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An Insight Into
Single Section Digital Axle Counter (SSDAC-
G36)
Approved by RDSO
To SPEC No. RDSO/SPN/177/2005 Ver 2.0 with Amendment
1
By
G.G.Tronics India Private LimitedSB 168, 3rd Cross, Peenya 1st Stage, Peenya Industrial Estate, Bangalore-560 058
Ph : 080-28372449/50/51 Fax : 080 – 28372387 Web:www.ggtronics.com
April 8, 2023 An Insight into SSDAC-G36 2
Overview
SSDAC-G36 is a fail-safe microcontroller based system with 2 out of 2 architecture suited for proving Block Section and Entry/Exit of station.
Supports the following configurations with fool proof arrangement of communication path and addressing scheme.
2 DP-SS : in Straight Line (2D) 3 DP-SS : in Point Zone / Set Points (3D) 3 DP-2S : for two consecutive sections in
Straight Line AS : auto signaling
Third party Verification and Validation of software completed for all configurations complying to CENELEC En50128 with SIL-4 level
April 8, 2023 An Insight into SSDAC-G36 3
Application of SSDAC-G36
2DP version is intended for providing clear/occupied status of a single section block or entry/exit of a station.
3DP-1S version used for proving point zone/set points working
3DP-2S version employed for proving two consecutive sections in a straight line treating each independent of the other
April 8, 2023 An Insight into SSDAC-G36 4
Functional Aspects Detection and counting of wheels / axles
Detection of direction of axle movement
Declaring a block section as occupied on the very first count of an axle
Transmission/Reception of counts, system status and many vital information to other SSDAC unit via FSK communication employing quad cable
Carrying out count comparison between local and remote units
Declaring the track section clear after both the local and remote counts match after clearance of the last vehicle
Displaying axle counts, unit status and error messages locally in each unit and also remotely in the Reset box connected to the unit
Logging vital information in event logger, for downloading on PC with GUI package through RS232C
April 8, 2023 An Insight into SSDAC-G36 5
Functional Aspects (Contd…)
Shunting operation taken care of Train Shunting
No restrictions Wheel Shunting
Single sensor sensed once - allowed Single sensor sensed twice -Error mode Dual sensor - allowed up to 3 times Dual Sensor - 4 times - Error mode
Communication scheme Fail-safe feature incorporated to avoid wrong addressing Communication takes place only in fixed pairs
Com1Com2 : Normal Com1Com1 : Error mode Com2Com2 : Error mode
April 8, 2023 An Insight into SSDAC-G36 6
Functional Aspects (Contd…)
Data Logger report retrieval (Through PC using GUI based S/W)
Local – RS232 (Serial port)
Portable Data Logger (Optional) For downloads all the events from SSDAC event logger card
April 8, 2023 An Insight into SSDAC-G36 7
Main Requirements of Specification - Complied
To meet CENELEC SIL-4 Safety level
Employ phase reversal technique
Use of 2 out of 2 voting
Data logging for 14000 events
To work with 90-R, 52 Kg, 60 Kg rails
Use of industrial grade components
Stable operation in RE areas.
To work between –10° C to +70° C
MTBF more than 70000 hours ( As per QM115 method )
To work between train speeds of 5Kmph to 250Kmph
Not to need trolley suppression circuit
April 8, 2023 An Insight into SSDAC-G36 8
Salient Features
Common hardware/software for all configurations
Actuates Vital and Preparatory Relays
Preparatory Reset after line verification possible
Cooperative Reset from the station master cabin
Reliable inter-communication of data between the units at distances up to 25 km or -30dB loss through quad cables at 1200bps using V.23 protocol
Works with 24V DC power supply
April 8, 2023 An Insight into SSDAC-G36 9
Salient Features (Contd…)
Wide input voltage operation from 16.8 VDC to 32.0 VDC
Wrong operations totally avoided with unique addressing of units up to 255 combinations
Upgradation to higher configuration possible
Integrated with lightening surge protectors
Water logging on track does not affect the functioning of the system
April 8, 2023 An Insight into SSDAC-G36 10
Installation Details – Cable requirement
S TA TI O NB
S TA R T FED
TX 1 TX 2
R X 1 R X 2
END FED
TX 1 TX 2
R X 1 R X 2
S TA TI O NA
M O D E M C O M M UN I C AT I O N1 /2 q u ad c ab le
M AX I M UM 2 5 KM 's
AP P R O AC HD E T E C T O R SUP D I R E C T I O N
AP P R O AC HD E T E C T O R SD O W ND I R E C T I O N
6 c o r e c abl e1 .5 Sq m mR e s e t andR e pe atR e l aySi g nal
2 c o r e c abl e2 5 Sq m mpo w e r
6 c o r e c abl e1 .5 Sq m mR e s e t andR e pe atR e l aySi g nal
2 c o r e c abl e2 5 Sq m mpo w e r
1 /2 quadc abl e(o pt i o nal )s tat i o nm as te rc o m m uni c at i o n
1 /2 quadc abl e(o pt i o nal )s tat i o nm as te rc o m m uni c at i o n
2 1 KH Z 2 1 KH Z
2 1 KH Z 2 1 KH Z
2 5 KH Z
2 5 KH Z
2 5 KH Z
2 5 KH Z
April 8, 2023 An Insight into SSDAC-G36 11
Installation Details – Typical Installation- 2DPR a i l w a y Tr a c k
A x l e D e t e c t o r s
R X
A x l e D e t e c t o r s
S S D A C EF
S ta tio n B
S S D A C S F
R X
TXTX
P D 1 P D 2
C P U1
C P U 2
RD
2 DC
-DC
Co
nv
erter
P D 1 P D 2
C P U1
C P U 2
RD
1 DC
-DC
Co
nv
erter
CO
M2
SP
AR
E
SP
AR
E
S ta tio n A
Po we r s u pply
R e s e t B o x
CO
M1
SP
AR
E
SP
AR
E
R e s e t B o x
S MC P U /Eve n tL o g g e r
S MC P U /Eve n tL o g g e r
R e l a y B o xV i t a l R e l a y BP r e p R e l a y B
2 5 KHz2 5 KHz
D i s p l a y U n i t D i s p l a y U n i t
R e l a y B o xV i t a l R e l a y AP r e p R e l a y A
2 1 KHz2 1 KHz
To S S D A CS F Un i t
To S S D A CEF Un i tR S 2 3 2 / FS K
C om m u n ic ation
R S 2 3 2 / FS KC om m u n ic ation
Po we r s u pply
FS KC o m m u n ica t io n
24VD
C
24VD
C
F ilter U n it
F ilter U n it
2 1 K H z R X2 1 K H z TX
2 5 K H z R X2 5 K H z TX
April 8, 2023 An Insight into SSDAC-G36 12
Wheel Detection Principles
Phase detection employed
Signals fed at 21Khz and 25Khz to Tx coils – at 60V
Phase of signal output of Rx compared with Tx
AT PD Module/Card : Under No wheel Tx and Rx signals will be 180° OUT-OF-PHASE
>10V Under wheel condition Tx and Rx will be IN-PHASE <100mV
These are fed to CPU at 5V and 0V
Wheels above 500mm diameter only are detected
For a train at 250Kmph, pulse width is about 2.2ms
Frequency of Scanning by processor for PD signal is 300µs – 7 times for every wheel
April 8, 2023 An Insight into SSDAC-G36 13
Wheel Detection - Train Wheel - Count
Overlap Signal
PD1
PD2
April 8, 2023 An Insight into SSDAC-G36 14
Wheel Detection - Trolley Wheel - No Count
Non-Overlap Signal
PD1
PD2
April 8, 2023 An Insight into SSDAC-G36 15
Wheel Detection - Dip Lorry - No Count
No Detection
PD1
PD2
April 8, 2023 An Insight into SSDAC-G36 16
Schematic - 2DP Version
Operation on straight lines - station or block section
Communication using 1 pair / half Quad cable or OFC voice channel
Preparatory Reset with piloting
PR and VR contacts at detection points
DP-SF DP-EFStation Section
Station
Station A
Station BBlock Section
DP-SF DP-EF
Legend :RD1, RD2 Relay Drive Card
Com1, Com2 Communication
CardSF Start FedEF End Fed VR Vital RelayPR Preparatory Relay
DAC-2
Com1
PR
End Fed
DAC-1
Com2
Start Fed
RD1RD2
PR
VR VR
April 8, 2023 An Insight into SSDAC-G36 17
System Configuration - 2DP Version
Legend :RD1, RD2 Relay Drive Card Com1, Com2 Communication
CardSF Start FedEF End Fed VR Vital RelayPR Preparatory Relay
DAC-2
Com1
PR
End Fed
DAC-1
Com2
Start Fed
RD1RD2
PR
VR VR
2DP Card Configuration in SSDAC G36
DAC-1 DAC-2P
hase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Rela
y D
rv-1
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
April 8, 2023 An Insight into SSDAC-G36 18
Schematic - 3DP-1S Version
Operation on point Zones / Set points
Communication using quad cable or OFC voice channel
Detection at any point and clearing at any point
Preparatory Reset with LV
VR contacts at detection points
DP-B
DP-C
DP-A
Legend :RD1, RD2 Relay Drive
Card Com1, Com2
Communication CardVR Vital Relay
DAC-1
Com1 Com2
Unit A
RD2VR
DAC-2
Com1 Com2
Unit B
RD2VR
DAC-3
Com1 Com2
Unit C
RD2VR
April 8, 2023 An Insight into SSDAC-G36 19
System Configuration - 3DP-1S
Legend :RD1, RD2 Relay Drive
Card Com1, Com2
Communication CardVR Vital Relay
DAC-1
Com1 Com2
Unit A
RD2VR
DAC-2
Com1 Com2
Unit B
RD2VR
DAC-3
Com1 Com2
Unit C
RD2VR
3DP Card Configuration in SSDAC G36
DAC-1 DAC-2 DAC-3P
hase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
April 8, 2023 An Insight into SSDAC-G36 20
Schematic - 3DP-2S Version
Station A
Station B
Section A Section B
Block Section
DP-SF DP-EFDP-CF
Legend :SF : Start Fed CF : Centre Fed EF : End Fed CFVR - A : Vital Relay for Sec A at Centre Fed CFVR - B : Vital Relay for Sec B at Centre FedCom1, Com2 : Communication Card EFVR - A : Vital Relay at Sec B for End FedPR : Preparatory Relay SFVR - A : Vital Relay at Sec A for Start Fed
DAC-SF Com2
SF
RD2SFVR-APR A
Reset-SFSection-A
Reset-CFSection-B
Station-A
DAC-EFCom1
EF
RD1EFVR-BPR B
Reset-CFSection-A
Reset-EFSection-B
Station-B
DAC-CFCom1 Com2
CF
RD2 RD1CFVR-APR A
CFVR-BPR B
April 8, 2023 An Insight into SSDAC-G36 21
Schematic 3DP-2S (Contd…)
Operations on two consecutive sections on a straight line.
Section A and B are independent and can be reset individually
Communication using single pair / half quad cable or OFC voice channel.
Co operative Preparatory reset with piloting
April 8, 2023 An Insight into SSDAC-G36 22
System Configuration - 3DP-2S
3DP-2S Card Configuration in SSDAC G36
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
Rela
y D
rv-1
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
Com
-1
SM
-CP
U
Even
t Log
ger
Rela
y D
rv-1
Ph
ase D
ete
cto
r C
ard
-1
Ph
ase D
ete
cto
r C
ard
-2
DC
-DC
Con
vert
er(
+2
4V
)
CP
U-1
CP
U-2
SM
-CP
U
Even
t Log
ger
Com
-2
Rela
y D
rv-2
DAC-SF Com2
SF
RD2SFVR-APR A
Reset-SFSection-A
Reset-CFSection-B
Station-A
DAC-EFCom1
EF
RD1EFVR-BPR B
Reset-CFSection-A
Reset-EFSection-B
Station-B
DAC-CFCom1 Com2
CF
RD2 RD1CFVR-APR A
CFVR-BPR B
April 8, 2023 An Insight into SSDAC-G36 23
AS or Auto Signalling
Operation on continuous sections in suburban areas or on a long track
Up to 128 SSDAC’s can be daisy chained in series
Communication using single pair / half quad cable or OFC voice channel
Option of Preparatory Reset with or without piloting
Block 1 Block 2 Block n+1
Section n+1
Section C
Section B
Section A
April 8, 2023 An Insight into SSDAC-G36 24
Hardware Modules / Cards
CPU Card (CPU1 & CPU2) Failsafe 2 out of 2 architecture for controlling and monitoring the SSDAC for reliable
operation Houses the system software that schedules the overall operation as per configuration
Phase Detector Card (PD1 & PD2) A vital card that detects the movement of train axles/wheels that is more than 550mm
diameter Rejects trolley, dolly, spoke wheels and push trolley wheels Counts the total number of train axles and updates the system
Communication Card (Com1 & Com2) Communication between two SSDAC systems is through FSK communication at 1200bps
V.23 standard along with CRC check Vital data like axle counts and system status are transmitted/received between the
SSDAC system units
Relay Drive Card (RD1 &RD2) Axles sensed by Detector Coils are fed to PD card which in turn feeds signal to CPU. The
relay drive card receives instructions from CPU for actuating Vital relay for blocking a section as soon as the first axle is detected. It is cleared after both IN and OUT counts of the section match
Power Supply Card Generates required multiple power outputs from 24VDC input
April 8, 2023 An Insight into SSDAC-G36 25
Hardware Modules / Cards (Contd…)
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
April 8, 2023 An Insight into SSDAC-G36 26
Typical SSDAC-G36 Unit
LCD Status Display module
PD Cards
CPU Cards
24VDC Power Supply
Relay Drive Card
Event Logger Card
Communication Card
April 8, 2023 An Insight into SSDAC-G36 27
Typical Site Installation
SSDAC-G36 installed in Location Box
April 8, 2023 An Insight into SSDAC-G36 28
SSDAC-G36 unit with PR and VR Relays in a box and Display Module
April 8, 2023 An Insight into SSDAC-G36 29
Internal wiring with LDU and fuse
April 8, 2023 An Insight into SSDAC-G36 30
Axle detector coils web mounted on to a track
April 8, 2023 An Insight into SSDAC-G36 31
Checking for Not Sensing of Trolley wheel
April 8, 2023 An Insight into SSDAC-G36 32
Reset Box with LCD Display – Clear condn of track
RESET Box installed at Station
April 8, 2023 An Insight into SSDAC-G36 33
Reset Box with LCD Display – Occd condn of track
April 8, 2023 An Insight into SSDAC-G36 34
Reset Philosophy
Types of Reset
Co-operative Preparatory Reset with piloting for 2D and 3D-2S
configurations
Direct Reset with line verification for 3D configuration
Reset Procedure
2D : System powered onReset ModePrep ModePilotingClear
Mode
3D-2S: System powered onReset ModePrep
ModePilotingClear Mode
3D : System powered on Reset ModeLVClear Mode
April 8, 2023 An Insight into SSDAC-G36 35
Installation Procedure
The installation can be taken up with the following parallel activities
Laying foundation as per Railway standards for fixing the location box
Trenching for running the required length of cable
Drilling of track for fixing TX/RX coils with the template
Fixing of TX/RX coils on the track
Laying of power cables, signalling cables and cables from TX/RX coils
Painting and fixing of required planks and fuse the terminal block
Digging Earth pit and getting ready the earthing arrangement
Checking for the compliance of pre commissioning check list
Placing the unit along with related PCB modules/cards and Display module
Connecting earth terminal of the unit chassis to the main chassis and on to the main earth through copper cables
April 8, 2023 An Insight into SSDAC-G36 36
Installation Procedure (Contd…)
Placing Relay box adjacent to the unit
Fixing of the MS Coupler cable assemblies on to the designated mating Couplers on the rear panel of the system
Checking continuity and insulation resistance between cable pairs and also between the chassis and the cables
Connecting all the shields and the screen wires to the earth
Fixing of the reset box in a convenient location in the station
Connecting the wires coming from the system to the reset box
Connecting 24V DC to power supply
Connecting the power cables coming from the system to the source of power supply of 24V DC at the station, keeping the FTB connector open
April 8, 2023 An Insight into SSDAC-G36 37
Maintenance
Periodicity Maintenance
WeeklyCheck for the proper voltage at the
battery source for the unit
Fortnightly
Check and record the readings of1. Power supply module 2. PD module3. Check the coil Voltages
Half yearly / Yearly
Replace defective parts if any
Every 5 YearsPower Supply/DC-DC Converter
modulesmust be replaced
April 8, 2023 An Insight into SSDAC-G36 38
Backup Spares (Recommended)
Sl.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
12SSDAC unit (housing with mother board, without
modules)1
13 Relay Box 1
April 8, 2023 An Insight into SSDAC-G36 39
Recommended Tools
Sl.No Tools Quantity
1PC/Laptop for downloading event logger
data for analysis and report generation1
2Pure sine wave Digital Multimeter (Fluke
make 187 or Rishab make 28S or similar1
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
April 8, 2023 An Insight into SSDAC-G36 40
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
Further slides indicate the messages, their analysis and the corrective action to be taken
April 8, 2023 An Insight into SSDAC-G36 41
Trouble Shooting
Error Code ondisplay of CPU
Errors Analysis Corrective measure
1 PD1_BOARD_MISSINGError occurred due to missing of the Phase
detector 1 module (PD1- 21KHz) during run time and boot time diagnosis.
Place the PD1 module in the slot and reset the system
2 PD2_BOARD_MISSINGError occurred due to missing of the Phase
detector 2 module (PD2- 25KHz) during run time and boot time diagnosis.
Place the PD1 module in the slot and reset the system
3 SM_CPU_MISSINGError occurred due to missing of the SM-CPU
module during run time and boot time diagnosis.
Place the SM-CPU module in the slot and reset the system
4MODEM_MODULE_A_MISSIN
G
Error occurred due to missing of the Communication A module during run time and boot time diagnosis.
Place the Communication A module in the slot and reset the system
5MODEM_MODULE_B_MISSIN
G
Error occurred due to missing of the Communication B module during run time and boot time diagnosis
Place the Communication B module in the slot and reset the system
6 RELAY_DRIVE_A_MISSINGError occurred due to missing of the Relay
Drive A module during run time and boot time diagnosis
Place the Relay Drive A module in the slot and reset the system
7 RELAY_DRIVE_B_MISSINGError occurred due to missing of the Relay
Drive B module during run time and boot time diagnosis
Place the Relay Drive B module in the slot and reset the system
April 8, 2023 An Insight into SSDAC-G36 42
Trouble Shooting Contd…
8 PEER_CPU_MISSINGError occurred due to missing of the any
one of the CPU module during run time and boot time diagnosis
Place the CPU module missing in the slot and reset the system
9 COMM_LU1_TO_US1_FAILUREWhen EF CPU1 could not transmit to
remote unit (CF or SF) CPU1
Check the communication links (MS Coupler) and Reset the system
10 COMM_LU1_TO_US2_FAILUREWhen EF CPU1 could not transmit to
remote unit (SF or CF) CPU2
Check the communication links (MS Coupler) and Reset the system
11 COMM_LU1_TO_DS1_FAILUREWhen SF CPU1 could not transmit to
remote unit (CF or EF) CPU1
Check the communication links (MS Coupler) and Reset the system
12 COMM_LU1_TO_DS2_FAILUREWhen SF CPU1 could not transmit to
remote unit (CF or EF) CPU2
Check the communication links (MS Coupler) and Reset the system
13 COMM_US1_TO_LU1_FAILUREWhen EF CPU1 could not receive any
response from the remote unit (SF or CF) CPU1
Check the communication links (MS Coupler) and Reset the system
14 COMM_US2_TO_LU1_FAILUREWhen EF CPU2 could not receive any
response from the remote unit (SF or CF) CPU1
Check the communication links (MS Coupler) and Reset the system
15 COMM_DS1_TO_LU1_FAILUREWhen SF CPU1 could not receive any
response from the remote unit (CF or EF) CPU1
Check the communication links (MS Coupler) and Reset the system
April 8, 2023 An Insight into SSDAC-G36 43
Trouble Shooting Contd…
16 COMM_DS2_TO_LU1_FAILUREWhen SF CPU2 could not receive any
response from the remote unit (CF or EF) CPU1
Check the communication links (MS Coupler) and Reset the system
17 COMM_LU2_TO_US1_FAILUREWhen EF CPU2 could not transmit to
remote unit (SF or CF) CPU1
Check the communication links (MS Coupler) and Reset the system
18 COMM_LU2_TO_US2_FAILUREWhen EF CPU2 could not transmit to
remote unit (SF or CF) CPU2
Check the communication links (MS Coupler) and Reset the system
19 COMM_LU2_TO_DS1_FAILUREWhen SF CPU2 could not transmit to
remote unit (CF or EF) CPU1
Check the communication links (MS Coupler) and Reset the system
20 COMM_LU2_TO_DS2_FAILUREWhen SF CPU2 could not transmit to
remote unit (CF or EF) CPU2
Check the communication links (MS Coupler) and Reset the system
21 COMM_US1_TO_LU2_FAILUREWhen EF CPU1 could not receive any
response from the remote unit (SF or CF) CPU2
Check the communication links (MS Coupler) and Reset the system
22 COMM_US2_TO_LU2_FAILUREWhen EF CPU2 could not receive any
response from the remote unit (SF or CF) CPU2
Check the communication links (MS Coupler) and Reset the system
23 COMM_DS1_TO_LU2_FAILUREWhen SF CPU1 could not receive any
response from the remote unit (CF or EF) CPU2
Check the communication links (MS Coupler) and Reset the system
April 8, 2023 An Insight into SSDAC-G36 44
Trouble Shooting Contd…
24COMM_DS2_TO_LU2_FAILU
RE
When SF CPU2 does not receive any response from the remote unit (CF or EF) CPU2
Check the communication links (MS Coupler) and Reset the system
25MODEM_ERROR_NO_CARRI
ERCarrier signal is being blocked by
modemReplace the faulty module
26 PEER_CPU_LINK_FAILURE
Error occurred due to missing or error in CPU/ SM-CPU module during run time and boot time diagnosis
Check for the error or presence of SM-CPU/CPU module in the system, rectify the error and reset the system
27 FAILURE_AT_DS Error at Down stream unitCheck the error at remote unit,
rectify the error and reset the system
28 FAILURE_AT_US Error at Up stream unitCheck the error at remote unit,
rectify the error and reset the system
33 PD1_SUP_LOW
PD1 module supervisory is low for 3 seconds and TX and RX coils is not connected properly
Check the PD1 module, coils and reset the system
34 PD2_SUP_LOW
PD2 module supervisory is low for 3 seconds and TX and RX coils not connected properly
Check the PD2 module, coils and reset the system
35 PD1_PULSINGError occurs when any one
sensor is influenced two or more times.
Reset the system
36 PD2_PULSINGError occurs when any one
sensor is influenced two or more times.
Reset the system
37 PD_STATE_MISSINGError occurs when double sensor
is influence in the sequenceReset the system
April 8, 2023 An Insight into SSDAC-G36 45
Trouble Shooting Contd…
38 PD_SUP_PULSATINGIf supervisory signals pulsates more
than 4 timesReset the system
39 PD_STATE_FAILError occurs when any state
sequence is missingReset the system
40 PD_NOT_SENSINGError occurs when both the PD
modules doesn’t sense the wheel for more than 3 times
Reset the system
41 PREPARATORY_RELAY_A_FAILURENo/Improper feedback from
Preparatory A relay
Check the connections of Preparatory relay A (PRA) and reset the system
42 PREPARATORY_RELAY_B_FAILURENo/Improper feedback from
Preparatory B relay
Check the connections of Preparatory relay B (PRB) and reset the system
43 VITAL_RELAY_A_FAILURENo/Improper feedback from Vital
Relay A relay
Check the connections of Vital relay A (VRA) and reset the system
44 VITAL_RELAY_B_FAILURENo/Improper feedback from Vital
Relay B relay
Check the connections of Vital relay B (VRB) and reset the system
45 DIRECT_OUT_COUNTWithout IN COUNT, OUT COUNT
registeredReset the system
49 TRANSIENT_POWER_FAILURE_DS1 Power failure at Down stream CPU1 Reset the system
50 TRANSIENT_POWER_FAILURE_DS2 Power failure at Down stream CPU2 Reset the system
51 TRANSIENT_POWER_FAILURE_US1 Power failure at Up stream CPU1 Reset the system
52 TRANSIENT_POWER_FAILURE_US2 Power failure at Up stream CPU2 Reset the system
April 8, 2023 An Insight into SSDAC-G36 46
Trouble Shooting Contd…
57INVALID_NETWORK_ADDRE
SSWhen CPU address range wrong
Change the address settings by using LK10 to LK17 links and reset the system
58 INCORRECT_CODE_CRC
This is a Boot Up error. When CRC of the code mismatches with the stored CRC
Re-program the processor and code memory checksum
59 INVALID_CONFIGURATIONWhen unit type and address of
CPU is wrong
Change the address and configuration settings as per the requirement and reset the system
60 INVALID_COUNTS Train with 10,000 wheels Reset the system
61 RAM_TEST_FAILEDThis is an Boot up error when
RAM (In- built memory of Microcontroller) is failed
Replace the Micro Controller
April 8, 2023 An Insight into SSDAC-G36 47
Do’s and Don'ts
Sl.No DO’s
1
The interconnection drawings are to be followed for connecting the Transmitter and 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
11
It is recommended that heat resisting paint to be used on the apparatus case so that the
temperature inside apparatus case is maintained lower in comparison to other normal paints
April 8, 2023 An Insight into SSDAC-G36 48
Do’s and Don'ts Contd…
Sl.No DON’Ts
1Don’t cut or join the Transmitter/Receiver cables supplied along with the coil. It would result in change of levels of signals.
2Don’t remove the modules from SSDAC Units under POWER ON condition of
system. Remove module if necessary after switching OFF the power to the Unit.
3Local Address of the CPU-1 and CPU – 2 and configuration settings of the
system should not be changed at the field.
4
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.
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
5Caution Board has to be placed near the SSDAC Axle detectors to avoid
damage to theCoils from packing machines
April 8, 2023 An Insight into SSDAC-G36 49
IV&V of Software Highlights
V&V as per CENELAC En50128 by RelQ Software has been completed successfully as below .
Review of Documents as per CENELAC En50128
Review of Source Code as per Coding Standards
White Box Testing for DE, 2D, 3D, 3D-2S, AS
HSI Testing for 2D, 3D, 3D-2S, AS
Regression Testing for 2D, 3D, 3D-2S, AS
Project Closure Reports
April 8, 2023 An Insight into SSDAC-G36 50
Speed-Test using Real-time Wheel Simulator
The SSDAC G-36 speed-test setup along with Tx & Rx DP’s mounted for axle detection at varying speeds from 0 to 250kmph is shown in the figure
The wheel simulator simulates actual train wheel (918mm dia) at varying speeds from 0 to 250Kmph
The speed of wheel simulator was varied from 0 to 250Kmph and axle counts of RPM meter and counts on LCD panel of SSDAC were noted
The RPM counts and wheel counts on LCD panel of SSDAC matched upto max of 9999 counts and at speeds of 5, 50, 150, 200, 225, 250 kmph
ALL SSDAC systems are tested with the Real-time Wheel Simulator and supplied
Tx Rx Coils
Wheel dia 918mm
Odometer
RPM meter
April 8, 2023 An Insight into SSDAC-G36 51
Conclusion
SSDAC-G36 is a rugged system, designed to meet the stringent Railway environment. It can be easily integrated into the family of signaling systems for effortless management of Block and Section proving at stations.
Thank You