MULTI ENTRY AXLE COUNTER

Introduction
Merging of Single entry and Multi entry axle counter, a new axle counter is
developed known as universal axle counter. A Single unit of universal axle
counter can be used to detect up to maximum-4 detection points. 3-D system can
be converted in to 4-D system and vice versa by changing jumpers in the card.
Evaluator cards
Card No.-1 Attenuator/Amplifier/ Rectifier Card No.-6 Logic No.-2
Card No.-2 Attenuator/Amplifier/ Rectifier Card No.-7 Counter Comparator
Card No.-3 Pulse Shaper Card No.-8 General Supervision.
Card No.-4 Pulse Shaper Card No.-9 Relay Driver.
Card No.-5 Logic No.-1
Card No.-1 Reads for A B C D Channel and Card No.-2 reads for E F G H these
channels are used in 3D and 4D system. Card No.-5 is also used for 3D and 4D
system.
Power supply arrangement.
Evaluator 24V (Min. 21.6V Max. 28.8V Current 1.5 Amps)
EJB 24V (Min. 21.6V Max. 28.8V Current <250mAmps)
Reset box Min. 21.6V Max. 28.8V Current 500mAmps
Standard parameters
• Ripple Voltage at charger for 24 Volt should not be more then 40mV
• DC-DC Converter in put - 21.6 to 28.8V and Current 1.5 Amps.
• Evaluator I/P Voltage on CTB - 178 mv to 900mv (rms)
• O/P of Evaluator Voltage (at card No.-1) - 105mv to 115mv(rms)
• Rx Coil O/P Voltage (Before amplification card of EJB)
- 0.7 to1.1V(rms)
• Rx Coil O/P Voltage (After amplification card of EJB) more than
0.6V(rms)
• Oscillator o/p frequency - 5kHz
• Regulator o/p - 10V steady
• Oscillator o/p - 60V(rms)+ 10% 5KHz + 20% Cycles
• Tx Coil circulating current - 420ma ± 10%
A train after passing the detection point generates pulse equal to axles in it and
these pulses encountered and stored by evaluator as "INCOUNTS".
At the time of exit of train, the same detection point will be encountered and it
generates equal number of pulses as during entry. These pulses are also counted
and recorded as "OUTCOUNTS" by the evaluator.
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When Incount and Outcount are same, the system gives a “Track clear/ Green”
indication, otherwise “Track occupied/ Red ” indication.
CABLE
For connecting the output of EJB (Electronic Junction Box) to Evaluator, the
following cables are to be used under different field conditions.
Type of cable Specification No.
i) 4 Quad axle counter cable TC-30 (0.5 and 0.9 mm dia)
ii) 4 Quad axle counter cable TC-31 (0.5 and 0.9 mm dia)
iii) PET quad of main telecom. cable TC-14/75 (0.9 mm dia)
iv) Polythene jelly filled telephone cable TC-40/91(0.5,0.63 & 0.9 mm dia)
Distance Electrified Non Electrified
Up to 2Kms TC 30,TC14/75,TC40/91 TC30,TC31,TC14/75,TC40
Up to 5Kms TC 30,TC14/75,TC40/91 TC30,TC31,TC14/75,TC40
Beyond TC 30,TC14,TC40/91 TC30,TC31,TC14/75,TC40/91(0.
5Kms 9mm dia)
 Trolley protection track circuit:
♦ Use only closed type track circuit.
♦ Use only QT-2 track relay with QNA1 as its repeating relay in RE and
QN1 in Non-RE.
♦ Use the first repeating relay for trolley suppression track circuit.
♦ Install track device in centre of track circuit in single line section and at
a distance from block joint in the direction of movement. as given in the
table.
Speed in S/L Track Section D/L Track Section
KMPH Device in Length of Device Length of
TC TC
UP to 50 Centre 1T 6.5 Meter 1T
UP to 140 Centre 3T 20.0 Meter 2T
UP to 160 Centre 4T 25.0 Meter 3T
UP to 200 Centre 5T 28.0 Meter 3T
Precautions before installation
♦ The track device is fixed in the centre of track circuit in case of single line
section. In case of double line section, the device is fixed either in the centre
or at the end of track circuit.
♦ The track device is not to be fixed under any circumstances within the
sleepers carrying the rail joints.

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♦ The separation between two track devices of different axle counter system
should be at least 3 meters, so at to, avoid mutual interface.
♦ The track device should be fixed as per nomenclature given in Drg. no.
RDSO/UAC-311 for 1D system, Drg. no. RDSO /UAC-312 for 2D system,
Drg. no. RDSO /UAC-313 for 3D system and Drg. no. RDSO/UAC-314 for
4D system.
 Installation
♦ The clear spacing between two sleepers in which both the track devices are
fixed is minimum 520 mm.
♦ The design of track device is suitable for 52 Kg , 60 Kg rails.
♦ Use 'C' clamp type of base clamp for mounting of Tx and Rx device.
♦ Use nylogrip op loctite adhesive on all the nuts for firm grip
♦ The maximum size of packing required are as follow.
A) For 52 Kg- 6mm (3mm X 2 packing)
B) For 60 Kg- 12mm (3mm X 4 packing)
♦ Fix Rx side of base clamp on inner side of rail and Tx side on outer side of
rail as shown in fig. below.

Track Device Assembly

♦ Transmitter assembly should butt against the foot of the outer side of rail.
Required number of nylon packing piece (minimum 3mm packing) should be
placed between the base plate and transmitter base.
♦ The receiver coil assembly is fixed on the inner side of the rail and a paper
gap should be available between receiver housing and the rail web. Similar to
transmitter coil, nylon-packing piece/pieces should be used below the
receiver housing.
♦ The transmitter and receiver coils are provided with 10/15 meter length lead
cable and have to be taken directly to location box with out any loop. coil
should be provided in zigzag manner.
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♦ These cables are carried in HDPE (high density poly-ethylene) pipe for
safety and laid not less than 1 meter below from bottom of rail.
♦ A transmitter and receiver cables are run separately at a minimum separation
of 500 mm. Transmitter and receiver cables of individual track devices are to
be laid in different pipes.
♦ Fix the deflector plate on both side at a distance of 500 mm from centre of
the track device base clamp.
♦ Before fixing deflector plates, it should be ensured that the transmitter
deflector plate (smaller width) comes in front of transmitter and Receiver
deflector plate (larger width) comes in front of receiver.
 Adjustment of Dip
♦ Keep Tx coils on the outer side of rail base clamp butting against rail.
♦ Keep Rx coils on the inner side of rail base clamp with a paper gap from
rail web.
♦ Connect EJB to the Tx coils and Rx coils.
♦ Measure Rx coil output to be greater than 1Volt in each coil.
♦ Check the Dip in each coil with the help of dummy wheel adjust for the
type of rail (52 Kg or 60 Kg) to get 10% of adjusted signal as shown in
fig. below.

Dip Adjustment
♦ To get 10% Dip required nylon spacers below Rx coils wherever necessary
may be added.
♦ Ensure after adjustment of Dip, each Rx coil output is more than 1Volt.
♦ After final adjustment, all nuts bolt connections are checked and secured
properly.

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 Convertibility Table of 2D/3D/4D
Type of Card Configuration
2D 3D 4D
Card-1 Normal Normal Normal
Card-2 Dummy-2 Normal Normal
Card-3 Normal Normal Normal
Card-4 Dummy-4 Normal Normal
Card-5 Dummy-5 Normal Normal
(with looping of) Jumper-J2 Jumper-J1
Jumper-J4 Jumper-J3
Card-6 Normal Normal Normal
(with looping of) Jumper-J1,J3,J5 Jumper-J2,J4,J6 Jumper-J1,J3,J5
and J7 and J8 and J7
Card-7 Normal Normal Normal

Card-8 Normal Normal Normal

(with looping of) Jumper-J1 Jumper-J2 Jumper-J1
Jumper-J3 Jumper-J4 Jumper-J3
Card-9 Normal Normal Normal
(with looping of) Jumper-J2,J4,J7 Jumper-J1,J3,J6 Jumper-J1.J3,J5
and J10 and J9 and J8
 Maintenance
 Outdoor equipment
♦ Ensure supply voltage to EJB (Electronic Junction Box) is between 21.6Volt
to 28 Volt and battery bank properly connected to the load.
♦ Check all nuts and bolts of base clamp, receiver and transmitter, housing and
ensure that these are fully tight.
♦ Ensure that when both Tx coils are connected in series with EJB
• Oscillator output is 54 to 66 Volt (RMS).
• Oscillator frequency is between 4980-5020 Hz
• Transmitter coil current is 380-460 mA.
♦ If the Rx coil output is less than 600 mV. Change the polarity series
connection of one of Tx coils.
♦ Ensure EJB output with Rx coil connected is
• More than 2Volt when Evaluator end is disconnected.
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 • More than 1.3 Volt when Evaluator end is connected.
♦ Measure the oscillator circulating current is 420 mA ± 10 %.
♦ Check the dip of the rail inductors, it should be more than 90 % of the output
voltage of EJB.
1. Check track circuit completely i.e. its connection, block joints etc. are in
goods condition. CAMTECH publication on DC track circuit No.
CAMTECH/S/DCTC/ 1.0/ 2000 may be refer.
 Indoor equipment
 Measurements and adjustment on Evaluator.
2. Ensure for each channel Voltage is more than 100mV (RMS) on cable
termination rack.
3. Adjustment of pads.
• Keep potentiometer on card 1and 2 in extreme clock wise position.
• Go on adding pads (0.5,1,2,4,8 and 16 DB) in the circuit till the Voltage
at the test terminal is less than 150 mV (RMS).
• Solder the pad wires and adjust the potentiometer to get 105 mV on test
terminals.
4. EV and SUP relays are Plug-In QS3 type should be connected with BY 127
diode across relay coils.
5. Measure EV and SUP relays voltages and ensure that these are more than 10
Volt. Ensure that voltages across EV and SUP relay in the dropped conditions
should not exceed 0.5 V.
6. Record the reading and compare it with reading taken previously. If the
difference of the readings is more than 10% adjust the track device and check
the EJB.
7. Observe the IN-COUNT and OUT-COUNT on the display unit during
passing of train on controlling section and compare it with the actual no. of
axles of the train. Verify that the counting is correct.
8. Check the indication of evaluator panel and it should be same as that is
available on SM reset box.
9. Check the battery set i.e. specific gravity, voltage and electrolyte level. For
the maintenance of battery refer CAMTECH publication no.
CAMTECH/S/1-96.
10. Check the charging equipment and adjust if necessary.
11. Ensure that RESET BOX and LINE VERIFICATION BOX are sealed
properly.

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♦ Check working of trolley suppression track circuit and working of SM reset
box .
12. Check the AC ripple voltage of charger. It should not be more than 40 mV.
13. Ensure earthing of axle counter rack to separate earth (Other then cable
earth)
♦ Measure the value of earth resistance and take appropriate action if value
increases as given in table below.
Sr. Apparatus Resistance value in ohm
1. For lightning discharger Less than 10 Ohm
2. For equipment Less than 10 Ohm
3. Jelly filled telephone cable Less than 5 Ohm
in RE area
4. Al. Sheathed telecom. Less than 1 Ohm
cable screened in RE area
5. 4 quad axle counter cable Less than 1 Ohm
screened
6 Jelly filled/4 quad non RE Less than 1 Ohm
axle counter cable
armoring.
 DO’s and Don’ts
 DO’s
♦ Check the dip with the help of dummy wheel and it should be less than 10%
of normal output.
♦ Ensure that the power supply for EJB is 21.6 to 28.8 Volt for 24Volt EJB.
♦ Check the oscillator output is 60 Volt rms +10%.
♦ Check the oscillator circulating current is 420mA + 10%.
♦ Check the DC current drain of DC supply is less than 175 mA
♦ Ensure that all nuts and bolts of track device and rail deflector are properly
tightened.
♦ Use prescribed digital multimeter for measurement.
♦ Always compare the reading with previous reading and take appropriate
action after through checking and testing.
♦ Ensure that charger ripple voltage is below than 40 mili. volt.
♦ Ensure that all equipment earth connections are fully tighten.

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♦ Make sure that there is no train in the section before resetting the system
after any adjustment,
 Don’ts
♦ Do any adjustment at site when train is already in the controlled section or
approaching in the controlled section.
♦ Do any wiring or replacement of card when train is already in the controlling
section or approaching in the controlled section.
♦ Resetting of Axle counter when train is in section.
♦ Forget to ensure correct fitting of rail deflector.
♦ Connect the EJB or evaluator card with undue force.
♦ Use of +10 Volt available on evaluator for indication (CLR or Occ) on SM
reset box or evaluator.
♦ Use of AC immunised shelf type relay for EV and SUP.
♦ Give any bend to display card flat cable.

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