SSDAC Presentation Detailed

Central Electronics Central Electronics LimitedLimited

Single Section Digital Axle CounterSingle Section Digital Axle Counter

Presented By

G.Babu Rao,

Chief Manager - CEL

New Axle Counter New Axle Counter GenerationGeneration

Presented By :Presented By :

•Amit TibrewalAmit Tibrewal

(M.R.Trading (M.R.Trading Co.)Co.)

CEL CEL

CEL is a public sector Enterprise CEL is a public sector Enterprise under the Department of Scientific under the Department of Scientific and industrial Research, Ministry of and industrial Research, Ministry of Science & Technology, Govt. of India.Science & Technology, Govt. of India.

•CEL is presently the largest indigenous CEL is presently the largest indigenous manufacturer of Electronic Railway manufacturer of Electronic Railway Signalling Equipment.Signalling Equipment.

•CEL is equipped and committed for the CEL is equipped and committed for the development & manufacture of state of development & manufacture of state of the art Signalling systems for railways.the art Signalling systems for railways.

Axle Axle Counters(Indigenous)Counters(Indigenous)

SnSnoo

TypeType YeaYearr

Track Circuit Track Circuit ApplicationApplication

11 Single Single Entry/ExitEntry/Exit

19719777

Single SectionSingle Section

22 Multi Entry/ExitMulti Entry/Exit 19819855

Single Section/Point Single Section/Point ZonesZones

33 Universal Axle Universal Axle CounterCounter

19919944

-do--do-

44 Digital Axle Digital Axle CounterCounter

20020033

Single SectionSingle Section

• Product History

More than 5000 Axle Counters of first three types are deployed in various locations of Indian Railways.

CEL & RDSO have now designed & developed Digital Axle Counter for single section.

Advantages of Axle Advantages of Axle CountersCounters

• Monitors very long track sectionsMonitors very long track sections• Last vehicle check is done Last vehicle check is done

automaticallyautomatically• No effect due to ballast resistanceNo effect due to ballast resistance• Insensitive to temperature variationInsensitive to temperature variation• Train detection on rusted, sanded & Train detection on rusted, sanded &

water logged trackswater logged tracks• Immune to traction return currentsImmune to traction return currents

Single Section Digital Single Section Digital Axle CounterAxle Counter

• Designed as per CENELEC* Standards Designed as per CENELEC* Standards of highest Safety Integrity Level 4 (SIL-of highest Safety Integrity Level 4 (SIL-4).4).

• Micro controller based designMicro controller based design• First time developed indigenously by First time developed indigenously by

CEL & RDSO.CEL & RDSO.• Import substitute.Import substitute.

CENELEC-Committee European de Normalisation Electro technique

SSDAC- ApplicationSSDAC- Application

• Station LinesStation Lines

• Yard LinesYard Lines

• Block SectionBlock Section

• Intermediate Block SignallingIntermediate Block Signalling

• Auto SectionsAuto Sections

• Train actuated warning at LC gatesTrain actuated warning at LC gates

SSDAC-DesignSSDAC-Design

• Micro controller based designMicro controller based design• Decision based on 2 out of 2 logic for each Decision based on 2 out of 2 logic for each

SSDAC unitSSDAC unit• Decision based on 4 out of 4 logic for complete Decision based on 4 out of 4 logic for complete

sectionsection• Continuous monitoring of counts and health of Continuous monitoring of counts and health of

SSDAC unitsSSDAC units• Fail safe operationFail safe operation• Vital Relay output at both stations Vital Relay output at both stations

SSDAC - SSDAC - FunctionsFunctions

• Generation of carrier signal for TX coilsGeneration of carrier signal for TX coils• Demodulation of signal from RX coilsDemodulation of signal from RX coils• Generation of valid pulsesGeneration of valid pulses• Count the pulses to compute the number of Count the pulses to compute the number of

passing wheelspassing wheels• Exchange & Comparison of counts between two Exchange & Comparison of counts between two

SSDAC unitsSSDAC units• Giving a Vital Relay outputGiving a Vital Relay output• Error checking and displayError checking and display

MLB 1

MLB 2RELAYDRIVE(24V)

MODEM

PULSE 1

PULSE 2

TO NEXTSSDAC

Rx1 SCC1

VITALSIGNAL

RELAY 'Q'TYPE

RX1

TX1

RX2

TX2

SCC2

AXLEDETECTOR

AXLEDETECTOR

LEGEND

SCC 1 & 2 : SIGNAL CONDITIONER CARDMLB 1 & 2 : MICROCONTROLLER LOGIC BLOCK

SSDAC-Block DiagramSSDAC-Block Diagram

SSDAC-CommunicationSSDAC-Communication

• Communication between two SSDAC units Communication between two SSDAC units is in the form of data packetsis in the form of data packets

• Data packet consists ofData packet consists of– Count change informationCount change information– Count update informationCount update information– Reset information if anyReset information if any– Error information if anyError information if any

• Transmission on Cable, OFC, Radio by Transmission on Cable, OFC, Radio by means of V.21 Modem (full duplex)means of V.21 Modem (full duplex)

SSDAC-MonitoringSSDAC-Monitoring

• Display of error by means of LEDsDisplay of error by means of LEDs• Function wise LED’s in each cardFunction wise LED’s in each card• RS-232 port for on-line monitoringRS-232 port for on-line monitoring• Event logger card (optional)Event logger card (optional)

SSDAC – Front ViewSSDAC – Front View

MODEM CARD

SIGNALS SIGNALS

MLB2MLB1SCC - 2SCC - 1

STATUS STATUS2.2V DC

0V DC

ADJ

2.2V DC

0V DC

OSC OK

ADJ

OSC OK

LD OK

PULSEOK

OCCUPIED

CLEAR

OCCUPIED

CLEAR

5V

12V

24V

GND

+15VISO

DC- DC

Tx

Rx

MODE

CD

LD OK

PULSEOK

RELAYDRIVE

RELAY CARD

MLB 1

CLOCK

CLEAR

MLB 2

CLOCK

CLEAR

ERRORSERRORS

•Various Kinds Of Various Kinds Of Errors Are As Errors Are As Follow:Follow:

ERRORSERRORSError No 14- CARD PRESENCE TESTThe presence of each card is checked in the system. if all cards are intact and present in the system this error will not appear. If any card is removed or not inserted properly in the unit the errorno.14 is displayed.

Error noError no Action req.Action req.

The error No.14 is displayed as The error No.14 is displayed as flashing if any card is removed flashing if any card is removed or not inserted properly.or not inserted properly.

Insert all cards properly.Insert all cards properly.

Error No 15- RELAY TESTDuring Power On Self Test (POST) the vital relay connected to the system is checked. if the relay present this error will not appear. If relay is not connected the error no.15 is displayed as given below.

Error noError no Action RequiredAction Required

The error No.15 is displayed The error No.15 is displayed as flashing if the relay and as flashing if the relay and connection are not proper.connection are not proper.

Check the presence of relay. Check the presence of relay. Check the connection of Check the connection of relay .Make proper connection.relay .Make proper connection.

ERRORSERRORSError No 30- LINK ERRORThe link error is detected when the link between two SSDAC units is open. This is displayed as error no.30


The error No.30 is displayed The error No.30 is displayed when link is open.when link is open.

Check the communication link Check the communication link between the units & rectify the between the units & rectify the fault.fault.

Error No 31- SEQUENCE ERRORSoftware checks the pulse sequence when axle is detected on the sensor.


The error No.31 is displayed The error No.31 is displayed when the sequence of pulses when the sequence of pulses is not correct.is not correct.

Check the arrangement of the Check the arrangement of the detectors. Check card 1 & 2 and detectors. Check card 1 & 2 and replace if necessary.replace if necessary.

Error No 32- SELF COUNT MISMATCHSoftware checks count difference in the MLB after detection of every axle passing the sensor.

ERRORSERRORS

Error No 33- INOUT ERRORThis error code will be displaced if software detects difference in Axles entered in the section and exited from the section.


The error No.33 is displayed if The error No.33 is displayed if the number of axles goining the number of axles goining out of the section is more then out of the section is more then the coming into the section.the coming into the section.

Check the arrangement of the Check the arrangement of the detectors. Adjust the Dip and detectors. Adjust the Dip and apply the reset to make the apply the reset to make the system normal.system normal.

Error No 34- OUT BEFORE IN ERRORThis error appears when detector B is normal and giving dip for train movement and detector A is not giving any dip.


The error No.34 is displayed The error No.34 is displayed when detector B is working when detector B is working and A is not working.and A is not working.

Check the set of A detector.Check the set of A detector.

Check the SCC1 card & replace Check the SCC1 card & replace if found faultyif found faulty


The error No.32 is displayed if The error No.32 is displayed if there is difference between the there is difference between the counts of the MLB’s.counts of the MLB’s.

Reset the system; if error Reset the system; if error persists replace the MLB cards persists replace the MLB cards with the spare cards for repairs.with the spare cards for repairs.

ERRORSERRORSError No 35- NEGATIVE COUNT ERROR This error will be displayed if a count registered in the system is less at the entry end while train entering the section then counts registered at the exit end while train is leaving out of section i.e. counts into the section are less then the counts out of the section.


The error No.35 is displayed The error No.35 is displayed with flashing LED’s when with flashing LED’s when counts out of the section are counts out of the section are more then the counts in to the more then the counts in to the section.section.

Check signals and dips at both Check signals and dips at both locations. Check DC Voltages locations. Check DC Voltages and LED’s in SCC 1 & 2 card and LED’s in SCC 1 & 2 card and replace if necessary.and replace if necessary.

Error No 36- SHUNT ERRORThis error will displayed when train moving forward & backwards (shunting) on axle detectors without proper direction. The system checks and locks this as an error.


The error No.36 is The error No.36 is displayed for improper displayed for improper shunting on axle detectors.shunting on axle detectors.

Stationmaster applies reset after Stationmaster applies reset after section is verified as per SWR. section is verified as per SWR. Movement of pilot train in the Movement of pilot train in the section makes system clear.section makes system clear.

ERRORSERRORSError No 37- SUPERVISORY ERROR Supervisory error is displayed when train moving forward & backwards (Shunting) on axle detectors without proper direction. The system checks and locks this as an error.


The error No.37 is displayed The error No.37 is displayed when any of the axle detector when any of the axle detector signals becomes low.signals becomes low.

Check the Tx & Rx signal level of Check the Tx & Rx signal level of the axle detectors. It should be the axle detectors. It should be as per the recorded readings. as per the recorded readings. Check the SCC 1&2 card DC Check the SCC 1&2 card DC voltages. Adjust or replace if any voltages. Adjust or replace if any of the above is not OK.of the above is not OK.

Error No 38- SHUNT ERRORThis error will displayed when train moving forward & backwards (shunting) on axle detectors without proper direction. The system checks and locks this as an error.


The error No.38 is displayed The error No.38 is displayed for improper shunting on for improper shunting on axle detectors.axle detectors.

Stationmaster applies reset after Stationmaster applies reset after section is verified as per SWR. section is verified as per SWR. Movement of pilot train in the Movement of pilot train in the section makes system clear.section makes system clear.

ERRORSERRORSError No 40- COMMUNICATION ERROR The communication error is displayed when communication between two units is not proper i.e. packet information is corrupted


The error No.40 is displayed The error No.40 is displayed when communication between when communication between two units is improper.two units is improper.

Stationmaster applies reset Stationmaster applies reset after section is verified as per after section is verified as per SWR. Movement of pilot train in SWR. Movement of pilot train in the section makes system clear.the section makes system clear.

Error No 50-RELAY REMOVED (PHYSICALLY OUTSIDE FROM THE PLUG BOARD)During Power On Self Test (POST) of the system the presence of relay is checked. If relay is not present then, the error No.50 is displayed.


The error No.50 is displayed The error No.50 is displayed when the relay is not present when the relay is not present during diagnostic.during diagnostic.

Check the presence of Vital relay Check the presence of Vital relay in the relay box of the system & in the relay box of the system & insert in the plug board.insert in the plug board.

ERRORSERRORSError No 51- RELAY DROP FAILURE IN OCCUPIED STATEDuring SECTION OCCUPIED of the system the presence of back contact (Dropped) of the vital relay is checked. If it is found open when section is occupied, the error No.51 is displayed.


The error No.51 is displayed if The error No.51 is displayed if back contacts of the relay are back contacts of the relay are open when the system is open when the system is occupied.occupied.

Check the back contacts (D5 & Check the back contacts (D5 & D6)of the vital relay used for D6)of the vital relay used for read back in the system & read back in the system & rectify.rectify.

Error No 52-RELAY PICKUP FAILURE IN UNOCCUPIED STATE.After balance of count from the train passed in the section, the system goes to unoccupied state (clear). The relay driver card drives the vital Relay ON, but relay fails to pickup then the error No.52 is displayed.


The error No.52 is displayed if The error No.52 is displayed if pickup contacts of the relay pickup contacts of the relay are not made when the system are not made when the system is unoccupied (Clear) is unoccupied (Clear) ConditionCondition

Check the pick up contacts of the Check the pick up contacts of the vital relay and rectify or replace vital relay and rectify or replace the relay.the relay.

ERRORSERRORSError No 53- RELAY DROP FAILURE IN OCCUPIED STATEThe system after detection of train in the section goes to OCCUPIED state but vital relay fails to drop then the error No.53 is displayed.


The error No.53 is displayed if The error No.53 is displayed if back contacts of the relay are back contacts of the relay are open when the system is open when the system is occupied.occupied.

Check the back contacts of the Check the back contacts of the relay & rectify or replace the relay & rectify or replace the relay.relay.

Error No 61-SECONDARY CPU ERRORBoth MLB’s will be working in tandem and are in agreement for any decision. Suppose MLB1 card is to be in different state then the MLB2 card or vice versa, the system will generate the error no.61.


The error No.61 is generated The error No.61 is generated if MLB1 detects that the if MLB1 detects that the adjacent MLB2 is in different adjacent MLB2 is in different state or vice versa.state or vice versa.

Replace the MLB card that is not Replace the MLB card that is not giving error. The system is to be giving error. The system is to be resetted.resetted.

ERRORSERRORSError No 62-SECONDARY CPU FAIL.The error is generated if any of the CPU fails to respond as per its adjacent CPU due to failure any components.


The error No.62 is generated in The error No.62 is generated in case the MLB card detects the case the MLB card detects the adjacent MLB card is faulty.adjacent MLB card is faulty.

The MLB card is faulty. Replace The MLB card is faulty. Replace the MLB card with the spare the MLB card with the spare card.card.

Error No 70-CONFIGURATION ERROR DURING ‘POST’.The error is generated if address of the units is found to be different as per the factory setting both Entry and both Exit units have been used in the section.


Error 70 is generated if the Error 70 is generated if the unit address of any unit is unit address of any unit is changed or both units have changed or both units have the same address.the same address.

Check and install the Entry and Check and install the Entry and Exit units in the section.Exit units in the section.

ERRORSERRORSError No73- CONFIGURATION ERROR DURING NORMAL WORKING. The error is detected when the address of unit is changed.


The error No.73 is generated The error No.73 is generated when, the unit address is when, the unit address is disturbed/changed after disturbed/changed after commissioning.commissioning.

The unit address is rectified to The unit address is rectified to as per the factory setting. Reset as per the factory setting. Reset is applied.is applied.

Error No 80-REMOTE ERROR.This error code will be displayed if any error is detected in the remote unit.


Error 80 is displayed locally if Error 80 is displayed locally if the remote unit is in error the remote unit is in error state.state.

The local unit is OK.The local unit is OK.

Check the errors in remote unit Check the errors in remote unit and rectify.and rectify.


ERRORSERRORSError No73- CONFIGURATION ERROR DURING NORMAL WORKING. The error is detected when the address of unit is changed.


The error No.73 is generated The error No.73 is generated when, the unit address is when, the unit address is disturbed/changed after disturbed/changed after commissioning.commissioning.

The unit address is rectified to The unit address is rectified to as per the factory setting. Reset as per the factory setting. Reset is applied.is applied.

Error No 80-REMOTE ERROR.This error code will be displayed if any error is detected in the remote unit.


Error 80 is displayed locally if Error 80 is displayed locally if the remote unit is in error the remote unit is in error state.state.

The local unit is OK.The local unit is OK.

Check the errors in remote unit Check the errors in remote unit and rectify.and rectify.


ERRORSERRORSError No7F- REMOTE RESET ERROR The error is generated in the remote unit when resetted.


The error No.7F is generated in The error No.7F is generated in local unit if the remote unit is local unit if the remote unit is resetted.resetted.

Apply reset in the local unit or Apply reset in the local unit or else apply reset in both side else apply reset in both side units.units.

Error No 3F-SELF RESET ERRORThe error no 3F is generated in the local unit has been resetted.


Error no 3F is generated in Error no 3F is generated in the local unit when it is the local unit when it is resetted and remote unit is resetted and remote unit is not resetted.not resetted.

Remote unit is to be resetted or Remote unit is to be resetted or else both units are to be resetted.else both units are to be resetted.


STATION TO STATION BLOCKSTATION TO STATION BLOCK

SSDAC-1 SSDAC-2VITAL RELAY

POWER

VITAL RELAY

POWER

TYPICAL 10 - 20 KM

BLOCK SECTION

AS

BLOCK/INTERLOCKING

EQUIPMENT

4 4

2 BLOCK/INTERLOCKING

EQUIPMENT

4 4

STATIONA

STATIONB

SSDAC - StatusSSDAC - Status

• System has passed all the safety System has passed all the safety tests. tests.

• System software has been System software has been independently verified and okayed.independently verified and okayed.

• System has been approved by RDSO.System has been approved by RDSO.• System has been inducted in Indian System has been inducted in Indian

Railways (100 nos have already been Railways (100 nos have already been supplied)supplied)

Ckt old2Ckt old2

Circuit Diagram1Circuit Diagram1

Ckt new 1Ckt new 1

Ckt new 2Ckt new 2

Cbl req1Cbl req1

Cbl req 2Cbl req 2

Relay StatusRelay Status

Det.rly stsDet.rly sts

Det.rly pos3Det.rly pos3

Det.rly pos2Det.rly pos2

ConclusionConclusion

We are terminating our presentation We are terminating our presentation and thanking you all for attending and thanking you all for attending the seminar, hope it will be a good the seminar, hope it will be a good help for you’ll in the maintenance of help for you’ll in the maintenance of our system.our system.

Documents

SSDAC Presentation Detailed