pre commission check list for 2dp1s-ver1 pdf

7/29/2019 Pre Commission Check List for 2DP1S-Ver1 PDF

1/21

PageDate of

issue

Pre Commissioning C hec k List for Single Section Digital Axle

Counter SIGVer 1

1 of 2117.08.2007

{2DP1S Configuration}(SW Version: S002)

Of M/s G.G.TRONICS, Bangalore

0606

SSDAC Unit Sl. No (SF UNIT) ---------------- (EF UNIT) --------------

0 General Information:

0.1 Station / Section Name0.2 Division / Zonal Railway

0.3 Contact Details of Railways at site0.4 Contact Details of Railways at HQr / Division 0.5 Total No of Detection point / Section0.6 Contract No./PO No.0.7 Date of Pre commissioning inspection0.8 Name of firms authorized Rep

Note : 1. System should be installed and commissioned by authorized

technical staff of manufacturer only.2. Installation practices of SSDAC model SSDAC-G36 for Phase Reversal

should be strictly adhered to and checked before commissioningcovering all points in the following document

1 Out door(Location Box)

ObservedOK / Not

OKSl.No.

Item RequiredSF

UNITEF

UNIT

1.1Relay used inRelay Box VR &PR

Q type, 24V, 1000 Ohm(Printed Sticker of VR/PR either onfront cover or inside bottom of relaybox.)

1.2Diode across eachrelay coil inreverse bias.

Should be provided with BY127/ IN4007 / IN5408

1.3 Unused Quad pair To be terminated on terminals.

1.4Dressing of Quadpair

To be properly dressed withinsulated tape


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0606

2 Outdoor (track device)

ObservedOK / Not

OKSl.No.

Item RequiredSF

UNITEF

UNIT

2.1

Wiring of TX / RX

coils & MS couplercables

Wired on approved Wago/

Phoenix make terminals.

2.2

Condition of wornout of Rail60 Kg - 13 mm52 Kg - 8 mm90 R - 5 mm

Should be within vertical limit ofworn out159 -172 mm148 -156 mm138 -143 mm

2.3

Marking of holeson rail(From bottom ofthe rail)

GGT Jig as per drawing no.DRG-23 of Installation ManualVersion 1.0 Revision 1 to beused as per rail section.60 Kg - 84 mm52 Kg - 68 mm90 R - 57 mmFrom the bottom of the rail.

2.4Drilling of holes in

the web of rail

Should be of 14mm dia. Shouldbe square (perpendicular),

should not be oblong.

2.5

Torque applied tofix track deviceusing Torquewrench

Jaicom make JPR65 orequivalent - 88 Nm.

2.6 Fixing of TX Outside the rail

2.7 Fixing of RX Inside the rail

2.8 Fixing of axledetectors at entry& exit end

On the same rail as per

drawing no. DRG-12 ofInstallation ManualVersion 1.0Revision 1

2.9Laying of axledetector cable

In corrugated / HDPE pipe

2 10Screen of axle

Should be earthed


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0606

Observed

S.No. Item Required SFUNIT

EFUNIT

RemarksOK /

NOT OK

2.12 Rail section 60 Kg / 52 Kg / 90 R

2.13Nuts, bolts &washers for fixing

rail contacts

Insertion of bolt from RX coilside i.e., inside of the rail

2.14Position ofdeflector

30 cm away from TX / RX coilsin the next sleeper

2.15 Height of deflectorShould not be higher than therail top

2.16Clearancebetween sleepers

400 mm between sleepers

2.17 Embossing on railShould not be covered by Track

device


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0606

3 Outdoor Quad Cable

3. Outdoor (Quad Cable / PIJF twisted pairs telecom cable for Axle countersystem working in station area, As per RDSO letter no. STS / E / SSDAC /

SPN / 177 dated-28 / 30.08.2006)

3.1 Test format for testing of QUAD cable / PIJ F twisted pair telecom cable

before commissioning of SSDAC in Station area

Sl.No.

Item ExpectedMeasured /Observed

Remarks(OK / Not OK)

3.1.1CommunicationMediaType of Cable

Only Quad cable / PIJF twistedpair telecom cable is to beused between field units.No Signaling Cable is to beused in totality / parts.

3.1.2 Use of pair

Proper pair of wires to be usedfor connectivity.Annexure 1 for Quad cablemay be referred

3.1.3

Duplication of

Wires

No wires to be paralleled for

reducing conductor resistance.

3.1.4Insulationresistance ofQuad cable

Shall be greater than / equal to10 M ohm.

3.1.5Loop resistanceof designatedpair

Not to exceed 56 ohm / Kmsfor Quad Cable at 200 C &_______* ohms / Kms for PIJFtelecom cable.

Annexure 2 for correctionfactor may be referred.

3.1.6Attenuation lossmeasured at 2KHz

Shall not be greater than 30.0dB for full length of the cableused.

3.1.7Near End CrossT lk (NEXT)

Shall be better than 55 dB ford bl


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0606

Sl.No.



3.1.10Separate Earth ofQuad / PIJFtelecom cable

Shall be less than One ohm

3.1.11Cable allocationtable

Shall be filled up & attached

3.1.12Unused Quadpair

To be terminated on terminals.

3.1.13Dressing of Quadpair

To be properly dressed withinsulated tape.

3.1.14Spiral beforetermination.

No individual conductor to bemade spiral

3.2 Test format for testing of QUAD cable before commissioning ofSSDAC /BPAC / SSBPAC (D) used in between Station to station

Sl.No.



3.2.1Block sectionlength limit

12 Km.

3.2.2CommunicationMediaType of Cable

Only Quad cable is to beused between field units.No Signaling Cable is to beused in totality / parts.

3.2.3 Use of pair

Proper pair of wires to beused for connectivity.Annexure 1 may bereferred

3.2.4Duplication ofWires

No wires to be paralleledfor reducing conductorresistance.

3.2.5Insulationresistance ofQ d bl

Shall be greater than /equal to 10 M ohm.


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0606

Sl. No. Item ExpectedMeasured /Observed


3.2.6Loop resistance of

designated pair

Not to exceed 56 ohm/Kms at20

0C.

See Annexure 2 forcorrection factor.

3.2.7Attenuation lossmeasured at 2KHz

Shall not be greater than 30.0dB for full length of the cableused.

3.2.8Near End CrossTalk (NEXT)

Shall be better than 55 dB forquad cable.

3.2.9 Far End CrossTalk (FEXT)

Shall be better than 55 dB forquad cable.

3.2.10Continuity of cablearmour

Continuity shall be there

3.2.11Separate Earth ofquad cable


3.2.12Cable allocation

tableShall be filled up & attached

3.2.13 Unused Quad pairTo be terminated onterminals.

3.2.14Dressing of Quadpair


3.2.15Spiral beforetermination.



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0606

3.3 Test format for testing of local QUAD / PIJF twisted pair telecom cable & OFC before

commissioning of SSDAC/BPAC/SSBPAC (D)on OFC in betweenstation to station.



3.3.1 QUAD / PIJF

3.3.1.1CommunicationMediaType of Cable

Jelly filled telecom cable /Quad cable to be usedbetween field units &OFC Equipment room.Signaling Cable shall notbe used at all.

3.3.1.2 Use of pairProper pair of wires to beused for connectivity.Annex-1 may be referred

3.3.1.3Duplication ofWires


3.3.1.4Insulationresistance ofQuad cable

Shall be greater than/equal to 10 M ohm.

3.3.1.5

Loop

resistance ofdesignated pair

Not to exceed 56ohm/Kms at 20

0C for

Quad cable & _____*

ohm / Kms for PIJFtelecom cable.See Annexure 2 forcorrection factor.

3.3.1.6Earth of quadcable

Shall be less than Oneohm

3.3.1.7Cableallocation table

Shall be filled up &attached

3.3.1.8

Unused Quad

pair

To be terminated on

terminals.

3.3.1.9Dressing ofQuad pair

To be properly dressedwith insulated tape.

3.3.1.10Spiral beforetermination.

No individual conductor tobe made spiral


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0606



3.3.2 OFC

3.3.2.1Channel lineup

For 0 dB Trans signallevel, the receivedsignal level at otherend shall not be more

than-15dB.

3.3.3 Test format for testing of QUAD cable before commissioning ofSSDAC /BPAC / SSBPAC (D) used in between Station to Location Unit

Measured / ObservedSl. No. Item Expected

SF EF

Remarks(OK / Not

OK)

CommunicationMedia

Only Quad cable / PIJFtwisted pair telecom cableis to be used between fieldunit to Reset Box.3.3.3.1

Type of CableNo Signaling Cable is to beused in totality / parts.

3.3.3.2 Use of pairProper pair of wires to beused for connectivity.Annexure 1 for Quadcable may be referred

3.3.3.3Duplication ofWires


3.3.3.4Insulationresistance ofQuad cable

Shall be greater than /

equal to 10 M ohm.

3.3.3.5

Loopresistance ofdesignatedpair

Not to exceed 56 ohm /Kms for Quad Cable at 200

C & _______* ohms / Kmsfor PIJF telecom cable.Annexure 2 for correction


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0606

Measured / ObservedSl. No. Item Expected

SF EF

Remarks(OK / Not

OK)

3.3.3.9Continuity ofcable armour

Continuity shall be there

3.3.3.10Separate Earthof Quad / PIJF

telecom cable


3.3.3.11Cableallocation table

Shall be filled up & attached

3.3.3.12Unused Quadpair

To be terminated onterminals.

3.3.3.13Dressing ofQuad pair


3.3.3.14Spiral beforetermination.


* PIJF telecom cable is available with three types of Conductor dia-

Sl. No Condr Dia used in PIJFcable

Resce at 200 C Loop Resce /KM

1 0.50 mm 86 ohm +/- 6 172 ohm / Kms2 0.63 mm 58 ohm +/- 4 116 ohm / Kms3 0.90 mm 28 ohm +/- 2 56 ohm / Kms

Note: Procedure for test-

Attenuation Loss: The output/Input impedance of signal generator / dB meter shall be 600ohm.

Near End Crosstalk:Test tone of 150 KHz to be fed in the adjacent pa ir of the same quad &

NEXT to be measured at the same end on the other pair of the same quad.

Far End Cross talk: Test tone of 150 KHz to be fed in the adjacent pa ir of the same quad &FEXT to be measured at the far end on the other pa ir of the same quad.


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0606

4 Outdoor electronics

ObservedSl. No Item Required

SF UNIT EF UNIT

OK /Not OK

4.1

a. Sl. No. ofSSDAC units

b. Details of Trackcircuit

Same serial number pairs.Example 001 (SF Unit),

001 (EF Unit)

Track circuit No.

4.2Placement of Cards/ modules

Should be in proper position

4.3Firmness of card /Modules

Should be tightened with screw /clip provided

4.4 MS Couplers Installed and tightened properly

4.5 MS coupler cablesWired properly as per color / label

code

4.6Earthing of SSDACunits

Should be provided firmly throughcopper strips or other standardcopper cable.Value < 1 Ohms

4.7Earthing of RelayBox

Should be provided firmly throughcopper strips or other standardcopper cable.

Value < 1 Ohms4.8

Fixing of SSDACunit

Should be firmly fixed usingclamp

4.9Fixing of RelayBox

Should be firmly fixed usingclamp

4.10

Cable for taking24v D.C. fromcentral location to

SSDAC unit.

2 X 25 sq. mm Al.

4.11

External SurgeProtection Deviceson input, outputand power supplylines

Indicative type, plug able or easyto install on a DIN rail. Non plugable shall be connected inparallel.

Address pair should be different


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0606

ObservedOK /

Not OKSl. No Item Required

SF Unit EF Unit

4.16

Input voltage withChargerOFF.(Keep chargerOFF for 15 minutes

before takingreading )

22 V to 30 V DC

4.17Ripple of InputPower Supply

Less than 10 mV rms /50 mV peak to peak.

4.18

Relay drive outputto the Vital Relay.(This may be

checked across R1& R2 of coil of vitalrelay in relay box).

4.18 aSectionUnoccupied (Clear)

>20V

4.18 b Section Occupied < 2V

4.19

Relay drive outputto the Preparatory

Relay. (This maybe checked acrossR1 & R2 of coil ofPreparatory relay inrelay box).

4.19 a Section Clear >20V

4.19 b Section Occupied < 2V

4.20

Drive voltage ofrepeater relays inpicked upcondition, whencharger is OFF for15 minutes.

4.21 VPR >22V

4 22 PPR >22V


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0606

5.0 INDOOR POWER SUPPLY / CT RACK

ObservedSl.No

Item Required SFUNIT

EFUNIT

RemarksOK / Not

OK

5.1 PPR & VPR RelaysShall be of Q type 24 V ,

1000 ohms5.2 Fuse Ratings 2.0 Amps

5.3 Power supply for axlecounter

a) Charger should be fit foraxle counter use.b) There should not be anyother load on the powersupply except axle counter.c) Class B & C types surge

protection must beprovided on 230 V mainsline.

5.4Ripple of Input PowerSupply

Less than 10 mV rms / 50mV peak to peak.

5.5Glitch in Input PowerSupply by putting ON /OFF the charger

No glitch should be there

5.6Drive voltage of theVPR. (This may bechecked across R1 &R2 of coil of relay).

>22V

5.7

Drive voltage of thePPR. (This may bechecked across R1 &R2 of coil of relay).

>22V


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Date of

issue

17.08.2007

Pre-commissioning C heck List for Single-Section Digital Axle

Counter

{2DP1S configuration}(SW Version: S002)

Of M/s GG TRONICS, BangaloreSIG 0606 Ver 1

6.0 INDOOR(Reset Box Location)

ObservedSl.No.

Item RequiredSF UNIT EF UNIT

RemarksOK / Not OK

6.1 Reset BoxWired as per drg given inInstallation Manual

6.2 Reset BoxEarthing.

Connected to earthproperly.

a) Reset not possible whenAxle Counter section isclear and healthy.

6.3Reset function b) Reset not possible when

Axle counter section is inPreparatory reset mode.

6.424 VDC level atReset boxinput.

22V DC to 30 V DC

6.5Level of resetsignal fromreset box.

48 V 4 V DC

6.6

Level of resetsignal atSSDAC unit

input.

38 V to 50V DC 2V DC

7.0 COMMISSIONING

Sl.No.

Item RequiredMeasured /Observed

Remarks (OK/ Not OK)

7.1 CommissioningSystem should be installed &commissioned by personal trainedby the manufacturer.

7.2 TrainingRailway personnel should be trainedbefore commissioning.

System to be monitored for 72 hoursfor trouble free operation before


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Commissioning Log sheet of SSDAC [Phase reversal detection Type]Model : SSDAC-G36, Software version : S002

The following card version should be checked:

Sl.No. Type of Card Part No. Version SFUNIT

EFUNIT

RemarksOK / Not

OK

1 Phase Detector Card 1 H001M01R1 00

2 Phase Detector Card 2 H001M02R1 00

3 CPU Card 1 of SF H001M09R1 00 * NA *

4 CPU Card 2 of SF H001M10R1 00 * NA *

5 CPU Card 1 of EF H001M11R1 00 * NA *

6 CPU Card 2 of EF H001M12R1 00 * NA *

7SMCPU/Event LoggerCard

H001M03R1 00

8 Communication Card 1 H001M04R1 00 * NA *

9 Communication Card 2 H001M05R1 00 * NA *10 Relay Driver Card 1 H001M07R1 00 * NA *

11 Relay Driver Card 2 H001M06R1 00 * NA *

12DC-DC ConverterCard

H001M08R1 00

13 LCD Display Box H001M24R1 00

14Relay Box with Q-type;24 V ; 1000 Ohmrelay-6F/6B

G36-RB2R00 00

15 Filter Box G36-RSFL00 00

16Axle detectors(Web type TX Coils)

G36-T212500 00

Axle detectors


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Counter



Annexure-I

Precautions to be taken care during the wiring/connections are to be done at the time ofcommissioning of SSDAC/BPAC/SSBPAC (D)

Position of One Quad in Quad cable:

White(A)X

Red (C) X X (D) Grey

X(B)

Quad color

1st

pair = White & Quad colour i.e A & B Wires2

ndpair= Red & Grey colour i.e C & D Wires of designated colour of Quad.

Each Quad is binded by the respective Quad colour binder

Table-1

Colour scheme of PE insulated Quads

Quad Colour

QuadNo

PairNo.

A - Wire B -Wire PairNo.

C- Wire D - Wire

Orange 1 1A White Orange 1B Red Grey

Blue 2 2A White Blue 2B Red Grey

Brown 3 3A White Brown 3B Red Grey

Green 4 4A White Green 4B Red Grey

Yellow 5 5A White Yellow 5B Red Grey

Black 6 6A White Black 6B Red Grey

Precautions to be taken for using QUAD Cable:

Designated pair of wire of the same quad (mentioned in Table -1) should be used.

Do not use one wire from one quad and another wire from some other quad.


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Counter



Annexure-II

TEMPERATURE CORRECTION FACTOR FOR CONDUCTOR RESISTANCE FOR ANNEALEDHIGH CONDUCTIVITY COPPER

Temp.Deg C

1.

Corre.factor

2.

Temp.deg C

1.

Corre.Factor

2.

Tempdeg C

1.

Corre.factor

2.

Temp.deg C

1.

Corre.factor

2.

Temp.deg C

1.

Corre.Factor

2

5. 1.0638 17 1.0122 29 0.9653 41 0.9225 53 0.8834

5.5 1.0618 17.5 1.0101 29.5 0.9634 41.5 0.9208 53.5 0.8818

6. 1.0593 18 1.0081 30 0.9615 42 0.9191 54 0.8803

6.5 1.0571 18.5 1.0060 30.5 0.9597 42.5 0.9174 54.5 0.8787

7. 1.0549 19. 1.0040 31. 0.9579 43. 0.9158 55. 0.8772

7.5 1.0526 19.5 1.0020 31.5 0.9560 43.5 0.9141 55.5 0.8757

8. 1.0504 20. 1.0000 32. 0.9542 44.. 0.9124 56. 0.8741

8.5 1.0482 20.5 0.9980 32.5 0.9524 44.5 0.9107 56.5 0.8726

9. 1.0460 21. 0.9960 33. 0.9506 45. 0.9091 57. 0.8711

9.5 1.0438 21.5 0.9940 33.5 0.9488 45.5 0.9074 57.5 0.8696

10. 1.0417 22. 0.9920 34. 0.9470 46. 0.9058 58. 0.8681

10.5 1.0395 22.5 0.9900 34.5 0.9452 46.5 0.9048 58.5 0.8667

11. 1.0373 23. 0.9881 35. 0.9434 47. 0.9025 59. 0.8651

11.5 1.0352 23.5 0.9862 35.5 0.9416 47.5 0.9009 59.5 0.8636

12. 1.0331 24. 0.9843 36. 0.9398 48. 0.8993 60. 0.8621

12.5 1.0309 24.5 0.9823 36.5 0.9380 48.5 0.8977 60.5 0.8606

13. 1.0288 25. 0.9804 37. 0.9363 49. 0.8961 61. 0.8591

13.5 1.0267 25.5 0.9785 37.5 0.9346 49.5 0.8945 61.5 0.8576

14. 1.0246 26. 0.9766 38. 0.9328 50. 0.8929 62. 0.8562

14.5 1.0223 26.5 0.9747 38.5 0.9311 50.5 0.8913 62.5 0.8547

15. 1.0204 27. 0.9728 39. 0.9294 51. 0.8897 63. 0.8532

15.5 1.0183 27.5 0.9709 39.5 0.9276 51.5 0.8881 63.5 0.8518

16. 1.0163 28. 0.9690 40. 0.9259 52. 0.8863 64. 0.8503

16 5 1 0142 28 5 0 9671 40 5 0 9242 52 5 0 8850 64 5 0 8489


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Counter



Annexure-III

Response test of digital Axle Counter with different type of TrolleyWheels done jointly with railways

S.No. Type of Trolley wheelObserved Result( No

influence / Goes to error/ Counted / other)

Remarks

4 spoke wheel

Wheel Dia with flange

Wheel base

Flange thickness

Wheel Flange

1

Spoke width

6 spoke wheel


Wheel Width

Flange width

Flange depth

2

Spoke width

Solid Wheel with 6

holes


Wheel Width

Flange width

3

Flange depth

8 spoke wheel



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Counter



S.No. Type of Trolley wheelObserved Result( No

influence / Goes to error/ Counted / other)

Remarks

8 spoke with slots


Wheel Width

Flange width

Flange depth

5

Spoke width

Perforated

No. of perforation withdia.


Wheel Width

Flange width

Flange depth

6

Spoke width Solid wheel


Wheel Width

Flange width

7

Flange depth

Motor trolley wheel ,Solid


Wheel Width

Flange width

8


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Counter


Of M/s GG TRONICS, BangaloreSIG 0606

S.No. Type of Trolley wheel

Observed Result( Noinfluence / Goes toerror / Counted /

other)

Remarks

Material Trolley solid

wheel


Wheel Width

Flange width 10

Flange depth

Motor Trolley wheel with6holes


Wheel Width

Flange width

11

Flange depth

Tower Wagon

Wheel Dia with flange Wheel Width

Flange width

12

Flange depth

13 Motor trolley following a train

Ver 1


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Page 20 of 21

Date of

issue

Pre-commissioning Check List for Single-Section Digital Axle

Counter{2DP1S configuration}(SW Version: S002)

SIG 0606 Ver 117.08.2007

Of M/s GG TRONICS, Bangalore

Signature of G.G.Tronics Rep Signature of Railway RepWith Name, Designation & Date with Name, Designation & Date

Maintenance log sheet for SSDAC (SF UNIT)

DC DC Converter

DC Volts

Description.

Ba

ttery(24V)

Tx1

Vrms /

freq

Tx2Vrms /

freq

Rx1Vrms

Rx2Vrms

Phase Detector 1DC Volts

Phase Detector2

DC Volts

With PushTrolley on

axle detectors

(4 spokes) 5 V 12 V -12 V +18V 24 V

RX PH-SIG &GND Socket



Test

Points FTB

1 & 2

FTB31 &32

FTB33 &34

FTB35 &36

FTB37 &38 Normal

Dummywheel

NormalDummywheel

PD1 PD2

Monitoring Sockets on DC-DC convertercard

(Limit)

for

Phase

Date

22-30V

40 to

70 V

20.802to

21.302KHz

40 V to

70V

24.750to

25.250KHz

300mV to1.2V(AC)

300mV to1.2V(AC)

10 V to12 V

< 1 V 10 V to12 V

< 1 V10 Vto 12

V10 Vto 12

V4.75to

5.25V

11.75Vto12.25V

-11.75

Vto

-12.25V

17.75V

to18.25

V22Vto

26V


21/21

Page 21 of 21

Date of

issue

Pre-commissioning Check List for Single-Section Digital Axle

Counter{2DP1S configuration}(SW Version: S002)

SIG 0606 Ver 117.08.2007

Of M/s GG TRONICS, Bangalore

Signature of G.G.Tronics Rep Signature of Railway RepWith Name, Designation & Date with Name, Designation & Date

Maintenance log sheet for SSDAC (EF UNIT)

DC DC Converter

DC Volts

De

scription.

Battery(24V)

Tx1

Vrms /

freq

Tx2Vrms /

freq

Rx1Vrms

Rx2Vrms

Phase Detector 1DC Volts

Phase Detector2

DC Volts

With PushTrolley on

axle detectors

(4 spokes) 5 V 12 V -12 V +18V 24 V




Test

Points FTB

1 & 2

FTB31 &32

FTB33 &34

FTB35 &36

FTB37 &38 Normal

Dummywheel

NormalDummywheel

PD1 PD2

Monitoring Sockets on DC-DC convertercard

(Limit)

for

Phase

Date

22-30V

40 to

70 V

20.802to

21.302KHz

40 V to

70V

24.750to

25.250KHz

300mV to1.2V(AC)

300mV to1.2V(AC)

10 V to12 V

< 1 V 10 V to12 V

< 1 V10 Vto 12

V10 Vto 12

V4.75to

5.25V

11.75Vto12.25V

-11.75

Vto

-12.25V

17.75V

to18.25

V22Vto

26V

pre commission check list for 2dp1s-ver1 pdf

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