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भारतभारतभारतभारत सरकारसरकारसरकारसरकार GOVERNMENT OF INDIA
रेलरेलरेलरेल मंऽालयमंऽालयमंऽालयमंऽालय MINISTRY OF RAILWAYS
(केवलकेवलकेवलकेवल काया�लयीनकाया�लयीनकाया�लयीनकाया�लयीन
ूयोगूयोगूयोगूयोग हेतुहेतुहेतुहेतु ) (For official use only)
ृृृृॉॉॉॉशशशशरररर एएएए ससससीीीी एएएएसससस 2000
मममम����टटटटीीीी ससससेेेे����शशशशनननन ििििडडडडििििजजजजटटटटलललल
एएएए����""""लललल ककककााााउउउउ$$$$टटटटरररर
परअअअअननननुुुुरररर''''णणणण हहहहःःःःततततपुिस्तका
Maintenance Handbook on
FRAUSCHER ACS2000
Multi Section Digital Axle Counter
कैमटेक/एएएएसससस////ूूूूोोोजजोजज////2222000011115555 –
11116666////एएएएममममएएएएचचचचबबबबीीीी-एफ__
एमएएएएससससडडडडीीीीएएएएससससीीीी////1111....0000
माचर् 2222000011116666CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
March 2016
MAHARAJPUR, GWALIOR – 474 020
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Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page
ii
ॉशर ए सी एस 2000म ट से शन डिजटल ए ल काउ टर
परअनरु ण ह तपिु तका
Maintenance Handbook on
FRAUSCHER ACS2000 Multi Section Digital Axle Counter
कैमटेक/एस/ ोज/2015–16/एमएचबी-एफ__ एमएसडीएसी/1. 0 माच 2016
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0 March 2016
Table of Contents
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ा कथन
ेक स कट गाड़ी क उपि थती क जाँच करने म मह वपूण भू मका नभात ेह
,िजनके वारा गा ड़यो के संचालन म संर ा सु नि चत होती है । डिजटल ए सल
काउ टर ेक स कट का एक उ नत प है, िजसके अपने लाभ तथा संर ा स बंधी अ त
र त वशषेताय ह। तकनीक उ नयन के साथ भारतीय रेलवे म नवीन ा प का आगमन
हुआ है।
वतमान वकास के साथ कदम मलात ेहु ये कैमटेक न ेइस ह तपुि तका को
तैयार कया है, िजसम नवीनतम अनुमो दत ॉशर एसीएस 2000 डिजटल ए सल काउ टर
क जानकार सि म लत है । मुझे इस ह तपुि तका को स नल क मक हेतु तुत करते
हु ये हष होता है और मुझ ेआशा है, क इसके वारा उ ह अपने से शन म उपरो
त ए सल काउंटर के अनुर ण म सहायता मलेगी ।
कैमटेक वा लयर ए. आर. तुपे दनाँक: 10.03.2016 कायकार नदेशक
Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page
iii Table of Contents
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FOREWORD
Track circuits play a vital role in train operation by detecting
the presence of train
vehicle, thereby ensuring safety in train operation. Digital
axle counter is the
advanced form of track circuit which has its own advantages and
additional
safety features. With technological advancements, new versions
are being
introduced in Indian Railways.
To keep pace with latest developments, CAMTECH has prepared this
handbook
consisting information on newly approved Frauscher ACS 2000
Digital Axle
Counter. It gives me pleasure in presenting this handbook to
Signal personnel
and I hope that this will help them in maintaining the subject
Digital Axle
Counters in their section.
CAMTECH Gwalior Date: 10.03.2016
A.R.Tupe Executive Director
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भू मका
वतमान मे डिजटल ए सल काउ टर स न लगं णाल का एक मह वपूण अवयव है। म
ट
से शन डिजटल ए सल काउंटर का सीध े से शन म, टेशन े के वाइंट जोन म
तथा
लॉक से शन म अनु योग है । टेशन अथवा लॉक से शन म ए सल काउ टर क
खराबी
गा ड़य के संचालन को बा धत करती है तथा उनक समय ब ता को भा वत करती
है।
टे नॉलॉजी म सुधार के कारण नये नमाताओ का ए सल काउंटरो के उ नत सं
करण के
साथ आगमन हो रहा है । ॉशर से सर टे नॉलॉजी उनमे से एक फम है जो क
भारतीय
रे वे म ए सी एस 2000 म ट से शन डिजटल ए सल काउंटरो को उपल ध करान
ेतथा
सं थापन हेत ुअनुमो दत है।
इस ह तपुि तका को फ ड का मको को अपने से शन मे ॉशर ए सी एस 2000
डिजटल
ए सल काउ टर के ु ट वह न काय हेतु अनुर ण करने म सहायता करन े के
लए तैयार
कया गया है। ह तपुि तका व श ट भाग म वभािजत है िजसम णाल के
सहंावलोकन,
सं थापन, अनुर ण, ु ट नवारण तथा सावधा नय को सि म लत कया गया
है।
हम ी पी के वमा, नदेशक/संकेत/VII/आर. डी. एस. ओ./लखनऊ, ी जनादन
सहं, व र ठ
संकेत एवं दरूसंचार अ भय ता (सम वय)/सीएसट मु बई/म य रेल, मै. ॉशर
से सर
टे नोलॉजी बगलु के ी पी. वी. के. सु हम णयन/ नदेशक/इंजी नय रंग एवं
उनके सहयोगी
तथा मु बई डवीजन/म य रेल एव ंआगरा डवीज़न/उ तर म य रेल के फ ड का मक
के
अ यंत आभार ह िज ह न ेहम इस ह तपुि तका को तैयार करन ेम सहायता क
।
चू ं क तकनीक उ नयन एवं श ण एक मक या है, अतः इस ह तपुि तका म
आप
कुछ जोड़न ेया सुधारने क आव यकता महसूस कर सकत ेह | य द ऐसा है तो
कृपया अपने
सुझाव हम ईमेल [email protected] पर भेज अथवा इस पत े पर लख
भेज :
भारतीय रेल, उ च अनुर ण ो यो गक क , होटल आ द याज़ के सामने,
महाराजपुर,
वा लयर (म ) 474020
कैमटेक वा लयर दनेश कुमार यादव द.: 10.03.2016 नदेशक (संकेत एव
ंदरूसंचार)
Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page
v Table of Contents
mailto:[email protected]
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PREFACE
At present Digital Axle counter is an important part of the
signalling system. Multi Section Digital Axle Counters have
applications in straight sections and point zones of Station area
as well as in proving of Block section. Failure of axle counters in
a station or block section paralyses the movement of trains thereby
affecting their punctuality. Due to improvement in technology, new
vendors are coming with enhanced versions of axle counters.
Frauscher Sensor Technology is one such firm who is approved for
supply and installation of ACS 2000 Multi Section Digital Axle
Counters on Indian Railways.
This handbook has been prepared to help the field personnel in
maintaining Frauscher ACS 2000 Digital Axle Counters in their
section for trouble-freeperformance. The handbook has been divided
into specific sections; containing overview, installation,
maintenance, troubleshooting and precautions for the above
system.
We are sincerely thankful to Shri P.K.Verma/Director
Signal/VII/RDSO/ Lucknow, Shri Janardan Singh, Senior Divisional
Signal & Telecom. Engineer (Co)/CST Mumbai/Central Railway,
Shri P.V.K.Subramanian, Director Engineering of M/s Frauscher
Sensor Technology India Pvt. Ltd. Bangalore and his team and field
personnel of Mumbai division, CentralRailway and Agra division,
North Central Railway who helped us in preparation of the
handbook.
Since technological upgradation and learning is a continuous
process, you may feel the need for some addition/modification in
this handbook. If so, please give your comments on email address
[email protected] or write to us at Indian Railways Centre
for Advanced Maintenance Technology (in front of Adityaz Hotel),
Maharajpur, Gwalior (M.P.) 474020.
D.K.M.Yadav CAMTECH Gwalior Date: 10.03.2016 Director
(S&T)
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वषय सूची Table of Contents
ा कथन
Foreword....................................................................................iii/ivभू
मका Preface
...........................................................................................v/viवषय
सूची Table of Contents
.......................................................................
viiसुधार पच Correction slip
..............................................................................
xड लेमर तथा हमारा उ े य Disclaimer & Our
objective............................ xi
सं त श दावल Abbreviations
....................................................................xiii
1 ॉशर ए सी एस 2000 म ट से शन डिजटल ए सल काउ टर Frauscher ACS2000
Multi Section Digital Axle Counter ….……….....1
1.1 प रचय
Introduction.....................................................................................11.2
ए सी एस 2000 णाल के घटक
Components of Axle counting system ACS2000
.....................................1 1.3 सहायक द तावेज Supporting
documents ...................................................11.4
णाल का ववरण System
description........................................................21.5
संचालन क े कार Modes of
operation..........................................................31.6
घटक का ववरण Description of
components............................................51.7 केबल
बछाने क योजना Cabling
scheme...................................................11
2 ह ल से सर आर एस आर 180 का सं थापन Installation of Wheel sensor
RSR180
.........................................................12
2.1 घटक तथा अ य अवयव Components and fixing
elements...................122.2 आलंबन हेतु सामा य नदश General
mounting instructions......................122.3 रेल लॉ का आलंबन
Rail claw
mounting..................................................132.4 ह ल
से सर क ेआलंबन हेतु आव यक औजार
Tools required for mounting of Wheel
sensor.............................................13 2.5 लगाना एवं
समायोजन Fixing and
adjustments.......................................142.6 केबल का
संयोजन Connection of
cable....................................................152.7 धुरा
गणना क दशा का प रवतन
Changing the direction of axle
counting....................................................16
कैमटेक प्रकाशन CAMTECH
Publications..................................................xii
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2.8 पी बी 200 क सहायता से आर एस आर 180 क ऑकु पे सी डटे शन
of RSR180 using PB200………….…………………………………… 16 2.9 पी बी 200 क
सहायता से ह ल ससर आर एस आर 180 पर ेवर सगं
का स यलेुशन करना Simulation of traversing over Wheel sensor
RSR180 using PB200
...............................................................................17
2.10 ह ल ससर तथा ट एलजेबी के सं थापन हेतु जांच सूची Checklist
for installation of Wheel sensor and
TLJB.............................18
3 समायोजन एवं मापन Adjustments and
measurements…..................... 203.1 पावर स लाई Power
supply…....................................................................203.2
एव युएशन बोड पर मापन एवं समायोजन
Measurements and adjustments at the Evaluation
board.........................20
3.3 एबीपी क डप ि वच सै टंग DIP-switch settings of
ABP.......................213.4 रसेट बॉ स पर मापन Measurements at
the Reset box ..........................253.5 र सेट बॉ स म ज पर सै
टंग Jumper settings in the Reset box...............25
4 काया मक पर ण Functional
testing…………….................................. 264.1 काया मक पर ण
के कार Types of functional tests..............................264.2
काउं टंग हेड नधारण प र ण Counting head assignment test
.................264.3 आइसोलेटेड मोड म गणना क दशा का स यापन
Verification of counting direction in isolated mode
.................................26 4.4 ांस मशन मोड म गणना क दशा का
स यापन
Verification of counting direction in transmission
mode…......................274.5 र सेट ऑपरेशन का स यापन
Verification of reset operation.. ...................27
5 अनुर ण
Maintenance................................................................................
295.1 पर ण /जांच
Tests/Checks........................................................................295.2
औजार तथा मापन उपकरण Tools and measuring
equipment...................295.3 एवलु एशन बोड के टे ट सॉकेट पर
मापन
Measurements at the test sockets of the Evaluation
board........................29 5.4 ह ल से सर , रेल डफले टर तथा
लाइन वे र फकेशन बॉ स का
प र ण /जाँच Testing/checking of Wheel sensor, Rail deflector
andLine verification box
.................................................................................29
क� �मता क� जांच करना Checking occupancy detection capability
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5.5 एसीबी का पर ण Testing of
ACB...........................................................305.6
डीआईओबी का पर ण Testing of
DIOB...............................................305.7 रसेट बॉ स
का पर ण Testing of Reset box
........................................31
6 नदान एवं ु ट नवारण Diagnostics & Troubleshooting
..................... 326.1 नदान एवं ु ट नवारण हेतु सामा य नदश
General instructions for diagnostics and
troubleshooting.........................32 6.2 ु ट कोड का दशन
Display of error codes
............................................326.3 एसीबी का पॉवर अप
Power-up of ACB
....................................................326.4 ु ट कोड
को पढना Reading of error
codes..............................................336.5 ु ट कोड,
कारण एवं नवारण Error codes, causes and remedies…......346.6 ु ट
नवारण
Troubleshooting.....................................................................426.7
ॉशर नदान णाल Frauscher diagnostic
system...................................45
7 सावधा नयां एवं या कर व या न कर Precautions and Do’s &
Don’ts…………………….............................. 46
7.1 बोड/मॉ यू स का बंधन Handling of
boards/modules...............................467.2 बोड/मॉ यू स को
बदलना Replacement of boards/modules....................467.3 ु ट
नवारण म सावधा नयां Precautions while
troubleshooting................477.4 या कर व या न कर Do’s &
Don’ts.....................................................47
अनुल नक AnnexuresI ए सी एस 2000 नदान एवं ु ट नवारण हेतु लो चाट 1
ACS 2000 Diagnostics & Trouble shooting Flowchart
1…………….…..….49
III दोहरा उपयोग Double
usage...........................................................................51
IV ट्रॉल� प्रोटेक्शन Trolley
protection.................................................................52
II ए सी एस 2000 �नदान एवं त्र�ुट �नवारण फ्लो चाटर् 2 ACS 2000
Diagnostics & Troubleshooting Flowchart
2.................................50
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सुधार प चय को जार करना
ISSUE OF CORRECTION SLIPS
इस ह तपुि तका के लए भ व य म जार क जाने वाल सुधार प चय के मांक इस
कार से
रहगे:
The correction slips to be issued in future for this handbook
will be numbered as follows:
केमटेक/एस/ ोज/2015 – 16/एमएचबी –एफ_ एमएसडीएसी/1.0 # XX द
.................
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC /1.0# XX date .......
जहां “XX” स बं धत सुधार पच क म सं या है (01 से शु होकर)Where
“XX” is the serial number of the concerned correction slip
(starting from 01 onwards).
सुधार पच याँ जार क गयीं CORRECTION SLIPS ISSUED
सुधार पच क म सं या
Sr. No. of Correction
Slip
जार करने क तार ख Date of
issue
संशो धत पृ ठ मांक एवं मद
सं या Page no. and Item
No. modified
ट प णयाँ Remarks
Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page
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�डस्क्लेमर यह स्पष्ट ि कया जाता है ि क इस हःतपुिःतका म; दी गयी
जानकारी िस>नल इंजीिनयिरंग मै$युअल,रेलवे बोड� ूकाशन@ तथा आर डी एस
ओ ू काशन@ के ि कसी भी वत�मान आलेख@ को िवःथािपत नही ंकरतीं है | यह
दःतावेज वैधािनक नही ंहै वरन इसम; िदए गए िनदGश केवल माग� दश�न हेतु
हH | य�द �कसी िब$दु पर िवरोधाभास I9ीगोचर होता है, तब िस>नल
इंजीिनयिरंग मै$युअल, रेलवे बोड� ूकाशन@, आरडी एस ओ माग�दश�न अथवा
जोनल रेलवे के िनदGश@ का प ालन कर; |
Disclaimer It is clarified that the information given in this
handbook does not supersede any existing provisions
laid down in the Signal Engineering Manual, Railway Board and
RDSO publications. This document
is not statuary and instructions given in it are for the purpose
of guidance only. If at any point contradiction is observed, then
SEM, Railway Board/RDSO guidelines may be referred or prevalent
Zonal Railways instructions may be followed.
हमारा उद्देश्य
अनुर'ण ूौMोिगकी और काय�ूणाली का उ$नयन करना तथा उPपादकता और रेलवे
की प िरसQपिR एवं जनशिS के िनंपादन म; सुधार करना िजससे अंतिव�षय@ म;
िवVसनीयता, उपयोिगता और द'ताूाX की जा स के
Our objectiveTo 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.
य�द आप इस स$दभ� म; कोई िवचार और सुझाव देना चाहते हH तो कपया हम;
इस पते पर िलख;:
संपकर् सतू्र: िनदेशक (सकेंत एवं दरूसचंार)भारतीय रेल उ]च अनुर'ण
ूौMोिगकी क; िपत्राचार का पता :
टेलीफ़ोन:
फैक्स:ई2मेल:
महाराजप ुर, >वािलयर (म. ू.) �पन कोड – 474 0200751-2470185
0751-2470841
[email protected] If you have any suggestion & any
specific comments, please write to us: Contact person: Director
(Signal & Telecommunication)
Postal address: Centre for Advanced Maintenance Technology,
Maharajpur Gwalior (M.P.) Pin Code – 474 020
Phone:
Fax:
Email:
07512 2470185
07512 2470841
[email protected]
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xiiTable of Contents
कैमटेक प्रकाशन 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 publicationsOn Internet:Visit
www.rdso.indianrailways.gov.inGo to Directorates → CAMTECH →
Publications for download → S&T Engineering
On Railnet:Visit RDSO website at 10.100.2.19Go to Directorates →
CAMTECH → Publications → S&T Engineering
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 [email protected]
Or
FAX to 0751-2470841 (BSNL)
Or
Write atDirector (S&T)Indian Railways Centre for Advanced
Maintenance Technology,In front of Hotel Adityaz, Airport Road,
Maharajpur,Gwalior (M.P.) 474020
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सं��प्त शब्दावल� AbbreviationsIn this document the following
abbreviations are used: ABP AC ACB ACS AXR BBK BGT BSI004 CTR DC
DEACT DIOB DIP DIR/DIR’ DN/DN’ DP EB EMC FDS Fm FRA FRD GND GS IMC
LB LVB MSDAC P PB200 RDSO RSR180 RSTBOX SCI SIC SEM SK140 SRC SSDAC
Sys1/Sys2 TLJB TS
Axle counting backplane Alternating current Axle counting board
Axle counting system Axle counter rack Clamping bolt Board rack
Overvoltage protection board, type 004 Cable termination rack
Direct current Deactivation inputs/outputs used for counting head
control Digital input/output board Dual in - line package (DIP -
switch) Direction inversion and/or addressing DIP-switch for
channels 1 and 2 DN - DIP switch for channel 1 and 2 (for double
usage) Detection point Evaluation board Electro magnetic
compatibility Frauscher diagnostic system Track section clear
indication relay contact (= status of track section ‘unoccupied’)
Frauscher Reset acknowledgement pcb Frauscher Rail deflector Ground
Equipment version Evaluation board with microcontroller (integrated
microcontroller evaluation board) Soldering jumper Line
verification box Multi section digital axle counter Test relay
contact (= status of track section ‘occupied’) Testing plate, type
PB200 Research Designs and Standards Organization Wheel sensor,
type 180 Reset box Serial communication interrupted Fuse board with
crowbar driver Signal engineering manual Rail claw, type 140 Strain
relief clamp Single section digital axle Counter Sensor systems of
a wheel sensor Track lead junction box Track section
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Figure 1.1: Front view of ACS2000 system
The Frauscher Axle counting system ACS2000 is a microcontroller
based system developed by M/s Frauscher GmbH, Austria and
manufactured in India by M/s Frauscher Sensor Technology India Pvt.
Ltd., Bangalore. The system comprises two mutually independent
channels with identical hardware. The channels are fed in parallel
with the same input data. Track clear indication is obtained only
when results from two mutually independent comparators
coincide.
1.2 एसीएस 2000 धरुा गणक के घटक Components of Axle counting
system ACS2000
Figure 1.2: Wheel sensor RSR180
Figure 1.3: ACS2000 System rack
Trackside equipment • Wheel sensor RSR180 with moulded cable and
protection tube• Rail claw with clamping bolts• Rail deflector FRD•
Strain relief clamp SRC• Track lead junction box TLJB• Line
verification box LVB (for ‘conditional hard reset’ application
only)
Indoor installation • Overvoltage protection board BSI• Board
rack BGT• Axle counting backplane ABP• Fuse board SIC• Evaluation
board IMC (EB)• Axle counting board ACB• Digital input/output board
DIOB (optional for transmission mode)• Reset box RSTBOX (for
‘preparatory or conditional hard reset’
applications)• Frauscher Reset acknowledgement pcb FRA (for
‘preparatory reset’
application only)
1.3 सहायक दस्तावेज Supporting documentsFor more detailed
description and information on the axle counting system ACS2000,
refer to documentation “D10043 Part 01 to 13 of the axle counting
system ACS2000” and “D1414-3 Mounting and commissioning of wheel
sensor type RSR180” supplied by M/s Frauscher.
The axle counting system ACS2000 is a modular system and, when
fully configured, comprises the following components/boards:
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1 फ्रॉशर ए सी एस 2000 मल्ट� सेक्शन �डिजटल एक्सल काउन्टर
Frauscher ACS2000 Multi Section Digital Axle Counter 1.1 प�रचय
Introduction
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CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
1.4 प्रणाल� का िववरण System descriptionWheel sensors are
provided at the beginning and end of each track section. Wheel
sensor, together with the evaluation board, operates as the
counting head. The counting head detects all train wheels
traversing this section as well as their driving direction. Each
wheel sensor is connected to an evaluation board by means of a
four-wire signalling cable (typically star-quad cable). This cable
carries the power for the wheel sensor and the axle detection data
for the evaluation board.
The axle counting system ACS2000 works on power supply voltage
from +19 V DC to +72 V DC. The axle counting board ACB is capable
of evaluating the information, supplied byevaluation boards, of up
to 6 independent counting heads.
In case of adjacent track sections, double usage (same wheel
sensor is shared between two track sections) of the counting head
at the separation joint is possible depending on the configuration.
For a track section with more than 6 counting heads (up to 12
counting heads maximum), two ACBs can be interconnected with a null
modem cable to evaluate and provide track clear indication (Please
refer Annexure III, Page 51).
The evaluation board IMC provides counting head control
functionality. The track section ‘clear/occupied’ status output
from the axle counting board ACB is fed to the evaluation board IMC
for counting head control purposes using the RJ45 sockets on the
backplane ABP. The counting head control outputs (track section
“clear” status and referred to as DEACT OUT) from an ACB must be
connected to the corresponding counting head control inputs (DEACT
IN) using the patch cables. When counting head control is wired,
the counting head remains fully functional and activated, however,
no occupied status output is delivered in the event of a mistimed
occupancy. This increases the availability, as no faults will occur
from maintenance work (e.g. metal of tools temporarily above a
wheel sensor). The principle of counting head control is that
individual connected counting heads are desensitised as long as all
adjacent track sections are ‘clear’ (unoccupied). If an adjacent
track section is occupied or its system enters fault mode, the
counting head is sensitised. This counting head control feature of
the evaluation board IMC is used for trolley suppression by axle
counting system in Indian Railway applications (Please refer
Annexure IV Page 52 & 53).
The axle counting board ACB of the axle counting system compiles
the axle detection data received from all counting heads connected.
It generates “track clear” or “track occupied” indication for the
corresponding track section as an overall result. The output of
this result is given to direct relays (potential-free). The front
panel of the axle counting board ACB features two toggle switches
for “pre-Reset”. The axle counting board ACB also provides inputs
for “Reset” of the axle counting system and the reset inputs are
wired from the reset box.
The reset box allows carrying out of ‘preparatory reset’ or
‘conditional hard reset’ of the axle counting system by the
authorised operating personnel depending on the respective track
section’s requirement. In ‘preparatory reset’, after the reset has
been applied and accepted by the ACS2000, the track section clear
status will occur only after the track section has been correctly
traversed by a sweep train. In case of ‘conditional hard reset’,
the line verification box is used to communicate to the ACS2000
system that the track section is clear after physical verification.
Once the ACB has accepted the ‘conditional hard reset input’, the
resetting of the ACS2000 will occur immediately with no need for
traversing of the track section by a train.
The Frauscher Reset acknowledgement PCB FRA transmits the “reset
acknowledgement” status from the ACB to the reset box when the
‘preparatory reset’ command is applied and accepted by the
system.
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Advantages:
• No drilling of holes is required for mounting wheel sensors to
the rail.• No electronic components (e.g. EJB) are installed at
site.• No earthing is required at site.• No frequent adjustments
are required at site. However, inspection and adjustments of indoor
and
outdoor equipment shall be carried out according to the
schedules specified in section 5“Maintenance”.
1.5 संचालन के प्रकार Modes of operationThe axle counting system
ACS2000 can be configured to work in following modes:
• Isolated mode (this is generally used for track sections
within the station area)• Transmission mode (in this mode, an
optional Digital input/output module (DIOB) can be used)
When the ACS2000 system is used in transmission mode with DIOB,
additional 16 digital arguments (e.g. information, messages,
commands) can be transmitted bi-directionally via modem. Arguments
are read in by optocouplers and output by direct relays (potential-
free).
Generally, the ACS2000 system is used in transmission mode for
block applications (e.g. absolute block, automatic signalling
etc.). The axle counting system ACS2000 can be configured for SSDAC
and MSDAC applications.
Figure 1.4: ACS2000 block diagram in isolated mode
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Figure 1.5: ACS2000 block diagram in transmission mode
Figure 1.6: ACS2000 block diagram in transmission mode with
DIOB
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TS1 TS1
TS1 TS1
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1.6 घटक� का िववरण Description of components1.6.1 Evaluation
board IMC The evaluation board IMC is used to power and evaluate a
wheel sensor with two sensor systems (System 1 and System 2). The
output switching signals are transmitted to the axle counting board
ACB via the axle counting backplane ABP. Description of IMC front
panel illuminated LED and control elements are shown in activated
state in Figure 1.7:
Figure 1.7: Front panel of IMC
Serial Interface .......................... serial interface IMC
GS03: Diagnostic connection
PWR ......................................... supply voltage
channel 1 present
Sys1 .......................................... system 1
occupied (illuminated) or faulty (flashes)
A1 ............................................. output
direction 1
B1 ............................................. output system
1
Adjust ....................................... required for IMC
adjustment
Test ........................................... required to
adjust IMC/simulate an occupancy of system 1
V+, GND .................................. 2 mm test sockets,
voltage corresponds to the analogue wheel sensor current via a 100
Ω shunt
PWR ......................................... supply voltage
channel 2 present
Sys2 .......................................... system 2
occupied (illuminated) or faulty (flashes)
A2 ............................................. output
direction 2
B2 ............................................. output system
2
Adjust ....................................... required for IMC
adjustment
Test ........................................... required to
adjust IMC/simulate an occupancy of system 2
V+, GND .................................. 2 mm test sockets,
voltage corresponds to the analogue wheel sensor current via a 100
Ω shunt
Type key: nnn ............................................ board
identification code beginning with 001
xx..yy ........................................ operating
voltage range
zz ...............................................version
beginning with 01
1.6.2 Fuse board SIC
Figure 1.8: Front panel of Fuse board SIC
The fuse board SIC is used as supply voltage protection for
ACS2000.
Si1............................. fuse for the supply voltage of
channel 1
Si2............................. fuse for the supply voltage of
channel 2
Type key: nnn............................ board identification
code beginning with 001 xx...yy........................ operating
voltage range zz............................... version beginning
with 01
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Figure 1.9:Front panel of ACB
5 V............................. voltage supply channel 1
present
Occupied................... track section occupied (LED
illuminated)/faulty (LED flashes)
Display...................... number of axles / information on
status (error)
pre - Reset.................. elimination of the reset
restriction (actuated: causes the same function as HIGH level at
the "pre- Reset" inputs)
5 V............................. voltage supply channel 2
present
Serial Interface.......... D - SUB socket / RJ45 socket
Type key: nnn............................ board identification
code beginning with 001 xx...yy........................ operating
voltage range zz .............................. version beginning
with 01
1.6.4 Digital input/output board DIOB
The digital input/output board DIOB is an optional board used
for the transmission of digital data via modem. The DIOB is not
necessary for implementing axle counting track section
applications. It shall be used only where there is a need for
transmitting digital information between two locations.
In the case of non safety - relevant applications, up to 16
arguments (bits or functions) can be transmitted. When applications
are safety - relevant, transmission of up to 8 arguments is
possible. The DIOB can only be used in transmission mode and will
only operate in combination with an ACB. The data (switching
status) is read in by optocouplers, serially transmitted and output
at the partner device by direct output relays (potential -
free).
Description of DIOB front panel elements is given in Figure 1.10
(Display illuminated):
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1.6.3 Axle counting board ACBThe axle counting board ACB
processes the counting head data supplied by the evaluation boards.
Based on the data of the evaluation boards, the clear or occupied
status of the track section being monitored is determined. The
track status output (“clear/occupied”) is delivered using potential
- free relay contacts on the ACB. The maximum number of wheels that
can be counted per track section by the ACB is 8191. Description of
ACB front panel illuminated LED and control elements are shown in
activated state in Figure 1.9:
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5V.............................. voltage supply channel 1
present SCI............................ serial connection present
IN............................... HIGH signal present at the
relevant input OUT........................... relay contact closed
at the relevant output
5V.............................. voltage supply channel 2
present SCI............................ serial connection present
IN.............................. HIGH signal present at the
relevant input OUT........................... relay contact closed
at the relevant output
Serial Interface.......... D - SUB socket
Type key: nnn............................ board identification
code beginning with 001 xx...yy........................ operating
voltage range zz............................... version beginning
with 01
Figure 1.10: Front panel of DIOB
1.6.5 Axle counting backplane ABPEach track section requires one
axle counting backplane ABP. The axle counting backplane ABP
comprises two backplanes (back side & inside of board rack) and
is used to connect up to 6 evaluation boards IMC, one axle counting
board ACB, one fuse board SIC and one digital input/output board
DIOB (optional).
A 9 pin D- SUB plug is available on the ABP for connection of a
modem for configuring the system in transmission mode.
The axle counting backplanes ABP are available in the following
versions depending on the combination of boards required for a
track section.
• Backplanes with slots for 1 ACB + 1 SIC + 2/3/4/5/6 evaluation
boards IMC (5 combinations)• Backplanes with slots for 1 ACB + 1
SIC + 1 DIOB + 2/3/4/5/6 evaluation boards IMC (5
combinations)The minimum configuration of backplane is with
slots for 1 ACB + 1 SIC + 2 evaluation boards IMC.
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Figure 1.11: Front view (inside face) of ABP002- 6 backplane (1
ACB + 1 SIC + 6 IMC + 1 DIOB)
`
Figure 1.12: Rear view (backside of housing) of ABP002- 6
backplane (1 ACB + 1 SIC + 6 IMC + 1 DIOB)
DIR, Mode & DIP - switch (Channel 1)
DN - DIP switch
(Channel 1)
Screw-type terminal for19 to 72 V
DC input(Channel 1)
ST4 (Channel 1),
ST5 (Channel 2)connectors for DIOB
RJ45 Counting head control
I/P1/J7,2/J10,3/J13,4/J16,5/J19,6/J22
1’/J8,2’/J11,3’/J14,4’/J17,5’/J20,6’/J23
ST6 connector Clear, Occupied, pre - Reset, Reset interface
RJ45 Double usage I/P
3/J1,4/J2,5/J3,6/J4
ST1 connectorRSR180 interface
RJ45 Counting head control output
1/J5, 2/J6
DIR, Mode DIP - switch (Channel 2)
DN -DIP switch
(Channel 2)
9 pinD- SUB plugRS232C for
Modem interface
RJ45 Double usage outputs1/J9, 2/J12, 3/J15, 4/J18, 5/J21,
6/J24
Screw type terminal for 19 to
72 V DC input (Channel 2)
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Figure 1.14: Rear view (backside of housing) of ABP002 - 2
backplane with 1 ACB + 1 SIC + 2 IMC
Figure 1.13: Front view (inside face) of ABP002 - 2 backplane
with 1 ACB + 1 SIC + 2 IMC
1.6.6 Board rack BGT
Figure 1.15: Board rack BGT
The boards of the axle counting system ACS2000 require a board
rack BGT. The board rack houses the boards and provides mechanical
protection. The board rack is an aluminium frame with a labelling
bar.
1.6.7 Overvoltage protection board BSI
Figure 1.16: BSI
1.6.8 Reset box RSTBOX
Figure 1.17: Reset box
The over-voltage protection board BSI protects the indoor
installation against interference voltages that may be induced into
the cable between wheel sensor and cable termination rack (or BSI)
due to lightning or overhead line short- circuit. The over-voltage
protection board BSI is connected between the evaluation board and
the wheel sensor and mounted on a DIN rail in the indoor
installation.
The reset box RSTBOX comprises reset push button, reset counter
and LED indicators. It is used by the operating personnel to carry
out ‘preparatory reset’ or ‘conditional hard reset’ of the axle
counting system. The reset box interfaces with the axle counting
board ACB and transmits the reset command. A plug- in berg jumper
on the pcb inside the reset box is used to set the reset
configuration. If the reset box is configured for ‘conditional hard
reset’, it will also be connected to the line verification box LVB
for ‘line verified’ input.
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Figure 1.18: FRA pcb
1.6.10 Wheel sensor RSR180
Figure 1.19: Wheel sensor RSR180
1.6.11 Rail deflector FRD
Figure 1.20: Rail deflector
The reset acknowledgement pcb FRA is required for the
‘preparatory reset’ configuration. It is used to transmit the
“reset acknowledgement” status (“waiting for clearing of track”)
from the ACB to the reset box via potential - free relay
contacts.
The wheel sensor comprises two sensor systems. System 1 (Sys1)
is located on the left side and System 2 (Sys2) is located on the
right side. Configuration of Sys1 and Sys2 is symmetrical. The
wheel sensor has a moulded four- wire cable with a standard length
of 5 m (10 m and 15 m cable lengths are also available). One wire
of each sensor system is assigned to transmit the sensor system
signal to the evaluation board. The other two wires are used for
the voltage supply of the wheel sensor. Together with an evaluation
board, wheel sensor RSR180 acts as a counting head. The wheel
sensor is mounted to the rail using the rail claw. Exceptionally,
the wheel sensor may be mounted directly to the web of the
rail.
The rail deflectors FRD protect the wheel sensors against any
mechanical damage from hanging parts of train. The rail deflectors
are fixed inside the rail (wheel flange side) and mounted adjacent
to either side of the wheel sensor. The distance between the centre
of the wheel sensor and rail deflectors on either side in the
longitudinal direction should be at least 350 mm.
The rail deflectors consist of two profiles with mounting bolts
and nuts, one each for right hand and left hand side of the wheel
sensor systems. The rail deflectors FRD are suitable for both 52 Kg
and 60 Kg rail profiles.
1.6.12 Track lead junction box TLJB
Figure 1.21: TLJB
In the track lead junction box TLJB, the wheel sensor cable
(standard length = 5 m) and the star quad cable from the indoor
installation (cable termination rack/BSI) are terminated.
Typically, each wheel sensor requires one track lead junction box.
There are no electronic components inside the TLJB and the TLJB is
installed on a concrete foundation.
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1.6.9 Reset acknowledgement pcb FRA
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Figure 1.22: LVB
1.6.14 Strain relief clamp SRC
Figure 1.23: SRC
1.6.15 Testing plate PB200
The line verification box LVB is used for axle counting section
that is configured for ‘conditional hard reset’. The LVB has a key
actuated push button switch inside the box and is provided with a
key/lock mechanism to prevent unauthorized access. It is typically
mounted inside the location box closer to the track section.
The strain relief clamp SRC protects the wheel sensor cable from
strain and stress created by ballast packing. The strain relief
clamp allows the cable to move along with the wheel sensor and
avoids stress when the train traverses over the wheel sensor.
Different sizes of strain relief clamps are used for 52 Kg and 60
Kg rail profiles. One strain relief clamp is required for each
wheel sensor installation.
The Testing plate PB200 is used to check occupancy detection
capability of the wheel sensor and simulate traversing of a train
wheel (axle). During the simulation of traversing, the PB200
touches the rail head like a real wheel.
Figure 1.24: Testing plate PB200
1.6.16 ModemTransmission mode of the ACS2000 system requires an
RS2 32 compatible modem link. The type of modem shall depend upon
the communication medium (copper or optic fiber cable) between the
two locations. The modem shall be of any reputed make meeting the
technical requirements of the axle counting system ACS2000. M/s
Frauscher Sensor Technology shall be consulted for selection of
modem.
1.7 केबल �बछाने क� योजना Cabling schemeThe axle counting system
ACS2000 is connected to the wheel sensor via TLJB. A star- quad
outdoor signalling cable is used between the indoor and outdoor
equipments. See Figure 1.25 for the cabling scheme:
Figure 1.25: ACS2000 Indoor- outdoor interface cabling
scheme
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
1.6.13 Line verification box LVB
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2 व्ह�ल सेन्सर आर एस आर 180 का ससं्थापन Installation of Wheel
sensor RSR180
2.1 घटक तथा अनय अवयव Components and fixing elementsThe
arrangement, mounting and commissioning of the wheel sensor RSR180
with rail claw must be carried out according to documentation
“D1414 - 3 Mounting and commissioning of wheel sensor type RSR180”
supplied by M/s Frauscher.Correct mounting in compliance with
instructions is the basis for a long service life of the sensor.
For mounting of wheel sensor RSR180 with rail claw and connecting
it to the indoor installation, the following components and fixing
elements are required:
Figure 2.1: Wheel sensor & Rail claw
• Wheel Sensor RSR180 with moulded connecting cable,standard
length of 5 m (10 m and 15 m cable lengths are alsoavailable),
consisting of 4 wires – brown (System 1), yellow(System 2), green
(Vcc) and white (GND). A protection tubesuitable for the connecting
cable length is clamped to thewheel sensor.
• Rail claw type SK140 with fixing bolts according to the
railprofile.
• Track lead junction box.• Outdoor star quad cable.
Figure 2.2: Track lead junction box
2.2 आलंबन हेत ुसामान्य �नद�श General mounting instructions
Figure 2.3: Installation of Wheel sensor & TLJB
• Wheel sensor RSR180 is to be mounted at the insideface of the
rail (wheel flange side).
• In curves, the wheel sensor RSR180 is to bemounted at the
inside face of the curve.
• In point areas, the minimum admissible spacebetween rails is
100 mm (inside width betweenheads of rail).
• Minimum spacing between two wheel sensors on thesame rail is
two sleeper spaces.
• Minimum spacing between a wheel sensor and the next rail joint
or the next rail-weld is 1.5 m to 2.5 m.• The wheel sensor must be
mounted concentrically between two sleepers.• Mounting of the wheel
sensor RSR180 in the short pitch corrugation area is to be avoided
where possible• The wheel sensor housing must not touch the head of
rail.In case of possible need to deviate from mounting
instructions, please consult the manufacturer.
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min. width of foot of rail 110 mm
max. width of foot of rail 155 mm
min. height of rail 130 mm
max. height of rail 180 mm
height (vertical) between the top of the railhead and the top of
the sensor (Measurement A, see Figure 2.4)
40 to 45 mm
depth (horizontal width) between the side of the railhead and
the inner face of the sensor (Measurement B, see Figure2.4)
0 to 8 mm
Figure 2.4: Wheel sensor measurement of A and B
In case of variation in the above guiding values, please consult
the manufacturer. Following are the type of rail claw and clamping
bolts according to the rail profiles:
Rail profile Claw type Bolt type
60 Kg rail SK140-011 BBK 22
52 Kg rail SK140-012 BBK 17.5
90 lb rail SK140-013 BBK 22
2.4 व्ह�ल सेन्सर के आलंबन हेत ुआवश्यक औजार Tools required for
mounting of Wheel sensor
Steel wire brush and WD40 spray used to clean the rail surface
area for easy fixing of rail claw.
Torque wrench (range 15 2 60 Nm) used to fasten the bolts at
specified torque.
Socket spanner SW19 and SW17 & screw drivers
Fixed spanner SW36/Friction type ratchet – used to fix rail claw
in the rail. Steel tape measure* Plumb bob for level measurement (2
m length)
Figure 2.5: Wheel sensor mounting tools
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2.3 रेल क्लॉ का आलंबन Rail claw mountingThe following parameters
and guiding values are to be considered for rail claw mounting of
wheel sensor RSR180 to the rail:
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*Note: In RE area Fibre/wooden tape measure may be used instead
of steel tape measure.
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• Mount wheel sensor with respective fixing bolt to rail claw,
if not already mounted. Cleanmounting area at foot of rail from
coarse dirt using steel wire brush and WD40 spray.
• Place rail claw pos.2 on the foot of rail from the inside of
the rail.• Clip tie- rod pos.2.2 and spring washer pos.2.7 on the
outside face of rail.• Tighten nut pos.2.3 until the rail claw
pos.2 touches the foot of rail on both sides (ensure
parallelism with foot of rail).
Note: The housing must not touch the head of rail. Ensure
correct position of strain washer pos.3.4and pos.3.5 (bulge of
washer outside). The hexagon socket head screw pos.2.6 must not be
changed.
• Determine measurement “B” with tape measure.Rated range: 0 to
8 mm.If measurement “B” is outside of rated range, see “Horizontal
position correction”.
• Determine measurement “A” with steel tape measure.Rated range:
40 to 45 mm.If measurement “A” is outside of rated range, see
“Height correction”.
2.5.2 Horizontal position correction Note: If for the purpose of
height correction, strain washers pos.3.4 (pos. 3.5) are removed,
ensurecorrect position when placed again (bulge of washer
outside).
If measurement “B” is not within rated range.
a) Place washer pos. 3.3 (dash lined) on the inside face of
support pos. 2.1 and/or
b) Replace the fixing bolt.• Tighten nut pos.3.1 with 15 Nm.•
Tighten nut pos.3.2 (pos.2.4) with 40 Nm.
2.5.3 Height correction • Loosen nut pos.2.4.• Shift support
pos.2.1 until measurement “A” is between 40 mm and 45 mm.Note: If
for the purpose of height correction strain washer pos.2.5 is
removed, ensure correct positionwhen placed again (bulge of washer
outside).
• Tighten nuts pos.2.4 with 40 Nm.
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
2.5 लगाना एवं समायोजन Fixing and adjustmentsThe following
mounting instructions apply to rail claw mounting of wheel sensor
RSR180 (see Figure 2.6).
2.5.1 Fixing
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Figure 2.6: Rail claw mounting of Wheel sensor RSR180
2.6 केबल का संयोजनConnection of cable
The moulded 4 wire wheel sensor cable together with protection
tube shall be inserted through the cable gland in the track lead
junction box. The 4 wires of the wheel sensor cable and of the
star- quad cable from the indoor equipment shall be connected to
the cage- clamp terminal block in the TLJB and each pair of
diametrically opposed wires in the star quad cable from cable
termination rack shall be used for wheel sensor according to Figure
2.7.
Figure 2.7: Cabling in the TLJB
Note: Prior to connection of wheel sensor cable check, isolation
from earth of earthing cable wires.
4-Quad cable
from Loc Box Wheel sensor
cable
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
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• Method 1By setting DIR - DIP switches (located on the
backplane ABP) ON or OFF in isolated mode. In case of transmission
mode, these switches have different functions and either Method 2
or 3 will have to be used. See section 3.3 for more details on
setting of DIP - switches.• Method 2By interchanging the wheel
sensor systems cable wiring as shown in Figure 2.8.
Figure 2.8: Wheel sensor systems RSR180 reversed wiring
connection
• Method 3By changing the mounting place of the wheel sensor to
the other rail as shown in Figure 2.9.
2.8 पी बी 200 क� सहायता से आरएसआर 180 क� ऑकुपेन्सी �डटेक्शन क�
�मता क� जाँच करना Checking occupancy detection capability of RSR180
using PB200
The occupancy detection capability of wheel sensor RSR180 can be
checked by simulation using the testing plate PB200.
Figure 2.10: Check occupancy detec- tion capability using
PB200
1. Place PB200 on the left edge of the wheel sensor. When
placingthe PB200 to the left edge of the wheel sensor for
checkingSys1, the corresponding evaluation board IMC connected
toSys1 will output an occupancy (i.e. track section status
willchange from “clear to occupied”). The LED Sys1 on the
frontpanel of the associated evaluation board IMC will light
up.
2. Place PB200 on the right edge of the wheel sensor.
Whenplacing the PB200 to the right edge of the wheel sensor
forchecking Sys2, the corresponding evaluation board IMCconnected
to Sys2 will output an occupancy (i.e. track sectionstatus will
change from “clear to occupied”). The LED Sys2 onthe front panel of
the associated evaluation board IMC will lightup.
ABP TLJB
RSR systems
BSI004RSR CTR ST.1
reversed
e.g.:Terminal
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
2.7 धरुा गणना क� �दशा का प�रवतर्न Changing the direction of axle
countingThere are three methods for changing the direction (count
in or out) of axle counting:
Figure 2.9: Changing wheel sensor mounting side on rail
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Figure 2.11: Methods of using Testing plate PB200
1. During the simulation of traversing, place the Testing plate
PB200 such that ittouches the rail head like a real wheel.
2. Initial position: Wheel sensor is not occupied.3. Position
PB200 on left of sensor Sys1, laterally to the head of rail, and
move (pull) it
evenly in the direction of arrow over the sensor Sys1: Sensor
Sys1 is occupied.4. Move (pull) PB200 evenly in the direction of
arrow in to the centre of the two sensor
systems (Sys1 & Sys2): Sensors Sys1 and Sys2 are occupied.5.
Move (pull) PB200 evenly in the direction of arrow over the sensor
Sys2: Sensor
Sys2 is occupied.
Note that one wheel count is counted at the end of step 5.6. End
position: Both sensors are not occupied.
Similarly, move PB200 from Sys2 to Sys1 for simulation of
traversing in opposite direction.
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
2.9 पी बी 200 क� सहायता से वह�ल स�सर आर एस आर 180 पर टे्रवर�सगं
का �सम्यलेुशन करना
Simulation of traversing over Wheel sensor RSR180 using PB200
The traversing of a train over the wheel sensor RSR180 can be
simulated with the help of testing plate PB200 as shown in Figure
2.11 and described below:
1 2 3
4 5 6.
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Station: Line Up / Down: Date:
Wheel sensor part #: Wheel sensor serial #: Wheel sensor (DP)
ID: TLJB ID:
S.No. Check description Unit Expected result
Check result
Notes
1 Specify the rail profile in which the wheel sensor is mounted.
- 60 Kg / 52 Kg/ 90 lb
2
Specify the side of rail in which the wheel sensor (DP=Detection
Point) is mounted:
3 Specify the wheel sensor cable length used: Mtr 5/10/15
4
Check that correct rail claw is used and configured according to
rail profile. 60 Kg = BBK22 52 Kg = BBK17.5 90 lb = BBK22
���� / ���� ����
5 Torque value (wheel sensor to BBK) [Nm] 15 Nm 6 Torque value
(BBK/front plate to rail claw) [Nm] 40 Nm
7 Check that the wheel sensor is mounted at the inside face of
the rail (wheel flange side). ���� / ���� ����
8 In curves, check that the wheel sensor is mounted at the
inside face of the curve. ���� / ���� ����
9
Check that the minimum spacing between a wheel sensor and the
next rail joint or the next rail weld is 1.5 m to 2.5 m.Note: The
minimum spacing between two wheel sensors on the same rail is two
sleeper spaces.
���� / ���� ����
10 Check that the wheel sensor is mounted concentrically between
two sleepers. ���� / ���� ����
11 Check that the wheel sensor housing does not touch the head
of rail. ���� / ���� ����
12 Check that there is no gap between the rail claw and foot of
the rail. ���� / ���� ����
13 Check that the wheel sensor is not mounted on the welded part
of the rail. ���� / ���� ����
14 Check that the wheel sensor surface is in parallel with the
head of rail in longitudinal direction of the rail.
���� / ���� ����
15
Check that the wheel sensor is mounted 1 m away from centre of
S-bond towards direction of train movement in non- rope portion of
loop provided for AFTC (see Figure 2.12)
���� / ���� ����
16 Check that the wheel sensor is mounted 1 m away from tuning
unit in case of Alpha bond provided for AFTC (see Figure 2.13)
���� / ���� ����
17 Check that the spring washers (pos.2.5, pos. 3.4
&pos.3.5) used for rail claw mounting are positionedcorrectly
with the bulge of washer outside.
���� / ���� ����
18 Check of measurement A (vertical spacingbetween the wheel
sensor and head of the rail) [mm] 40 to 45 mm
19 Check of measurement B (horizontal spacingbetween the wheel
sensor and head of the rail) [mm] 0 to 8 mm
20 Check that correct strain relief clamp is used ���� / ����
����
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
2.10 व्ह�ल स�सर तथा ट�एलजेबी के संस्थापन हेत ुजांच सचूीChecklist
for installation of Wheel sensor and TLJB
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according to the rail profile and it is securely mounted to the
rail base for protecting the wheel sensor cable.
21 Check that rail deflectors are mounted adjacent to either
side of the wheel sensors and on the inside face of the rail (wheel
flange side).
���� / ���� ����
22 Check that the top edge of the rail deflector is not in
contact with the rail head. ���� / ���� ����
23 Check that the rail deflectors are mounted at least 350 mm
away from the wheel sensor on either side. ���� / ���� ����
24
Installation of TLJB: Check that it is firmly erected, straight,
within permissible height and away from the permissible distance
from the nearest rail as per the Railway’s Schedule of Dimensions
(SOD). It should not infringe with the Railway’s SOD.
���� / ���� ����
25 Check that the opening of TLJB is preferably away from
trackside. ���� / ���� ����
26 Check that the wheel sensor cable to the TLJB is provided
with protection tube. ���� / ���� ����
27 Check that the wheel sensor cable is laid 400 mmbelow sleeper
level. ���� / ���� ����
28 Check that the wheel sensor cable to the TLJB is laid through
double wall corrugated pipe. ���� / ���� ����
29 Check that only star quad cable is used between the BSI in
equipment room and the TLJB (no signalling cable is to be
used).
���� / ���� ����
30 Check of the insulation resistance for the quad cable used
between the wheel sensor and the BSI in the equipment room.
≥ 10 MΩ MΩ
31 Check of the earth resistance for the quad cable used between
the wheel sensor and the BSI in the equipment room.
≤ 1Ω Ω
32
Check of the loop resistance for the star quad cable (0.9 mm
wire diameter) between the wheel sensor and the BSI in the
equipment room.
Resistance between SYS1 wire and GND wire < 56.6 Ωper km
Ω
Resistance between SYS2 wire and GND wire < 56.6Ωper km Ω
Resistance between VCC wire and GND wire < 56.6Ωper km Ω
33 Check that the length of star quad cable between the wheel
sensor and the BSI in the equipment room is < 4 km (for 0.9 mm
wire diameter).
���� / ���� ����
34 Check that the unused cores/pairs of star quad cable in the
TLJB are cut such that none of the conductors remain exposed.
���� / ���� ����
35 Check that no wires are paralleled to reduce conductor
resistance. ���� / ���� ����
Figure 2.12: Installation of Wheel sensor in AFTC with S Bond
Figure 2.13: Installation of Wheel sensor in AFTC with Alpha
bond
Train direction 1 mtr Train direction
TU
1 mtr
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
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3 समायोजन एवं मापन Adjustments and measurements
3.1 पावर सप्लाई Power supplyThe axle counting system ACS2000
requires stable power supply. It is recommended to derive the power
from the IPS (Integrated Power Supply)/regulated power supply.
Apply and measure the supply voltage:
Voltage supply range +19 V to +72 V DC
Typically 24 V DC power supply is used for installations on
Indian Railway.
3.2 एवल्यएुशन बोडर् पर मापन एवं समायोजन Measurements and
adjustments at the Evaluation board The test sockets are provided
on the front panel of the evaluation board. Measurement of a
voltage that is proportional to the sensor current can be done on
these test sockets.
3.2.1 Tools and measuring equipment mV-Meter: Range 1000 mV DC,
precision ± 0.5 %
Two probes with 2 mm male connectors (for connection of
evaluation board with mV meter)
3.2.2 Measurement of Wheel sensor current
Wheel sensor currents are measured as proportional voltages at
the test sockets across an internal 100 Ohm shunt resistance. Thus
100 mV corresponds to a sensor system current of 1 mA. The sensor
current in system 1 and system 2 must have a value between 2.8 mA
and 5.0 mA, which corresponds to 280 mV and 500 mV DC at the test
sockets. System 1 measured voltage must not differ from system 2
measured voltage by more than 20 mV DC (0.2 mA or 5% maximum of the
sensor current). If multimeter is used for measurement of sensor
current, the multimeter shall be set to measure DC voltages.
Figure 3.1: Measurement of Wheel sensor current
1) If a measured value exceeds the rated range, wheel sensor
RSR180 must not be operated undersuch condition.
2) System currents of wheel sensor depend mainly on:• Rail
profile and mounting of rail claw.• Mounting position (measurement
“A”, measurement “B”, concentrically between sleepers).• Metal
parts in direct proximity of the RSR (e.g. earthing connectors).•
Cable loop resistance of the star quad cable between the indoor and
outdoor equipment.
3.2.3 Adjustment of the Evaluation board IMC Apart from
commissioning of new installation, adjustment of the IMC board is
also required after replacement of the IMC board, replacement of
the wheel sensor or dismounting and mounting of the wheel sensor
due to repair, cleaning or track work or in case of changes in the
cable run (changes in loop resistance).
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
Note:
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Figure 3.2: Push switches on thefront panel of Evaluation board
IMC
• At the IMC to be adjusted, push the switches (TA1 and
TA2)simultaneously to the left in direction “Adjust“
(simultaneousmeaning within 500 ms).
• Both switches must remain in this position for at least 500
ms.• Release both switches simultaneously within 500 ms.• Switches
must not remain in normal position for more than 2
seconds.• Push both switches simultaneously within 500 ms to the
right
in direction “Test“.• Both switches must remain in this position
for at least 500 ms.• Release both switches simultaneously within
500 ms.
Successful adjustments are signalled by LEDs Sys1 and Sys2,
which light up for approximately 2 seconds.
Failed adjustments are signalled by fast flashing (10 times per
second) of LEDs Sys1 and Sys2 for 4 seconds. In that case, the
operating sequence described above must be repeated.
3.3 एबीपी क� �डप िस्वच स�ैटगं DIP-switch settings of ABPThe
functioning of the axle counting system ACS2000 depends upon the
configuration settings of the DIR-, MODE- and DN - DIP switches on
the ABP. The DIR-, MODE- and DN - DIP switches can be accessed from
the back of the board rack and are located above and below of plug
connector ST6.
• In isolated mode, the DIR-, MODE- and DN - DIP switch settings
of channel 1 must not differ from channel 2.
• In transmission mode, the MODE and DN DIP switch settings of
channel 1 must not differ from channel 2 of the same ACS2000
system. In transmission mode, the DIR - DIP switch settings have an
addressing function.
• The DIP switches DIP1 -7, DIP2 -7 and DIP2- 8 of channel 1 and
DIP1’- 7, DIP2’ -7 and DIP2’ -8 of channel 2 have no function.
See Figure 3.3 for configuration of DIP- switches for channel 1
and channel 2.
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
Prior to adjustment, it is necessary to verify that the wheel
sensor connected to the IMC board was correctly mounted and that
there is no train in the track section.
During the adjustment procedure, the wheel sensor connected to
the IMC board must not be damped (no metal parts or testing plate
in direct proximity of the sensor), as adjustment under such
conditions is not completed or will be faulty.
Prior to adjustment, measure system currents as in section 3.2.2
above.
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Figure 3.3: Configuration of DIP-switches for Channel 1 and
Channel 2 on ABP
3.3.1 MODE DIP- switches The MODE DIP- switches (DIP1/DIP1’ -
Switch 8) are used to set the operating mode of the ACS2000 system
(Isolated mode or Transmission mode).
3.3.2 DN - DIP - switches
The DN- DIP- switches (DIP2/DIP2’ - Switches 1 to 6) indicate
the ACS2000 as to which input of the ACB is used for double usage
of counting head. In case of double usage, one counting head input
is shared and evaluated by two ACBs of adjacent track sections.
3.3.3 DIR- DIP switches in Isolated mode The DIR- DIP- switches
(DIP1/DIP1’ - Switches 1 to 6) are used to configure the counting
direction of each counting head in isolated mode.
3.3.4 DIR - DIP switches in Transmission mode
In transmission mode, the DIR- DIP- switches cannot be used (as
in isolated mode) to configure the counting direction. In
transmission mode these switches are used for defining the
following configurations of ACB: -DIP1/DIP1’ - Switch 1 is used to
define an ACB as MASTER or SLAVE (one of the two ACBs that are
connected shall be defined as Master and the other as Slave). The
ACB that is defined as Master will start the serial communication
in transmission mode.
If two ACBs are connected in transmission mode, one of the ACBs
is defined as Master by placing the DIP1/DIP1’ - Switch 1 (of both
channel 1 and channel 2) in ON position. The other ACB is
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Sys1 to Sys2 Figure 3.4: Traversing directions over Wheel
sensor
Sys2 to Sys1
Isolated mode Traversing
from DIR - DIP
- switch Counting process
Sys1 to Sys2 OFF Count in Sys1 to Sys2 ON Count out Sys2 to Sys1
OFF Count out Sys2 to Sys1 ON Count in
Table 3(a): Counting direction in Isolated mode
Transmission mode Traversing
from RSR system
wiring Counting process
Sys1 to Sys2 Not reversed Count in Sys1 to Sys2 Reversed Count
out Sys2 to Sys1 Not reversed Count out Sys2 to Sys1 Reversed Count
in
Table 3(b): Counting direction in Transmission mode
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defined as Slave by setting the corresponding DIP1/DIP1’ Switch
1 (of both channel 1 and channel 2) in OFF position.
DIP1/DIP1’ – Switches 2 to 6 are used to set an internal 10- bit
address for serial data communication between the two ACS2000
systems. The 10 - bit internal address and corresponding switch
setting must be identical for those two systems that communicate
with each other. For a bit value of 1, the switch is set in ON
position and, for a bit value of 0 it is set in OFF position.
If several ACS2000 systems are used in an installation (for
example, UP line and DN line), unique serial addresses shall be set
for UP line and DN line axle counting systems to detect / prevent
accidental wrong connection of the modem line.
In transmission mode, the counting direction can be changed by
interchanging the wheel sensor systems cable wiring as shown in
Figure 2.8. See Figure 3.4 for traversing directions over wheel
sensor, Table 3(a) for counting direction in isolated mode and
Table 3(b) for counting direction in transmission mode.
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DIP- switches (in Isolated mode) Switch Position Function
Channel 1 Channel 2
DIP1- Switch 1 to 6
DIP1’- Switch 1 to 6
OFF Count in (When traversing from Sys1 to Sys2) ON Count out
(When traversing from Sys1 to Sys2) OFF Count out (When traversing
from Sys2 to Sys1) ON Count in (When traversing from Sys2 to
Sys1)
DIP1 - Switch 7 DIP1’- Switch 7 OFF or ON No function
DIP1- Switch 8 DIP1’- Switch 8 OFF Isolated mode ON Transmission
mode
DIP2- Switch 1 to 6
DIP2’-Switch 1 to 6
OFF Counting head double usage at respective input (1 to 6)
ON No counting head double usage at respective input (1 to 6)
DIP2- Switch 7 & 8
DIP2’-Switch 7 & 8
OFF or ON No function
Table 3(c): Setting of DIP switches in Isolated mode
DIP switches (in Transmission mode) Switch Position Function
Channel 1 Channel 2
DIP1- Switch 1 DIP1’- Switch 1 OFF Axle counting board is
defined as SLAVE ON Axle counting board is defined as MASTER DIP1 –
Switch 2 to 6
DIP1’ –Switch 2 to 6
OFF Respective serial address bit set to “0”
ON Respective serial address bit set to “1”
DIP1- Switch 7 DIP1’- Switch 7 OFF or ON No function
DIP1- Switch 8 DIP1’- Switch 8 OFF Isolated mode ON Transmission
mode
DIP2- Switch 1 to 6
DIP2’-Switch 1 to 6
OFF Counting head double usage at respective input (1 to 6)
ON No counting head double usage at respective input (1 to 6)
DIP2- Switch 7 & 8
DIP2’-Switch 7 & 8
OFF or ON No function
Table 3(d): Setting of DIP - switches in Transmission mode
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
See Tables 3(c) and 3(d) for setting of DIP - switches according
to the configuration and requirement.
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Note: In the event of double usage of a counting head, the
counting direction must be configured for both axle counting
systems using the corresponding DIR/DIR’ - DIP switches on the ABP.
If an input of the ACB is not used, the associated DIR/DIR’ - DIP
switch will have no function. However both channels must have same
setting (both OFF or both ON).
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• Input power supply voltage range +19.2 V to +30 V DC
When reset is applied: • Switched reset output voltage at
RST+/RST = reset input voltage at RV+/RV.• Check the duration of
switched reset output voltage pulse length > 3 to 5 seconds
without
interruption.• Check the count increments in the non -
resettable counter.
3.5 र�सेट बॉक्स म� जम्पर सै�टंग Jumper settings in the Reset
boxThe plug - in berg jumper on the pcb inside the reset box is
used to configure the reset type.
• Set jumper to position “P” for ‘preparatory reset’.• Set
jumper to position “H” for ‘conditional hard reset’. (This reset
will require “line verified”
input from line verification box).
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3.4 �रसेट बॉक्स पर मापन Measurements at the Reset boxApply and
measure the power supply voltage:
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• Counting head assignment test• Verification of counting
direction in isolated mode• Verification of counting direction in
transmission mode• Verification of reset operation
4.2 काउं�टगं हेड �नधार्रण पर��ण Counting head assignment
testUpon initial commissioning of the ACS2000 system, it is
necessary to verify the assignment of the counting heads.
The assignment of the wheel sensors is to be checked for each
wheel sensor that is assigned to a track section.• Damp (traverse)
wheel sensor RSR using a testing plate PB200.• LEDs for Sys1 and
Sys 2 of respective evaluation board must turn on.• Assigned axle
counting boards ACB must detect occupancy (including double usage)
and turn on
“occupied” status LED.
4.3 आइसोलेटेड मोड म� गणना क� �दशा का सत्यापन Verification of
counting direction in isolated mode
Counting direction of the axle counting system in isolated mode
is verified as follows: • Enter one or more wheels into the track
section (wheels may also be simulated using the testing
plate PB200):The axle counting system turns on “occupied” status
LED and the number of wheels counted areshown in the display of the
ACB.
• Exit the wheel(s) from the track section:The axle counting
system turns off “occupied” status LED and the ACB display shows
“0”.
• Repeat this procedure with each wheel sensor assigned to a
track section.• If counting direction is incorrect, switch both the
DIR and DIR’ DIP switches to ON or OFF for
the associated wheel sensor. Thereby the counting direction is
reversed.
Note: The following factors determine whether the axle counting
board ACB will count IN or countOUT of the wheels during traversing
the wheel sensor: • Trackside, where counting head is mounted.•
Direction, in which wheels traverse the counting head.• DIR- DIP
switches ON or OFF.
• Wiring of wheel sensor systems.
Note: Reversal of direction is possible by:
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4 कायार्त्मक पर��ण Functional testing
4.1 कायार्त्मक पर��ण के प्रकार Types of functional
testsFunctional tests are required upon initial commissioning and
after modifications made to the installation. If necessary, a reset
may be performed between the functional tests. After a reset,
response of the assigned ACB is to be checked. The following
functional tests are required to be performed:
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• DIR - DIP switches ON or OFF.• Changing the mounting side (if
not contrary to mounting and commissioning instructions of
wheel sensor). In case of double usage, this method does not
apply.
4.4 ट्रांस�मशन मोड म� गणना क� �दशा का सत्यापनVerification of
counting direction in transmission mode
Counting direction of the axle counting system in transmission
mode is verified as follows: • Enter one or more wheels into the
track section (wheels may also be simulated using the testing
plate PB200):The two axle counting systems operating in
transmission mode turn on “occupied” status LEDand the number of
axles counted is shown in the displays of both ACBs.
• Exit the wheel(s) from the track section:The two axle counting
systems operating in transmission mode turn off “occupied” status
LEDand “0” is shown on the displays of both ACBs.
• Repeat this procedure for each wheel sensor assigned to a
track section.• If counting direction is incorrect, reverse wheel
sensor systems wiring at respective input (Sys1 ��Sys2).The DIR DIP
switch settings have a different functionality in transmission mode
than in isolatedmode.
Note: The following factors determine whether the axle counting
board ACB will count in or countout of the wheels during traversing
the wheel sensor:
• Trackside, where counting head is mounted.• Direction, in
which wheels traverse the counting head.• Wiring of wheel sensor
systems.
Note: Reversal of direction is possible by:
• Reversing the two sensor systems wiring (Sys1 ��Sys2).•
Changing the mounting side (if not contrary to mounting and
commissioning Instructions of
wheel sensor). In case of double usage, this method does not
apply.
4.5 र�सेट ऑपरेशन का सत्यापन Verification of reset operationThe
reset procedure is dependent upon the type of ACB, reset box and
reset configuration (‘preparatory reset’ or ‘conditional hard
reset’).
The verification of the reset box functionality requires the
respective axle counting section in the “failed” status.
Preparatory reset: • Simulate incorrect wheel counts in or out
using the testing plate PB200.• Apply reset command from the reset
box. The count increments in the reset counter.• Once the reset
command is accepted by the ACB, the axle counting system will be
reset and an
LED “PREP RESET” on the reset box is turned on.• Simulate
correct passage of train through counting head(s) assigned to the
respective track
section (enter one or more wheel(s) in to and exit the wheel(s)
from the track section using thetesting plate PB200).
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• After correct traversing by a train, the axle counting system
will turn off “occupied” status LEDand display ‘0’ on the ACB front
panel.
Conditional hard reset: • Simulate incorrect wheel counts in or
out using the testing plate PB200.• Provide “line verified” input
from the line verification box.• Apply reset command from the reset
box. The count increments in the reset counter.• Once the reset
command is accepted by the ACB, the axle counting system will be
reset. The axle
counting system will turn off “occupied” status LED and display
‘0’ on the ACB front panel.
Note: The verification of reset operation may only be carried
out when there are no trains on the associated track section(s).
After completion of the reset verification, it must be ensured that
the axle counting system is restored to normal working
condition.
CAMTECH/S/PROJ/2015-16/MHB-F_MSDAC/1.0
Table of Contents
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Maintenance Handbook on Frauscher ACS2000 MSDAC March 2016 Page
29
• mV Meter range 1000 mV DC, precision +/- 0.5 %• 2 measuring
strips with 2 mm connector• 2 measuring strips with testing tips•
Testing plate PB200
5.3 एवल्यएुशन बोडर् के टेस्ट सॉकेट पर मापन Measurements at the
test sockets of the Evaluation board Cycle: < 2 years
Tests: Perform measurements as given in section 3.2.2 and, if
necessary, adjust the evaluation board. The wheel sensor current of
wheel sensor RSR180 is set at 2.8 to 5 mA. The wheel sensor system
currents must be measured in the undamped status, with the sensor
correctly mounted. It is recommended to record the measured
values.
5.4 वह�ल सेनसर , रेल �डफलेकटर तथा लाइन वे�र�फकशेन बॉकस का
पर��ण/जाँच Testing/checking of Wheel sensor, Rail deflector and
Line verification box
5.4.1 Testing of Wheel sensor RSR180 Cycle: < 2 yearsTest:
Perform visual inspection and mechanical checks of wheel sensor
RSR180.
• Traverse wheel sensor with a train or• Damp (occupy) the wheel
sensor using the testing plate PB200.The wheel sensor‘s occupancy
detection capability must be tested once in two years by means of
traversing or by damping with the testing plate PB200. This is done
by means of traversing (both system 1 and system 2) of at least one
axle, which must be counted in and out correctly by the
corresponding ACB. Compliance with standards of mounting,
commissioning and maintenance is required.
5.4.2 Checking of Rail deflector Cycle: < 2 yearsCheck 1:
Perform visual inspection and mechanical checks of rail deflectors
mounted on both sides
of a wheel sensor.
Check 2: Measure the distance between the centre of the wheel
sensor and rail deflectors on either
side in the longitudinal rail direction; it should be at least
350 mm away from the wh