SINGLE SECTION DIGITAL AXLE COUNTER
Contents
1. Page 7 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 2 1 10 Event Logger logs the events occurring in the field unit with date and time stamping 2 2 Abbreviations 2 2 1 dB Decibel 2 2 AWS Auxiliary Warning System 2 2 3 TPWS Train Protection amp Warning System 2 2 4 TX Transmitter 2 2 5 RX Receiver 2 2 6 KHz Kilo Hertz 2 2 7 LED Light Emitting Diode 2 2 8 LCD Liquid Crystal Display 2 2 9 AFTC Audio Frequenoj 3 0 Applicable documents drawi IS 9000 ae testing procedures for electronic a a ric Siggaling and Interlocking Equipment IEC529 EN 6 Specification for degree of protection provided by enclosures IP code EN 61000 4 2 Electromagnetic compatibility EMC testing and measurement techniques electrostatic discharge immunity test and basic EMC ity systems model for quality assurance in B development production installation and 6 EN 61000 4 4 Electromagnetic compatibility testing and measurement techniques electrical fast transient burst immunity test and basic EMC publication 7 EN 61000 4 5 Electromagnetic compatibility testing and measurement techniques surge and immunity test Page 8 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 8 PrEN50126 Railway applications specific2. 4 0 8 Axle counter be suitable for train speeds up to 250 Km h 4 0 9 Axle counter system shall be designed for ease of maintainability and testability 4 0 10 The equipment shall be robust in construction and shall work on the permanently energized principle Any defect occurring in the equipment shall not result in a condition that will lead to unsafe situation 4 0 11 The equipment shall be of continuously self checking type and shall have separate indication to show conditions of track clear and track occupied including fault Any disturbance or failure in the equipment including power supply failure shall result in withdrawal of clear indication and occupied indication shall be lit Page 10 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 0 12 Card wise failure indication shall be provided It is desirable to give suitable indication of the nature of failure Also total system failure and O K indications shall be provided 4 0 13 Axle detector Track Device amp field units shall have no moving parts and shall require negligible maintenance 4 0 14 The equipment shall be so constructed as to prevent unauthorized irregular access to sub assemblies of the system Authorized persons should however have access to these sub assemblies for the purpose of installation and maintenance by unlocking the outer cover breaking of seal provided on the outer cover
3. Page 1 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Draft copy for comments Ver 3 SINGLE SECTION DIGITAL AXLE COUNTER SPECIFICATION NO RDSO SPN 177 2012 Version 3 0 RESEARCH DESIGNS amp STANDARDS ORGANISATION MINISTRY OF RAILWAYS MANAK NAGAR LUCKNOW 226011 Page 2 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments DOCUMENT DATA SHEET Designation RDSO SPN 177 2012 Version 3 0 Title of Document Single Section Digital Axle Counter Specification Authors See Document Control Sheet Signed by Name Prashant K Varma Designation Director Signal Approved By RDSO Name Shri Mahesh Mangal Designation Sr ED Signal RDSO Abstract This document defines Single Section Digital Axle Counter Specification Page 3 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments Document Control Sheet Designation Organization Function Level Director Signal RDSO Member Prepare Sr ED ED Signal RDSO Approval Page 4 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments AMENDMENTS Version Chapter Amendments Effective Date Annexes 1 0 First issue 14 01 2003 1 0 with Amendment 1 Clause 10 modifi
4. 15 4 Details of hardware e g schematic diagrams o its components details for each type of assembled PCB and i itted for type approval 16 Purchaser s Responsibility 16 1 The commissioning of the equipment shall be done un ervision of the manufacturer However purchaser i i ay waive off this clause by specifying so in the tender 17 Supply of documents 17 1 Two copies of the followi all be sup ng type approval and one copy each shall be supplied Documents have to be 17 1 1 17 1 2 Ig anuaFincluding Dos amp Don ts 17 M i h sub system rack 17 1 4 i showing mounting arrangement of various components 17 1 5 ime procedures along with test voltages and waveforms at various test points inghe PCBs 17 1 6 Pre commissioning checklist 18 Item to be specified by Purchaser 18 4 The configuration of which SSDAC s by default 2 DP 1 section are required 18 2 The length of cable 5 10 15 m required with each track device Default length is 10m Page 32 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 18 3 Supply option i e 18 3 1 Standard SSDAC or 18 3 2 High availability SSDAC system using 18 3 2 1 With Single track sensor device or 18 3 2 2 With Dual track sensor devices 19 Tools for maintenance 19 1 The manufacturer shall indicate special maintenance instruments and tools that may be necessary for proper adjustment and mainte
5. 8 2 12 2 Month and year of manufacture 8 2 13 Solder Mask Solder mask shall be applied on solder side and component side of the board 8 2 14 The distribution of the power supply on the cards should be such that different voltage tracks 0 5V etc follow the same route as far as possible The track of power supplies should be as thick and wide as possible Page 21 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 8 2 15 Housing Rack shall be as per RDSO SPN 144 9 0 Performance 9 1 Time for failure detection Failure indication shall occur not later than after the passage of the first train over the relevant track section 9 2 Occurrence of any failure or error of operation in the axle counter component parts must not lead to any hazards It may slowly result in transition to a safe state 9 3 The Axle counter service life shall not be less than 20 years 9 4 The Axle Counter equipment only shall have M hrs er than 70 000 10 0 Inspections and Testing 10 1 General 10 1 1 Inspection and tests shall be carried out to ensur specification are complied Conditions of tests shall be carried out at ambient i iti or inspection of material relevant clauses of IRS S 227and R all also apply requirements of this 10 2 Type Approval 10 2 1 Initial Type Approval r its equivalent giving complete tests and their results Ken by manufactur
6. It is capable of counting axles doing count comparison finding direction of axle movement supervision relay drive and transmission of counts and health of axle detectors amp field units 4 0 2 Track clear indication shall only be given when IN count and OUT count are equal and equipment is functioning all right This implies that until all axles that enter a section are completely counted out the section concerned shall not show as Clear 4 0 3 Axle counter shall show occupied the moment any of the axle counter sub assemblies belonging to the section is damaged missing or has become faulty 4 0 4 Axle Counter shall use amplitude phase change tech iques r any other fail safe techniques for safe and reliable wheel det 4 0 5 Axle counter shall have arrangement so that w dollies etc are not counted by it These whe going to error Trolley protection track circuit detection RDSO drawing no RDSO TM 05 10 4 0 6 Axle counter operation shall be independent of we of wheels as permitted vide Indian Railway s Sched i ion displacement of wheels on rails etc The manufactureg inffnum diameter of the wheels condition of wheels etc to Whi mance of equipment shall not be affected 4 0 7 Axle Counter operation such as Wooden Beer o ork on all types of rail profiles and S welded rails of 52 kg 60 kg 90R etc Axle r wornout rail as given below ertical wear in mm 13 00 8 00 5 00
7. 1 0 1 1 1 2 2 0 2 1 2 1 1 2 1 2 2 1 3 2 1 7 2 1 8 2 1 9 SPECIFICATION FOR SINGLE SECTION DIGITAL AXLE COUNTER Scope This document sets forth general operational technical performance amp type tests requirements of Single Section Digital Axle counter This specification does not cover requirements of external cable and protective devices to be used in conjunction with Digital Axle Counter for its installation Terminology amp Abbreviations Terminology The terminology referred to in the specifica i e definitions given in IRS Specification no S 23 IS Spec S given below direction of movement device keepiagsthe ack section or occupancy output It is capable of communicating with other e track section is clear oce based on the information of detected in counts and out counts numbegs of axles which is received from the axle detectors confining the section in qu stion Resetting Resetting results in bringing to zero the records of counted axles Preparatory Reset After resetting axle counter shall continue to show occupied until one train movement through the section carries out correct balancing of track section Conditional Hard Reset The reset is activated after physical verification of a condition from different location like the clearance of the track section from site using line verification box The axle counter will show clear after the conditional reset
8. at specified torque using torque wrench 4 3 6 Axle counter performance shall not be affected by the flooding of track 4 3 7 The axle detector shall be actuated only by wheel flanges and not by other parts of trains e g rail brakes toilet pipes suspended chains electrical inductors in locomotives air conditioning equipments ical electronic equipment in train engine 4 3 8 One set of axle detector shall not influence ano ted gt 2 meters away 4 3 9 The axle detector should not infringe witk nsions of Indian Railways 4 4 4 4 1 4 In case OUT count has been registered before any IN count 4 4 2 Itshall be possible to reset each field unit from reset box only For HA SSDAC auto resetting module will send reset automatically if one channel only has failed 4 4 3 If all the field units of an axle counter section are placed in the same station same one reset box can be used to reset all the field units of one section in parallel 4 4 4 If any field unit of an axle counter section is placed in different station then separate reset box shall be used for resetting that field unit Page 14 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 4 5 4 4 6 44 7 4 4 8 4 4 8 6 Preparatory 4 4 8 7 4 4 8 8 If reset is applied to only one field unit the axle counter section will not reset and will continue in occupied condition In two det
9. e size of software with version number of each sub system j lying for type approval 11 0 Quality Assurance 11 2 The equipment shall be manufactu pe ityPassurance procedure laid down so as to meet the require monitoring of QA proce part of type approval The required e ts as per RDSO s Standards shall be available 12 0 12 1 e on Marking given in RDSO SPN 144 12 2 e connected to track power supply etc shall be marked 12 3 e be provided in a conspicuous position giving manufacturer s name specificgtion reference serial no of the equipment date of manufacture version no l cal address remote address etc 12 4 A plate indicating the configuration to be adopted for entry point unit and exit point unit shall be provided in a conspicuous position on the equipment 12 5 Proper marking should be on Tx Rx coil 13 0 Packing Packing shall be done to RDSO SPN 144 Page 31 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 14 0 Warranty The warranty of the equipment shall be in accordance with IRS Specification No S 23 15 0 Documentation 15 1 Documents shall be prepared to meet EN 50128 and EN 50129 requirements 15 2 Safety case documents as per CENELEC standards for SIL 4 Railway Signalling to be submitted for type approval 15 3 Guaranteed performance data technical amp other particulars of the equipment to be submitted for type approval
10. production testing in the sequence as follows Suitable records shall be maintained regarding the compliance of these tests Vibration Test PCBs in unpacked condition shall be j ation test for 10 minutes at the resonant frequency i inimum acceleration in the axis axes pe i ounting of components In addition to physical chec ters are also to be monitored after the vibration t Bump Test PCBs modules units in pac at 40 g for 1000 bumps tried out as per sampling plan given in Clause 7 S 42 85 for Axle Counter Equipment In additi i electrical parameters are also to be Subjected to bump test ycling is from 0 to 70 C 2 hour at each temperature for 9 hour at each temperature for the 10 cycle Dwell time of 1 joints exposed through thermal stress VITA l5 hr hr Page 30 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments The rate of rise fall of temperature shall be minimum 10 C minute In addition to physical checks the electrical parameters are also to be monitored after this test 10 5 10 4 Power Cycling The power supply modules shall be subjected to 60 sixty ON OFF cycles for one hour The ON OFF switch usually provided in the modules may not be used for this purpose 10 5 11 The test for Software check sum Through suitable means the total size of the sub system shall be measured and recorded The manufactur
11. 4 4 6 5 4 7 4 7 1 4 8 4 8 1 4 8 2 Suitable arrangements shall be made for providing electrical isolation between external relay circuit and internal circuit It shall have provision for setting unique address of each field unit The address shall be of minimum 8 bits Communication It shall be possible to use copper cable or voice channel in optical fibre cable communication for transmission of data between field units The copper cable will be quad cable as per IRS TC 30 2005 0 9 mm dia or quad cable as per RDSO SPN TC 72 2007 1 4 mm dia or PIJF Telecom Cable as per IRS TC 41 97 0 9 mm dia No separate external interface should be required for using any of these two transmission mediums Impedance matching between communicat odem shall be provided It shall be capable of transmission of axle information between field u or error detection and the hamming distance of th all be at least 5 The code transmission should be s i 3 imunication should be as per CCITT standard bn to occupied state a safe state The manufacturer length of the axle counter section for which the axle Earthing Provision of earthing should be there in the field unit and reset box The earth terminal shall be suitable for taking upto 4mm dia copper wire with lug Event Logger Each field unit should be provided with in built event logger The event logger should work automatically without any other input required to be g
12. 4 0 15 The field unit shall be provided with testing measuring and adjusting facilities for maintenance 4 0 16 The equipment shall be fully solid state using carefully grade as per details given in SPN 144 components of 4 0 17 The system shall provide for continuous supervisi cable connecting the counting device and axle be immediately detected error code displayed and the mode defect in these shall ld go in error 0 18 The maximum axle count the axle c 4 0 19 4 0 20 4 0 21 of digital axle counter shall be such that it is fit to be dian Railways including suburban sections 4 0 22 4 0 23 i Xle counter shall take into account switching transients that may occur either inside or outside the system and of any magnitude up to and including interruption of full short circuit current 4 0 24 Axle counter shall withstand the effect of lightning amp surges incorporating lightning amp surge protection as per RDSO SPN 144 4 0 25 The equipment shall conform to the Safety Integrity Level 4 as per CENELEC Standard 4 0 26 The axle counter should not affect the operation of other wayside signalling equipments Page 11 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 0 27 The axle counter shall neither affect or be affected by presence in vicinity of track side signalling equipments like AFTC TPWS AWS etc 4 0 28 Error rate should no
13. 5 5 3 10 5 5 4 10 5 5 5 equipment shall be kept energized during the test and status of relay shall be recorded After completion of test the equipment shall be subjected for standard recovery of 2 hours 15 35 degree C RH 45 75 96 After recovery the equipment shall be checked visually for any damage and its insulation resistance shall be measured which shall not be less than 10 Mega ohms at 40 degree C and 60 RH Dry Heat test The equipment shall be tested as per IS 9000 PLIII Sec 5 The test severity shall be 70 2 deg C and duration of exposure 16 hrs After stability in the chamber has been reached Rate of change of temperature shall be 1 degree per minute The equipme alk be switched ON when the temperature in the chamber has stabi ined active during the above tests and status of relay shal er completion of test the equipment shall be subjected fi urs 15 35 degree C RH 45 75 After checked visually for any apparent dama resistance shall be measured which shallMot than 10 Mega ohms at 40 degree C and 60 RH Cold test The equipment shall be tes 990 Pt II Sec 3 The test severity shall be 10 of exposure 2 hrs After stability in the chamb Rate of change of temperature shall be 1 degree the temperature i mber has stabilized and remained active during 35 degree checked visuall any apparent damage or deterioration and insulation easured which shall not be less than 10 Mega
14. No piggyback PCB shall be connected to any PCB The components shall be soldered with wave soldering machine Any exception to wave soldering machine shall have specific approval of RDSO Lucknow The cards shall be provided with testing points and the corresponding voltages waveforms shall be indicated in the fault diagnostic procedure and service manual to facilitate testing and fault tracing Heat Dissipating Components All components dissipating 3 W or more power shall be mounted in such a manner that the body is not in contact with the board unless a clamp heat sink or other means are used for proper heat dissipation Page 20 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 8 2 9 Conformal Coatings Assembled PCBs should be given a conformal coating to enable them for functioning under adverse environmental conditions The coating material should be properly chosen to protect the assembly from the following hazards 8 2 9 1 Humidity 8 2 9 2 Dust and dirt 8 2 9 3 Airborne contaminates like smoke and chemical vapours 8 2 9 4 Conducting particles like metal clips and filings 8 2 9 5 Accidental short circuit by dropped tools fasteners 8 2 9 6 Abrasion damage and 8 2 9 7 Vibration and shock to a certain extent 8 2 10 Burning in Test 8 2 11 5 Part numb 8 2 12 Following deg ription shall be marked on the PCB 8 2 12 1 The manufacturing serial number
15. ation and demonstration of reliability availability maintainability and safety 9 PrEN50128 Railway applications Signalling and Communications Software for Railway Control and Protection system 10 PrEN50129 Railway application Safety related electronic systems for signalling 11 EN 50159 1 amp 2 Railway Application Signalling and Communication Safety related communi i d and open Transmission system 12 IRS S TC 30 Underground Railway S amp T installations 13 RDSO SPN TC 72 1 4mm dia Copper conductor 4 ad cable 14 IRS S 99 Datalogger systema 15 aososennos smes vaea s PL IRS S 86 Battery ger Se S ho di asco nfbeecH UL faa Sy We Requirement of Electronic ent ing for Digital Axle Counter Reset Box with By fascia one Porawing for High Availability SSDAC system reset V with display RDSO TM 05 Wheel for Inspection Push trolley RDSO S 20002 Drawing for Verification Box 3 1 Wherever in this specification any of the above mentioned specification is referred the latest issue of the same is implied 4 0 General Requirements 4 0 1 Single section digital Axle counter consists of axle detectors amp associated electronics 1 or 2 or 3 or 4 confining a track section connected together by a Page 9 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments transmission medium where transmission is in VF range
16. e equi during the test and in its normal opera sprayed from eight showerheads four o of 45 degree on each of the uppermost c S above the highest point of item t shall be kept in the chamber in its normal energized state After the completion of the hecked visually for undue penetration of water and mage or deterioration Insulation resistance shall be Il not be less than 10 Meg ohms at 40 degree C and 60 subjected in the chamber at laboratory temperature in switched off condition The temperature of the chamber shall then be raised to a value of 40 deg C 3 deg C with a relative humidity not exceeding 50 shall be maintained in the test chamber When the temperature stability has been attained the test item shall then be subjected to a stream of dust laden air for a period of one hour After standard recovery of 2 hours the equipment shall be checked for any deterioration and insulation resistance shall be measured which shall not be less than 10 Meg ohms at 40 deg C and 6096 RH Page 28 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Draft copy for comments Ver 3 10 5 6 Shock Test on axle detectors only Axle detectors shall be tested for this test Shock test as per IS Peak acceleration 40 g 9000 Pt VII Sec 1 Clause 9 Duration of the pulse 11 m sec No of shocks 18 Velocity change Half sine pulse Equipment in unpacked condition shall be subjec
17. ection point single section and three detection point two section configuration when reset is applied to both the field units the axle counter section should go in preparatory reset mode The preparatory reset LED in both reset boxes should glow and reset counter should increment The axle counter section will be still in occupied state although the axle counts of individual field units will become zero The axle counter section will become clear only after more than one in count from one end and same number of out count from the other end have taken place The common field unit in three detection point two section configuration shall accept reset command from two separate reset boxes for adjacent sections In one detection point single section three det ction poi le section and in four detection point single section configurati box will be transmitted only after verifying t pressed amp turned in the verification box at site section being clear physically On availabilit units of a section the section will reset and show cle increment mmand to all the field eset counter should 24V DC supply The as per Reset Box drawing no dication LED 3mm Green Line verificat On indication LED 3mm Yellow Reset box shall have provision for a data download port along with necessary memory to store last thousand events Page 15 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy
18. ed for 10 02 2003 Typographical errors regrouping inclusion of tests etc 1 0 with Amendment 2 i Clause 4 8 4 13 5 2 1 7 2003 5 10 10 3 1 10 4 1 1 10 4 2 1 10 5 11 2 ii New addition of clause 10 5 12 2 0 15 04 2005 2 0 with Amendment 1 i Cl 4 0 23 4 0 27 4 0 28 4 4 6 4 4 7 4 6 5 5 1 2 10 5 5 6 modified New addition of clauses 3 0 18 4 0 35 4 0 36 4 2 5 4 4 12 4 5 7 amp 18 1 ii 3 0 i Cl 4 04 Inclusion of SSC comments ii Inclusion of ver 2 0 amndt 1 iii New addition of clauses inclusion of High availability system Page 5 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments le of Content Cl No Item Page No 1 0 Scope 6 2 0 Terminology amp Abbreviations 6 3 0 Applicable document drawings 7 4 0 General requirements 8 5 0 Diagnostics 17 6 0 Traction amp Supply 18 7 0 DC Input Power Supply 18 8 0 Hardware standards 18 9 0 Performance 21 10 0 Inspection amp Testing 30 11 0 Quality assurance 30 12 0 Marking amp Identification 30 13 0 Packing 30 Warranty 31 31 31 31 31 32 ematic HA SSDAC 33 34 Page 6 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments
19. er or independent safety assessor conform to the CENELEC standards for SIL 4 Railway are amp hardware validation shall be done by accredited reputed in independent third party The agency to be engaged for validation shall be got apptoved by RDSO 10 2 1 2 While granting initial type approval it shall be ensured that the system conforms to all the clauses amp passes all type tests as mentioned in clause 10 3 10 2 2 Maintenance Type Approval At the end of validity period RDSO may call for fresh samples for type testing for the purpose of maintenance of Type Approval as per the provisions of Directorate Operating Procedure The sample must pass all type tests as per Clause 10 3 Page 22 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 3 Type tests 10 3 1 The following shall comprise type tests 10 3 1 1 Visual inspection C1 10 5 1 10 3 1 2 Performance test C1 10 5 2 10 3 1 3 Applied high voltage test C1 10 5 3 10 3 1 4 Insulation resistance C1 10 5 4 10 3 1 5 Climatic tests C1 10 5 5 10 3 1 6 Shock tests Cl 10 5 6 10 3 1 7 7 KV static discharge test Cl 10 5 7 10 3 1 8 Vibration Test CI 10 5 8 10 3 1 9 Fail safety tests Cl 10 5 9 10 3 1 10 The test for Software check sum CI 10 3 2 One equipment shall be tested successfully pass the entire t specification If the equi discretion may call for a e equipment shall
20. for comments 4 4 0 The possibility of reset will be as per table below This shall be controlled by software S No Conditions Whether reset permitted Yes No 1 No in count No out count No section clear amp healthy 2 No in count No out count Yes Error has occurred 3 Only in count No out count No System healthy 4 Only in count No out count Error has occurred 5 In count amp out count started System healthy 6 In count amp Out count started Error has occurred Vs No in count but only out counts system goes to error 8 System in preparatory mode 4 4 10 Provision shall be made for recordidg eve jon offesetting by means of non resettable counter For one rese r ter should not increment by more than one 4 4 11 There shall be provision o 4 5 4 5 1 It shall have 2 6ut of 2 architecture 4 5 2 It shall detect and count axles passing over the axle detector 4 5 3 It shall determine the direction of passing of axles 4 5 4 Provision should be there for lightning amp surge protection in the field unit power supply input and communication line input output 4 5 5 The field units should be able to communicate with each other for transmission loss up to 30dB Page 16 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 5 6 4 5 7 4 6 4 6 1 4 6 2 4 6 3 4 6
21. g conformity with this e tests RDSO at their the same type and subject it to occurred No failure shall be 10 3 2 j e manufacturer or supplier shall submit nance type approval the samples shall be regular production lots so as to be as representative as er consideration A Type approval certificate shall be er if samples pass all the prescribed tests in accordance 10 3 4 i l certificate once issued shall not be valid if a change in design unless this change has the approval of RDSO 10 4 Acceptance Test amp Routine Test 10 4 1 Acceptance Test 10 4 1 1 Inspecting authority shall carry out acceptance tests on all the equipment sub units The following shall comprise acceptance tests 10 4 1 1 1 Visual inspection CI 10 5 1 10 4 1 1 2 Performance test C1 10 5 2 Page 23 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 4 1 1 3 Insulation resistance Cl1 10 5 4 10 4 1 1 4 Records of Environmental Stress Screening Tests ESS Cl 10 5 10 10 4 1 1 5 The test for Software check sum C1 10 5 11 10 4 1 2 A complete test report of all the tests conducted shall be submitted by inspecting authority giving the detailed observations made in every case and actual values recorded Specific mention shall be made whenever the equipment has failed to comply with the requirements and indicating as to how far it has failed to comply 10 4 1 3 Disp
22. iven by staff Page 17 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 8 3 4 8 4 4 8 5 4 8 6 4 8 7 4 8 8 4 8 9 4 8 9 1 Resetting of a track section field unit 4 8 9 2 Failures errors in field units 4 8 9 3 Breakdown of communication link s 5 2 5 3 5 4 Digital Axle Counter failures shall not affect in any way the correctness of the information recorded in the Event Logger neither shall it cause its loss nor change The event logger shall record events happening in the axle counter system The data registered in the event logger must be secured against erasing by unauthorized persons Event logged should be date time stamped It should be possible to download logged events to a commercial computer through standard port The process of event logging and downloadi events should not hamper the normal working of axle counters infny manngi The event logger shall record following events reset box thrg gh alphanumeric LED LCD display The same display should normally show in count out count and software version no when the system is switched on initially Diagnostic information should not be considered vital Diagnostic functions shall be carried out on a permanent basis without disturbing normal operation of the equipment Information on the state of the equipment in failure mode and on operations performed b
23. nance equipment and supply these if so required by the purchaser KKK KK K lt i Ver 3 Draft copy for comments Specification of SSDAC RDSO SPN 177 2012 Issued date Page 33 of 34 I Annexure ztoz Amt LL NdS OV ASIS z t00 Nds 2vass ztoz AJ0suas yes Aus usn 2vgss Aupigeriee yTy Joy JudWAsUEUY COE fuip UOIPENUAYe eur gp OE e uo peseq sisupi 87 81 Jo tuo NID uinturxe A e qe penb wut p T Obs ul pue ej qe gib uru Go uo supp gTJo e uejsip uinuimeul e o dn YOM ue IVSS pua uonoesoporq atu jsnf you pue amp TIun 95 uaa t 3ue sopqeo pe 2umpnpur y fua UNMO pene si adueysip uinturpxe A S 04dde BUG PasiApe aq peys spejop pedojaaap st sissetp Suis e ung pae anug ejoy 9 pie wopo IED 4055820 e powzuepunpa 3urAPu uajs s vqss Aupqepere utu y adAy jasas Asopesedaid jo aq Ajuo gra Sugesod re sa Ageoneuro ne pr eap 3urous apnpow iun Mo seatou IPA SUIMOYs srjndjno ayy jo euo UsYyAr eets XIU ut u Aous jua Wa BUPUE Je ay Spuosas OT uey eJour0J pardno 940 peno eipaur assaaip Suis Ape te laq jjeus sapeu yq55 peeordnp wos uogeominurulo aq 10j soe yesan aly ye pe rauu etg uo paAoydap eq Apqesajaud ppnoys 10sues zerp pansus aq p arp ORAL spe acy yo euo Aue uo ynd aq eus suosuas SIJON 9 qepie g JOU IG H Z RIpet HEA l VG Dvass Aypqepe v uiia p O v5 Aupqeje v Y3tH TRIPS 461 peto INIA T uapas pog Ver 3 Draft copy fo
24. ndications of the a form of vital relay pick up and drop 4 2 2 For one detection point single sec tion point single section configurations each field uni 1 al relay The field unit of the common detection point i i a 5 shall drive two relays of adjacent sections 4 2 3 For three int si tion and four detection point single section ed in any one of the field units 4 2 4 1000 ohm plug in type In section clear output shall be more than 20V DC and in occupied 4 2 5 porate fail safety feature such that when the vital relay is elay coil which can pick up the vital relay then the system should detectft and the concerned axle counter section track section will go to error state Spark quenching arrangement should be provided across vital relay coil operated by the field unit 4 3 Axle detector 4 3 1 It comprises of two sets of TX RX coils sensors 4 3 2 The TX RX coils shall operate at frequencies above 20 KHz 4 3 3 Different frequencies shall be used for each set of TX RX coils Page 13 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 4 3 4 These shall be capable of withstanding environmental conditions given and specified later The inductance of axle detectors shall not vary more than 6 within the specified temperature range 4 3 5 The transmitter receiver coils in the track shall be of web mounted type The fasteners should be tightened
25. ohms at RH gent shall be tested as per IS 9000 Pt V Sec 2 The upper e shall be 40 deg C lower temperature 25 degree C RH 95 equipment shall be kept energized during the test No intermediate measurements required only relay status to be recorded After standard recovery of 2 hours the equipment shall be checked visually for any apparent damage or deterioration and insulation resistance shall be measured which shall not be less than 10 Meg ohms at 40 degree C and 60 RH Damp Heat Test Steady state The equipment shall be tested as per IS 9000 Pt IV The temperature shall be maintained 40 2 deg C and relative humidity 95 96 4 296 3 The duration of the test is 4 days The equipment shall be kept Page 27 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 5 5 6 10 5 5 7 10 5 5 8 10 5 5 9 energized during the test No intermediate measurements required only relay status to be recorded After standard recovery of 2 hours the equipment shall be checked visually for any apparent damage or deterioration and insulation resistance shall be measured which shall not be less than 10 Meg ohms at 40 degree C and 60 RH Salt Mist Test This test shall be carried out as per RDSO SPN 144 Driving Rain Test for Axle Detectors The unit shall be subjected to this test fo 9000 Pt XVI and shall withstand the same Th
26. oper housing of cards 10 5 3 Applied High voltage test The equipment shall withstand for one minute without puncture and arcing at a test voltage of 2000 AC r m s applied between po ts and the body of equipment which shall be earthed The tes e approximately sine wave of any frequency between 50 and 1 onic component which is likely to get damaged by the app disconnected during the test 10 5 4 Insulation Resistance Test 10 5 4 1 This test shall be carried out 10 5 4 1 1 Before the high voltage test 10 5 4 1 2 After the high voltage test 10 5 4 1 3 After completion of the ea imatic t efities in type test change in the values measured before and after letion of climatic test the values shall not be ipment at a temperature of 40 deg C and be done as per the sub clauses mentioned below After the tests high voltage test Clause 10 5 3 amp insulation resistance t lause 10 5 4 shall be repeated 10 5 5 1 Change of Temperature Test 10 5 5 1 1 The equipment shall be tested as per IS 9000 Pt XIV Sec 2 10 5 5 1 2 The test severity shall be 1 Lower Temperature 10 C 3 C ii Higher Temperature 70 C 2 C Rate of cooling and heating 1 degree per minute Duration of test 3 cycles of 3 hrs each after stability in the chamber has been reached The Page 26 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 5 5 2 10
27. osal of samples Sample equipment tests shall not form part of supply subjected to type 10 4 2 Routine test 10 4 2 1 Following shall constitute routine test all be conducted by manufacturer on every equipment sub units and te ts shall be submitted during the inspection 10 4 2 1 1 Visual inspection CI 10 5 1 10 4 2 1 2 Performance test C1 10 5 2 10 4 2 1 3 Insulation resistance 10 4 2 1 4 10 4 2 1 5 10 5 10 Page 24 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Draft copy for comments Ver 3 10 5 2 Performance tests 10 5 2 1 Equipment sub units DC DC converter No load current Output load Line regulation Effect of frequency variation Relay driver ap Software Functi tesfs Signal conditioner card b ow U Mem e Rb b 4 10 5 2 2 System level checkin 10 5 2 2 4 CO 10 5 2 2 5 Functio 10 5 2 3 Card level checking 10 5 2 3 1 PCB laminate thickness 10 5 2 3 2 Quality of soldering 10 5 2 3 3 General track layout 10 5 2 3 4 Conformal coating and shielding 10 5 2 3 5 Legend printing 10 5 2 3 6 Green masking Page 25 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 5 2 3 7 Mechanical polarization 10 5 2 3 8 General shielding arrangement of individual cards 10 5 2 3 9 Indication and display 10 5 2 3 10 Mounting and clamping of connectors 10 5 2 3 11 Pr
28. ower which is supposed to be dissipated in them The voltage rating of the capacitor shall be at least 50 above peak value The resistors shall be of tolerances not more than 5 Tolerance of capacitors shall be as under Metallised Polycarbonate MPCAR 5 Polypropylene PPSAR PSAR 15 Page 19 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 8 1 5 8 1 6 8 1 7 8 1 8 8 2 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 8 2 7 8 2 8 Polystyrene PFD 2 Electrolytic 20 All power supplies on cards should be locally decoupled where digital ICs are used using a capacitor with good high frequency characteristics Recommended value of capacitor is 0 01 uf Shielding at card level by providing a metallic plate over the cards Shielding at chassis rack level Terminals provided for cable connections shall pe of Wago or Phoenix or any other reputed make Screw type couplers used for any connections s Printed Circuit Board PCB material Material for the PCB s e per clad glass epoxy of grade FR 4 or equivalent Outline Dimensions PCBs sh angement Mechanical arrangement e g a clip or a serted position shall be provided Screws should be PCB when it is pulled out The PCB shall be ards shall be specifically designed to suit the circuitry used and no extra W or jumpers shall be used for interconnection of components on the PCB
29. r comments Specification of SSDAC RDSO SPN 177 2012 Issued date Page 34 of 34 JISSP P Super ospi Ld fy eyeopiaurg euss 10508 ype jend Jurn Jyass Aupigereae u3ry 10 wuswWaBuedy apy giqegeae ysy ugs rau d9 pp uo saosues ype jenp Jo esf adA 38591 A10jejedoud Jo aq Ajuo qr 3uneso v auo papey eui 185a Ajeoneuroj ne pnr 9v gss 0U5 SI toto sea at A eID SEIVASS ot Jo euo UJM Kl oq eus z as s 7 wass Juey vss vH puas 0 1 ueo eq aouejsip euoZetp tuz aunsua I spe 13u9499JIp 07 uo 1nd eq j eus s rosuoas OM JOSAH uorpesoporg
30. rd card This system also facilitates use of redundant communication channels by using quad OFC to overcome common mode failures System provides two vital relay outputs from two channels that are used in OR mode to interface with interlocking block circuits System uses Page 12 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments Auto reset Feature to reset the failed channel of system by correctly working channel under steady state conditions Complete electronics of high availability SSDAC system is integrated in the same chassis of a standard single channel SSDAC Interfaces for the operator still remains the same and he is required to manually reset the system only when both channels of the systems have failed Single reset interface will send reset command to both the channels and the reset command is extended to electronic via drop contact of vital relay of concerned channel The High Availability SSDAC system can be provided with 4 1 6 1 Single track sensor input fed to both channels of HA SSDAC Annexure I Drg 2012 SSDAC 001 sheet 1 of 2 attached 4 1 6 2 Dual track sensor inputs fed to different channels Drg 2012 SSDAC 001 sheet 2 of 2 attached SSDAC Annexure I Note The option selection of single trac sensor can be exercised by the ordering authority based on j MTBF requirements 4 2 Vital Relay Drive 4 2 1 Free and occupied i
31. t be more than 2 errors per million correctly counted axles and if there is error it should not result in unsafe condition 4 0 29 The equipment shall be capable of simultaneously counting in and or counting out from the ends of the monitored section 4 0 30 Response of rocking of wheels on Axle Detector If any sensor is influenced two or more times consecutively without a proper count pulse the system should go to error If both sensors are influenced four or more times consecutively without a proper count pulse the system should go to error 4 0 31 Axle counter should tolerate induced voltage of AC 50Hz on the quad cable Any external surge protection devi i ieve this shall be part of SSDAC supply 4 0 32 It shall fulfill fail safety requirements as per RD 4 0 33 It shall fulfill the requirements of Signal En ing Manual as per RDSO SPN 144 4 0 34 The software shall fulfil the software re 4 0 35 Both hardware and software functio i 1 ed to ensure that integrity of certified design will not i freugh routine software and hardware upgrades axle counter will work in following 4 1 4 Four detection points Single section In point zone 4 1 5 Three detection points two sections and also scalable for consecutive sections in a straight line 4 1 6 Use as High Availability SSDAC system HA SSDAC e g for BPAC applications High availability system uses proven electronic circuits of standard SSDAC duplicated on same boa
32. ted to Bump test In addition ical cks the assembly shall be subjected to 10 5 7 7 KV Static Discharge Test 10 5 7 1 The test shall be done as per RDSO SP 10 5 8 Vibration Test The equipment shall be subjected to vi VIII per IS 9000 Part 3 20 sweep cycle per axis duration for the 20 sweep cycles 1 hour 45 minutes when frequency of vibration is changed as per clause 6 3 of IS 9001 Pt XIII 81 during each sweep If resonance is observed endurance tests at resonant frequency 10 minutes at each resonant frequency Specification Severities Observation Details Remarks Vibration test 10 Hz 55 Hz as per IS 90 Pt VIII 0 35mm 0 to peak Equipment shall be or 5g visually examined for any apparent damage After completion of the test the equipment shall be tested for its normal operation Page 29 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 10 5 9 10 5 10 10 5 10 1 10 5 10 2 10 5 10 3 Fail safety test Fail safety tests shall be carried out as per RDSO SPN 144as covered under the clause 4 0 and as per CENELEC EN50129 Environmental Stress Screening Tests ESS for Printed Assembly Boards PAB and Subsystems The manufacturer shall carry out the following ESS tests on all modules on 100 basis except bump test during
33. y the staff shall be registered Page 18 of 34 Issued date Specification of SSDAC RDSO SPN 177 2012 Ver 3 Draft copy for comments 6 Traction and supply 6 1 Axle Counter system shall be capable of working in all sections including non electrified 25 kV 50 Hz AC 1500 V DC amp 750V DC electrified areas 6 2 The axle counter should operate correctly under traction return currents of up to following magnitudes 6 2 1 25 kV 50Hz 1000 A 6 2 2 1 5kV de 6000 A 6 2 3 750V dc 3000 A 6 3 The currents or their harmonics flowing in th amp rails shall not affect the digital axle counter 6 4 The equipment shall be immune to extraneous eldgjsuch as due to traction return currents on electrified s i ailures vehicle magnetism or due to any other source 6 5 The electromagnetic brakes in its both on and off states affect the axle counter 7 DC Input Power Supply 7 1 The field unit shall work wi DC fed from a remote location The input volta 20 to 30 amp will have a maximum ripple of 50m V s 7 2 ipment shall be low It should be less than 3 3 Df over voltage under voltage and polarity reversal 8 0 8 1 8 1 1 The ICs used e equipment shall be of industrial grade 8 1 2 The discrete components like diodes transistors SCRs etc should conform to HIREL program of CDIL or equivalent 8 1 3 All resistors and rectifiers used shall be rated for at least double the p
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