1.

Troubleshooting Flowchart for Analog Card of AzLM (RED LED H1-1 OR H2-1 IS ON IN ABSENCE OF WHEEL)

Red LED H1-1 (for SK1) is

on in absence of wheel

Adjust MESSAB1 and

PEGUE1 using Tool kit

Red LED H1-1

goes OFF & Yes
Green LED H1-2
starts flashing

No (LED states remain same)

On the Motherboard, connect the SK1

conductors of SK2 and connect the SK2
conductors to connectors of SK1

Red LED H1-1

Replace SK1 or SK2 Yes goes OFF & Red
(TX1/RX1) and adjust
LED H2-1 comes
MESSAB and PEGUE
on

No (H1-1 remain ON)

Red LED H1-1 (for SK1) is

on in absence of wheel

Reset the section

 1. Troubleshooting Flowchart for Analog Card of AzLM (RED LED H1-1 AND H2-1 ARE ON IN ABSENCE OF WHEEL)

Red LEDs H1-1 (for

SK1) & H2-1 (for SK2)
are on in absence of
wheel

Adjust MESSAB and PEGUE using Toll kit

Red LEDs H1-1 & H1-2 goes Yes

OFF and `Green LEDs H1-2
&H2-2 starts flashing

No (LED states remain same)

Adjust MESSAB and PEGUE using Toll kit

Replace Analog card and adjust MESSAB,

PEGUE

Red LEDs H1-1 & H1-2 goes

Replace SK1 (TX1/RX1) and SK2 No (LED
OFF and `Green LEDs H1-2
(TX2/RX2), adjust MESSAB, PEGUE states
&H2-2 starts flashing
remain
same)
Yes

Reset the section

 2. Troubleshooting Flowchart for Digital Card of AzLM

Digital card in hang

mode

On Analog card, Red No One set LEDs on

Rectify problem following Trouble Yes
LEDs H1-1 or/and H2-1 Digital card is
Shooting Flow chart of Analog card
is are permanently ON completely OFF

Yes
No
Hang problem
persists? Power off the EAK and Reinsert Replace Digital Card
both card and power On

Reset the section Hang problem

Reset the section
persists?

Ensure that (i) DC voltage across connectors 3/13 in EAK is within 54-120v, (ii) Ripple voltage across
3/13 is below 30mVAC. (III) Replace the quad pair between 3/13 and the CTR. (iv) Ensure that the quad
cable screens are properly earthed.

Hang problem No
Reset the section
persists?

Reset the section

Replace Digital Card

Hang problem No
Replace Digital Card Reset the section
persists?
 2. Troubleshooting Flowchart for Serial I/O Card of AzLM (Upper LED of Serial I/O Card hangs)

Upper LED in serial I/O

card is OFF

Check cable continuity between Yes Yes

Serial I/O card ok Reset the section
serial I/O card and CTR if the cable
is not ok replace the same
No

Red LED on No
PDCU is ON

Yes
DC voltage
No Rectify power supply & ensure
across terminals
Replace PDCUs Fuse proper voltage across 1 & 2 of
1&2 of PDCU is
PDCU
within 54-120

Yes No Yes
Serial I/O
Reset the section
card OK
No Serial I/O
EAK is ON
card OK
Make EAK on through following steps: No Yes
(i) Check EAK address
Yes
(ii) Check and replace cable between
EAK & CTR Replace serial I/O card
(iii) Replace PDCU
(iv) Replace EAK Reset the section

Serial I/O No
Reset the section
card OK

Yes
3. Lower LED of Serial I/O Card is not blinking

Lower LED in Serial I/O

card is not blinking

No Check EAK address. Rectify the problem in

EAK is working EAK following trouble-shooting flowcharts
of Analog and Digital card

Yes

No
Replace serial I/O card

Serial I/O card ok

Yes
Reset the section

Reset the section

 4. Troubleshooting Flowchart for Parallel Card (section disturb/defect) in AzLM

Axle counter section

disturbed/defect Check Serial I/O card Check EAK Check PDCU

Check section status Rectify problem following Trouble Rectify problem following Trouble
Rectify problem following Trouble
with diagnostic Shooting Flow chart of Analog and Shooting Flow chart of Serial I/O card
Shooting Flow chart of Serial I/O card
computer Digital card

Reset the section

Section
Section defect
disturbed

Reset the section

No
LEDs (Yellow) on 24v DC available Replace Reset Box
1st & 2nd of No across RST(+) &
Parallel I/O card RST(-) in reset No
glowing box Replace the Cable
Reset the section
Yes Cable between
Yes Reset Box and
Unplug & Replug the parallel Parallel I/O card
I/O card of corresponding Reset the section
is ok
section Replace Parallel I/O card

Yes
No Section accept No
Apply Reset Replace the Cable
reset Reset the section On RR PCB in ACE
Cabinet, Red LED
Yes for
corresponding
Reset accepted Reset accepted
section Glows Reset the section
 TROUBLE SHOOTING
SL. NO. PROBLEM ACTION REMERKS
1 TOTAL MSDAC OFF CHECK ALL FUSE AND IF ANY LINK OPEN. IF ALL OK, CHECK IPS MODULE.
CHECK SAND FUSE USED FOR MSDAC OUTDOOR SUPPLY (54-120V), CHECK PDCU & PDCU GLASS FUSE(316mA),
2 EAK POWER OFF (54-120V) IF FUSE AND CABLE OK, CHECK EAK OR PDCU.
CHECK IF ANY LINK OPEN FROM EAK 3/13 TO PDCU 4/5.
CHECK SAND FUSE USED FOR MSDAC ACE SUPPLY (24V), CHECK 24V AVAILABLE IN ACE INPUT TERMINAL, CHECK IF ALL OK THEN CHECK POWER SUPPLY (PSU)
3 AXLE COUNTER EVELUATOR POWER OFF (24V)
GLASS FUSE (10A) IN POWER PCB FOR ACE SUPPLY. CARD IN ACE.
CHECK SAND FUSE USED FOR MSDAC AUX SUPPLY (24V), CHECK 24V AVAILABLE IN ACE INPUT TERMINAL,CHECK
4 AUXILIRY POWER OFF (24V) IF ALL OK, CHECK AUX PCB.
GLASS FUSE (3A) IN POWER PCB FOR ACE SUPPLY.
CHECK SAND FUSE USED FOR MSDAC FAN-LIGHT SUPPLY (24V), CHECK 24V AVAILABLE IN ACE (FAN-LIGHT)
5 FAN LIGHT POWER OFF (24V) IF ALL OK, THEN CHECK FAN, LIGHT IN ACE.
INPUT TERMINAL,CHECK GLASS FUSE (2A) IN POWER PCB FOR FAN LIGHT SUPPLY.
CHECK GLASS FUSE (3A) IN POWER PCB FOR RESET PANEL SUPPLY, CHECK IF ANY LINK OPEN FROM ACE POWER
6 RESET PANEL POWER OFF (24V) IF ALL OK CHECK CABLE.
PCB TO RESET PANEL 1,2/3,4 WAGO TERMINAL.
ANALOG CARD H1/1 & H2/1 RED, IF ONE OR CHECK IF RAIL CONTACT WIRE IF DISCONNECTED FROM EAK, CHECK IF ANY CARD LOOSE OF EAK, CHECK RAIL IF ALL OK CHECK ALL CARD OF EAK AND RAIL
7
BOTH LED ON CONTACT DISMANTAL FROM THE RAIL PROFILE. CONTACT.
CHECK IF RAIL CONTACT WIRE IF DISCONNECTED FROM EAK, CHECK IF ANY CARD LOOSE OF EAK, CHECK RAIL
ANALOG CARD H1/2 & H2/2 RED, IF ONE OR IF ALL OK CHECK ALL CARD OF EAK AND RAIL
8 CONTACT DISMANTAL FROM THE RAIL PROFILE, ELECTRICAL AND MECHANICAL ADJUSTMENT OUT OF
BOTH LED NOT FLASHING CONTACT.
PARAMETER.
DIGITAL CARD H1/1 & 2, H2/1 & 2 ABNORMAL CHECK IF LOOSE CONNECTION IN ANALOG OR DIGITAL CARD OR BOTH. CHECK IF THE ADRESS SETTING IS
9 IF ALL OK CHECK THE DIGITAL CARD.
BLINKING DIFFERENT IN BOTH SIDE OF MOTHER BOARD.
RAIL CONTACT TX VOLTAGE AND FREQUENCY MEASURE RESISTANCE VALUE (1-1.5)ohm FOR TX AND FOR RX (6-9)ohm, RAIL CONTACT COIL OPEN, PHYSICALY IF ALL OK CHECK DP ADJUSTMENT, EAK, AND RAIL
10
NOT PROPER IN EAK TERMINAL DIFECTIVE. CONRACT.
CHECK SERIAL CARD INDICATION PROPER, IN RESET BOX 2A FUSE OF RESET PULSE OUT, PARALLEL CARD INPUT- IF ALL OK CHANGE RESET BOX OR PERELLAL CARD
11 RESET NOT ACCEPTED BY SYSTEM
OUTPUT LOCK. NOTE: TIMING OF RESET PULSE SHOULD 3-6 SEC.
CHECK IF R1-R2 RELAY DIODE SHORT, CHECK RELAY INPUT FUSE OF POWER PCB, CHECK WIRING OF PARALLEL
12 VR NOT PICKUP IF ALL OK CHECK PARALLEL CARD.
CARD OF TERMINAL NO 9,10,11,12.
13 SERIAL LED NOT GLOW CHECK EAK POWER, PDCU WIRING 14/15 TO SERIAL CARD 9,10,11,12 SHILDED CABLE, PDCU FUSE. IF ALL OK CHECK PDCU, SERIAL CARD, EAK.
IF ALL OK CHECK PDCU, SERIAL CARD AND QUAD
14 SERIAL CARD COMMUNICATION LED NOT GLOW CHECK PDCU WIRING 14/15 TO SERIAL CARD 9,10,11,12 SHILDED CABLE.
CABLE EAK 3/13 TO PDCU 4/5 AND DIGITAL CARD.
IN PARALLEL CARD RESET AVAILABILITY IF ALL OK CHECK QUAD CABLE, EAK 3/13 TO PDCU
15 CHECK ALL DPs FOT THAT PARTICULAR SECTION.
INDICATION NOT COMING 4/5 AND DIGITAL CARD.
IF ALL OK CHECK INDOOR CABLE FROM ACE TO
16 RESET ACCEPTANCE NOT GLOW IN RESET BOX CHECK IN PARALLEL CARD TERMINAL 5/6 24V ACTIVE FOR 3 SEC AFTER APPLYING RESET.
RESET PANEL, RESET ACCEPTANCE PCB.
SECTION CLEAR BUT IN RESET BOX GREEN LED
17 CHECK LINK FROM VR TO RESET BOX. IF ALL OK CHECK GREEN LED IN RESET BOX.
NOT GLOWING
18 AUTO RESET PULSE NOT COMING CHECK SUP RELAY PICKUP AND SECTION RELAY DROP. IF ALL OK CHECK AUTORESET BOX AND WIRING.
19 PSU CARD INDICATION NOT PROPER CHECK PSU CARD AFTER DISCUNNECT POWER FROM IPS TO ACE. IF ALL OK CHANGE PSU CARD.
20 CPU CARD INDICATION NOT PROPER CHECK CPU CARD AND PROGRAM PLUG AFTER DISCONNECT POWER FROM IPS TO ACE. IF ALL OK CHANGE CPU CARD.