (-6 dB)

DC –DC Converter Card (Card 8)

Measure the DC –DC Converter output voltages with respect to respective ground for 24 V
DC input fed to the SSDAC.
S. Parameter Limit (DC Volts) Measured

No. output
(DC Volts)
1. 5V 4.75 to 5.25 V
2. 12 V 11.50 to 12.50 V
3. 24 V 23.50 to 24.50 V
4. 15 v ISO 14.50 to 15.50 V
Fig.5.5: Front view of DC-DC Converter
Relay Drive (Card 7)

Check and record Relay drive output to the Vital Relay with section clear and section
occupied condition. (This may be checked across R1 & R2 of relay coil in vital relay box).
S.No. Parameter Measuring Limit (DC volts) Measured output (DC volts)
1. Clear mode >20 V
2. Occupied mode <2 V
4.4 Troubleshooting through LED indications

The two MLB cards continuously check and monitor the health of the system. During normal
working condition of the system, all the LEDs are OFF. When the system detects error, it
will be displayed on these cards by means of flashing/glowing one or more LEDs for the
particular error.
The errors occurring in the system during the operation of the SSDAC are encoded and are
indicated by means of the 8 - LED block present on the front panel of the MLB cards. A
glowing LED implies a 1 while OFF LED indicates a 0. All the LEDs are numbered as given
below. DS1 to DS4 are designated for Least Significant Bits (LSB) and DS5 to DS8 are
designated for High Significant Bits (HSB). The value given to each LED is given in Fig. (b)
below:

Fig. 5.6: (a) Numbering of LED indications for errors (b) Values given to each LED
The Errors are given in Hexa decimal codes which can be read as given below:
Example
If LEDs 1 & 3 of LSB glow and LEDs 5 & 6 of HSB glow and all other LEDs are OFF. By
adding LSB+HSB LED values, (1 + 4) + (10 + 20) = 35. Thus error no. is 35.
Fig. 5.7: Details of controls and indications of SSDAC unit

4.5 System Error Codes

Details of error corresponding to the error no. and action to be taken can be seen from table
below:
Indicates LED is Flashing
Indicates LE is ON
Indicates LE is Blank
Sr. Error Process/Error Cause Action to be Indications
No. No.(Hex taken
Decimal)
1. 00 No error System Normal No action to be
taken
2. 11 ROM test Memory of MLB Replace the

during Power card is corrupted. microcontroller
On Self Test IC or MLB
card.
3. 12 RAM test Memory of MLB Replace the

during Power card is corrupted. microcontroller
card.
4. 13 Serial port test On chip serial Replace the

during Power port is corrupted. microcontroller
card.
5. 14 Card presence Any card is Insert all the

test removed or not cards properly
inserted properly. or replace the
MLB cards
6. 15 Relay test Relay and its Check the

during Power connections are presence of
On Self Test not proper relay. Check
the connections
of relay. Make
proper
connections.


No. No.(Hex taken
Decimal)
7. 21 ROM Test fail Memory of MLB Replace the
during system card is corrupted. microcontroller
working IC or MLB
card.
8. 22 RAM Test fail Memory of MLB Replace the

during system card is corrupted. microcontroller
working IC or MLB
card.
9. 24 Card presence Any card is Insert all the

test during removed or not cards properly
system working inserted properly. or replace the
MLB cards
10. 30 Link error Link between two Check the

SSDAC units is communication
open or loss of link between
Carrier Detect the units and
(CD). rectify the fault.
11. 31 Sequence error Sequence of pulse Check the

not correct when arrangement of
axle is detected the detectors. It
on the sensor. shall be at
proper height
from top of rail.
Check card 1 &
2 and replace if
necessary.


No. No.(Hex taken
Decimal)
12. 32 Self count Difference in Reset the
mismatch counts of the two system. If error
MLB cards in persists replace
local unit after the MLB cards
detection of all with the spare
the axles passed cards. Send the
over the axle cards for repair.
detectors.
13. 33 IN/OUT error The number of Check the
axles going OUT system for error
of the section is and apply reset
more than coming to normalize
INTO the section. the system.
This error is also
displayed after
reset is applied
and while the
system is trying
to synchronize,
there is train
movement in the
section.
14. 34 OUT before IN The system Check the axle
error is in preparatory detectors A.
state and train Check
exits SCC1 card &
from the section replace if found
without entering faulty.
into the section.
15. 35 Negative count Counts OUT of Check signals
error the section are dip at both
more than the locations in
counts INTO the single line
section. section. Check
signals dip and
coil position at
entry end in
double line
block section.
Check DC
voltage in SCC
1 & 2 cards.


No. No.(Hex taken
Decimal)
16. 36 Shunt error Train moving Station master
forward & has to apply
backwards reset after
(shunting) on axle section is
detectors without verified as per
proper direction SWR.
influencing only Movement of
external detector pilot train in the
twice without section makes
affecting internal system clear.
detector.
17. 37 Supervisory Any of the Check the Tx &
error axle detector Rx signal level
signals becomes of the axle
low. detectors. It
should be as per
the recorded
readings.
Check the SCC
1 & 2 card DC
voltages.
Adjust or
replace if any
of the above is
not OK.
18. 38 Internal shunt When train is Station master
error moving forward has to apply
& backwards reset after
(shunting) on axle section is
detectors without verified as per
proper direction SWR.
in such a way that Movement of
both detectors are pilot train in the
influenced and section makes
internal detector system clear.
is influenced
twice.


No. No.(Hex taken
Decimal)
19. 39 Count unequal Mismatch of If the error is
error counts by both continuously
MLB cards. displayed,
replace the
MLB cards.
20. 40 Communication Communication Check the pair

error between the two used for the
units is not proper communication.
i.e. packet Check that no
information is parallel wires
corrupted due to are used for
noise in the Quad modem
Pair used. communication.
Check that
correct Quad
pair is used for
communication.
If problem
persists, replace
the spare pair.
21. 41 CRC error Data of the Check the pair
packets got used for
corrupted thereby communication.
CRC of Check that no
the packet not parallel wires
matching. are used for
modem
communication.
Check the
correct Quad
pair is used for
communication.
If problem
persists replace
the spare pair or
improve the
earthing to the
unit.


No. No.(Hex taken
Decimal)
22. 42 EOB error Data of the Check link
packets got between the
corrupted thereby two units.
End of packet Check the
information is not modem cards
detected. and apply reset
in the system.
23. 43 Wheel shunt Sequence of Check whether
error pulses from the the position of
axle detectors and axle detectors is
SCC cards is OK and correct.
disturbed Check for
failure due to
motor trolley,
perforated push
trolley, dip
lorry, etc and
apply reset in
the system.
24. 44 Independent If the wheel is Check whether
pulses error moved in such a the position of
way that axle detectors is
independent OK and correct.
pulses are Check for
generated by failure due to
system in motor trolley,
FORWARD perforated push
direction. This trolley, dip
happens only if lorry, etc and
motor trolley apply reset in
wheel that are the system
similar in
diameter is
moved beyond
the permissible
limit.


No. No.(Hex taken
Decimal)
25. 45 Independent If the wheel is Check whether
pulses error moved in such a the position of
way that axle detectors is
independent OK and correct.
pulses are Check for
generated by failure due to
system in motor trolley,
REVERSE perforated push
direction. This trolley, dip
happens only if lorry, etc and
motor trolley apply reset in
wheel that are the system.
similar in
diameter is
moved beyond
the permissible
limit.
26. 46 Exit mismatch The section Reset the
error occupancy and system.
section clearance
by different type
of wheel
i.e. section is
occupied by train
but clears by
motor trolley
wheel and vice
versa.
27. 47 Train trolley Following Motor Reset the
mismatch error trolley shunts system.
back or if only
train entered the
section and
crossed exit and
leaving two
counts, now
motor trolley
leaves section
balancing counts.


No. No.(Hex taken
Decimal)
28. 48 Non overlap If motor trolley Reset the
pulses before enters the section system
overlap pulses and after that
error train enters the
section
29. 50 Relay removed During power on Check the

(physically self test (POST) presence of
from plug of the system the Vital relay in
board) presence of relay the relay box of
is not detected. the system &
insert in the
plug board.
30. 51 Relay contacts When section is Check the back
failure in occupied and the contacts (D5 &
occupied state back contact of D6) of the vital
the vital relay is relay used for
found open. read back in the
system &
rectify.
31. 52 Relay contacts When section is Check the pick
failure in clear after up contacts of
unoccupied passage of train the
state (clear) but front contact vital relay and
of vital relay is rectify or
found open. replace the
relay.
32. 53 Relay drop The system after Check the back
failure in detection of train contacts of the
occupied state in the section relay
goes to and rectify or
OCCUPIED state replace the
but vital relay relay.
fails to drop
33. 60 Tracing error Both MLBs work Replace the
in tandem and MLB card
software follow a which is
particular displaying the
sequence, but any error.
sequence is
missed.


No. No.(Hex taken
Decimal)
34. 61 Secondary CPU If MLB1 detects Apply reset to
error that the adjacent normalise the
MLB2 is in system
different state or
vice versa.
35. 62 Secondary CPU When MLB The adjacent
fails card detects the MLB card is
adjacent MLB faulty. Replace
card is the adjacent
faulty. MLB card with
spare card.
36. 66 Watchdog Power supply is Check the

Reset interrupted power supply to
thereby DC-DC the system and
converter rectify.
voltages are also
interrupted in the
system.
37. 70 Configuration The unit address Check and
error during of any unit is install the Entry
self test disturbed or both and Exit Units
units have the with correct
same address. address setting
in the section.
38. 71 J packet The unit address Check and
configuration of any unit is install the Entry
error disturbed or both and Exit Units
in the section.
39. 72 R packet The unit address Check and
in the section.


No. No.(Hex taken
Decimal)
40. 73 Configuration The address of Rectify the unit
error during unit is address as per
normal working disturbed/changed the factory
while the system setting. Reset is
is running. applied.
41. 74 U packet The unit address Check and

in the section.
42. 80 Remote error The remote unit is Check the

in error state. The errors in remote
local unit is OK unit and rectify.
43. 7F Remote Reset The remote unit Apply reset in

error has been reset. the local unit or
else apply reset
in both SSDAC
units.
44. 3F Self Reset error The local unit Remote unit is
is reset and is to be reset or
waiting for else both
remote unit to be SSDAC units
reset. are to be reset.
Other type of errors

Sr. Condition Error System status Action required
No. No.
1. Entry counts are No Error Vital relays are dropped. 1. Check Exit end axle detectors
more than Exit System may fail for each and align them properly.
counts train movement. 2. Check SCC1 & 2 cards and its
output

4.6 Reset box functions

The reset box has the following components
1. The LED indications displaying the section status

(a) Section Clear GREEN indication LED of 10mm.
(b) Section Occupied RED indication LED of 10mm.
(c) Power ON YELLOW indication of 3mm.
(d) Prep. Reset GREEN indication of 3mm.
(e) Line Verification YELLOW indication of 3mm.
2. SM s Key actuator
3. Push Button RED colour
4. Counter for recording the number of reset operations.
5. Alphanumeric 20 X 2 row LCD display with Backlit for

(a) Axle Counts of Local and Remote unit
(b) Error Code in Numeric format
(c) Section Status
(d) Last 10 Errors with date and time
6. 4 Keys Keypad for setting the date and time operation.
7. 9 pin D-sub connector is given on the motherboard of reset box which can be used for
downloading the data from flash for analysis purpose.
8. Miniature reset switch for refreshing the LCD display.
The reset box is connected in the Station master’s room and is used for applying the reset by
station master.

The following processes take place in the working of reset box:

(i) During POWER ON of reset box, the reset box will display the Software version of
the SSDAC software used and its checksum.
(ii) After the checksum, the reset box will wait for the user to apply the reset to SSDAC
system. The screen will display RESET THE SYSTEM .
(iii) The reset shall be applied as defined in the resetting procedure given below. On
pressing of Reset button and SM s Key, the PREPRESET indication will start
flashing. The remote unit also required to be reset. When reset is applied to both the
local and remote SSDAC units, the flashing PREP reset indication will become
Steady when the system attains the Preparatory state. At this point the LCD will
display the following message.
(iv) When Pilot train is moved in the section, the LCD will display the axle counts in
local DP on the Entry side Reset Box and in Remote DP on the Exit side Reset
Box as shown below. The section status is displayed as Preparatory state.

(v) When Pilot train is moved out of the section, The LCD displays the axle counts in
Remote DP on the Entry side reset Box and in Local DP on the exit side reset
Box. When the axle counts are matched, the section status is displayed as Clear
and Section CLEAR indication glows.
(vi) The axle counts are incremented or decremented according to the direction of
train movements. In case of failure, Error code is displayed at both the ends. The
Error code along with its description is displayed. This Error code is required to
be recorded by SM s before applying Reset.
(vii) On applying the reset, this Error code will get refreshed and is stored in flash. List
of 10 recent error codes are stored in Error log entry. This Error Log can be
viewed by maintainer at all times without the use of PC. By pressing reset button
for 10 secs, last 10 Errors will be displayed with Date and time one by one. After
the complete Error log, the LCD display will come back to its original state. This
Error log can be activated at any time but is recommended not to done during the
reset procedure.
(viii) One reset switch is provided on the interface card or motherboard which can be
used for resetting the display of LCD. This switch can be accessed by removing
the top cover of the reset box. This reset will not affect the status of the section
and be applied at any time but it is recommended to not to use it during the reset
operation.
(ix) In case the cable pair from location box to SSDAC unit is not provided, the
display information on the reset box will not appear.

4.7 Troubleshooting through Event Logger

Event logger card is designed to capture and store important signals from the remote and
local SSDAC units. The stored data can be downloaded from the event logger card for the
purpose of analyzing the events occurring during the operations of the SSDAC. The data can
be analyzed with the help of CEL data analyzer software. Following signals are captured by
the event logger card.
 Card removal information

 Serial packets from
 MLB1 (Local unit)
 MLB2 (local unit)
 Remote unit (communication failure and composite information from MLB1 &
MLB2)
For capturing the signals of SSDAC unit, Event Logger card is required to be plugged in the
SSDAC unit in the appropriate slot
4.7.1Data Analyzer Software

For analyzing the data stored in flash of the event logger card, EL card is connected to a PC
(or laptop) through a COM PORT (or USB port) using a standard cross connected RS-232
cable (or USB to RS232 converter cable).
Data download procedure

Data analyzer software is installed in a PC using Auto run facility in the software CD or
running setup.exe command. After the software is installed, run the software for carrying out
various EL related activities.
From Main menu, Card function option is selected.
a) COM port setting: Select COM port Settings from the drop down menu of card function
(use default setting for the selected Com Port as 19200, n, 8, 1).
b) Select desired Com Port, click OK.
4.7.2 Other card functions

Check CRC: For checking the checksum stored in the micro-controllers of MLB cards. To
check the CRC, data must be downloaded first from the event logger card.
Reset flash: For resetting the flash, click on reset flash.
Erase flash: To erase all 4096 pages of the flash memory, click on to “Erase flash” and then
click on to “Erase” button. “Flash erased” message will be displayed on the host computer
screen. Further writing of the flash memory will start from page number 0.Before erasing the
flash, time stamping is recommended.

Time stamping:
Click on to the “Time stamping” option.
Click on the “Select the current time”
Click on “Form packet”.
Click on “Send packet”, time packets are sent to the event logger card.
Show current time stamping: Once clicked on this option the system shows the current time
stamping. The date time will appear in the following format: {15:03:2005|12:27:00}
4.7.3Downloading data
Data from the Event Logger card is downloaded from flash memory of event logger.
Case 1: When flash page number is >0 and flash is not circulated, the controller generates a
message downloading buffer followed by page number of current page. Once the command
is executed, data is downloaded from the flash memory from page number 0 to the current
page number.
Case 2: When flash is circulated, the controller generates a message downloading buffer
followed by page number of current page. Here in this case data is downloaded from current
page to last page (4096) of the flash and then page number 0 to the current page number.
Steps for downloading the data.

Open the CEL data analyzer application. Go to Start > All Programs > Data Analyser-
SSDAC > Data analyser-SSDAC
Go to card function.
Click on the com port setting

Click on com1/com2/com3/com4 as per the comport availability.
Check the setting for 19200 bauds, parity none, data bits 8 and stop bit 1.
Now click on to download data.

Give file name and save. Data starts getting downloaded.
On completion of downloading the message downloading completed appears.

Forced download: In forced download; we get complete flash data from page 0 to page 4096
irrespective of restored page number and loop number. This is given to download data if
flash pointer is restored and one is interested for the old data. But this will always download
data from page 0 to page 4096.
4.7.4Data analysis
Run the Data Analyzer Application
Click on select data, then select file form the list or from the path where the files are saved.
Give name of station or station code. Station name / code should be at least 3 characters long.
Click on OK button. Then files will start getting created.
After creating the files message will appear “Files are created and now you can analyze the
data”.
The required time slots in “From” and “To” windows for which the analyzing is to be done
should be selected. After time zone selection, click on VIEW, The result menu comes on
having information regarding serial packets and Card removal information.

Current Report and Error Report for the selected *.dat file are ready to be viewed. The
current report can be exported in the Excel format by clicking on “Export to Excel” button. If
Microsoft Excel is not installed in the PC or Laptop, then the user can use the Print button to
print the report directly or the “Save Report button” to save the report in a text file.
Search feature is provided in data analyzer software to search and analyze the data on the
basis of time stamps or error codes.
Detailed help instructions are provided in the help menu of the software.

4.8 Status chart of SSDAC for various conditions

The status includes when power connected, Reset applied, Preparatory, Occupied (Train Entry in Section), Clear (Train Exit from Section).
S. Condition Station A Station B

No. SM’s Room Relay Location SM’s Room Relay Location
(Reset Box) Room (Reset Box) Room
Q- Q- System Q- Q- System Status
Relay Relay Status Relay Relay
Status Status Status Status
1. 24 V DC is Occupied PPR PR 24V DC is No PPR PR System is OFF
connected at (RED) LED VPR VR available to indication VPR VR
Station A indication system.
(Fuse glows System is
connected) ON &
waiting for
Reset.
2. 24 V DC is - do - - do - -do- -do- Occupied -do- -do- 24 V DC is
connected at (RED) LED available to
station B indication the system.
(Fuse glows System is ON.
connected) Waiting for
Reset.
3. Reset (i) Inserted PPR PR (i) Reset is -do- -do- -do- -do-
applied at SM’s VPR VR applied to
station A Key, system.
turned The self
and kept test starts
pressed. in the
(ii) Reset system
button and goes
pressed to error
(iii) Both due to far
Section IV - Troubleshooting - DACF 710 A & DACF 710 P CEL SSADC September 2013

released. end unit is
(iv) Occupied not
(RED) released
indication
remains.
4. Reset Occupied PPR PR Error due to i) Insert PPR PR i) Reset is
applied (Red) VPR VR far SM's key, VPR VR applied to
at LED indication end unit is turned & system.
Station B glows. not keep ii) The self
synchronized. pressed test starts in
ii) Reset the system and
button hand
pressed. shakes with
iii) Occupied the other end
indication unit.
remains.
5. System Power On PPR* PR* Both Units Power ON PPR PR Both Units
enters remains VPR VR communicate remains. VPR VR Communicates
Preparat OCC each other by OCC with
ory reset indication means of Indication each other by
mode remains. packets remains. means of
Preparatory and enters Preparatory packets and
Reset into Reset enters into
indication preparatory Indication preparatory
glows. reset mode glows state mode.
Reset counter Reset counter

increments by increments by
1 count. 1 count
*After PR & PPR relays are picked up, the system is in No. Error Condition, But, the VR & VPR Relays of both stations are
forced to remain in dropped condition by the system. Therefore LSS cannot be lowered. The 1st train is to be piloted in the
section to register balance of counts and thereby to drive VR relays ON at both stations.
6. 1st train Power On LED PPR PR System Power On PPR PR System
enters the (Yellow) VPR VR registers LED glows. VPR VR registers
block remains. wheel counts Prep. Reset wheel
section Occupied & PR relays LED counts at
from stn A (Red) LED remains remains ON. station A. PR
remains. Prep pickup. & PPR relays
Reset LED remains
remains ON. picked up.
7. 1st train Power On LED PPR PR Counts in Power on PPR PR Counts in both
clears the glows. VPR VR both units LED glows. VPR VR units of
section from Prep. Reset of the system Prep. Reset the system
Stn B. LED become LED become
becomes OFF. equal. The becomes equal. The
Occupied decision to OFF. decision to
LED becomes drive VR Occupied drive VR relay
OFF & relay ON is LED ON is given.
clear LED given. VR becomes VR relay picks
glows relay picks OFF & clear up.
up. LED
becomes ON
8. On Power on LED PPR PR System Power on PPR PR System

subsequent glows. VPR VR registers in LED glows. VPR VR registers in
trains entry Prep. Reset counts at Prep. Reset counts at stn
in the block LED is OFF. station A. LED is OFF. A. System
sectio Occupied LED System goes Occupied goes to OCC
becomes ON. to OCC LED state. VR is
Clear LED state. VR is becomes driven OFF.
becomes OFF. driven OFF. ON. Clear
LED
becomes
OFF.
9. Trains clears Power on LED PPR PR System Power on PPR PR System
the block glows. VPR VR registers out LED glows. VPR VR registers out
section and Prep. Reset counts at Prep. Reset counts at stn
enters stn B LED is OFF. station B. LED is OFF. B. After
Occupied LED After count Occupied count
becomes balancing LED balancing the
OFF. Clear the system becomes system goes to
LED becomes goes to OFF. Clear clear state.
ON. clear state LED
becomes
ON.
Note: In the wiring circuit of Reset Box contacts of PPR & VPR are not proved. Hence reset voltage is extended to system in
PPR or VPR pick up condition. Reset is however possible only in error or occupied state after registration of at least one
out count.
4.9 Relay status chart
Sr. Condition Station A Station B

No. Relay room Location Relay room Location
1. 24 V connected VPR PPR VR PR VPR PPR VR PR
2. Reset applied (SM s key inserted, VPR PPR VR PR VPR PPR VR PR
reset button operation, etc)
3. System enters preparatory reset VPR PPR VR PR VPR PPR VR PR
mode
4(a) First train enters the section (Pilot VPR PPR VR PR VPR PPR VR PR
train)
4(b) First train clears the section (after VPR PPR VR PR VPR PPR VR PR
counts equal in both units
5(a) Subsequent trains when occupy VPR PPR VR PR VPR PPR VR PR
the section
5(b) Subsequent trains when clears VPR PPR VR PR VPR PPR VR PR
the section

Go to index
Section V
Troubleshooting
of
SSDAC-G36
G.G.Tronics Single Section Digital Axle Counter

September 2013
Click for Contents

Contents
Section V - Troubleshooting of SSDAC-G36 G.G.Tronics Single Section Digital
Axle Counter
5.1 Introduction 1
5.2 Modules of G36 SSDAC 1
5.3 Configurations 1
5.4 Reset Box 1
5.5 Power Supply Arrangement 2
5.6 Protective devices 3
5.7 Maintenance 3
5.8 Troubleshooting 5
Go to Chapter index
Click for Contents

Section V
Troubleshooting of
SSDAC-G36
G.G.Tronics Single Section Digital Axle Counter
5.1 Introduction
SSDAC G36 manufactured by M/s G.G.Tronics India Pvt. Ltd., is a microcontroller
based system with 2 out of 2 architecture suited for proving station and block section.
5.2 Modules of G36 SSDAC

The hardware and software for all the configurations are same. The main modules for
SSDAC-G36 are listed below:
 SSDAC unit
 Reset box
 Axle Detectors (Tx & Rx coils factory tuned to 21 KHz & 25 KHz with
associated cables of 15 Mtrs.each)
5.3 Configurations
SSDAC-G36 units can be installed to work in the following 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].
5.4 Reset Box

The Reset Box has the following controls and displays.
Fig. 3.4.:
Reset box
front view
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.
Section V - Troubleshooting - G-36 G.G.Tronics SSDAC September 2013

Click for Contents
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.
Line Verification Box

Line verification Box is supplied only for case where hard reset has to be adopted instead
of a preparatory reset.
Indications
One 10 mm Green and Red LED are provided for indicating status of block section.
One 5 mm green LED for indicating the status of preparatory reset. Flashing- when local
reset is applied. Steady - when reset is applied at the other end also & the system is
waiting for pilot train. OFF – when the section becomes clear.
One 5 mm Yellow LED for indicating the line verification status. Normally OFF; glows
only when line verification key is operated for executing direct reset.
One 5 m Yellow LED for indicating power ON condition.
Counter
One 6 digit non-resettable counter is provided which increments after each resetting
operation.
Display
One LCD display with 4 lines & 40 characters gives display of events, System Status,
Checksum and Version No, Counts and error code.
The reset box is connected to the system with one pair of quad cable for FSK
communication and 12 core signal cable for transfer of reset commands and reception of
the signals from the system.
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.
5.5 Power Supply Arrangement

The SSDAC system works on 24V DC supply. This has to be provided by the respective
station through power cables. The continuous current drain, requirement of battery and
battery charger are as indicated in Table below:
S. No. Configuration Continuous Battery capacity Charger capacity

current drain
1. 2DP1S version < 2 Amp. 24 V/40 A.H. – 1 set 5 Amp. – 2 Nos.
2. 3DP1S version < 3 Amp. 24 V/40 A.H. – 1 set 5 Amp. – 1 No.
3. 3DP2S version < 3 Amp. 24 V/40 A.H. – 3 sets 5 Amp. – 3 Nos.
Input supply to be maintained between 22 V and 26 V DC.

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5.6 Protective devices

The details of protective fuses and surge arrestors are as given below:
Table A -Fuses
Path FTB Point Rating Quantity
Input 24 V DC Power supply to system 1,2 6.3 Amps 2 Nos. on + limbs
Spare 5,6,7,8 6.3 Amps 4 Nos.
DC 24 V supply to Relay Box 11,12,13,14 6.3 Amps 4 Nos.
Connection from System to Relay box 15 to 22 2 Amps 8 Nos.
Connection to VPR & PPR relays in 23,24,25,26 2 Amps 4 Nos.
Relay room
Quad cable to system 27,28 2 Amps 2 Nos.
To reset box in the station 35,36,43,44 2 Amps 4 Nos.
Tx/Rx coil connections 51 to 58 2 Amps 8 Nos.
Table B - LDUs (Lightening Discharge Protection Units)

Path Type Quantity
Input 24 V DC Power Supply to System 24 V DC 1 No.
Termination of Quad cable to System 24 V DC 1 No.
Quad cable from System to Reset Box 24 V DC 1 No.
Quad cable from Reset Box to System for reset 48 V DC 1 No.
5.7 Maintenance
Adjustments required in the field
The adjustment has to be done after measuring the voltages at monitoring points provided on
different modules, tabulated in the Table C.
Output voltages of DC-DC Converter

Measure the input voltage of 24 V DC between GND and the corresponding input monitoring
point; this should be within 22 V and 26 V DC.
With the same GND measure the other voltages.
Adjust +5V precisely to 5V with the help of potentiometer provided for the purpose on the
front plate of DC-DC Converter.
Similarly adjust +18V fed to the PD card.
Settings in PD cards for different voltages

In the PD cards adjustment facility is provided for Rx signal, Supervisory signal and phase
adjustment of Rx with respect to Tx. All the adjustments have to be carried out under no
wheel condition and the voltages are to be as indicated in Table D. Adjustments have to be
carried out on each of the 21 KHz & 25 KHz PD cards individually.

Click for Contents
Table C: Monitoring points of SSDAC

Module Monitoring item Measured values
range
DC-DC +5V DC and GND 4.75V to 5.25 V
Converter +18V DC and GND 17.75V to 18.25 V
+12V DC and GND 11.75V to 12.25 V
-12V DC and GND 11.75V to 12.25 V
+24V DC and GND 22V to 26V
CPU1 EN1B O/P and GND 11.5V to 12.5V DC
(For SF, CF, 3DP1S units)
EN1A O/P and GND (For EF, CF) 11.5V to 12.5V DC
CPU2 EN2B O/P and GND 11.5V to 12.5V DC
(For SF, CF, 3DP1S units)
EN2A O/P and GND (For EF, CF) 11.5V to 12.5V DC
RELAY DRIVE VITAL RELAY A O/P(+) >20V DC
1 (For EF,CF) VITAL RELAY A O/P(-)
RELAY DRIVE VITAL RELAY B O/P(+) >20V DC
(For SF,CF,3D VITAL RELAY B O/P(-)
units)
Table D – Settings of PD cards

Module Monitoring point Expected values
Without wheel With wheel
Phase RX-SIG and GND (Rx Adj.) 900 mV to 1.2 V AC < 350 mV AC
Detector SUP-OUT and GND 4V to 5V DC 3 V to 3.9 V DC
(PD1 and WHEEL-M-OUT and GND 4.5V to 5V DC 3 mV to 5 mV DC
PD2) WHEEL-S-OUT and GND 4.5V to 5V DC 3 mV to 5 mV DC
RX-PH-SIG and GND (PH 10V to 12V DC 0.1 or 0.2 V (Min.)
Adj.)
SUP-ADJ and GND (SUP 4V to 5V DC 3 V to 3.9 V DC
Adj.)
Wheel influencing both -- < 2 V in both PD
detectors cards
Note: (i) The above monitoring points should be checked monthly.

(ii) For measuring AC voltages of Tx/Rx coils and at Phase Detector terminals, it is
essential that a true RMS voltmeter with Digital Multi-meter of 100 kHz bandwidth
like Fluke model 187 or higher and their equivalents of other manufacturers is used
for getting proper readings.
(iii) Presence of train wheel condition is to be created with the help of dummy wheel.

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LCD Status Display
Relay Drive
PD
CPU Event Logger
Communication 24VDC Power

Card
Fig. 3.5.: SSDAC 36 unit with LCD display
5.8 Troubleshooting
 For ease of maintenance in the field messages are provided in the Display Module
both during healthy and Error conditions
 About 61 possible conditions have been identified which drives the system into Error
mode.
 The errors are displayed in plain English on the Display Module
 Many Error Messages are displayed that suggest faulty module to take immediate
corrective action by the service personnel. Detail report can be downloaded from
Event Logger card for analysis and the corrective action to be taken
Troubleshooting chart
Error Errors Analysis Corrective measure
Code on
display of
CPU
1 PD1_BOARD_MISSING Error occurred due to Place the PD1 module
missing of the Phase in the slot and reset the
detector 1 module (PD1- system
21KHz) during run time
and boot time diagnosis
2 PD2_BOARD_MISSING Error occurred due to Place the PD1 module
missing of the Phase in the slot and reset the
detector 2 module (PD2- system
25KHz) during run time
and boot time diagnosis.
3 SM_CPU_MISSING Error occurred due to Place the SM-CPU
missing of the SM-CPU module in the slot and
module during run time reset the system
4 MODEM_MODULE_A_MISSING Error occurred due to Place the

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Code on
display of
CPU
missing of the Communication A
Communication A module in the slot and
5 MODEM_MODULE_B_MISSING Error occurred due to Place the
missing of the Communication B
Communication B module in the slot and
and boot time diagnosis
6 RELAY_DRIVE_A_MISSING Error occurred due to Error occurred due to
missing of the Relay missing of the Relay
Drive A module Drive A module
during run time and boot during run time and
time boot time
diagnosis diagnosis
7 RELAY_DRIVE_B_MISSING Error occurred due to Place the Relay Drive
missing of the Relay B module in the slot
Drive B module and reset the system
during run time and boot
time
diagnosis
8 PEER_CPU_MISSING Error occurred due to Place the CPU module
missing of the any one of missing in the slot and
the CPU module during reset the system
run time and boot time
diagnosis
9 COMM_LU1_TO_US1_FAILURE When EF CPU1 could Check the
not communication links
transmit to remote unit (MS Coupler) and
(CF or Reset the system
SF) CPU1
(SF or Reset the system
CF) CPU2
11 COMM_LU1_TO_DS1_FAILURE When SF CPU1 could not Check the
transmit to remote unit communication links
(CF or (MS Coupler) and
EF) CPU1 Reset the system
13 COMM_US1_TO_LU1_FAILURE When EF CPU1 could Check the

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Code on
display of
CPU
receive any response (MS Coupler) and
from the Reset the system
remote unit (SF or CF)
CPU1
CPU1
15 COMM_DS1_TO_LU1_FAILURE When SF CPU1 could not Check the
receive any response communication links
from the (MS Coupler) and
remote unit (CF or EF) Reset the system
CPU1
16 COMM_DS2_TO_LU1_FAILURE When SF CPU2 could not Check the
receive any response communication links
from the (MS Coupler) and
remote unit (CF or EF) Reset the system
CPU1
CF) CPU1
CF) CPU2


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Code on
display of
CPU
CPU2
CPU2
23 COMM_DS1_TO_LU2_FAILURE When SF CPU1 could Check the
from Reset the system
the remote unit (CF or
EF)
CPU2
24 COMM_DS2_TO_LU2_FAILURE When SF CPU2 does Check the
from Reset the system
the remote unit (CF or
EF)
CPU2
25 MODEM_ERROR_NO_CARRIER Carrier signal is being Replace the faulty
blocked Module
by modem
26 PEER_CPU_LINK_FAILURE Error occurred due to Check for the error or
missing or error in CPU/ presence of SMCPU/
SM-CPU module during CPU module in the
run time and boot time system, rectify the error
diagnosis and reset the
system
27 FAILURE_AT_DS Error at Down stream Check the error at
unit remote unit, rectify
the error and reset the
system
28 FAILURE_AT_US Error at Up stream unit Check the error at
remote unit, rectify the
error and reset the
system
30 BOOTUP_PD_FAIL PD Wheel Detection Reset the System
during Power On
Condition.
Cause 1: Train moving in
the
Section on TX / RX coils,

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Code on
display of
CPU
power OFF & ON in
fraction of seconds.
33 PD1_SUP_LOW PD1 module supervisory Check the PD1 module,
is low for 3 seconds and coils and reset the
TX and RX coils is not system
connected properly
34 PD2_SUP_LOW PD2 module supervisory Check the PD2 module,
is low for 3 seconds and coils and reset the
TX and RX coils not system
connected properly
35 PD1_PULSING Error occurs when any Reset the system
one
sensor is influenced two
or
more times
36 PD2_PULSING Error occurs when any Reset the system
one
sensor is influenced two
or
more times
37 PD_STATE_MISSING Error occurs when double Reset the system
sensor is influence in the
sequence
38 PD_SUP_PULSATING If supervisory signals Reset the system
pulsates
more than 4 times
39 PD_STATE_FAIL Error occurs when any Reset the system
state
sequence is missing
40 PD_NOT_SENSING Error occurs when both Reset the system
the PD
modules doesn’t sense the
wheel for more than 3
times
41. PREPARATORY_RELAY_A_FAIL No/Improper feedback Check the connections
URE from of Preparatory relay A
Preparatory A relay (PRA) and reset the
system
42 PREPARATORY_RELAY_B_FAIL No/Improper feedback Check the connections

URE from of Preparatory relay B
Preparatory B relay (PRB) and reset the
system
43 VITAL_RELAY_A_FAILURE No/Improper feedback Check the connections
from of Vital relay A (VRA)
Vital Relay A relay and reset the System

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Code on
display of
CPU
44 VITAL_RELAY_B_FAILURE No/Improper feedback Check the connections
from of Vital relay B (VRB)
Vital Relay B relay and reset the system
45 DIRECT_OUT_COUNT Without IN COUNT, Reset the system
OUT
COUNT registered
49 TRANSIENT_POWER_FAILURE_ Power failure at Down Reset the system
DS1 stream
CPU1
50 TRANSIENT_POWER_FAILURE_ Power failure at Down Reset the system
DS2 stream
CPU2
51 TRANSIENT_POWER_FAILURE_ Power failure at Up Reset the system
US1 stream
CPU1
52 TRANSIENT_POWER_FAILURE_ Power failure at Up Reset the system
US2 stream
CPU2
57 INVALID_NETWORK_ADDRESS When CPU address range Change the address
wrong settings using LK10 to
LK17 links and reset
the system
58 INCORRECT_CODE_CRC This is a Boot Up error. Re-program the
When CRC of the code processor and code
mismatches memory checksum
with the stored CRC
59 INVALID_CONFIGURATION When unit type and Change the address and
address of CPU is wrong configuration settings
as per the requirement
and reset
the system
60 INVALID_COUNTS Train with 10,000 wheels Reset the system
61 RAM_TEST_FAILED This is an Boot up error Replace the Micro

when Controller
RAM (In- built memory
of
Microcontroller) is failed


 Go to Chapter index

Click for Contents
CAMTECH/S/PROJ/13-14/HB-DAC (T)
ANNEXURE I
ABBREVIATIONS
Section I :Az LS Eldyne SSDAC
AC Alternating Current
AzLM Thales Multi Section Digital Axle Counter
AzLS Thales Single Section Digital Axle Counter
DC Direct Current
DIP Dual in line Packeged
DP Detection Point
EAK Tack side Electronic Unit
ETU001 Test equipment (Tool Kit)
Hz Hertz
LED Light Emitting Diode
MESSAB1 Rx voltage for SK1
PCB Printed circuit Board
PEGUE1 Reference voltage for SK1
RMS Root Mean Square
Rx Reciever
Sk1, Sk2 Tx /Rx coil sets
SK30H Rail contacts
Tx Transmitter
Zp30CA-2. Detection points
Section II: Az LM Eldyne MSDAC

ACE Axle Counter Evaluator
AzLM Thales Multi Section Digital Axle Counter
AzLS Thales Single Section Digital Axle Counter
DC Direct Current
DIP Dual in line Packeged
DP Detection Point
EAK Tack side Electronic Unit
ETU001 Test equipment (Tool Kit)
Hz Hertz
ISDN Integrated Services Digital Network
PCB Printed circuit Board
RMS Root Mean Square
Rx Reciever
Sk1, Sk2 Tx /Rx coil sets
SK30H Rail contacts
Tx Transmitter
Zp30CA-2. Detection points
Troubleshooting of Digital Axle Counters

ANNEXURE I - Abbreviations Click for Contents September 2013
Section III: Az S 350 U Siemens MSDAC

AFTC Audio Frequency Track Circuit
AWS Automatic Warning System
AzGrH Auxiliary Axle Count Reset Button
AzGrT Axle Count Reset Button
Az S 350 U Siemens Multi Section Digital Axle Counter
BLEA Block Input/Output
CH Channel
DC Direct Current
DIN Standards setting organization for Germany
kHz Kilo-Hertz
mV Milli Volt
PC Personal Computer
RR Reset Restriction
SIRIUS Serial computer interface universal board
SOPP Internal Software Test
STEU Control& Diagnostic
TVDS Track Vacancy Detection Section
VAU Processing & Monitoring
vAzGrT Preparatory Axle Count Reset Button
VESBA Amplifier, trigger and band-pass filter
WDE Wheel Detection Equipment
ZP 43 Wheel detection equipment
Section IV: DACF 710 A & DACF 710 P CEL SSDAC

BPAC Block Proving by Axle Counter
CD Carrier Detection
CEL Central Electronic Ltd.
DACF 710 A Amplitude Modulation type Digital Axle Counter
DACF 710 P Phase Reversal type Digital Axle Counter
dB Decibel
DC Direct Current
DIP Dual In line Packaged
DNLD Download
LCD Liquid Crystal Display
LD Level Detector
LV Last Vehicle
MLB Micro Controller Logic Block
PR Preparatory Reset Relay
PPR Preparatory Proving Relay
RDSO Research Designs & Standards Organisation
Rx Reciever
SCC Signal Conditioning Card
SM Station Master
SSDAC Single Section Digital Axle Counter
TP Trolley Protection
Tx Transmitter
VR Vital Relay
Section V: G36 G.G. Tronics SSDAC
AH Ampere Hour
CF Centre Fed
CPU Central Processing Unit
CFVR Vital Relay for Centre Fed
DC Direct Current
2DP1S Two detection points Single section
3DP1S Three detection points Single section
3DP2S Three-detection points for two consecutive sections in a straight line
EF End Fed
EFVR Vital Relay for End Fed
FSK Frequency Shift Keying
FTB Fused Terminal Blocks
GND Ground
Hz Hertz
KHz Kilo Hertz
LCD Liquid Crystal Diode
LDU Lightning Detector Unit
MS Mild Steel
PD Phase Detector
PPR Repeater relay for Preparatory Relay
PR Preparatory Relay
QNA1 Style Q AC immunized relay
RDSO Research Design & Standards Organisation
Rx Receiver
SF Start Fed
SFVR Vital Relay for Start Fed
SM Station master
SSDAC Single Section Digital Axle Counter
Tx Transmitter
VPR Repeater relay for Vital Relay
VR Vital Relay


ANNEXURE II
REFERENCES
 RDSO Specification No.RDSO/SPN/177/2012 Version 3.0
 RDSO specification No.RDSO/ SPN /176 /2005 Version 2.0
 AzLS installation guideline – M/s Eldyne Electro-Systems Pvt. Ltd.
 AzLM installation guideline – M/s Eldyne Electro-Systems Pvt. Ltd.
 Installation Manuals - Single section Digital Axle Counter DACF -710 A &
DACF 710 P – M/s Central Electronics Ltd.
 SSDAC G-36 2DP1S Operation and Maintenance Manual (SSDAC-2DP1S-MM)

Version 1.0– M/s G.G.Tronics India Pvt.Ltd.
 Maintenance Instructions Az S 350 U Microcomputer Axle Counting System – M/s

Siemens Ltd.
 Installation and Maintenance Instructions DEK 43 Electronic Double Wheel

Detector for ZP 43 Wheel Detection Equipment – M/s Siemens Ltd.
 Operating & Service Manual ZP43 (S210) Wheel Detection Equipment


ANNEXURE II - References Click for Contents September 2013
About Troubleshooting Of Digital Axle Counters

Introduction
For quick remedy of faults in any equipment, troubleshooting procedures must be well
defined based on the symptoms during the failure. Digital Axle Counters are
microcontroller and software based systems, hence sometimes the faults cannot be seen
physically unlike in some signaling gears such as signals, track circuits, points etc. As we
all know that failures can be avoided upto a great extent by doing preventive
maintenance, but still the faults are sometimes unavoidable hence troubleshooting
methods should be effective.
There may be a large number of possible faults in each type of Digital Axle Counter
system. Troubleshooting can be done by following methods according to the nature of
failure:
(i) By physical observation

Some minor faults can be noticed through physical observation such as loosening of
fixing nuts and bolts, damage to Tx or Rx coil, wire breakage etc. These type of faults can
be easily rectified.
(ii) By measurement of parameters

Measurement of values of voltage, current, frequency etc. and comparing these with the
standard permissible range can help to rectify some failures.
(iii) By LED indications

LED indications are provided on the front plate of some PCBs to show the status of Axle
Counter. Nature and type of faults can be ascertained through pattern of lit LED
indications and pre-defined error codes and action can be taken accordingly to rectify the
failure.
(iii) Through diagnostic PC

In Digital Axle Counters, system diagnostics can be done with the help of a PC loaded
with diagnostic software. It shows the status of section, detection points, interfaces,
versions etc. on the PC screen. This is also useful when sometimes it is required to know
the history of events or values at the time of failure which occurred earlier. The historical
data may be used to reconstruct the sequential occurrence of events.
The subsequent sections of this handbook cover the information on Digital Axle Counters
of different RDSO approved manufacturers which shall be useful in diagnostics and
troubleshooting.
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Troubleshooting of Digital Axle Counters September 2013

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Digital Axle Counter PDF

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GOVERNMENT OF INDIA

CAMTECH/S/PROJ/2013-14/HB- DAC (T)

MAHARAJPUR, GWALIOR – 474 005

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CAMTECH Gwalior A.R.Tupe

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We are sincerely thankful to Shri S. Bandopahyay, Sr.D.S.T.E./ Bhopal/WCR, Shri

CAMTECH Gwalior D.K.M.Yadav

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Handbook on Troubleshooting of Digital Axle Counters

Section Description Pages

About Troubleshooting of Digital Axle Counters 1

I Troubleshooting – Eldyne AzLS Digital Axle Counter 1-9

II Troubleshooting – Eldyne AzLM Digital Axle Counter 1-24

III Troubleshooting- Siemens Az S 350 U Multi Section Digital 1-16

V Troubleshooting of SSDAC-G36 G.G.Tronics Single Section 1-5

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CAMTECH/S/PROJ/2013-14/HB-DAC(T)/2.0# XX date .......

CORRECTION SLIPS ISSUED

Sr. No. of Date of Page no. and Item No. Remarks

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Contact person: Director (Signal & Telecommunication)

Postal Address: Centre for Advanced Maintenance Technology, Maharajpur,

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CAMTECH/S/PROJ/2013-14/HB- DAC (T)

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1.2 LED indications on Analog card 1

1.3 Sequence of LED indications on Analog card with wheel 1

1.5 LED diagnostics after restart 4

1.6 Diagnostics through LED indications on Digital Card 5

1.7 Troubleshooting chart for analog card of AzLS 7

1.8 Troubleshooting chart for digital card of AzLS 9

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1.2 LED indications on Analog card

LED Colour Indication

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1.4 LED indications on Digital card

Fig.1.3: LED indications on Digital Card (As viewed from top)

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LED Colour Indication if permanently Indication if Flashing

1.5 LED diagnostics after restart

Section I: Troubleshooting Eldyne AzLS September 2013

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1.6 Diagnostics through LED indications on Digital Board

→ LED ON (Steady), ☼ ☼ → LED ON (Blinking), Ο Ο → LED OFF (Blank)

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Section I: Troubleshooting Eldyne AzLS September 2013

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1.7 Troubleshooting charts for Analog Card of AzLS

Fig.1.5 (i): Troubleshooting chart for Analog Card of AzLS

Section I: Troubleshooting Eldyne AzLS September 2013

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Fig.1.5 (ii): Troubleshooting chart for Analog Card of AzLS

Section I: Troubleshooting Eldyne AzLS September 2013

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1.8 Troubleshooting chart for Digital Card AzLS

Fig.1.6 : Troubleshooting chart for Digital Card of AzLS

Section I: Troubleshooting Eldyne AzLS September 2013

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Case 1 Case 2 Case 3

H2-1 H2-2 H2-2 H3-2 H4-2 H-1 H3-2

Section I: Troubleshooting Eldyne AzLS September 2013