Handbook On GGTronics HASSDAC

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Handbook on
GGTronics High Availability Single Section
Digital Axle Counter (HA-SSDAC G36R)
CAMTECH/S/PROJ/2020-21/SP4/1.0
August 2020
INDIAN RAILWAYS
Centre for Advanced Maintenance Technology
Maharajpur, Gwalior (M.P.) Pin Code – 474 005
i
Handbook on
GGTronics High Availibility Single Section Digital Axle
Counter (HA-SSDAC G36R)
CAMTECH/S/PROJ/2020-21/SP4/1.0
August 2020
ii
Foreword
Axle counter plays a vital role in detection of rolling stock on a specified
portion of track and it is an important component of signalling system. However
failure of an axle counter may paralyze the movement of traffic thereby
affecting the punctuality of trains. The High Availability Single Section Digital
Axle Counter (HASSDAC) is developed with the aim to enhance the
availability of Digital Axle Counters. It consists of dual processing units and
auto resetting feature hence redundancy is provided at every level.
CAMTECH is continuously making efforts in documentation and upgradation

of information on advanced maintenance practices. CAMTECH has prepared
this handbook to make the signal personnel familiar with the HASSDAC system
of RDSO approved firm M/s GGTronics.
I hope that the information given in this handbook will help signal personnel
in maintaining the above system.
CAMTECH Gwalior Jitendra Singh

Principal Executive Director
iii
Preface
Digital Axle Counters are very effective in proving the presence of train in a
signalling system so long their performance is flawless. In some Railways, to
avoid failures dual detection is provided with the help of conventional track
circuits or AFTC along with Digital Axle Counters. For simplicity, ease of
maintenance and availability of dual detection in one single system, High
Availability Single Section Digital Axle Counter (HASSDAC) has been
developed by RDSO.
This handbook has been prepared to help the field personnel in maintaining
GGtronics G36R HASSDAC installed in their section for trouble-free
performance. All the useful information such as recording of signal levels,
maintenance schedule, troubleshooting, error codes etc. have been covered in
this handbook. A pre-commissioning checklist is also included in the handbook.
We are sincerely thankful to Signal Directorate, RDSO and M/s GGTronics

India Pvt. Ltd., Bangalore and all those Signal Engineers and technicians of
Indian Railways who helped us in preparation of this handbook.
Since technological upgradation and learning is a continuous process, you

may feel the need for some addition/modification in this handbook. If so, please
give your comments on email address 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 Dinesh Kumar Kalame

Joint Director (S&T)
iv
Table of Contents
Foreword ...................................................................................................................................ii
Preface ..................................................................................................................................... iii
Table of Contents .................................................................................................................... iv
Issue of correction slips .......................................................................................................... vi
Disclaimer ...............................................................................................................................vii
Our Objective ....................................................................................................................... viii
CAMTECH Publications ....................................................................................................... ix
GGTronics
High Availability Single Section Digital Axle Counter
HA-SSDAC-G36R .................................................................................................................... 1
1.1 Overview .................................................................................................................................. 1
1.2 Modules of HA-SSDAC-G36R system ...................................................................................... 2
1.3 Salient Features ...................................................................................................................... 9
1.4 Principle of Wheel Detection................................................................................................ 10
1.5 Installation Guidelines .......................................................................................................... 12
1.5 Technical Advisory Note (TAN) No. STS.E.TAN –7008 for installation of HASSDAC ............ 17
1.6 Earthing ................................................................................................................................. 21
1.7 Reset criteria ......................................................................................................................... 21
1.8 Reset Procedure .................................................................................................................... 22
1.9 Configuration Setting in CPU modules (Links 18 to 25) ....................................................... 23
1.10 Address Setting in CPU modules (Links 10 to 17 ) ............................................................... 24
1.11 Event logging through SM-CPU or Event Logger Card ......................................................... 26
1.12 Trouble shooting ................................................................................................................... 29
1.13 Precautions to be taken for trouble free operation ............................................................ 35
1.14 Maintenance ........................................................................................................................ 39
1.15 Advanced Applications of High Availability Single Section Digital Axle Counter( HA
SSDAC-G36R) ........................................................................................................................ 47
1.16 Commissioning of HA SSDAC system ................................................................................... 50
1.17 Do’s and Don'ts ..................................................................................................................... 53
1.18 Backup Spares (Recommended 1 set for 5 systems) ........................................................... 54
1.19 Recommended Tools ............................................................................................................ 54
v
Annexure: ........................................................................................................................................... 1
Pre-commissioning check list for High Availability Single Section Digital Axle Counter................. 1
vi
Issue of correction slips
The correction slips to be issued in future for this report will be numbered as follows:
CAMTECH/S/PROJ/2020-21/SP4/1.0# 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 issue Page no. and Item Remarks

Correction No. modified
Slip
vii
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
Signal Engineering Manual, Telecom Engineering Manual Railway
Board/RDSO guidelines may be referred or prevalent Zonal
Railways instructions may be followed.
viii
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 :Jt. Director (Signal & Telecommunication)
Postal Address : Centre for Advanced Maintenance Technology,
Phone : 0751 - 2470185
Fax : 0751 – 2470841
Email : dirsntcamtech@gmail.com
ix
CAMTECH Publications
CAMTECH is continuing its efforts in the documentation and up-gradation of information on
maintenance practices of Signalling & Telecom assets. Over the years a large number of
publications on Signalling & Telecom subjects have been prepared in the form of handbooks,
pocket books, pamphlets and video films. These publications have been uploaded on the
internet as well as railnet.
For downloading these publications
On Internet:
Visit www.rdso.indianrailways.gov.in
Go to Directorates → CAMTECH Gwalior → Other Important links → Publications for
download - S&T Engineering
or click on link
https://rdso.indianrailways.gov.in/view_section.jsp?lang=0&id=0,2,17,6313,6321,6326
On Railnet:
Visit RDSO website at 10.100.2.19
Go to Directorates → CAMTECH → Publications → S&T Engineering
Or click on the link
http://10.100.2.19/camtech/Publications/CAMTECH%20Publications%20Online/SntPub.htm
A limited number of publications in hard copy are also available in CAMTECH library which
can be got issued by deputing staff with official letter from controllong officer. The letter
should be addressed to Director (S&T), CAMTECH, Gwalior.
For any further information regarding publications please contact:
Director (S&T) – 0751-2470185 (O)(BSNL)
SSE/Signal - 7024141046 (CUG)
Or
Email at dirsntcamtech@gmail.com
Or
FAX to 0751-2470841 (BSNL)
Or
Write at
Director (S&T)
Indian Railways Centre for Advanced Maintenance Technology,
In front of Hotel Adityaz, Airport Road, Maharajpur,
Gwalior (M.P.) 474005
CAMTECH/S/PROJ/20-21/SP4 1
GGTronics
High Availability Single Section Digital Axle Counter
HA-SSDAC-G36R
1.1 Overview
 To ensure safety and improve efficiency in train operation, any signalling system
requires continuous availability. The High Availability Single Section Digital
Axle Counter (HA-SSDAC) has been designed to increase the availability of the
existing Single Section Digital Axle Counter (SSDAC).
 HASSDAC conforms to RDSO specification no.RDSO/SPN/177/2013 Ver. 3.0
 In GGTronics HA- SSDAC- G36R system, one SSDAC system is mounted on
one rail which communicates via quad cable, and another SSDDAC system is
mounted on another rail which communicates via separate pair of Quad cable /
OFC voice channel or Direct fiber (Direct fiber interface can be provided by
G.G.Tronics).
 Wheel Detectors are mounted apart one axle gap on either side of rail to avoid
axle rocking.
 Separate power supply arrangement is provided to avoid common mode failure.
 Vital Relays of both SSDAC systems are in parallel to avoid block failure. The
safety is taken care by at least one SSDAC system.
 Manual Reset is required only when both SSDAC systems fail, which is a remote
occurrence
 Cable redundancy for both Signal and Power is provided to reduce failures during
cable faults.
 HA SSDAC-G36R is a fail-safe microcontroller based system with 2 x 2 out of 2
architecture suited for proving Block Section and Entry/Exit of station.
 HA SSDAC-G36R can be used for several applications like 2DP1S Block
section, IBS and Auto signalling with high availability .
 Here high availability is achieved through the dual axle counter system. If any
one of the systems fails, another one takes care, thus availability is achieved
through redundancy.
GGTronics HASSDAC G36R August 2020

1.2 Modules of HA-SSDAC-G36R system

The HA-SSDAC-G36R system consists of following hardware modules namely:
1.2.1 Axle Detectors (Phase Reversal type)

 An Axle Detector consists of 2 Transmitter (Tx) and 2 Receiver (Rx) coils.
 One pair of Tx & Rx coil works on 21 KHz frequency and other on 25 KHz.
 The HA-SSDAC-G36R system consists of:
 Transmitter (TX) coils – 4 Nos. (2 Normal & 2 Redundant) fed with 21 kHz
and 25 kHz carrier signals.
 Receiver (RX) coils – 4 Nos. (2 Normal & 2 Redundant) to receive the
transmitter signal.
 The Rx signal is phase modulated with each train wheel passing over the
detection point.
 The Tx & Rx coils are factory tuned at 21Khz & 25Khz and are supplied with
15 meter cables which are to be run in individual HDPE pipes up to the location
box.
 They have to be web mounted on the rail with Tx on the outer side and Rx on
the inner side where the wheel flange passes over the coils.
 The pilot holes in the jig are to be used to ensure proper height of the coils on
52Kg, 60Kg & 90-R rails by fixing the jig on the bottom of the rail.
 Coils are to be fixed with antitheft bolts & nuts provided by the manufacturer.
Figure 1: Web mounted Axle detectors (Tx Rx Coils)
1.2.2 HA-SSDAC G36R unit

It is provided in the outdoor location box and consists of following PCB modules:
 Phase detector Card 1 - 21 KHz – 2Nos.
 Phase detector Card 2 - 25 KHz – 2Nos.
 Central Processing Unit 1(CPU1) – 2Nos.
 Central Processing Unit 2(CPU2) – 2Nos.
 Communication module . – 2Nos.
 Relay Drive Module – 2Nos.
 SM-CPU /Event logger module – 2Nos.
 DC/DC Converter – 2Nos.

Figure 2:HA-SSDAC G36R unit with Dual Electronics system

Note:
(i) CPU1 & CPU2 have unique addresses.
(ii) Communication and relay drive modules are equipped in different positions in
SF/EF units for unique port addressing.
The details of PCB modules are as given below.
(a) Phase Detector Card [PD card]

(i) Each card generates the carrier signals, which is transmitted, to its transmitter
coil mounted on each detection point.
 PD card (21 KHz) to TX Coil A.
 PD card (25 KHz) to TX Coil B.
(ii) Demodulation and Pulse generation
Each card demodulates its receiver signal from Rx coil A & B to generate
pulses corresponding to wheels passing over the detection point. These
pulses are then validated and fed to Central Processing Unit Cards.
 Rx Coil A to PD1 (21 KHz).
 Rx Coil B to PD2 (25 KHz).
The PD Cards (PD) generate high frequency (21 KHz, & 25 KHz) carrier signals,
which are transmitted to the two independent TX coils of axle detectors. The two
independent Rx coils receive these signals, which are at a phase difference upto 180°
with respect to reference signal of TX coils.
The SSDAC system with phase reversal type track devices does not require short
length DC track circuits (3 Rail Length.) and its TPR relay connections for trolley
suppression.
PD1
Phase Detector 1 card is 21KHz wheel detector card responsible to get connected to
21 KHz wheel sensor in the field. This card generates Transmitter voltage to Tx coil
and senses back receiver signal. It compares the Transmitter and Received signal
phase and amplitude to generate wheel pulses and supervisory voltages. Whenever
wheel passes the wheel sensor the Phase change in terms of wheel pulses of Wheel 1
is generated by this card to process further by CPU cards for wheel counting. This
card also generates Supervisory signal to CPU card for checking health of the wheel
sensor and PD1 card working.
PD2
Phase Detector 2 card is 25 KHz wheel detector card responsible to get connected to
25 KHz wheel sensor in the field. This card generates Transmitter voltage to Tx coil
and senses back receiver signal. It compares the Transmitter and Received signal
phase and amplitude to generate wheel pulses and supervisory voltages. Whenever
wheel passes the wheel sensor the Phase change in terms of wheel pulses of Wheel 2
is generated by this card to process further by CPU cards for wheel counting. This

card also generates Supervisory signal to CPU card for checking health of the wheel
sensor and PD2 card working.
(b). Central Processing Unit [CPU card]

The Central Processing Unit are the heart of the unit. Two identical cards have been
implemented to give 2-out-of-2 decision. These cards perform the functions related
to counting of pulses, count validation, communication through Modem with 2nd
Unit of SSDAC and decision making to give output. The input pulses are given to
both the Central Processing Unit Blocks. Both the Central Processing Units
continuously monitor each other’s health and wheel counts. If the results are not
matching then the system goes into Error state.
The results of count check and health between 2 Central Processing cards are always
matched to arrive at a clear decision by the system.
Vital relay read back feature is included in the Central Processing Unit to read back
the vital relay in occupied as well as in the clear state and checks as per the decision
given from the card.
CPU1 and CPU2

CPU 1 & 2 cards are the Central Processing Cards which are responsible for address
setting, configuration setting, Reset philosophy setting and wheel counting. These
cards also take care of Diagnostics features of the total safety of the system. These
cards generate CPU EN 1 & 2 signals to Vital Relay Drive RD1 and RD2 cards for
driving the VR relays indicating section status. These cards also signal RD card to
pickup and drop PR relay for Preparatory mode indication. The complete safety
feature of the SSDAC system in 2oo2 architecture is handled by these CPU cards.
(c). Relay Driver module

The card module checks and generates the vital relay drive output to finally
clear/occupied status of the corresponding track section. The output is used to drive
fail-safe vital relay.
The Relay Driver card (RD) is the output card for driving Vital Relay for Single
Section Digital Axle Counter (SSDAC). The card is of extended Euro size card
terminated with 64 pin standard Euro Connector. The card directly plugs into the
motherboard of SSDAC. One RD module is used in each SSDAC counting unit. The
Relay Driver card receives the enable of clear and clock signals from Central
Processing Units and drives the vital relay to energized condition (Pick up) when
section is clear. If a train occupies the section, the vital relay is dropped. The
command signals and vital relay Pick up is indicated on the card.
RD1 and RD2

RD1/ RD2 cards are Responsible for driving PR and VR relays by taking
instructions from CPU cards. The VR relays are driven by vital safety 2oo2 and fail
safe AND gate circuit to achieve highest degree of safety. This card also gives
feedback to CPU cards about VR and PR relay working status.

(d). Communcation Module

FSK Modem is V.23, used for communication between two units of SSDAC. The
digital packets generated by processor cards are sent to remote unit on a pair of
cable. Serial I/O Multiplexer is used to select the micro controller card that will
communicate with the modem on the remote unit.
The Salient features of the card include: -
(i). FSK Half Duplex modem chip
(ii). V.23 mode of operation ( 2 wire )
(iii). 1200 Baud rate
(iv). Multiplexes the two serial ports
(v). Originator (Entry unit) and Answerer (Exit unit) for V23 selected.
(vi). Automatic gain controls provided in receive path.
COM1 and COM2

COM1/COM2 cards are responsible for communicating through FSK protocol
communication between Entry and Exit ( SF & EF ) systems on quad cable or voice
channel of OFC system. The communication software running in CPU cards ensures
the integrity of the data packets for proper safety working of the SSDAC system.
(e). Event Logger module

Event Logger card is designed to capture and store important data (events) from
local SSDAC unit. 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.
SM-CPU/Event Logger Module

SM-CPU/Event Logger Module’s responsibility is to record and store all Events and
allow downloading through the computer. This card also has Station Master Reset
Box interface via FSK communication to give all the data required to be displayed
like Configuration, wheel counts, System status at the Reset Box display kept in
station room.
(f). DC-DC Converter card

The Card receives 24V battery input and generates 5V, +12V and -12V, 18V and
24V output with common ground for all circuit requirements.
The main features of the board are: -
i. Low Ripple
ii. Wide input line regulation
iii. Very good load regulation
iv. Input/output protected for short circuit.
v. Immune to EMI/RFI Interference.

1.2.3 Reset Box with Display

Reset Box which is kept in Station Room is used for Resetting HA-SSDAC System
while it is required to normalize and display all Error and Working status to the user.
Intelligent and interactive Reset Boxes are supplied for each of the SF/EF units &
are located in the stations connected with the block section to be proved. There will
be one reset box in each station for single line, and two boxes corresponding to up
line & down line for double line working.
The following controls & displays are provided for operation & maintenance (Refer
Fig.):
 The SM Key & the Reset Push Button are provided for resetting of the system.
 One green & one red LED of 10mm size are provided for indicating status of
block section.
 5mm green LED for indicating the status of preparatory reset is provided. It will
flash when local reset is applied. Become steady when reset is applied at the
other end also & the system is waiting for pilot train.
 This LED is put OFF when the section becomes clear.
 One 5 mm yellow LED is provided for indicating the line verification status. It
will be normally OFF & glows when line verification key is operated for
executing direct reset.
 One 5mm yellow LED is provided for indicating power ON condition.
 One 6 digit non resettable counter is provided which increments after each reset.
 One LCD display with 4 lines & 20 characters gives live display of events,
wheel counts & error messages.
 The Reset Box is connected to the system with, one pair of quad cable for FSK
Communication.
Figure 3:Dual Display Interactive Reset Box at Station with Automatic Reset Facility

Figure 4:Reset Box rear view
Reset Box features
 Rear Side of reset box having DIP switch settings for address.
 Two DIP switches are available for two different display.
 If the address matches only the display of reset box will shown the Status of the
system.
 In reset box HA SSDAC having individual system status LED’s and Common
section LED’s.
 In Rear Side HA SSDAC reset box Event downloader connector is available.
 Through the DB9 connector we can download the events of the systems.
 Last 3 error history will be scrolling in LCD display.
 Communication error packet list will be available in LCD display.
1.2.4 Voltage Window Card

Voltage Window card is responsible for accepting Reset Voltage applied to the
system to be Within working acceptable range of 48 volts +/- 5 volts.
1.2.5 Fused tag block assembly

Fused tag block (FTB) assembly with 6.3A fuses for power supply & 2A fuses for
signals for terminating both internal & external cables is provided. This tag block
houses 4 nos of lightening discharge units connected across external connections as
indicated below.
 In the path of 24V DC input supply. (24V rating)
 Quad cable connection between units. (24V rating)
 Quad cable connection between reset box & units. (24V rating)
 Input reset voltage supply. (48V rating)

1.2.6 Relay Box

The relay box houses the vital relay (VR) & the preparatory relay (PR) of Q-type
1000 ohm coils. Their outputs are connected to VPR & PPR relays in the relay room
through the FTB, for extending signals under different conditions of the system.
Feedback from the contacts of these relays is also taken to the system for processing.
1.2.7 Display Module

A display module placed above the SF/EF units provides plain English messages on
the status of the system and also wheel counts through a 4 line 20 characters
alphanumeric display.
Figure 5:Display Module
1.2.8 Other accessories

 Surge Voltage protection devices
 Filter unit
1.3 Salient Features

 RDSO/SPN/177/2012 Ver. 3.0
 Meets CENELEC SIL-4 Safety Level Standards, as per this standards mature
and rugged with inherent fail-safety, highest reliability, availability and
maintainability.
 Employs Phase reversal technique.
 Works between train speeds of 0Kmph to 250 Kmph. Can work on 90-R, 52Kg
& 60Kg rails, with proper drilling on the rails.
 Works with 24V DC power supply with variation of +20% & -30%

 Wrong operations totally avoided with hardware polarization & unique

addressing of units up to 255 combinations
 Protected with Fuses & lightening surge protectors
 Event logger stores more than 14000 events for future analysis
 Water logging on track does not affect the functioning of the system
 Can work from -10°c to +70°c.
 Can be employed in both RE & Non-RE areas without any modification.
1.4 Principle of Wheel Detection
 Phase detection employed

 Signals fed at 21Khz and 25Khz to Tx coils – at 40V to 70V
 Phase of signal output of Rx compared with Tx
 AT PD Module/Card :
 Under No wheel condition Tx and Rx will be IN-PHASE
 Under wheel condition Tx and Rx signals will be 180° OUT-OF-PHASE
 Under these conditions pulses are fed to CPU at 5V and 0V
 Wheels above 500mm diameter only are detected
Figure 6:Solid wheel and spoke wheel of push trolley

Figure 7:Wheel Detection - Train Wheel - Count
Figure 8:Wheel Detection - Trolley Wheel - No Count
Figure 9:Wheel Detection - Dip Lorry - No Count

1.5 Installation Guidelines

 An installation manual, data logger manual and pre-commissioning Check list
are supplied along with each unit for guidance.
 The HA SSDAC units are placed in full GRS location boxes along with Relay
box & display unit.
 A fused Tag block along with surge arrestors mounted on DIN rail is also fixed
in the location box.
 A detailed standard schematic of interconnection between the external cables &
internal cables is provided.
 The Quad cable between two units and between reset box and unit are to be
terminated.
 A signal cable is to be connected between the reset box & the unit.
 A power cable of 25 Sq mm (aluminium) to be terminated.
 In HA SSDAC dual system two set of coils are available. Both coils to be fixed
on opposite rails.
 Distance between two coils should be 2 meters in diagonally.
 Tx & Rx coils to be fixed on the rails by drilling 14 mm dia holes with the help
of the jig provided for fixing the distance of the holes from bottom on different
rails.
 These coils are fixed to the rails through tamper proof bolts.
 Tx & Rx coils are supplied with 15m cables. Each pair has to be taken up to the
system independently through HDPE pipes.
 Earthing should be provided with ≤1ohms resistance.
 The cables to be meggered and continuity checked before powering the system.
 The system is fully tested and adjusted for correct operation in the factory
before dispatch.
 Only potentials at PD card are to be adjusted after installation.
 RDSO have issued a pre commissioning check list which has to be complied in
all respects before commissioning the system. (Refer Annexure I).
Figure 10:Installation of Axle Detectors

Figure 11:Termination in location box with LDU and fuse
Cabling requirement
Type of cable Description

Quad Cable Between location to station / relay room (1 Pair* - System
communication via OFC and 1 Pair - communication (system to RESET
BOX)
Quad Cable Between location to location (1 pair - System communication FSK)
OFC Channel Between 2 stations for systems communication via OFC
Signal Cable From relay room to Location-
8 Core for repeating Relays (VPR1, PPR1,VPR2 and PPR2)
2 Core for Reset Voltage from reset box to Axle counter Location
From Relay Room to Reset Box:
14 Core signal cable for relay status and reset voltage to system.
Power Cable 2 Core 25 Sq mm Al. From Station to Location-
For System input voltage (24VDC)
If Signal cable used to power up the system 6C for B24 and 6C for N24.

Figure 12:HASSDAC G36R Cable Plan (Proposed)

STATION
STATION RES ET PANEL
RES ET PANEL CONTROL
CONTROL
24V DC
24V DC
Q UAD C ABLE
BATTERY
BATTERY
Q UAD C ABLE
S YS TEM 1 S F S YS TEM 2 S F S YS TEM 1 EF BATTERY

S YS TEM 2 EF CHARGER
BATTERY
CHARGER C C C C
S D S D S D S D
O O O O
M C M C M C M C
M M M M
C - C - C - C -
M M M M
P D P D P D P D
. . . .
U C U C U C U C
B B A A
PD1 PD2 PD1 PD2 PD1 PD2 PD1 PD2
C C C C C C C C
R R R R
P P P P P P P P
D D D D
U U U U U U U U
B B A A
1 2 1 2 1 2 1 2
PR VR
PR VR PR VR PR VR
TX2-25Khz TX2-25Khz TX2-25Khz

TX1-21Khz TX1-21Khz TX1-21Khz
TX1-21Khz TX2-25Khz
RX1-21Khz RX2-25Khz RX1-21Khz RX2-25Khz RX1-21Khz RX2-25Khz RX1-21Khz RX2-25Khz
 SSDAC-G36R 2DP1S system is used for the application of block section with redundant axle counters.
 The availability of a block section is increased by providing two axle counter systems in parallel per block area.
Figure 13:Scheme of Single Line Block Section with redundant SSDAC-G36R 2DP1S (Method-1)

Without Wheel Without Wheel

1/2 Quad Cable Detecting Electronics
Detecting Electronics
DUMMY
DUMMY
C
DUMMY
R R
O
D D D D
M
DUMMY
2 C
DUMMY
DUMMY
DUMMY
2 1 C
- - VR PR
DUMMY
C C S VR PR C C C S
M D D
P P P P O M
U U
C C C C
P U U M P
1 2 U 1 2 1 U
Relay Box Relay Box
DUMMY
DUMMY
DUMMY
C
R R
O
D D D D
M
P P 1 C P P 2 C
PR
2 VR PR
D D - VR D D -
DUMMY
C C C S C C S
1 2 P P O M D 1 2 P P M D
C C C C
U U M P U U P
1 2 1 U 1 2 U
With Wheel
Detecting Electronics OFC Cable / Quad Cable With Wheel
Detecting Electronics
Reduntant SSDAC system with single wheel detectors

LSS HOME
Reduntant Electronics in parallel for high availability
Figure 14:Scheme of Single Line Block Section with redundant SSDAC-G36 – 2 Nos. 2DP1S (Method-2)

1.5 Technical Advisory Note (TAN) No. STS.E.TAN –7008 for installation
of HASSDAC
(Ref.: RDSO letter no. STS/E/TAN/DSig - 6 Vol. 1 dated 16.12.2019)
1.5.1 Power supply

(i) Two pair of separate power conductors (2x25 sq. mm Al. power cable /equivalent
signalling cable) shall be provided from IPS room to location box in which
HASSDAC is installed.
(ii) Each pair of power conductor shall be connected to individual DC-DC converters
in the IPS and power supply cards of HASSDAC.
(iii) Rating of DC-DC converters shall be 5 Amp/24volt -32 volt.
1.5.2 Condition Monitoring

In HAAADAC, two SSDAC systems work in parallel. Health of individual system to
be monitored through data logger and exception reports/ alarms to be generated for
predictive maintenance.
In HASSDAC of M/s GGTronics make, repeater relays of the vital relays of each
individual system are available in relay room also. Pick up contacts may be used in
data logger to monitor the status of individual system and to generate exception report
/alarm.
1.5.3 Communication
(i) Both the systems of HASSDAC systems shall be provided with media diversity
for reliability i.e. one system on dark optical fibre or dedicated E1 channel (point
to point) and the other system on 6 quad cable.
(ii) Two set of independent cables shall be provided between locations to station for
individual systems.
(iii) Unused quad cable shall be terminated and tightened properly at CTR, locations
and in between junction box.
(iv) Quad cable screen and armour continuity shall be maintained from Entry
HASSDAC location to Exit HASSDAC location.
(v) This should also be ensured for local cables between HASSDAC location to
SM/RR Room.
(vi) Track devices for both the SSDAC systems shall be provided on separate rails
with specified staggering of minimum 1.5 meters.
1.5.4 Surge Protection

Surge Protection Devices (SPDs)
For surge protection devices arrangement a generic scheme is shown below:
(i) The SPDs as indicated above shall be indicative type and provided by OEM of
HASSDAC as stipulated in their user /installation manual.
(ii) OEM shall select appropriate rating of SPD for use in quad cable considering
effect of induced voltage.
(iii) Health of SPDs needs to be checked periodically, especially before monsoon
and after every heavy rain/lighting/storm, through their health indication/suitable
SP tester. In case of failure or deterioration in performance, same should be
replaced.

1.5.5 Compliance of Pre-commissioning checklist (PCCL)

(i) PCCL no. SIG 0616 ver. 0 or latest for M/s GG Tronics system needs to be
adhered strictly before commissioning.
(ii) Association of OEM during pre- commissioning check to be ensured.
1.5.6. Wiring, Earthing & Bonding

(i) Earthing and bonding arrangement to be ensured as per RDSO/SPN/ 197 Ver. 1.0
or latest.
(ii) Wiring discipline to be followed as per Technical Advisory Note (TAN) 6001.
1.5.7 Generic scheme for Power Supply arrangement.

(i) For double line application as per Figure 15.
(ii) For single line application as per Figure 16

(1) Each Modules of IPS

shall be of 24 V -32V
DC/5Amps.
(2) Presently in this scheme,
load sharing of IPS
modules is not indicated.
(3) If load sharing of IPS
modules is to be done, it
should be in 1+1 parallel
configuration and a total
module requirement will
be 8 (eight) in numbers.
(4) Individual power supply
shall be provided with
separate fuse.
(5) Separate conductor/cable
per separate Sys-1/Sys-2
of HASSDAC from
modules should be
provided.
(6) In case of total power
supply failure, system
should be switched
“ON”/”OFF” one by one
to avoid over loading of
modules due to
Figure 15: RDSO Drg. No. RDSO/S2 – Generic scheme for power supply arrangement of HASSDAC from IPS “INRUSH” current.
to location for DOUBLE LINE application

(1) Each Modules of IPS

shall be of 24 V -32V
DC/5Amps.
(2) If redundancy in IPS
modules is to be given,
it should be in 1+1
parallel configuration
and a total IPS module
requirement will be 4
(Four) in numbers.
(3) Individual power
supply shall be
provided with separate
fuse.
(4) Separate
conductor/cable per
separate Sys-1/Sys-2 of
HASSDAC from
modules should be
provided.
(5) In case of total power
supply failure, system
should be switched
“ON”/”OFF” one by
one to avoid over
Figure 16: RDSO Drg. No. RDSO/S2 – Generic scheme for power supply arrangement of HASSDAC from IPS
loading of modules due
to location for SINGLE LINE application
to “INRUSH” current.

1.6 Earthing
Following is the checklist of earthing of HASSDAC at Location box and station:
Sr. No. Item Maintenance Free Conventional Earth

Earth (< 2 Ω ) (<2Ω)
1 SPDs Yes No
2 Quad Cable Yes No
3 Signal Cable Yes No
4 Power Cable Yes No
5 Location Box Yes No
6 Chassis No Yes
7 Relay Box No Yes
8 Filter Box No Yes
9 Reset Box No Yes
Note: - Chassis, Relay box, Filter box and Reset box should be connected to
Conventional Earth separately or made Floating Earth (Open).
1.7 Reset criteria

 For Single line working one reset box is provided at the station associated with
SF or EF unit of that track
 In double line section each station will have two reset boxes corresponding to
the two units of the SF/EF for UP/Down lines.
 The reset potential has to be within the range of 36 to 52V.
 The system accepts reset under the following conditions:
 Initial power ON.
 When power fails & restores back when I/P voltage to the system fluctuates
beyond limits.
 The reset is applied to both the field units.
 When there is an in count at the entry & at least one out count at the exit
indicating the train has touched the end of block section.
 The system will not accept reset under the following conditions:
 When the section is clear.
 When the system is waiting for pilot train.
 When there is an in count but no out count is registered. (Occupied state)
 When reset is given only from one station (not co-operative)
 When the system is in permanent error status.
 When reset is applied at one end & the other end does not reset within 5
minutes.
 Removal of any of the PCB modules or fuses.
 Disconnection / damage of axle detector of coils

1.8 Reset Procedure

Two type of reset arrangements are available in HA SSDAC System:
 Auto Reset
 Manual Reset
 Manual Reset is required only when both SSDAC system fails which is a
remote occurrence
 Auto reset will be done if any one of the system fails.
 Individual reset counters are available for Manual reset and Auto reset.
1.8.1 Auto Reset
 Auto reset will be done when any one the system fails and another one is
showing Clear.
 For Auto resetting and indication purpose relay contacts of VPR1,VPR2,PPR1
and PPR2 are given to reset box.
 The reset box having intelligence for reading all relay inputs and take a decision
to reset the sections.
 Through the relay contacts reset box will monitoring the section status . If any
one system fails reset box will energies the auto reset.
 The reset pulse time is 5 seconds.
 After five seconds the failed section comes to preparatory mode.
Auto reset conditions

 When the Auto reset condition is available, the Microcontroller will start the in
build timer for 10 sec . After the time period Microcontroller will drive the
Auto reset miniature relay. The generated reset will applying to the system for
5 sec .
 After one auto reset the counter of auto reset will be increased by one.
 After one auto reset if failed system isn’t in preparatory mode the next auto
reset will be done only after another one section clear.(i.e. Another one train has
to pass the section.)
1.8.2 Manual Reset

 The Manual reset should be done when, both system showing error.
 The manual reset procedure is common as SSDAC system.
 Press the reset button and turn and press the SM-KEY simultaneously.
 The reset voltage will applied for both systems .
 After successful reset both systems will shown the section is in preparatory
mode.
1.9 Configuration Setting in CPU modules (Links 18 to 25)

 SSDAC-G36-2DP-1S version system consists of a start fed unit (SF) & end
fed unit (EF) which are located at either end of a block section. With the
common hardware & software of both the units, the configuration of SF/EF
have to be assigned uniquely. This can be achieved through jumper settings on
links 18 to 25 provided in the CPU cards.
 Figures below indicate the jumpers as seen from top view of component side.
The physical & logical setting for SF is shown below. This setting has to be
carried out on both CPU1 & CPU2 cards.
SSDAC - 2D SF Start Fed Configuration ( CPU Card Top View Component Side )
Up 12
LK LK
17 10 25 18
0
Down 1 Address Set t ing Refer Configurat ion Set t ing

Address set t ing t able
Polarizing
connector
LK25 LK24 LK23 LK22 LK21 LK20 LK19 LK18
0 0 0 0 0 0 0 1
Figure 17:2DP-1S Configuration Setting of SF (Links 18 to 25 - Physical & Logical setting)

2DP-1S Configuration Setting of EF (Links 18 to 25 - Physical & Logical setting)

SSDAC - 2D EF End Fed Configuration ( CPU Card Top View Component Side )
Up 12
LK LK
17 10 25 18
0
Down 1 Address Set t ing Refer Configurat ion Set t ing

Address set t ing t able
Polarizing
connector
0 0 0 0 0 0 1 0
Figure 18:2DP-1S Configuration Setting of EF (Links 18 to 25 - Physical & Logical

setting)
1.10 Address Setting in CPU modules (Links 10 to 17 )

 In each of the SF & EF units, unique address has to be set for CPU1 &
CPU2.For this purpose jumpers 10 to 17 are to be used. Addresses of 1, 2 up to
252 are assigned to the CPU’s of SF. For the processors of EF addresses of 3 &
4 up to 254 are assigned. The table below indicates the local addresses assigned
to the CPU’s.
 Logical setting of the jumper LK10 to LK17 for SF & EF are indicated below.
Jumper Settings
Address
Assigned
LSB MSB
1 0 0 0 0 0 0 0 1
0 1 0 0 0 0 0 0 2
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 0 1 1 1 1 1 1 252
Figure 19:CPU addressing of SF

Jumper Settings
LK10 LK11 LK12 LK13 LK14 LK15 LK16 LK17 Address

Assigned
LSB MSB
1 1 0 0 0 0 0 0 3
0 0 1 0 0 0 0 0 4
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
0 1 1 1 1 1 1 1 254
Figure 20:CPU addressing of EF
The table below indicates the summary of addressing scheme of SF & EF units.
SSDAC Unit SF Stat Fed Group Local EF End Fed Group Local
Address Address
SSDAC CPU-1 001 CPU-1 003

1-2 CPU-2 002 CPU-2 004

3-4 CPU-2 006 CPU-2 008

5-6 CPU-2 010 CPU-2 012
▼ ▼ ▼ ▼ ▼
▼ ▼ ▼ ▼ ▼
▼ ▼ ▼ ▼ ▼

‘n’ CPU-2 252 CPU-2 254

For setting the configuration & address, berg sticks are provided with links. These
links have to be set as per the above details.
Note: Under any deviation from the above settings of configuration, & addressing scheme,
the SSDAC – 2DP-1S system does not boot and enters into wrong configuration
status & error message 59, “Invalid Configuration” is displayed.
1.11 Event logging through SM-CPU or Event Logger Card

 SM-CPU or Event Logger Card:
 Monitors the SSDAC system and logs vital events during normal and error
operation with date and time stamp
 As many as 95 different events are recorded
 Optional display connected to Event Logger Card displays the
communication errors happening in Real-time which aids in assessing the
health of communication channel
 Event logged during normal operation

 Communication status ok
 Vital and Preparatory Relay pickup / drop
 Reset operations
 Event logged during error operation

 Communication link fail
 System down due to failure of any card
 Vital and Preparatory Relay error status
 +5 VDC variations
 Errors
1.11.1 Event Logger (Download & Analysis)

 Take the installation CD & download event logger program in the laptop
 Connect the USB cable from the laptop to the SMCPU-RS232 port.
 Install the cable software in COM-1 or COM-2
 Select the event in laptop to event logger. (Refer stage 1 in Fig.)
 Open the CPU communication setup.
 Enter the name of the ID (SF/EF) (Refer stage 2 in Fig.)
 Enter unit address- CPU1,2,3,4. (Refer stage 2 in Fig.)
 Enter SSDAC type SF/EF. (Refer stage 2 in Fig.)
 Enter the laptop COM-1 or COM-2 (Refer stage 2 in Fig.)
 Check the DAC status- to GREEN. (Refer stage 3 in Fig.)
 Enter Date & Time. (Refer stage 5 in Fig.)
 Delete all events in laptop, Now download the events. (Refer stage 6 in Fig.)

 Select My Computer
 Select C drive-Program file-Data logger.
 Move to SSDAC Microsoft Office.
 Copy & Paste the events.
 Analyze the report.
1.11.2 Downloading Procedure
Figure 21: Downloading stages

Figure 22: Downloading stages

1.12 Trouble shooting
 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
 Typical chart shows the messages, their analysis and the corrective action to be
taken
1.12.1 Trouble Shooting Chart
Error Error Reason Corrective action

Code Message
on CPU
display
PD1_BOA Missing of the Phase detector 1 Place the PD1 module in the
01 RD_MISSI module (PD1- 21KHz) during slot and reset the system
NG run time and boot time.
PD2_BOA Missing of the Phase detector 2 Place the PD2 module in the
02 RD_MISSI module (PD2- 25KHz) during slot and reset the system
NG run time and boot time.
SM_CPU_ Missing of the SM-CPU module Place the SM-CPU module
03 MISSING during run time and boot time. in the slot and reset the
system
MODEM_ Missing of the Communication A Place the Communication A
MODULE module during run time and boot module in the slot and reset
04
_A_MISSI time. the system
NG
MODEM_ Missing of the Communication B Place the Communication B
MODULE module during run time and boot module in the slot and reset
05
_B_MISSI time . the system
NG
RELAY_D Missing of the Relay Drive A Place the Relay Drive A
RIVE_A_ module during run time and boot module in the slot and reset
06
MISSING time . the system
RELAY_D Missing of the Relay Drive B Place the Relay Drive B
07 RIVE_B_ module during run time and boot module in the slot and reset
MISSING time. the system
PEER_CP Missing of the any one of the Place the CPU module
08 U_MISSIN CPU module during run time and missing in the slot and reset
G boot time. the system


Code Message
on CPU
display
COMM_L EF CPU1 could not transmit to 1.Check MS Coupler 6,
U1_TO_U remote SF CPU1Due to make proper connection.
09 S1_FAILU communication problem 2.Check CPU1 & COMM1
RE ( US- replace if found bad
Upstream)
COMM_L EF CPU1 could not transmit to 1. Check MS Coupler 6,
U1_TO_U remote unit SF CPU2. Due to make proper connection.
10
S2_FAILU communication problem 2. Check CPU1 & COMM1
RE replace if found bad
COMM_L SF CPU1 could not transmit to 1. Check MS Coupler 11,
U1_TO_D remote unit EF CPU2. Due to make proper connection.
11 RE replace if found bad
(DS-
Downstrea
m)
12
COMM_U EF CPU1 could not receive from 1. Check MS Coupler 6,
S1_TO_L remote unit SF CPU1. Due to make proper connection.
13
U1_FAILU communication problem 2. Check CPU1 & COMM1
S2_TO_L remote unit SF CPU2. Due to make proper connection.
14
COMM_D SF CPU1 could not receive from 1. Check MS Coupler 11,
S1_TO_L remote unit EF CPU2. Due to make proper connection.
15
RE replace if found bad.
16
U2_TO_U remote SF CPU1 make proper connection.
17
S1_FAILU Due to communication problem 2. Check CPU1 & COMM1


Code Message
on CPU
display
U2_TO_U remote unit SF CPU2. Due to make proper connection.
18
19
20
S2_FAILU communication problem. 2. Check CPU2 & COMM2
S1_TO_L remote SF CPU2 make proper connection.
21
U2_FAILU Due to communication problem 2. Check CPU1 & COMM1
S2_TO_L remote SF CPU2 make proper connection.
22
U2_FAILU Due to communication problem 2. Check CPU2 & COMM1
23
24
MODEM_ Modem in Replace COMM1 /
ERROR_N COMM1/COMM2 gone Bad COMM2
25
O_CARRI
ER
PEER_CP SM-CPU/Event Logger gone bad 1. Replace SM-CPU/Event
26 U_LINK_F OR Logger
AILURE CPU1/CPU2 gone bad 2. Replace CPU1/CPU2
FAILURE Error at Down stream unit. Check the error at remote
27 _AT_DS Failure in the remote unit unit, rectify the error and
reset the system.
28 FAILURE Error at Up stream unit Check the error at remote


Code Message
on CPU
display
_AT_US Failure in the remote unit unit, rectify the error and
reset the system.
BOOTUP_ Power problem OR Train moving 1.Check all the voltages in
PD_FAIL in the Section on TX / RX coils, DC-DC converter module if
during power ON . any one voltage is missing
30
then change the DC-DC
power supply.
2. Reset the System
PD1_SUP_ PD1 module supervisory is low 1. Make the connection
LOW for 3 seconds Properly
Cause 1: TX1/RX1 coils not 2. Replace TX1/RX1 coil
connected properly 3. Replace CPU1/CPU2
33
Cause 2: TX1/RX1 coil gone bad 4. Replace PD1 module
Cause 3: CPU1/CPU2 gone bad
Cause 4: PD1 module gone bad
PD2_SUP_ PD2 module supervisory is low 1. Make the connection

LOW for 3 seconds Properly
Cause 1: TX2/RX2 coils not 2. Replace TX1/RX1 coil
connected properly 3. Replace CPU1/CPU2
34
Cause2: TX2/RX2 coil gone bad 4. Replace PD2 module
Cause 4: PD2 module gone bad.
PD1_PUL Error occurs when any one 1. Make the connection

SING sensor is influenced two or more Properly
times. 2. Replace TX1/RX1 coil
35
Cause 1: Loose contacts of 3. Replace PD1 module.
TX1/RX1 connections
PD2_PUL Error occurs when any one 1. Make the connection
SING sensor is influenced two or more Properly
times. 2. Replace TX2/RX2 coil
36 Cause 1: Loose contacts of 3. Replace PD2 module.
TX2/RX2 connections
PD_STAT Error occurs when both sensors 1. Make the connection

E_MISSIN are influenced in sequence Properly
37
G Cause 1: Loose contacts of 2. Replace TX1/RX1,
TX1/RX1, TX2/RX2 connections TX2/RX2 coil


Code Message
on CPU
display
Cause 2: PD1, PD2 module gone 3. Replace PD1, PD2
bad module.
Cause 3: Rx phase in dummy 4. Check rail drilling
wheel setting in PD1 & PD2 measurements properly &
module not set properly with rectify the driller.
dummy wheel.
Cause 4: If Rx coil is mounted
down than prescribed in the
manual.
PD_SUP_P If supervisory signals pulsates 1. Make the connection
ULSATIN more than 4 times Properly
G Cause 1: TX1/RX1 or TX2/RX2 2. Replace TX1/RX1,
coils not connected properly TX2/RX2 coil
38 Cause2: TX1/RX1, TX2/RX2 3. Replace CPU1/CPU2
coil gone bad 4. Replace PD1, PD2
Cause 3: CPU1/CPU2 gone bad module
Cause 4: PD1, PD2 module gone
bad.
PD_STAT Error occurs when any wheel 1. Make the connection
E_FAIL counting state sequence is Properly
missing 2. Replace TX1/RX1,
Cause 1: TX1/RX1 or TX2/RX2 TX2/RX2 coil
coils not connected properly 3. Replace CPU1/CPU2
39
Cause2: TX1/RX1, TX2/RX2 4. Replace PD1, PD2
coil gone bad module
bad
PD_NOT_ Error occurs when both the PD 1. Make the connection
SENSING modules do not sense the wheel Properly
for more than 3 times 2. Replace TX1/RX1,
Cause 1: TX1/RX1 or TX2/RX2 TX2/RX2 coil
40 coils not connected properly 3. Replace PD1, PD2
Cause2: TX1/RX1, TX2/RX2 module
coil gone bad
bad.
PREPARA No/Improper feedback from 1. Make the connection
TORY_RE Preparatory A relay Properly
41 LAY_A_F Cause 1: Loose contacts of 2. Replace Relay Driver 1
AILURE Preparatory relay connections module
Cause2: Relay Drive 1 module 3. Replace CPU1/CPU2


Code Message
on CPU
display
gone bad module
Cause 3: CPU1/CPU2 module
gone bad.
PREPARA No/Improper feedback from 1. Make the connection
TORY_RE Preparatory B relay Properly
LAY_B_F Cause1: Loose contacts of 2. Replace Relay Driver 2
AILURE Preparatory relay connections module
42
gone bad
gone bad.
VITAL_R No/Improper feedback from Vital 1. Make the connection
ELAY_A_ Relay A relay Properly
FAILURE Cause1: Loose contacts of Vital 2. Replace Relay Driver 1
relay connections module
43
gone bad
gone bad.
VITAL_R No/Improper feedback from Vital 1. Make the connection
ELAY_B_ Relay B relay Properly
FAILURE Cause1: Loose contacts of Vital 2. Replace Relay Driver 2
relay connections module
44 Cause2: Relay Drive 2 module 3. Replace CPU1/CPU2
gone bad
gone bad
DIRECT_ OUT COUNT registered Without Reset the system after the
45 OUT_COU IN COUNT, train has passed the exit DP.
NT
TRANSIE Power failure at Down stream Make the connection
NT_POWE CPU1 Properly
49
R_FAILU Cause 1: Loose contacts of power
RE_DS1 connections
TRANSIE Power failure at Down stream Make the connection
NT_POWE CPU2 Properly
50
R_FAILU Cause 1: Loose contacts of power
RE_DS2 connections
TRANSIE Power failure at Up stream CPU1 Make the connection
51
NT_POWE Cause 1: Loose contacts of power Properly


Code Message
on CPU
display
R_FAILU connections
RE_US1
TRANSIE Power failure at Up stream CPU2 Make the connection
NT_POWE Cause 1: Loose contacts of power Properly
52
R_FAILU connections
RE_US2
INVALID_ When CPU address is wrongly 1.Change the address
NETWOR set settings as per instruction
57
K_ADDRE manual.
SS 2. reset the system
INCORRE This is a Boot Up error. When 1.Replace both CPU1 &
58 CT_CODE CRC of the code mismatches CPU2 card in both the units
_CRC with the stored CRC 2.Inform the Company
INVALID_ When unit type and address of Change the address and
CONFIGU CPU are wrongly set. configuration settings as per
59
RATION the requirement and reset
the system.
INVALID_ Train with 10,000 wheels. Reset the system
60
COUNTS
RAM_TES This is a Boot up error when 1.Replace both CPU1 &
61 T_FAILED RAM (In- built memory of Micro CPU2 card in both the units
controller) has failed 2.Inform the Company
1.13 Precautions to be taken for trouble free operation

1.13.1 Power Supply-24DC:
 Use Axle Counter type , ripple free Charger
 Use 120 AH battery with adequate life
 Use 25 sq mm AL cable for feeding power to the system
 Provide Class ‘B’ Surge Protector at source of 24 V DC in station
 Avoid tapping of different loads to the power source of Axle Counter
1.13.2 Quad Cable:

 Loss should be less than 30 db between SF and EF(1.2 db/km)
 Every joint adds loss to the cable, minimize joints and take care for making
good permanent joints .
 Insulation resistance to be more than 10 M ohms at 500 V DC between
conductors ,between pairs and between wire and armour.
 Loop resistance to be within 56 ohms/km

 Maintain continuity of armor between SF and EF & earth at both ends .
1.13.3 Parallel circuits

It has come to notice that usage, termination and wiring of quad cable is far from
satisfactory for trouble-free working of digital axle counters. Basic issue pertains to
electromagnetic interference from parallel circuits in the cable and location.
Following guidelines are recommended to enhance performance of DAC systems.
 Long parallel circuits shall be avoided in the same quad. Requirement is that
parallel circuit shall be as far spaced as possible. So, one long and one short
circuit can be accommodated in same quad but not both long circuits.
 DAC circuits in BPAC of up and down lines in double line sections shall be in
separate quads and kept one/two quads away from each other as far as possible
to avoid mutual interference due to long parallel circuits.
 DAC circuits in location shall not bunched along with parallel relay/power
circuits. Relay circuits are known to generate switching transients that can
couple enough energy in parallel circuits nearby and interference with low
power circuits data circuits.
 Any other parallel wiring (relay circuits/power circuits/earthling wires etc)
shall cross DAC circuits at perpendicular and any parallel portion shall be kept
at minimum 150mm lateral distance away from the wiring for DAC circuits.
 Relay circuits shall preferably be not taken in the same cable as DAC circuits.
In unavoidable circumstances relay circuits shall be in furthest quad (spatially)
from the one containing DAC circuits.
1.13.4 Twisting of cable pair

 Twisted pairs are required to avoid mutual interference between low level ac
signals. Even short lengths of non-twisting (few inches) can couple enough
differential mode electromagnetic signals to interfere with low voltage DAC
communication signals.
 Quad cable twisting shall be ensured during termination so that minimum one
twist per inch is maintained till the last inch into terminations.
 Any wiring from quad cable terminations to equipment shall be done by using
twisted singles of indoor signaling cable (1mm square) or any other approved
indoor twisted pair cable.
 Signaling cable or any other untwisted pair cable shall never be used in DAC
communication circuits to avoid intermittent type of failure.
1.13.5 Continuity and Earthing of cable armour & screen at intermediate

terminations/Joints:
 Screening of quad cable of effective when induced current can flow in the
screen thereby canceling/reducing the induction for the cable conductors. For
adequate induced current to flow in screen, it is necessary that good earth

connections are provided for screen & armor at all the cable terminations and
joints.
 Quad cable screen & armor shall be made continuous at the intermediate
terminations/joints by soldering and connecting both ends of cable screens &
amours at the locations.
 Connections to screen shall preferably be made by metallic clamps soldered to
screen to ensure good surface connection for electrical continuity.
 Combined earthing for both ends of armor and screen at intermediate
locations shall be ensured to be in good condition and having values as low as
possible but never more than 5Ω.
 Earthing connection shall be kept short and as straight as possible because any
loop or turns can create inductive elements that impede quick discharge of
transients and surges to ground.
1.13.6 Earthing
 Earth resistance to be less than 1 ohms

 If not archived by single earth provide multiple earth and parallel then
1.13.7 TX and RX coils

 Fix coils by marking holes on different rails with the help of jig provided
 Drill 14 mm holes horizontally
Figure 23:Drilling of holes with the help of jig

1.13.8 Prevention of damage to Axle Detectors

 Axle Detectors are vulnerable for damage due to Tamping machine.
 Provide warning boards for caution
Figure 24:Caution Board
 Provide deflectors to avoid damage to coils by hanging items on train.

 Run cables from coils though HDPE pipes to avoid damage to coils and cables by
miscreants and rodents
 Pack the space for cable entry in location box with sand and seal the top surface with
bitumen compound /cement plaster

1.13.9 Trolley Movement
 Push trolleys with solid wheels drive the system to error mode due to wobbling
of the wheels
 Use spoked trolley wheels
 Mount TX/RX coils on outer rails of the curves
 Provide trolley protection circuit .
1.13.10 Wiring & Terminations
Preferably quad cable shall be terminated in cage clamp type terminals that provide
solid 360 degree surface connection and sufficient pressure on the wire to make a
good electrical contact.
Cables shall be terminated at the bottom portion of location and equipment and
their wiring done at higher levels inside location. This will help in keeping wiring
of different types segregated from each other. All earth wires and surge protection
devices also shall be kept at the lower levels for the same reasons.
Wiring and cabling shall not be bent abruptly and shall be given sufficient bending
radius to ensure that conductors inside the cabling/wiring are not damaged due to
bending.
Wiring shall be properly supported by channels toughing and other means to
ensure that connections are not under pressure due to wire hang.
Wiring and cabling shall not be supported at any sharp edged object to ensure that
conductors are not damaged during their installation/maintenance.
1.14 Maintenance
1.14.1 Maintenance schedule as recommended by OEM
 The system needs very little maintenance in terms of power supply, quad cable
condition, earthing , proper voltages from RX coils to PD cards
 The table below gives the maintenance schedule
Periodicity Maintenance
Weekly • Check for the proper voltage at the battery source for the unit
• Check and record the readings of

• Power supply module
Fortnightly
• PD module
• Check the coil Voltages
Half yearly/ Yearly • Replace defective parts if any
• Power Supply/DC-DC Converter modules

Every 10 Years
• must be replaced

1.14.2 Monitoring points of HA SSDAC

• Voltage Readings at different monitoring points is shown below.
Module Monitoring point Expected values
DC-DC +5VDC and GND 4.75to5.25V DC

Converter +18VDC and GND 17.75to18.25VDC
+12VDC and GND 11.75to12.25VDC
-12VDC and GND 11.75to12.25VDC
+24VDC and GND 22V to 26V DC
CPU 1 EN1B O/P and GND 11.5Vto12.5VDC
(for SF, CF, 3DP1S units) 11.5V to 12.5V DC
EN1A O/P and GND
(for EF, CF)
CPU 2 EN2B O/P and GND 11.5V to 12.5V DC
(for SF, CF, 3DP1S units) 11.5V to 12.5V DC
EN2A O/P and GND
(for EF, CF)
RELAY DRIVE VITAL RLY A O/P (+) > 20V DC
1 (for EF, CF) VITAL RLY A O/P (-)
RELAY DRIVE VITAL RLY B O/P (+) > 20V DC
2 (for SF, CF, 3D VITAL RLY B O/P (-)
units)

Without wheel With wheel
PHASE RX-SIG and GND 900 mV to 1.2 V AC < 350mV AC
DETECTOR SUP-OUT and GND 4V to 5V DC 3V to 3.9V DC
(PD1 and PD2 ) WHEEL-M-OUT and GND 4.5V to 5V DC < 100mv
WHEEL-S-OUT and GND 4.5V to 5V DC < 100mv
RX-PH-SIG and GND 10 V to 12V DC < 500mv
SUP-ADJ and GND 4V to 5V DC 3V to 3.9V DC

1.14.3 Maintenance schedule as recommended by RDSO

(Ref: Maintenance guidelines for SSDAC (GGT make) - RDSO Maint. Note 7001
Ver.1.0 dtd. 23.05.2012)
(A) Maintenance Check List for SSDAC for Signal Maintainer

Periodicity – Every Month
To be performed by Maintainer once in a month
1. General Information
2. Station /Yard Name:
3. Section:
4. Division/Zonal Railway:
5. Contact Details of Railways at site:
6. Contact Details of Railways at HQ/Division
7. Contract No./P.O. No.
8. Application [Yard/ABS/IBS/BPAC]
9. Total Nos. Of Detections & Section:
10. Name and Address of manufacturer/supplier:

(RDSO Approved vendor)
11. Serial number of the equipment:
12. SSDAC working on: OFC /Radio / Quad

Cable
13. Date of installation:
14. Date of pre-commissioning inspection:
1. Voltage measurements
SI. Date Power Supply VR & VPR voltages Observation Signature

No
At IPS At Location VR at VPR at
SSDAC Location RR
1

2. DC/DC converter and other monitored voltages

Sr. Module Parameter Limit Measured
No (DC Volts) O/P (DC Volts)
1 DC-DC converter +5VDC and GND 4.75 to 5.25V DC
2 +18VDC and GND 17.75 to 18.25V DC
3 +12VDC and GND 11.75 to 12.25V DC
4 -12VDC and GND 11.75 to 12.25V DC
5 +24VDC and GND 22V to 26V DC
6 CPU 1 EN1B O/P and GND (for 11.5V to 12.5V DC
SF, EF, 2DP1S units) ( at ‘CLEAR’ state)
7 EN1A O/P and GND (for 11.5V to 12.5V DC
EF, EF) ( at ‘CLEAR’ state)
8 CPU 2 EN1B O/P and GND (for 11.5V to 12.5V DC
SF, EF, 2DP1S units) ( at ‘CLEAR’ state)
9 EN1A O/P and GND (for 11.5V to 12.5V DC
EF, EF) ( at ‘CLEAR’ state)
10 RELAY DRIVE VITAL RLY A O/P (+) > 22V DC
1 (for EF, CF) VITAL RLY A O/P (-) ( at ‘CLEAR’ state)
11 RELAY DRIVE VITAL RLY B O/P (+) > 22V DC
2 (for SF, CF, 3D VITAL RLY B O/P (-) ( at ‘CLEAR’ state)
units)

Without wheel With wheel
PHASE RX-SIG and GND 1.0 VAC >200 mVAC
DETECTOR SUP-OUT and GND 3.0V to 3.9V DC < 1.0V DC
(PD1and PD2) WHEEL-M-OUT and GND 3.0V to 5V DC < 1.0V DC
WHEEL-S-OUT and GND 3.0 V to 5V DC < 1.0V DC
RX-PH-SIG and GND 10 V to 12V DC 0.1 or 0.2V(min)
SUP-ADJ and GND 3.0V to 3.9V DC > 2.5 V DC
Wheel influencing both - <2V in both PD cards
detectors
3. Fuse checking
Sr. Date IPS/Battery SSDAC Cross Panel Observatio Signature
No Fuse Fuses protection of supply n
(24VDC VPR drive Fuses
) voltage Fuses
(24V DC)
At RR/ At At location & Relay
Battery room location RR Rack
1

4. Visual inspections
SI. Date DC/DC Indications Display Check whether all Observation Signature
N converter on SSDAC of CPU the wirings in the
o cards terminals are
securely tightened
1
5. Display of Reset Box
SI. Date Reset Box Observation Signature

No
Functionality of display Display of
Reset box
1 All 4 lines display are clear
and legible and correspond
to the manual details
6. Verification of Log Register
Sl. Verifying Document Observation Signature

No YES NO
1 User Data Log Folder (Reset counter register)
2 Event Data Log Folder
3. Failure Register
Sl. Activity to be checked Observation Signature

No
1 Check all nut & Bolts of Base clamp/web mounting
assembly (Tx, RX, Deflector plates etc)
2. Inspect wiring loop and terminations over wago /
couplers and Ensure they are in good condition and
connections are tight.
3. Inspect the connections of cards/modules of the Axle
counters
Signature with date of Railway Representative Name &

Designation

(B) Maintenance Check List for SSDAC for Signal Supervisor

Periodicity – Every Quarter
STATION NAME: __________________ Date of commissioning: __________
ZONAL RAILWAY: ___________________________
Date of visit: ______________
To be performed by SE/SSE every Quarter
Sl. ACTIONS/OBSERVATIONS OK/YES NOTOK/NO REMARKS

No X
VISUAL CHECK
1. Check whether Q type, 24V, 1000 Ohm relay is

provided in VPR/PPR in relay room
2. Check whether Diode across each relay coil in
reverse bias is provided.
3. Ensure Only Proper pair of wires of Quad cable is
to be used for connectivity between field units in
accordance to wiring practices laid down in TAN
6001.
4. Check the Attenuation loss of the quad cable (point
to point )
5. Ensure the Channel lineup of OFC cable. In
coordination with Tele supervisor.
6. Ensure communication of two adjacent SSDACs
information should be carried in two different time
slots to avoid interference.
7. Ensure the VPR relay drive voltages should be in
proper range (> Than 22 volts dc).
8. Ensure the IPS/Battery chargers which are suitable
for Axle counter are provided. Measure ripple
voltages (<20mv).
9. Check whether Axle counter wiring is totally
isolated from CT Rack & walls.


No X
SURGE PROTECTION DEVICE
1. Check whether Surge Protection devices is
provided for axle counter.(for Power line, Reset
line & Modem line )
2. Check whether 24V/12V/48V OBO surge
suppressor is provided
3. Ensure that for Converter/Isolator, if a shielded
twisted pair cable is used, then shield should be
connected to protective ground at one end only.
4. Check whether “Class C & D” surge protections
are provided location.

No X
EARTHING
1. Verify that all earth pits are visible and measure the
ring earth resistance/bus bar as per the maintenance
schedule
2. Check whether shields of all communication cables
are properly connected to earth ground at one end
only
3. Check whether painted surface are scraped to the
clean metal surface where grounding connections
are to be made
4. Check whether the earth connection between
Location busbar and the Eqpt earth point are as
short and there is no bend or any loose in the earth
wire (Green)
5. Check that Armoured Quad Cable used for Media
are Connected to Earth
6. Check whether all joints are being mechanically
and electrically effective (Example. clamped,
screwed, bolted, riveted or welded)
7. Check that there are no loose connections in any of
the earthing terminations
8. Check that there is no damage to earth wire
9. Earth pits are wetted on regular basis (This is

applicable only to non maintenance free earth pit
sites)


No X
MAINTENANCE AND MEASUREMENT ACTIVITY

1. Ensure there is no dust in Axle counter equipment.
2. Check that the glowing of healthy indication in

surge suppressors
3. Check that there is no failure indication for the
communication link
4. Check all the fuses visually for its proper working
5. Measure the “EARTH RESISTANCE VALUE”

(i.e., less than 1 ohm)
6. Ensure that all the DC-DC converters are working
properly
7. Measure all parameters as given in the maintenance
log sheet and compare with readings taken by
Maintainer.

No X
MISCELLANEOUS
1. Verify whether spare fuses/terminals of all types
are readily available at site
2. Check whether the “Axle counter reset register” is
properly maintained.
3. Check whether Maintainer has the correct tools for
use on the system.
Maintenance log sheet is given at the end of this booklet which has to be maintained by
Maintainer and Supervisor.
Date: SSE/SE Signature: Date: Next Maintenance

visit date:
Name:

1.15 Advanced Applications of High Availability Single Section Digital

Axle Counter( HA SSDAC-G36R)
 Block proving single / double line
 Intermediate Block Signalling IBS
 Automatic Block Signalling ABS
1.15.1.Intermediate Block Signalling – IBS
 The line between two stations may where required be divided into two section
known as “Intermediate Block Section".
 In order to increase the traffic over the lengthy block sections between the
stations.
 In order to reduce human intervention in operating the train movement
1.15.2 Automatic Block Signaling – ABS
 The line between two stations may where required be divided into a series of
section known as "Automatic Block Signaling Section".
 Space interval between the trains are secured automatically by using track
circuits or axle counters.
 In order to increase the traffic over the lengthy block sections between the
stations.
 In order to reduce human intervention in operating the train movement.
 Entry into each block signaling section is protected by a colour light Multiple
Aspect Stop Signal.
 Track Circuits or Axle Counters to controls the aspects of the Signal.
 By using HA SSDAC we can avoid external auto reset circuits for auto
section.
 In build reset box auto reset circuit will help us to achieve it.
1.15.3 Communication
 In HA SSDAC one unit having two modems. Which is giving voice channel
output V.23.
 To avail the high availability and avoid common mode error through the
communication one channel in Quad cable another one channel in OFC.

1.15.4 Communication Interface
(i) Communication between SF – DP and EF – DP through Quad cable
 The physical communication between SF – DP and EF – DP is very vital for

proper working of the system. The Quad cable termination has to be done with
care after making Quad cable jointing near location boxes. The selection of
proper pair, loop resistance, dB loss, IR value between cable pair, IR value
between cable pair with other pairs, IR value between cable pair and Armor /
shield, cross talk are very important parameters to be taken care and it should be
within the limits and suitable for Data communication as prescribed in the
RDSO recommended pre commissioning check list. The SSDAC system uses
two-wire CCITT standard V.23 half duplex communication protocol at 1200
bits/second. The maximum transmission distance depends on the dB loss of the
Quad cable selected pair and should be less than 30 dB at 2000 Hz. As a
reference a good quality communication cable will have dB loss of 1.0 to 1.3 dB
/ Km and maximum loop resistance of 56ohm/KM with capacitance of
45nF/Km. The IR value shall be measured with Megger with 500 Volts range
and should be more than 10 Meg Ohm. The cross talk values should be more
than 55 dB for both NEXT and FEXT.
 If the distance of the Block is more than 12 Km’s the termination Resistors of
type Carbon Film 600 Ohms Half Watts should be terminated at both the ends
of Quad cable pair used for matching the Impedance of the Quad cable as per
CCITT recommendations. For better reliability the Right pair identified as
below of star quad cable should be used with proper pair terminations. The
Quad cable used should not be loaded with another pair.
Figure 25:Quad cable 0.9 mm

Quad 1 : 1st Pair > Blue – White 2nd Pair > Red – Grey
Quad 2 : 5th Pair > Brown – White 6th Pair > Red - Grey
Quad 3 : 3rd Pair > Green – White 4th Pair > Red – Grey
Quad 4 : 7th Pair > Orange – White 8th Pair > Red – Grey
(ii) Communication between SF – DP and EF – DP through OFC
 The physical communication between SF – DP and EF – DP when it is

connected through OFC, the termination should be done on any one of
voice channel designated for signaling and safety purpose. The OFC system
Transmit and Receive gain of that particular channel should not be kept
with any amplification gain factors. These parameters should be checked
and confirmed with the responsible Telecom Staff of the section. The
connection between DP location box to nearest OFC room should be wired
with Quad cable only and all the tests as per Section 3.0 should be
followed.
 Caution should be taken by the division that OFC systems should not be
switched off without informing the concern signaling staff during OFC
maintenance as switching off of the OFC system will fail the system and
Block section. This needs Resetting the Axle Counter / section after
switching on the OFC system.
 24 VDC Power Supply Arrangements
 The SSDAC system is Microprocessor based Electronics Equipment and

needs a stable power supply for its operation. Since the SSDAC system is
Fail Safe system any problem in system, power supply or communication
link, the system goes to Error mode.
 For the proper operation of the SSDAC system 120 AH Batteries and Axle
Counter suitable Battery Chargers needs to be provided in the station. The
output 24 VDC power from Battery should be connected to both SF – DP
and EF – DP at respective stations. The power supply for Reset Box at
respective stations also should be powered with the same 24 VDC power
supply. At the input of the Battery Charger 220 VAC Surge Protection
devices needs to be provided. At the output of the Battery 24 VDC Surge
Protection device needs to be connected to protect the systems from
lightning and high voltages. The 24 VDC power to Reset Box should be
taken directly from Battery output (before Surge Protection device) with 2
Amps Slow blow or HRC fuse there by protecting Reset Box from any high
voltages entering from power cables. The output of the Surge Protection

device should be sent to individual location box to power the DP’s through
6 Amps slow blow or HRC fuse.
 The Battery charging and discharge test should be conducted to assess the
condition of Batteries by switching off the charger for 15 minutes with
SSDAC systems switched on and check for Battery voltages between 22 –
30 VDC before commissioning the SSDAC systems.
1.16 Commissioning of HA SSDAC system

The commissioning of HA SSDAC should be done only after fulfilling the
prerequisites of the Pre commissioning check list issued by RDSO Lucknow. Any
deficiencies found should be attended before commissioning. After switching on HA
SSDAC system and picking up VR Relay, the performance of the system should be
monitored for 72 Hours for trouble free operation before commissioning. If the Push
Trolleys used in the section is not Spooked Wheel as recommended by RDSO, the
Trolley Protection TP circuit should be provided with the support of the firm’s
representative.

Figure 26:Application 1 - Single Line with HA SSDAC G36R

Figure 27: Application 2 -Double Line with HA SSDAC G36R

1.17 Do’s and Don'ts
Sr. No DO’s
The interconnection drawings are to be followed for connecting the Transmitter and
1 Receiver Coils. Tx1 is 21 KHz, Tx2 is 25 KHz & Rx1 and RX2 coils are 21 KHz &
25 KHz, respectively
2 Ensure that Receiver and Transmitter coil cables are laid in different pipes.
3 Ensure that both the TX coils & RX coils are having proper alignment on Rail.
4 Ensure that packing of sleepers with ballast on both sides of Axle detector is proper
5 Check that metal sheaths of the outdoor cable are connected to earth at both ends
6 The recommended cables for wiring of the system at site should be used
7 The steady battery voltage 24 V should be maintained.
8 The cable connections should not be loose
9 The M.S Coupler connectors of SSDAC are checked and maintained firmly.
10 Preparatory Reset should be done only after ensuring that there is no train
It is recommended that heat resisting paint to be used on the apparatus case so that
11 the temperature inside apparatus case is maintained lower in comparison to other
normal paints
Sr. No DON’Ts
Don’t cut or join the Transmitter/Receiver cables supplied along with the coil.
1
It would result in change of levels of signals.
Don’t remove the modules from SSDAC Units under POWER ON condition of
2 system.
Remove module if necessary after switching OFF the power to the Unit.
Local Address of the CPU-1 and CPU – 2 and configuration settings of the system
3
should not be changed at the field.
The hardware of Communication module and Relay Drive module are similar for all
systems. However their positions of mounting is different in different unit types.
4 These modules have to be equipped correctly after verifying the drawings as
mentioned in the installation manual (DRG-1 to DRG-4) which indicates their
positions
Caution Board has to be placed near the SSDAC Axle detectors to avoid damage to
5
the Coils from packing machines

1.18 Backup Spares (Recommended 1 set for 5 systems)

Sr.No SSDAC Spares Quantity
1 Phase Detector modules1&2 (PD1 and PD2) 2
2 CPU1 and CPU2 Modules 2
3 Communication Modules 2
4 Relay drive Module 1
5 Event Logger/SM-CPU Module 1
6 DC-DC converter Module 1
7 Axle detectors 21 KHz/25KHz (TX coil) 2
8 Axle detectors 21 KHz/ 25 KHz (RX coil) 2
9 Hardware for mounting axle detectors 1
10 MS circular connectors (6 No.) 1
11 Reset box RB 1
12 SSDAC unit (housing with mother board, without modules) 1
13 Relay Box 1
1.19 Recommended Tools
Sr. No Tools Quantity
PC/Laptop for downloading event logger data for analysis and report
1 1
generation
Pure sine wave Digital Multimeter (Fluke make 187 or Rishab make
2 1
18S or similar
3 Train simulator 1
4 Extender module 1
5 Dummy wheel 1
6 Ring spanner 17-19,24-26 1
7 Open end spanner 17-19, 24-26 1
8 Socket spanner with handle 1
9 Torque wrench 1
10 Screw Driver No. 902 1
11 Screw Driver No. 935 1
12 Marking jig for drilling 1

Page Date of Pre Commissioning Check List for High Availability Single Section SIG Ver 1
1 of 28 issue Digital Axle Counter {2DP1S Configuration} (SW Version : S002)
19-11- of M/s G.G.TRONICS, Bangalore
2012
Annexure:
Pre-commissioning check list for High Availability Single Section Digital
Axle Counter
(Model : HA-SSDAC-G36R) 2DP -1Section (Redundant) (As per
RDSO/SPN/177/2012 ver-3)
HA-SSDAC Unit Sl. No (System 1) ---------------- (System 2) ----------------
General Information:
Station /Yard Name:

Section:
Division/Zonal Railway:
Contact Details of Railways at site:
Contact Details of Railways at HQ/Division
Contract No./P.O. No.
Application [Yard/ABS/IBS/BPAC]
Total Nos. Of Detections & Section:
Name and Address of manufacturer/supplier:
(RDSO Approved vendor)
Serial number of the equipment:
Software checksum:
Model: G-36/36-R : ‘DB 7B B6 77’
software version is ‘S002’
HA-SSDAC working on:
OFC / Microwave / Quad Cable
Date of installation:
Date of pre-commissioning inspection:
Note:
0. System should be installed and commissioned by authorized technical staff of

manufacturer only.
1. Commissioning of High Availability Single Section Digital Axle Counter (HA-

SSDAC)
has to be done by OEM as per RDSO’ pre-commissioning checklist No. SIG
0606 Ver.2.
2. OEM shall certify that verification of system installation has been completed
representative authorized by OEM and all necessary arrangements meet the
required standards of engineering for trouble free working of installed system.
(Ref: This office letter no.: STS.E.AC.Dig.Genl dt 21.06.2011)

A- CATEGORY:
Signature of G.G.Tronics Rep. Signature of Railway Rep.
with Name, Designation & Date with Name, Designation & Date
2012
(This part of work should to be done before commissioning )
1 Out door (Location Box)
Observed OK / Not
Sl. No. Item Required System1 System2 OK
CH 1 CH 2 CH 1 CH 2
Relay used in Relay Q type, 24V, 1000 Ohm
1.1
Box VR & PR
Diode across each Should be provided with BY127 /
1.2 relay coil in reverse IN4007 / IN5408
bias.
Unused Quad pair To be cut in such a way that none
1.3
of the conductors remains exposed.
Dressing of Quad To be properly dressed with
1.4
pair insulated tape.
Spiral before No individual conductor to be
1.5
termination. made spiral
2 Outdoor (track device)
OK / Not
Observed
OK
Sl. No. Item Required
System 1 System 2
Wiring of TX / RX
Wired on approved Wago/
2.1 coils & MS coupler
Phoenix make terminals.
cables
Condition of worn Should be within vertical limit of
out of Rail worn out
2.2 60 Kg - 13 mm 159 -172 mm
52 Kg - 8 mm 148 -156 mm
90 R - 5 mm 138 -143 mm
GGT Jig as per drawing no. DRG-
23 of Installation Manual Version
Marking of holes on 1.0 Revision 1 to be used as per
2.3 rail rail section.
(From bottom of the 60 Kg - 84 mm
rail) 52 Kg - 68 mm
90 R - 57 mm
From the bottom of the rail.
Should be of 14mm dia. Should be
Drilling of holes in
2.4 square (perpendicular), should not
the web of rail
be oblong.
Torque applied to fix Jaicom make JPR65 or equivalent
2.5 track device using - 88 Nm.
Torque wrench
2.6 Fixing of TX Outside the rail
2.7 Fixing of RX Inside the rail

2012
Laying of axle
2.8 In corrugated / HDPE pipe
detector cable
Staggering of Track (center to center hole) should be
device of system -1 >1.25 mtrs and < 1.75 mtrs
and system-2 Incase (This may be measured across
of Redundant system centre of hole (Track device sys-1
2.9 Fixture of Track at one rail) & center of hole of
devices of system 1 Track device sys-2 on another rail)
and system-2
Screen of axle
2.10 Should be earthed
detector cable
2.11 Rail section 60 Kg / 52 Kg / 90 R
Nuts, bolts &
Insertion of bolt from RX coil side
2.12 washers for fixing
i.e., inside of the rail
rail contacts
30 cm away from TX / RX coils in
2.13 Position of deflector
the next sleeper
Should not be higher than the rail

2.14 Height of deflector
top
Fixing of axle On the same rail as per drawing
2.15 detectors at entry & no. DRG-12 of Installation Manual
exit end Version 1.0 Revision 1
Clearance between
2.16 400 mm between sleepers
sleepers
Should not be covered by Track
2.17 Embossing on rail
device

2012
3 Outdoor Quad Cable
3. Outdoor (Quad Cable / PIJF twisted pairs telecom cable for Axle
counter system working in station area, As per RDSO letter no.
STS / E / SSDAC / SPN / 177 dated-28 / 30.08.2006)
3.1 Test format for testing of QUAD cable before commissioning of HA-SSDAC
BPAC / SSBPAC (D) used in between Station to station
Channel 1 Channel 2
Measured/Observed Remarks
Sl. No. Item Expected (OK/Not OK)
Channel 1 Channel2
Block section ≤ 12 Km.
3.2.1 length limit
Only Proper pair of wires
of Quad cable is to be used
for connectivity between
field units.
Communication No Signaling Cable is to be
3.2.2 Media used in totality / parts.
Type of Cable Annex-i for Quad cable
may be referred.
Wiring practices should be
adopted in accordance to
TAN 6001 dt 04.10.2011
See annexure -iii
Proper pair of wires to be
used for connectivity.
Annexure – i for quad cable
3.2.3 Use of pair may be referred.
Wiring practices should be
adopted in accordance to
TAN 6001 dt 04.10.2011
See annexure -iii
Duplication of No wires to be paralleled for
3.2.4 Wires reducing conductor
resistance.
Insulation Shall be greater than / equal
3.2.5 resistance of to 10 M ohm.
Quad cable

2012
Measured/Observed
Remarks
Sl. No. Item Expected
Channel 1 Channel 2 (OK/Not OK)
Not to exceed 56
Loop resistance ohm/Kms at 200 C.
3.2.6 of designated pair See Annexure – ii for
correction factor.
Shall not be greater than 30.0
3.2.7 Attenuation loss dB for full length of the
measured at 2 cable (including tail cables)
KHz used.
Near End Cross Shall be better than 55 dB
3.2.8 Talk (NEXT) for quad cable.
Far End Cross Shall be better than 55 dB
3.2.9 Talk (FEXT) for quad cable.
Continuity shall be there and
armour of the cable must be
earthed
3.2.10 Continuity of Wiring practices should be
cable armour adopted in accordance to
TAN 6001 dt 04.10.2011
See annexure -iii
Separate Earth of
3.2.11 Shall be  One ohm
quad cable
Cable allocation
3.2.12 table Shall be filled up & attached
3.2.13 Unused Quad pair To be terminated on

terminals.
3.2.14 pair insulated tape.
Spiral before No individual conductor to
3.2.15 termination. be made spiral

2012
3.2 Test format for testing of local QUAD / PIJF twisted pair
telecom cable & OFC before commissioning of HA-
SSDAC/BPAC/SSBPAC(D) on OFC in between station to
station.
Channel 1 Channel 2
Measured / Observed
Remarks
Sl. No. Item Expected
Channel 1 Channel 2
(OK/Not OK)
3.3.1 QUAD / PIJF
Jelly filled telecom cable /
Communication Quad cable to be used
3.3.1.1 Media between field units & OFC
Type of Cable Equipment room.
Signaling Cable shall not be
used at all.
Proper pair of wires to be
3.3.1.2 Use of pair used for connectivity.
Annex-1 may be referred
No wires to be paralleled
Duplication of
3.3.1.3 for reducing conductor
Wires
resistance.
Insulation
Shall be greater than
3.3.1.4 resistance of /equal to 10 M ohm.
Quad cable
Not to exceed 56 ohm/Kms
Loop resistance at 200 C for Quad cable &
3.3.1.5 of designated * ohm / Kms for
pair PIJF telecom cable.
See Annexure – 2 for
correction factor.
Earth of quad
3.3.1.6 Shall be less than One ohm
cable
Cable allocation
3.3.1.7 Shall be filled up &
table attached
To be cut in such a way that
Unused Quad
3.3.1.8 none of the conductors
pair
remains exposed.
Dressing of To be properly dressed with
3.3.1.9
Quad pair insulated tape.
Spiral before No individual conductor to
3.3.1.10
termination. be made spiral
3.3.2 OFC
For 0 dB Trans signal level,

the received signal level at
3.3.2.1 Channel line up other end shall not be more
than-3.0 dB.

2012
3.4 Test format for testing of QUAD cable / PIJF twisted pair telecom
cable in between HA-SSDAC unit and Station before commissioning
of HA-SSDAC (Quad cable between Location to Station at Station A
and Station B)
Sl. No. Item Expected Station A Station B OK/Not OK)
Only Quad cable / PIJF twisted
Communication pair telecom cable is to be
3.4.1 Media Type of used between field units.
Cable No Signaling Cable is to be
used in totality / parts.
Proper pair of wires to be used
3.4.2 Use of pair for connectivity.
Annexure – 1 for Quad cable
may be referred
Duplication of No wires to be paralleled for
3.4.3
Wires reducing conductor resistance.
Insulation
Shall be greater than / equal to
3.4.4 resistance of
10 M ohm.
Quad cable
Not to exceed 56 ohm / Kms
Loop resistance for Quad Cable at 200 C & * ohms / Kms for PIJF telecom cable.
3.4.5 of designated pair Annexure – 2 for correction
factor may be referred.
Attenuation loss
Shall not be greater than 30.0
3.4.6 measured at 2
dB for full length of the cable
KHz
used.
Near End Cross Shall be better than 55 dB for
3.4.7
Talk (NEXT) quad
cable.
Far End Cross Shall be better than 55 dB for
3.4.8
Talk (FEXT) quad
cable.
Continuity of
3.4.9 Continuity shall be there
cable armour

2012
Sl. No. Item Expected (OK/Not OK)
Station A Station B
Separate Earth of
3.4.10 Quad / PIJF Shall be less than One ohm
telecom cable
Cable allocation
3.4.11 Shall be filled up & attached
table
To be cut in such a way that
3.4.12 Unused Quad pair
none of the conductors
remains exposed.
3.4.13
pair insulated tape.
Spiral before No individual conductor to be
3.4.14
termination. made spiral
* PIJF telecom cable is available with three types of Conductor diameter
Sl. No Conductor Dia. used in PIJF cable Resistance at 200 C Loop Resistance /KM
0.50 mm 86 ohm +/- 6 172 ohm / Kms
2 0.63 mm 58 ohm +/- 4 116 ohm / Kms
3 0.90 mm 28 ohm +/- 2 56 ohm / Kms
Note: Procedure for test-
Attenuation Loss:The output/Input impedance of signal generator/dB meter shall be

600 ohm.
Near End Crosstalk: Test tone of 150 KHz to be fed in the adjacent pair of the
same quad &
NEXT to be measured at the same end on the other pair of
the same quad.
Far End Cross talk: Test tone of 150 KHz to be fed in the adjacent pair of the
same quad &
FEXT to be measured at the far end on the other pair of
the same quad.

2012
4. Outdoor electronics
Observed OK/
Sl. Item Required Not OK
No SYSTEM 1 SYSTEM 2
a. Sl. No. of Same serial number pairs.

4.1 HA-SSDAC units Example – 001 (System 1), 002
b. Details of Track circuit (System 2). Track circuit No.
Placement of
4.2 Should be in proper position
Cards / modules
4.3 Firmness of card / Modules Should be tightened with screw
/ clip provided
4.4 MS Couplers Installed and tightened properly
Wired properly as per color /
4.5 MS coupler cables
label code
Should be provided firmly
4.6 Earthing of SSDAC through copper strips or other
units standard copper cable.
Value < 1 Ohms
Should be provided firmly
4.7 Earthing of Relay Box through copper strips or other
standard copper cable.
Value < 1 Ohms
Fixing of
4.8 Should be firmly fixed using
HA-SSDAC unit
clamp
Fixing of Relay Box
4.9 Should be firmly fixed using
clamp
Cable for taking 24v D.C.
4.10 from central location to 2 X 25 sq. mm Al.
SSDAC unit.
Indicative type, plug able or
External Surge easy to install on a DIN rail.
Non plug able shall be
Protection Devices connected in parallel.
4.11 on input, output (i) On Power line
and power supply (ii) On data line
lines (iii) On reset line
(nearer to equipment)
Address pair should be
4.12 Address of SSDAC different from any SSDAC
system working on the same
station/ section.

2012
Sl. Observed
Item Required OK/Not OK
No SYSTEM 1 SYSTEM 1
4.13 Fuse 2A
Software version no.
4.14 S 002
4.15 Input voltage with Charger ON 22 V to 30 V DC
Input voltage with Charger
4.16 OFF.(Keep charger OFF for 15 22 V to 30 V DC
minutes before taking reading )
Ripple of Input Less than 10 mV
4.17
Power Supply rms /50 mV
peak to peak.
Relay drive output to the Vital
Relays. (This may be checked
4.18 across R1 & R2 of coil of vital
relay in relay box).
Section Unoccupied (Clear) >20V
4.18 a Channel 1
Section Unoccupied (Clear) >20V
4.18 b Channel 2
Section Occupied Channel 1 < 2V
4.18 c
4.18 d
Relay drive output to the
Preparatory Relays. (This may
be checked across R1 & R2 of
4.19 coil of Preparatory relay in
relay box).
4.19a Section Clear. Channel 1
>20V
4.19b Section Clear. Channel 2
>20V
4.19c
4.19d
Drive voltage of repeater relays
4.20 in picked up condition, when
charger is OFF for 15 minutes.
4.21 VPR >22V
4.22 PPR >22V

2012
5. INDOOR (Reset Box Location)
Sl. Observed Remarks

Item Required
No. UNIT-1 UNIT-2 OK / Not OK
Reset Box Wired as per drg given in
5.1 Installation Manual
Reset Box Earthing. Connected to earth properly.
5.2
a) Reset not possible when
Axle Counter section is
clear and healthy.
5.3 Reset function
b) Reset not possible when
Axle counter section is in
Preparatory reset mode.
24 VDC level at
5.4
Reset box input. 22V DC to 30 V DC
Level of reset signal
5.5 from reset box. 48 V  4 V DC
Level of reset signal
5.6 at SSDAC unit input. 38 V to 52V DC  2V DC
6. COMMISSIONING
Sl. Measured/Observed Remarks

Item Required
No. (OK/Not OK)
System should be installed &
6.1 Commissioning commissioned by personal trained by
the manufacturer.
Railway personnel should be trained
6.2 Training
before commissioning.
System to be monitored for 72 hours for
trouble free operation before
6.3 Verification of commissioning.
working During this period, effect of various
trolley wheels used in the section should
be checked as per para 7.0

2012
B- CATEGORY
(Pending issues to be attended within 15 days from the date
commissioning)
7.0 INDOOR POWER SUPPLY / CT RACK
Observed Remarks
Sl. Item Required
SYSTEM 1 SYSTEM 2 OK / Not
No
OK
Shall be of Q type 24 V ,
7.1 PPR & VPR Relays
1000 ohms
7.2 Fuse Ratings 2.0 Amps
a) Charger should be fit for
axle counter use.
b) There should not be any
7.3 Power supply for axle other load on the power
counter supply except axle counter.
c) Class B & C types surge
protection must be provided
on 230 V mains line.
Ripple of Input Power Less than 10 mV rms / 50 mV
7.4
Supply peak to peak.
Glitch in Input Power
7.5 Supply by putting ON / No glitch should be there
OFF the charger
Drive voltage of the
7.6 VPR1. (This may be >22V
checked across R1 & R2
of coil of relay).
7.7 PPR1. (This may be >22V
of coil of relay).
7.8 VPR2. (This may be >22V
of coil of relay).
7.9 PPR2. (This may be >22V
of coil of relay).

2012
8.0 Testing of Trolley movements on HA-SSADAC

Response test of digital Axle Counter with different type of
Trolley Wheels done jointly with railways
Observed Result
S.No. Type of Trolley wheel ( No influence / Goes to Remarks
error / Counted / other)
4 spoke wheel
Wheel Dia with flange
Wheel base –
8.1
Flange thickness –
Wheel Flange –
Spoke width –
6 spoke wheel
Wheel Dia with flange –
Wheel Width –
8.2
Flange width –
Flange depth –
Spoke width –
Solid Wheel with 6 holes
8.3
Wheel Width –
Flange width –
Flange depth –
8 spoke wheel
Wheel base –
8.4
Flange thickness –
Wheel Flange –
Spoke width –
8 spoke with slots
8.5 Wheel Width –
Flange width –
Flange depth –
Spoke width –
8.6 Perforated
No. of perforation with Dia.
Wheel Width –
Flange width –
Flange depth –
Spoke width –

2012
Observed Result
S.No. Type of Trolley wheel ( No influence / Goes to error/ Remarks
Counted / other)
Solid wheel
8.7
Wheel Width –
Flange width –
Flange depth –
Motor trolley wheel , Solid
8.8 Wheel Width –
Flange width –
Flange depth –
Rail Dolly Wheel solid
8.9
Wheel Width –
Flange width –
Flange depth –
8.10 Material Trolley solid wheel
Wheel Width –
Flange width –
Flange depth –
8.11 Motor Trolley wheel with 6 holes
Wheel Width –
Flange width –
Flange depth –
8.12 Tower Wagon
Wheel Width –
Flange width –
Flange depth –
Motor trolley following a train
8.13
8.14 Effect of Tower wagon **** ****
**** : Tower wagon may not be available in the section and it may affect
the commissioning. Please advice

2012
C- CATEGORY
(Pending issues to be attended within 30 days from the date of commissioning)
9.0 INDOOR CT RACK
Observed Remarks
Sl.
Item Required OK/Not OK
No UNIT-1 UNIT-2
Shall be of Q type 24 V,
9.1 PPR & VPR Relays
1000 ohms
Diode across each relay coil
Should be provided with BY127 /
9.2 (VPR/PPR) in reverse bias.
IN4007 / IN5408
Indicative type, plug able or easy to
install on a DIN rail. Non plug able
shall be connected in parallel.
External Surge Protection
1. On Power line
Devices on input, output and
9.3 2. On data line
power supply lines
3. On reset line (nearer to equipment)
Commissioning Log sheet of HA-SSDAC [Phase reversal detection

Type] Model : HA-SSDAC-G36R, Software version : S002
The following card version should be checked:
Sl.No. Type of Card Part No. Version Remarks

SYSTEM 1 SYSTEM 2
OK/Not OK
Phase Detector Card 1
1 H001M01R1 00
Phase Detector Card2
2 H001M02R1 00
3 CPU Card 1 H001M09R1 00
4 CPU Card 2 H001M10R1 00
SMCPU/Event Logger Card H001M03R1 00
5
Communication Card 1/2 H001M04R1 00
6
Relay Driver Card 1/2 H001M07R1 00
7
DC-DC Converter Card H001M29R1 00
8
9 LCD Display Box H001M24R1 00
Relay Box with Q- type; 24 G36-RB4R00 00
10 V ; 1000 Ohm relay-6F/6B
11 Filter Box G36-RSFL00 00
Axle detectors G36-T212500 00
12
(Web type TX Coils)
Axle detectors G36-R212500
13
(Web type RX coils)
14 Reset Box G36R- SBX00 00
Surge Voltage G36-LTDU00 00
15
Protection device

2012
Annexure-I
Precautions to be taken care during the wiring/connections are to be

done at the time of commissioning of SSDAC/BPAC/SSBPAC (D)
Position of One Quad in Quad cable:
White
(A)
X
Red (C) X X (D) Grey
X
(B)
Quad Colour
1st pair = White & Quad colour i.e A & B Wires

2nd pair= Red & Grey colour i.e C & D Wires of
designated colour of Quad. Each Quad is binded by the
respective Quad colour binder
Table-1
Colour scheme of PE insulated
Quads
Quad Colour
Quad Pair A - Wire B -Wire Pair C- Wire D - Wire
No No. No.
Orange 1 1A White Orange 1B Red Grey
Blue 2 2A White Blue 2B Red Grey
Brown 3 3A White Brown 3B Red Grey
Green 4 4A White Green 4B Red Grey
Yellow 5 5A White Yellow 5B Red Grey
Blac 6 6A White Black 6B Red Grey
k
Precautions to be taken for using QUAD Cable:
 Designated pair of wire of the same quad (mentioned in Table -1) should be
used.
 Do not use one wire from one quad and another wire from some other quad.
 If any wire of a pair of the quad is broken/Non functional, then use fresh pair of
wire.
 Do not parallel wires of quad cable.

2012
Annexure-II
TEMPERATURE CORRECTION FACTOR FOR CONDUCTOR

RESISTANCE FOR ANNEALED HIGH CONDUCTIVITY COPPER
Temp Corre. Temp Corre Tem Corre Temp Corre Temp Corre
. Deg factor . deg . p . . deg . . deg .
C 1. 2. C 1. Facto deg factor C 1. facto C 1. Facto
r 2. C 1. 2. r 2. r2
5. 1.0638 17 1.0122 29 0.9653 41 0.9225 53 0.8834
5.5 1.0618 17.5 1.0101 29.5 0.9634 41.5 0.9208 53.5 0.8818
6. 1.0593 18 1.0081 30 0.9615 42 0.9191 54 0.8803
6.5 1.0571 18.5 1.0060 30.5 0.9597 42.5 0.9174 54.5 0.8787
7. 1.0549 19. 1.0040 31. 0.9579 43. 0.9158 55. 0.8772
7.5 1.0526 19.5 1.0020 31.5 0.9560 43.5 0.9141 55.5 0.8757
8. 1.0504 20. 1.0000 32. 0.9542 44.. 0.9124 56. 0.8741
8.5 1.0482 20.5 0.9980 32.5 0.9524 44.5 0.9107 56.5 0.8726
9. 1.0460 21. 0.9960 33. 0.9506 45. 0.9091 57. 0.8711
9.5 1.0438 21.5 0.9940 33.5 0.9488 45.5 0.9074 57.5 0.8696
10. 1.0417 22. 0.9920 34. 0.9470 46. 0.9058 58. 0.8681
10.5 1.0395 22.5 0.9900 34.5 0.9452 46.5 0.9048 58.5 0.8667
11. 1.0373 23. 0.9881 35. 0.9434 47. 0.9025 59. 0.8651
11.5 1.0352 23.5 0.9862 35.5 0.9416 47.5 0.9009 59.5 0.8636
12. 1.0331 24. 0.9843 36. 0.9398 48. 0.8993 60. 0.8621
12.5 1.0309 24.5 0.9823 36.5 0.9380 48.5 0.8977 60.5 0.8606
13. 1.0288 25. 0.9804 37. 0.9363 49. 0.8961 61. 0.8591
13.5 1.0267 25.5 0.9785 37.5 0.9346 49.5 0.8945 61.5 0.8576
14. 1.0246 26. 0.9766 38. 0.9328 50. 0.8929 62. 0.8562
14.5 1.0223 26.5 0.9747 38.5 0.9311 50.5 0.8913 62.5 0.8547
15. 1.0204 27. 0.9728 39. 0.9294 51. 0.8897 63. 0.8532
15.5 1.0183 27.5 0.9709 39.5 0.9276 51.5 0.8881 63.5 0.8518
16. 1.0163 28. 0.9690 40. 0.9259 52. 0.8863 64. 0.8503
16.5 1.0142 28.5 0.9671 40.5 0.9242 52.5 0.8850 64.5 0.8489

2012
Annexure - III
Technical Advisory Note

Subject Digital Axle Counter – Wiring Discipline
Document Number STS/E/TAN/6001 Version 1.0
Dated 04/10/2011 Pages 2
It has come to notice that usage, termination and wiring of quad cable is far from
satisfactory for trouble-free working of electronic equipments like digital axle
counters/UFSBI. Basic issue pertains to electromagnetic interference from parallel
circuits in the cable and location.
Following guidelines are recommended to enhance performance of DAC systems.
1. Parallel circuits:
a. Requirement is that parallel circuits shall be as far spaced, spatially, as possible.
Long parallel circuits shall be avoided in the same quad. So, one long and one short
circuit can be accommodated in same quad but not both long circuits.
b. DAC circuits in BPAC of up and down lines in double line sections shall be in
separate quads and kept one/two quad distance away from each other to avoid
mutual interference in long parallel circuits.
c. DAC circuits in location shall not be bunched along with parallel relay/power
circuits. Relay circuits are known to generate switching transients that can couple
enough energy in parallel circuits nearby and interfere with low power DAC data
circuits.
d. Any other parallel wiring (relay circuits/power circuits/Earthing wires etc) shall cross
DAC circuits at perpendicular and any parallel portion shall be kept at minimum
150mm (lateral distance) away from the wiring for DAC circuits.
e. Relay circuits shall preferably be not taken in same cable as DAC circuits. In
unavoidable circumstances relay circuits shall be in furthest quad (spatially) from the
one containing DAC circuits.
2. Twisting of cable pair:
a. Twisted pairs are required to avoid mutual interference between low level data
signals. Even short lengths of non- twisting (few inches) can couple enough noise to
interfere with low voltage DAC communication signals.
b. Quad cable twisting shall be ensured during termination so that minimum one twist
per inch is maintained till the last inch into terminations.
c. Any wiring from quad cable terminations to equipment shall be done using twisted
singles of indoor signalling cable (1 mm square) or any other approved indoor
twisted pair cable.
d. Signalling cable or any other untwisted cable pair shall never be used in DAC
communication circuits to avoid intermittent type of failure.

2012
3. Wiring & Terminations:
a. Preferably, quad cable shall be terminated in cage clamp type terminals that provide
solid 360 degree surface connection and sufficient pressure on the wire to make a
good electrical contact.
b. Cables shall be terminated at the bottom portion of location keeping equipment and
their wiring at higher level inside location. This will help in keeping wiring of
different types segregated from each other. All earth wires and surge protection
devices also shall be kept at the lower levels for the same reasons.
c. Wiring and cabling shall not be bent abruptly and shall be given sufficient bending
radius to ensure that conductors inside the cabling/wiring are not damaged due to
bending.
d. Wiring shall be properly supported by channels troughing, cable clamps and other
means to ensure that connections are not under pressure due to wire hang.
e. Wiring and cabling shall not be supported at any sharp edged object to ensure that
conductors are not damaged during their installation/maintenance.
4. Continuity and Earthing of cable armor & screen at intermediate

terminations/Joints:
a. Screening of quad cable is effective only when sufficient induced current can flow in
the screen thereby cancelling/reducing the induction from 25KV AC for the cable
conductors. For adequate induced current to flow in screen, it is necessary that good
earth connections are provided for cable screen & armor.
b. Quad cable screen & armor shall be made electrically continuous at the intermediate
terminations/ joints by soldering and connecting both ends of cable screens & amours
at the locations.
c. Connections to screen shall preferably be made by hin metallic clamps soldered to

screens to ensure good surface connection for electrical continuity.
d. Combined Earth for armor and screen at intermediate locations shall have earth values as
low as possible but shall be never more than 5 ohms.
e. Earth connections shall be kept as short and as straight as possible because any loop or
turns can create inductive elements that impede quick discharge of transients and surges
to ground.

2012
Maintenance log sheet for

HA-SSDAC (System 1 Channel 1)
DC – DC Converter
Battery (24V)
Description.
Phase Detector With Push

Rx. Sup. Phase Detector 1
Tx1 Tx2 Rx1 Rx2 2 Trolley on axle DC Volts
Signal Level. DC Volts
Vrms / Vrms / Vrms Vrms DC Volts detectors
freq freq (4 spokes) -12
5V 12 V +18V 24 V
V
PD PD RX PH-SIG & RX PH-SIG & RX PH-SIG &

UTB UTB UTB UTB CARD CARD GND Socket GND Socket GND Socket
Points
FTB Monitoring Sockets on DC-DC

Test
36 & 38 & 40 & 42 & 1 2 1 2 Dumm

Date
1&2 Dummy converter card

37 39 41 43 Normal y Normal PD1 PD2
wheel
wheel
40 V to
40 to 300m 300m 11.75 -11.75 17.75
70V
70 V V to V to
(Limit)
900mV 10 V V V V
Phase
10 V to 10 V to 4.75 22V
1.2V 1.2V to 1.0V V to <1V 10 V to <1V to 12 to to to to
12 V 12 V to
(AC) (AC) (AC) V 12 V V 5.25 12.25 -12.25 18.25
24.750 26V
22-30 V V V V V
20.802 to
to
21.302
25.250
KHz
KHz

2012

DC – DC Converter
Battery (24V)
Description.

5V 12 V +18V 24 V
V

Points

Test
36 & 38 & 40 & 42 & 1 2 1 2 Dumm

Date

wheel
wheel
40 V to
40 to 300m 300m 11.75 -11.75 17.75
70V
70 V V to V to
(Limit)
900mV 10 V V V V
Phase
10 V to 10 V to 4.75 22V
12 V 12 V to
(AC) (AC) V 12 V V 5.25 12.25 -12.25 18.25
24.750 (AC) 26V
22-30 V V V V V
20.802 to
to
21.302
25.250
KHz
KHz

2012

DC – DC Converter
Battery (24V)
Description.

5V 12 V +18V 24 V
V

Points

Test
36 & 38 & 40 & 42 & 1 2 1 2 Dumm

Date

wheel
wheel
40 V to
40 to 300m 300m 11.75 -11.75 17.75
70V
70 V V to V to
(Limit)
900mV 10 V V V V
Phase
10 V to 10 V to 4.75 22V
to
12 V 12 V 12.25 -12.25 18.25
(AC) (AC) (AC) V 12 V V 5.25 26V
22-30 V 24.750 V V V V
20.802 to
to
21.302
25.250
KHz
KHz

2012

DC – DC Converter
Battery (24V)
Description.
Phase With Push

Tx1 Tx2 Rx1 Rx2 Detector 2 Trolley on axle DC Volts
5V 12 V +18V 24 V
V

Points

Test
36 & 38 & 40 & 42 & 1 2 1 2 Dumm y

Date

37 39 41 43 Normal wheel Normal PD1 PD2
wheel
40 V to
40 to 300m 300m 11.75 -11.75 17.75
70V
70 V V to V to
(Limit)
900mV 10 V V V V
Phase
10 V to 10 V to 4.75 22V
to
12 V 12 V 12.25 -12.25 18.25
(AC) (AC) (AC) V 12 V V 5.25 26V
22-30 V 24.750 V V V V
20.802 to
to
21.302
25.250
KHz
KHz

Quality Policy
“We at RDSO Lucknow are committed to maintain and update
transparent standards of services to develop safe, modern and cost
effective railway technology complying with statutory and regulatory
requirements, through excellence in research, designs and
standards by setting quality objectives, commitment to satisfy
applicable requirements and continual improvements of the quality
management system to cater to growing needs, demand and
expectations of passenger and freight traffic on the railways through
periodic review of quality management systems to achieve continual
improvement and customer appreciation. It is communicated and
applied within the organization and making it available to all the
relevant interested parties.”


INDIAN RAILWAYS
Centre for Advanced Maintenance Technology

Handbook On GGTronics HASSDAC

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GOVERNMENT OF INDIA

CAMTECH is continuously making efforts in documentation and upgradation

CAMTECH Gwalior Jitendra Singh

We are sincerely thankful to Signal Directorate, RDSO and M/s GGTronics

Since technological upgradation and learning is a continuous process, you

CAMTECH Gwalior Dinesh Kumar Kalame

Issue of correction slips

CAMTECH/S/PROJ/2020-21/SP4/1.0# XX date .......

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

To upgrade Maintenance Technologies and Methodologies and achieve

GGTronics HASSDAC G36R August 2020

1.2 Modules of HA-SSDAC-G36R system

1.2.1 Axle Detectors (Phase Reversal type)

Figure 1: Web mounted Axle detectors (Tx Rx Coils)

1.2.2 HA-SSDAC G36R unit

GGTronics HASSDAC G36R August 2020

Figure 2:HA-SSDAC G36R unit with Dual Electronics system

GGTronics HASSDAC G36R August 2020

The details of PCB modules are as given below.

(a) Phase Detector Card [PD card]

GGTronics HASSDAC G36R August 2020

(b). Central Processing Unit [CPU card]

CPU1 and CPU2

(c). Relay Driver module

RD1 and RD2

GGTronics HASSDAC G36R August 2020

(d). Communcation Module

COM1 and COM2

(e). Event Logger module

SM-CPU/Event Logger Module

(f). DC-DC Converter card

GGTronics HASSDAC G36R August 2020

1.2.3 Reset Box with Display

GGTronics HASSDAC G36R August 2020

Figure 4:Reset Box rear view

Reset Box features

1.2.4 Voltage Window Card

1.2.5 Fused tag block assembly

GGTronics HASSDAC G36R August 2020

1.2.6 Relay Box

1.2.7 Display Module

Figure 5:Display Module

1.2.8 Other accessories

1.3 Salient Features

GGTronics HASSDAC G36R August 2020

 Wrong operations totally avoided with hardware polarization & unique

1.4 Principle of Wheel Detection

 Phase detection employed

Figure 6:Solid wheel and spoke wheel of push trolley

GGTronics HASSDAC G36R August 2020

Figure 7:Wheel Detection - Train Wheel - Count

Figure 8:Wheel Detection - Trolley Wheel - No Count

Figure 9:Wheel Detection - Dip Lorry - No Count

GGTronics HASSDAC G36R August 2020

1.5 Installation Guidelines

Figure 10:Installation of Axle Detectors

GGTronics HASSDAC G36R August 2020

Figure 11:Termination in location box with LDU and fuse

Type of cable Description

GGTronics HASSDAC G36R August 2020

Figure 12:HASSDAC G36R Cable Plan (Proposed)

GGTronics HASSDAC G36R August 2020

S YS TEM 1 S F S YS TEM 2 S F S YS TEM 1 EF BATTERY