Indian Railways Institute of Signal Engineering

and Telecommunications
SECUNDERABAD

Monograph Report

Comparative study of reliability of Axle Counters of various

makes on WR. The project should include the comparison of
features of various makes, failure analysis, their maintenance
aspects etc.

Submitted By
Gaurav Singhal
IRSSE-2018
Introduction
Digital Axle Counters, both Single section and Multi Section have
applications in straight sections and point zones of Station area as well as
in proving of Block section. In every axle counter, different Digital PCBs
(Cards) play a vital role. Although, all Digital axle Counters work on the
same principle, the configuration of their cards may be different.

Figure 1 track side equipment

Comparative Study of Cards of different Digital Axle

Counters
Axle Counters play a very important role in detecting the presence of
train vehicle, thereby ensuring safety in train operation. Analog Axle
counters on the Indian Railways were introduced during the 1970s.
Digital Axle Counters were introduced in early 2000. Digital Axle
counters both Single Section and Multi-Section are installed on Indian
Railways due to their wide applications, such as in Station yard, Block
working, IBS, Automatic Signalling and Point Zones. Over the years due

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 to technological advancements, a number of firms have come up with
their axle counters.

Following table shows the names of RDSO approved manufacturers and

suppliers of Digital Axle Counters on Indian railways along with the brief
description of their model:

Sr. Name of the firm Axle Model

No. counter
version
1 M/s Central Electronics Ltd. SSDAC DACF 710 A & DACF 710 P
HASSDAC DACF - 720 P
MSDAC DACF 730
2 M/s Eldyne Electro Systems Pvt. SSDAC Az LS
Ltd. MSDAC AzLM

3 M/s Siemens Ltd. MSDAC Az S 350 U

4 M/s G.G.Tronics India Pvt. Ltd. SSDAC SSDAC G36
5 M/s Frauscher Sensor MSDAC ACS2000
Technology India Pvt. Ltd.

Although the principle of working is same for all versions of Digital Axle
counters, their Card configuration, LED indications and parameters are
different for different make. There may be more than one type of Digital Axle
Counters installed in the section of an SSE/JE or Signal Maintainer; hence
often he has to refer data of different types of DACs.
In view of above, an effort has been made to compile the card related
information of different types of Digital Axle Counters mentioned as above
in one single document for quick reference by maintenance personnel. This
report covers brief description of cards, their functions and indications for
diagnostics maintenance and important parameters.

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 Figure 2 Electronic junction box

Figure 3 Reset Box

Applications
These are being used presently for the following
(a) Monitoring of berthing tracks in station areas and yards.
(b) Monitoring of point zones in station areas and yard.
(c) Automatic Signalling systems.
(d) Block Proving by Axle Counter.
(f) Intermediate Block Signalling in Double line sections.

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 Both Single Section Digital Axle Counters and MSDAC are being used in
Western railway (MMCT and Ratlam division)
• CEL Make (SSDAC, MSDAC): Ratlam-dahod section, Valsad-dahnu road
• G G Tronics Make(Both SSDAC and MSDAC): Ratlam-dahod section
• Eldyne Make (SSDAC): Mumbai suburban, Ratlam-dahod, valsad
• Siemens Make: Mumbai suburban, Ratlam-dahod, valsad
• Frauscher Make: Mumbai suburban@ville parle, jogeshwari, Santacruz and
BDTS

Figure 4 MMCT division overview

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Figure 5 MMCT division overview

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 (a) Cards
CEL DACF Eldyne Eldyne Siemens Frauscher GG Tronics
730 (MSDAC) AzLS AzLM AzS350U ACS2000 SSDAC G36
(SSDAC) (MSDAC) (MSDAC) (MSDAC) (SSDAC)

1 & 2 Signal 1. Digital 1. Analog 1. Plug-in NA since no  Phase detector Card

Conditioner (Evaluator) Board connection for EJB 1 - 21 KHz
Cards Board WDE service  Phase detector Card
2. Analog 2. Digital equipment 2 - 25 KHz
3 Modem Card Board (ISDN)/  Central Processing
Evaluator 2. Lightning Unit 1(CPU1)
4 Dual Micro Total-2 Board protection  Central Processing
controller logic board Unit 2(CPU2)
block cards One spare slot  Communication
for Additional Total -2 3. Generator
module
board
5, 6 & 7 - PCB:  Relay Drive
Dummy  Digital PCB 4. Band-pass Module
of AzLS in filter board  M-CPU /Event
case of logger module
8 Power double 5. Supplementary  DC/DC Converter
Supply Module section board  LCD display
(DC-DC application. Module
converter) Total -5  7 Segment Display
 Digital PCB Module
of AzLM Additional:
Total -8 for Probe Adapter Total -10
interfacing Board(SCN
with AzLM. S25552-B43-D1
for for testing and
adjusting work on
the ZP 43 V WDE

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 (b) Cards of Indoor Equipment (Evaluator)

730 AzLS AzLM AzS350U (MSDAC) ACS2000 (MSDAC) SSDAC G36

(MSDAC) (SSDAC) (MSDAC) Frauscher (SSDAC)

1&2 D C -DC NA 1. CPU Card 1. SIRIUS2 (Serial 1. Overvoltage protection NA

converter No 2. Power computer interface board BSI No
Card Evaluator Supply universal) board -1 2. Board rack BGT Evaluator
Card No. 3. Axle counting
3,5,7,9,11 3. Serial I/O 2. BLEA12 ( Block backplane ABP
EM-08 Card Card input / output 4. Fuse board SIC
4. Parallel board with 12 5. Evaluation board IMC
4,6,8,10,12 I/O Card relay outputs) - 4 (EB)
Relay D r i v e r Nos 6. Axle counting board
Card Total - 4 3. STEU (Control ACB
and diagnostic) Total -6
board -2 Nos. Optional:
13 4. VESBA 7. Digital input/output
Configuration (Amplifier, trigger board DIOB (optional
Card and band-pass for transmission mode)
filter) board – 5 8. Frauscher Reset
Nos. acknowledgement PCB
14 Event 5. VAU(Processing FRA (for ‘preparatory
Logger Card & Monitoring) reset’ application only)
board – 2 Nos.
Total -14 6. DIGIDO (Digital Variants in use on
double-usage) Indian Railways:
board – 1 No. ACB 119 & ACB 130
7. SVK2150 (Power
supply board -1
No.

Total -16

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 (C) Possible configuration/Models
CEL Eldyne Eldyne Siemens Frauscher
DACF AzLS AzLM AzS350U ACS2000 GG Tronics
730 (SSDAC) (MSDAC) (MSDAC) (MSDAC) SSDAC G36
(MSDAC) (SSDAC)
730 -8DP (i) 2 DP- Different Upto Different
730-16DP Single configurations (i) 5 DP-4 configurations 2DP single section (1S)
730-24 DP Section upto max. 32 Sections upto 6 D P p e r 3DP single section (1S)
730-40 DP (ii) 3DP – DPs (direct) ACB 3DP single section (2S)
Single (ii) 3DP (Right For more than 6
Section hand DPs (Max. upto
(Points) Evaluation 12) - 2 ACBs
Computer interconnected
partner) -2 by null-modem
Sections cable
(remote)
(iii) 3 DP (Left
hand
Evaluation
Computer
partner) -2
Sections
(remote)

(d) Maximum No. of DPs per Evaluator

CEL Eldyne Eldyne Siemens Frauscher GG Tronics
DACF AzLS AzLM AzS350U ACS2000 SSDAC G36
730 (SSDAC) (MSDAC) (MSDAC) (MSDAC) (SSDAC)
(MSDAC)
40 NA 32 internal 5 Direct 6 NA
16 External 6 Remote

(e) Maximum No. of track sections per Evaluator

CEL Eldyne Eldyne Siemens Frauscher GG Tronics
DACF AzLS AzLM AzS350U ACS2000 SSDAC G36
730 (SSDAC) (MSDAC) (MSDAC) (MSDAC) (SSDAC)
(MSDAC)
40 1 32 4 5 2

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 (f) Counting capacity
CEL Eldyne Eldyne Siemens Frauscher GG Tronics
DACF AzLS AzLM AzS350U ACS2000 SSDAC G36
730 (SSDAC) (MSDAC) (MSDAC) (MSDAC) (SSDAC)
(MSDAC)
16384 -- -- 32767 axle per 8191 Wheels per --
Track Secton track section

(g) No. of vital input relays

CEL Eldyne Eldyne Siemens Frauscher GG Tronics
DACF AzLS AzLM AzS350U ACS2000 SSDAC G36
730 (SSDAC) (MSDAC) (MSDAC) (MSDAC) (SSDAC)
(MSDAC)
Maximum 1 Relay: 1 Relay: 1 Relay: 1 Relay: SF- 2 Relays: 1
40 VPR per VPR per VPR per VPR per VR & 1 PR
track track track track EF - 2 Relays: 1
section section section section VR & 1 PR
CF- 4 Relays: 2
VRs & 2 PRs

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 Failure analysis
Failure is considered for more than 5 event happened as ATFC is right an DAC is failed.
Make Siemens Frauscher Eldyne Total
Population 850 207 262 1379
Aug failure 151 53 40 247
Sep Failures 186 78 110 374
Oct Failures 182 58 76 316
Aug Failure % 17.76% 19.84% 19.32% 18.72%
Sept Failure % 21.88% 37.68% 41.98% 27.12%
Oct Failure % 21.41% 28.01% 29% 22.91%

Make Siemens Frauscher Eldyne Total

Card Defect 20 0 14 34
Sept21
Card Defect 13 0 05 18
Oct21

These DAC failures being analysed make wise and following points noted
Common causes of failure:
1. Power supply failure
The 24V DC power supply should be measured correctly. The 24V DC
should remain within specified limits. Any interference with power supply
and connections of SSDAC is likely to cause failure.
2. Surge: due to striking of lightning
3. Traction return current may also have adverse effect on working of
Eldyne SSDAC.
4. False detection even if no wheel is present on the track

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1. Eldyne

Following problems have been noticed in the failures of MSDAC that need
to be addressed:
1. In few failure cases, it is noticed that communication between ACE and
DP gets hanged and finally gets reset only after reinserting of parallel cards
in ACE.
2. At Borivali station (BVI), DAC of track 124T fails frequently due to
communication failing intermittently and reset not being accepted.
Furthermore, DAC of another track 113T fails frequently even though the
site parameters are within normal limit. Since this track deals with very
less train movements, it remains failed for long time.
3. At Andheri station (ADH), DAC of tracks 61AT & 11T fail frequently
for one train movement and gets restored after resetting. These failures
occur frequently despite keeping site parameters within normal range.
4. Also the loose-fitting clips of the cards of Outdoor unit in the DP
enclosure causes more failures and maintenance staff has to move at site
time and again at site to attend the same.

2. Siemens
a) Its parameters go out of range during first shower of rain which leads to
failure of DACs during monsoon when its dependability is more as AFTC
gets failed due to water logging.
b) There are few tracks in which if DAC fails due to miscount it only gets
reset after movement in diversion DP.
c) Outdoor cards as Generator Card, Filter Card and back plain card went
defective max case as required to change the cards.

Following are the details of failures for siemens:

1. Few DAC failure cases noticed where in its channel frequencies F1, F2
goes out of range during first shower of rain. During water logging also
few DACs failed. DACs should not fail due to rain, water logging or other

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 atmospheric changes. During Monsoon, a failure of DAC becomes
prolonged failure as it is quite difficult to attend while it is raining. This
results in punctuality loss in suburban section.
2. At VR, if track fails due to any reason (Miscount), both tracks enters in
preparatory mode after reset applied but do not get cleared if train passes
in normal direction. It only gets reset when train movement occurs in
diversion. In such type of failures DAC remains fail for more time as there
are less diversion movements

3. Frauscher
a) In this, M10 bolts (BBK 22) used to hold RSR 180 sensor to rail claw
get broken frequently and quality of these bolts become questionable as it
leads to failure. Also the holes on which it fixed gets enlarged leads to
loosening of fixture and finally results in failure.

Other causes of failure

1. cable defect
2. Parallel card defect
3. sensor loose or misplaced
4. DP damaged
5. Failed during Engineering block
6. Failed during material shifting by Engg staff

Maintenance
 Inspect the battery charger and check its charging current and ensure it
is properly charging the battery. Any interference with power supply
and connections of SSDAC is likely to cause failure. This should be
done only after ensuring that no train is occupying or approaching the
section.

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  Output voltages of DC-DC Converter Measure the input voltage of 24
V DC between GND and the corresponding input monitoring point;
this should be within 22 V and 26 V DC. With the same GND measure
the other voltages
 Adjust +5V precisely to 5V with the help of potentiometer provided
for the purpose on the front plate of DC-DC Converter. Similarly
adjust +18V fed to the PD card.
 Good earthing with an earth resistance of 1 to 2 ohms by providing
parallel or special earth is needed.
 Don’t remove the modules from SSDAC system under Power ON
condition. Remove the modules, if necessary, after switching OFF the
power to the SSDAC system.
 When section is in Occupied/Preparatory mode, Motor trolley wheel,
Push trolley with solid mass wheel and Material trolley wheel must not
be allowed to Enter/Exit the section to avoid SSDAC system going
into failure condition

Eldyne Check points for maintenance

a) In Eldyne make DAC failures occurs due to communication hanged and
can be put right by either disconnecting link or reinserting communication
card/parallel card.
b) In some cases, retaining clips of cards in outdoor DP assembly becomes
loose leading to failure so effective method for card enclosure can be
explored by OEM.
 Carry out visual inspection of trackside equipment i.e. EAK, rail
contacts and integral cables (connecting leads), earthing etc.
 Check physically whether the rail contacts and cabling including
earthing connections are proper. Ensure that Tx heads are clear of rail.
 Ensure the proper size and tightness of deflectors and that these are
fitted at least 250 mm away from rail contacts (Tx/Rx coils).
 Ensure for proper fixing of Track side connection box (EAK) on the
mushroom base plate and all 4 nos. screws are tight.
 Ensure that cable armours are properly earthed in location box.
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 Check for proper spacing (min. 350 mm) and packing of sleepers on
which track devices are fitted. Check that the earthing connection of
mushroom cover/apparatus case is intact and in good condition, the
earth lead wire and nut connecting earth wire etc. are not corroded.
 Check that cable pairs used are properly dressed and terminated in such
a way that no conductors remain exposed and check that no individual
conductor are made spiral. These should be twisted in pair to improve
EMC.

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  MAINTENANCE LOG-SHEET FOR ELDYNE MSDAC

Railway……………………

Division…………………
 Station……………
 DP No………… Track Section…………….

Date………… Item Permissible range Recorded

value
1 a) Power supply Channel 1 22…35 VDC
2 b) Power supply Channel 2 22…35 VDC
Selector c) ( Rectified Rx1 voltage w/o +80..+1000mV DC
dummy wheel ) MESSAB1
position 4
in (d) With dummy wheel set on -80..-1000mV DC

unit 5 (e) Reference voltage PEGUE1 Adjust as per (c)

(f) ( Rectified Rx1 voltage w/o +80..+1000mV DC
dummy wheel ) MESSAB2
7 (g)With dummy wheel set on 40 -80….-1000mV DC
mm
8 h)Reference voltage PEGUE2 Adjust as per (f)
Terminal i) Input Power supply voltage 54 V to 72 V DC
3 & 13 of
EAK
Terminal (j) Transmitter frequency SK1 30.0….. 31.25 KHz
SK1/S1 & (k) Transmitter voltage SK1 40……85 VAC

Terminal (l)Transmitter frequency SK2 27.4…..28.6 KHz

SK2/S1 & m)Transmitter voltage SK2 40……85 V AC

Indications n)H1-1 Red/H1-2 Green Note

Analog (o) H2-1 Red/H2-2 Green Note
board (p) H3-1 Red/H3-2 Green Note
Indications (q) H1-1 Green/H2-1 Green Note
Digital (r)H1-2 Green/H2-2 Green Note
board
(s) Signature

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Frauscher maintenance

5.1 Tests/Checks

The tests/checks listed in this section are to be carried out according to the
test/check cycles stated. In case of faults or if reasons for errors occurred
are unclear, the maintenance measures listed are to be carried out
immediately.

5.2 Tools and measuring equipment

mVMeter 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 Measurements at the test sockets of the Evaluation board

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 m u s t
be measured i n the undamped status, with the sensor correctly
mounted. It is recommended to record the measured values.

5.4 Testing/checking of Wheel sensor, Rail deflector and Line

verification box

5.4.1 Testing of Wheel sensor RSR180

Test: 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

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 correctly by the corresponding ACB. Compliance with standards of
mounting, commissioning and maintenance is required.

5.4.2 Checking of Rail deflector

Check 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 wheel sensor.

5.4.3 Checking of Line verification box

Perform visual inspection and mechanical checks of line verification box
wherever provided.
• Check correct and ease of operating the key operated push button
switch.
• When activating the push button switch, measure the output supply
voltage (it should be same as the input supply voltage).

5.5 Testing of ACB

Test (a) Traversing of a counting head connected to the ACB to be tested and
counting in and out of at least one axle or
Test (b) Counting in and out of at least one axle, using the testing plate
PB200

Within a period of 2 years, the axle counting system must at least once
switch from clear track status to occupied track status and from occupied
track status to clear track status (clear-occupied - clear or occupied-clear-
occupied).

5.6 Testing of DIOB

Test: There are two options to test the DIOB functionality:

For the purposes of testing, the installation (e.g. signalling box) must be
able to selectively switch on and off the information at the inputs of the
DIOB. The information from the DIOB outputs evaluated by the

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 downstream installation (e.g. signalling box) must be visible for control
purposes. This testing activity requires a second person at the other
subsystem (for switching on and off of the input information and monitoring
of output information).
Testing of the installation requires test plugs. The testing activity requires
a second person at the other subsystem (for connecting the test plug).
Note: The installation does not have to supply test signals. All inputs and
outputs are tested in one single test step, as the test plug in the second
subsystem returns the output signals of DIOB through its inputs to the
outputs of the first subsystem.
The DIOB outputs used require testing within one year so as to determine
whether they open when the respective input is not triggered.
The display of input and output states by the LEDs on the front panel is
only of informative nature and not failsafe. Therefore, the information
displayed by the DIOB front panel must not be used as basis for safety-
relevant operations by the operating, repair and maintenance personnel.

Error
Brief description Cause Remedy
code
00 no fault is present fault free operation
another subsystem is see error code of the
01
reporting a minor other subsystem
error serial communication has repeat Reset,
another subsystem is not
been temporarily interrupted check the
02 responding to the
or disrupted (component transmission medium,
applied Reset
error of a board) if necessary replace
partial traversing see error code of the
03
on another other subsystem
subsystem At least one axle must be correctly counted in and out
waiting for clearing again,
04 of track after Reset whereby one counting process must take place on each
(modem operation) subsystem (a train must traverse from one subsystem to
occupied/clear the other). carry out a reset; if the
05 (Hardware error) error occurs again, replace
transmission mode the affected ACB
for errors 21 to 26, if carry out a reset; if the
negative axle in
06 the serial error occurs again, replace
modem operation
communication is the affected ACB
interrupted or disrupted

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 reset restriction removed
through pre-Reset
pre--Reset carried
07 operation; the code is
out in modem
displayed after successful
operation
execution as confirmation
results of the counting EMC-interference
08 logic and hardware (Hardware error)
evaluation not the
same
waiting for clearing of At least one axle must be correctly counted in and out
09 track after Reset again. This counting in and out process can be carried out
(isolated operation) at each counting head belonging to a track section.

Figure 6 Field visits

Reliability
• As far as reliability is concerned Frauscher make DAC are more preferred
over ELDYNE and G G Tronics make axle counters.
• Maintenance: maintenance of Frauscher make axle counter is easy due to
its user friendliness and easy availability of spare parts required. but
maintenance of GG tronics and siemens make axle counters are not that
easy due to time consumed in fault detection and also availability of
material required. Frauscher make axle counter have least failures and easy
to fix it due to its compact size.
• In Mumbai suburban where frequency of trains is very high, frauscher
make DAC provides high reliability and least downtime.

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