Pocketbook - Frauscher FAdC

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Frauscher Advanced Counter

FAdC
CAMTECH/S/PROJ/2018-19/SP5
November 2018
Target group:
SSEs/JEs(Signal) & Signal Maintainers
Contact person: Director (S & T)

Indian Railways Centre for Advanced Maintenance Technology
Maharajpur, GWALIOR (M.P.) 474 005
) : 0751-2470185, FAX: 0751-2470841 e-mail: dirsntcamtech@gmail.com
Contents
Sr. Description Page

No. No.
1 Introduction 1
2 Brief description of outdoor 2

equipment
3 Brief description of boards of 3
indoor equipment
4 Power Supply 8
5 Tools and Measuring instruments 10
6 Mounting instructions for Wheel 12

Sensor RSR 180
7 Adjustment of Wheel Sensor RSR 13
180
8 Measurements in TLJB when 14
wheel sensor RSR180 is connected
9 Maintenance 16
10 Adjustment of AEB 18
Sr. Description Page
No. No.
11 Coding of AEB 19
12 Setting of the DIP switches 20
13 Local Diagnostics – AEB for 25

troubleshooting
14 LED Diagnostics – IO-EXB for 27
troubleshooting
15 Measurements at a glance 28
16 Reset operation 29
17 Steps in Components Replacement 31
18 Do’s & don’ts 31

CAMTECH/S/PROJ/2018-19/SP5 November 2018
1. Introduction
The Frauscher Advanced Counter FAdC is a Multi Section
Digital Axle counter which is modular in design and have
following advantages:
 Flexible architecture.
 No trackside electronics thus reduced interference.
 Track access for routine maintenance is less since the
sensor currents are monitored in the station equipment
room itself.
 Requirement of less space & extensive diagnostics
features.
 Easy and Quick to remove and reinstall during engineering
activities like machine working
The system comprises the following components/boards:
Trackside equipment
 Wheel sensor RSR180 with moulded cable and
protection tube
 Rail claw Sk140 with clamping bolts
 Track side connection box
Indoor installation
 Overvoltage Protection Board BSI
 Board Rack BGT
 Backplane BP-PWR & BP-EXB
 Power Supply Board PSC
 Communication Board COM
 Advanced Evaluation board AEB
 Input / Output Board I/O -EXB
1
2. Brief description of outdoor equipment
Wheel sensor RSR180 and Rail Claw SK140
The wheel sensor RSR180 consists of 2 sensor systems.
Sensor system 1 is on the left hand side and sensor system 2
is on the right hand side. On the wheel sensor there is a
moulded 4-wire cable with standard length of 5m. One wire
is assigned to each sensor system in which the sensor system
signal is transmitted to evaluation board. The other 2 wires
are used to supply power to the wheel sensor.
It is recommended to use a protection tube for the wheel
sensor cable.
RSR180
SK140
The rail claw SK140 is used to fix the wheel sensor RSR180
to the rail. Using the clamping bolts BBK, the rail claw
SK140 can be adjusted to all common rail profiles.
BBK Rail Claw type
Profile
60 Kg SK140-011
52 Kg SK140-012
3
90 lbs SK140-013
2
3. Brief description of boards of indoor equipment
Power Supply Board PSC

Power Supply Board PSC supplies the
power for the components of the system
and protects the components from
overvoltage. 2 boards can be used for
redundancy.
Overvoltage protection board BSI

The overvoltage protection board
BSI protects the indoor equipment
from interference voltages that
could have an impact on the cable
between the wheel sensor RSR180
and the cable terminating frame KA
(and/or the overvoltage protection
board) in the event of a lightning
strike or overhead contact line short
circuit. The overvoltage protection
board BSI is connected between the
evaluation board and the wheel
sensor RSR180.
3
Advanced Evaluation Board AEB
Diagnostic
Interface ASD
Status - System 1
Status – Power
Status -
Supply Channel1
Configuration &
data traffic
Status – FMA1
(Track Section 1)
Status - System 2
Status –Power
Supply Channel2 Status -
Configuration &
Status – FMA2 data traffic
(Track Section 2)
Toggle switches
Test sockets
One AEB Supplies and evaluates one wheel sensor
Outputs digital counting head data (systems & direction)
Optional –
• AEB can also count axles and generate failsafe clear and
occupied indication for upto 2 track sections (FMA)
• Outputs upto 8 track sections on 4 IO-EXBs.
4
Input/Output Board IO-EXB
Axle counts/error
code/bit status
Status indicator
Status indicator
(Track Section A)
(Track Section B)
or inputs
or outputs
Status indicator
Status indicator of
of the display
the display (Track
(Track Section A)
Section B) or
or inputs
outputs
Display toggle
switch Reset Toggle
switches
(configurable)
 The Input/Output Board IO-EXB can only be used in

combination with an AEB.
 Outputs clear/occupied status of upto 2 track sections
(+2 auxiliary outputs per each track section).
 Reads in and outputs failsafe or non-failsafe digital
arguments.
 Outputs counting head information (direction & system)
5
Communication Board COM
Diagnostic Interface
ASD
Status – Power Status of board

Supply Active board
Connection socket
for synchronization Connection to
between redundant network 1
boards (crossover
cable)
Connection to
Status-data
network 2
transmission
Status-transmission
speed
 It consists of 2 Ethernet connectors (configurable)

 Forwards vital counting head data in between AEBs via
Ethernet.
 Forwards non-failsafe diagnostics data (FDS)
 The CF card available in the COM board provides
configuration data for AEB and COM.
6
Provides
configuration
data for AEB &
COM (CF Card)
Backplane BP-PWR
The backplane BP-PWR is used to connect upto 8 AEB
and/or COM boards with 1 PSC.
Backplane BP-EXB
The backplane BP-EXB is used
to connect 1 AEB with upto 8
IO-EXB boards.
Board racks BGT

Board racks BGT consist of
an aluminium housing and
are equipped with a label
bar. They are used to house
the boards and as
mechanical protection. 11
7
4. Power Supply
The power supply range is +19 V DC to +72 V DC.
The connectors for the power supply X1 & X2 are on the
rear side of the backplanes BP-PWR and BP-EXB.
The external power supply must be connected to the
connector “X1” (“PWR IN”).
The connector “X2” (“PWR OUT”) is used to wire the
internal power supply from a BP-PWR and/or BP-EXB to
another BP-PWR and/or BP-EXB.
X2 –
PWR-IN/OUT
X1 –PWR-IN
Rear side of BP- Rear side of BP-

PWR with cage EXB with cage
clamp terminals clamp terminals
8
Cabling Scheme – Block Diagram
9
5. Tools and Measuring instruments

 Steel wire brush and WD40 spray -
used to clean the rail surface area
for easy fixing of rail claw.
 Adjustable Torque wrench
(range 15 - 40 Nm) -used to
fasten the bolts at specified
torque.
 Socket spanner SW19, SW17, hexagon allen 6 mm
 Ring spanner SW36/Friction

type ratchet – used to fix rail
claw in the rail.
 Steel tape measure

(Fibre/wooden tape measure
recommended in RE area)
10
Tools and Measuring instruments……
 Plumb bob for level measurement (2

m length).
 Multi-meter: Range 1000 mV

DC, precision ± 0.5 %
 Two probes with 2 mm male
connectors (for connection of
evaluation board with mV
meter).
 Testing plate PB200.
15
11
6. Mounting instructions for Wheel Sensor RSR 180

 To be mounted at the inside face of the rail (wheel flange
side).
 In curves - to be mounted at the inside face of the curve.
 In point areas, the minimum admissible space between
rails is 100 mm (inside width between heads of rail).
 Minimum spacing between two wheel sensors on the
same rail is 1200 mm.
 Minimum spacing between a wheel sensor and the next
rail joint is 600 mm.
 The distance between the centre of the wheel sensor and
rail deflectors on either side in the longitudinal rail
direction should be at least 350 mm away from the wheel
sensor.
12
7. Adjustment of Wheel Sensor RSR 180

 Adjust measurement “B” by adding a washer or
exchanging BBK type
 Adjust measurement “A” by moving mounting plate.
Washer for
Adjustment
of B
17
Toothing
Bolt for Adjustment of A
Important
→The wheel sensor housing must not touch the head of rail.
→Torque values must be adhered.
13
8. Measurements in TLJB when wheel sensor

RSR180 is connected
 Voltage between wires 3 and 4 - 12 V to 14 V DC.

 Current in wire 1 and/or 2 – 2.8 to 5 mA
 Current in wire 3 – 57 to 65 mA
If voltage is less than 12 V DC, the loop resistance must be

tested.
The maximum loop resistance of the cable from the TLJB to

the backplane AEB is 250 Ohms.
14
Measurements at the overvoltage protection board BSI
Voltage measurement :
Between clamps E3 and E4. Specified range12 V to 28 V DC (with wheel sensor
connected).
Between E1 & E4 – Specified range 1.5 V to 3.0 V DC
Between E2 & E4 – Specified range 1.5 to 3.0 V DC
CAMTECH/S/PROJ/2018-19/SP5
15
Current measurement:
At wire E3.Specified range 57 mA to 65 mA
November 2018
9. Maintenance
Measurements on the AEB when the wheel
sensor RSR180 is connected . Cycle: < 2 years
Measure voltage at test sockets for Sys1 and
for Sys2, Specified range: 280 mV to 500 mV
DC.
The measured voltage corresponds to the
wheel sensor system current across an internal
100 Ohm shunt resistance (100 mV
corresponds to 1 mA wheel sensor system
current). The voltage must be measured in the
unoccupied (Clear) status.
If the difference between the two voltages >
20 mV or 5% (max), then the possible reasons
are
• Incorrect wheel sensor mounting
• Wheel sensor RSR180 not mounted centrally
between the sleepers
• Metal parts below the wheel sensor RSR180
• A wheel sensor system is defective
V+, GND -- 2 mm test sockets, voltage
corresponds to the analogue wheel
sensor current via a 100 Ω shunt
Testing of AEB
Cycle: < 2 years
Test Counting in and out of at least one axle, using the
testing plate
16
Testing of Wheel sensor RSR180 , Cycle: < 2 years
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. This is done by
means of traversing (both system 1 and system 2) of at
least one axle, which must be counted in and out correctly
by the corresponding AEB as given below:
1 Start position:
The wheel sensor is not occupied.
(Sys1 & Sys2 LED of AEB - OFF)
2 Move (pull) the PB200 constantly in

direction of arrow over the first wheel
sensor system.
Wheel sensor system 1 occupied
(Sys1 LED of AEB -ON)
direction of arrow in the middle of
both wheel sensor systems.
Wheel sensor system 1 & 2 occupied
(Sys1 & Sys2 LED of AEB – ON)
direction of arrow over the second 21
wheel sensor system.
Wheel sensor system 2 occupied .
(Sys2 LED of AEB –ON)
17
10. Adjustment of AEB

The sensor currents must be measured prior to the
adjustment process as given on page NO. 17.
When & Why?

When wheel sensor is reconnected
/ adjusted or BSI replaced
Toggle
When AEB changed with correct
switch1 DIP switch setting
When current measurements on
AEB Sys1 & Sys2 exceeds
permitted values
Performed using toggle switches
Steps using Toggle swiches
1. Push both switches to the left
Toggle (“Adjust“) and keep at least 0.5
switch2
seconds
2. Release and allow both
switches in neutral position for
maximum 2 seconds
3. Push both switches to the right
(“Test“) and keep at least 0.5
seconds
4. Release both switches
Note: Check mounting of wheel sensor, clean dirt or
replace for any visible damage
18
11. Coding of AEB

In order to avoid that an AEB is plugged into a wrong
plug socke, an electronic coding must be carried out
during initial commissioning.
When & Why?
• When AEB is inserted in a different
socket with respective wheel
Toggle
sensor changed.
switch1 • Performed using toggle switches
that saves ID of AEB on the
respective socket of back plane.
• Avoid AEB plugged to wrong
socket
Note: ID must be set on AEB with
DIP switches
Toggle
Steps using Toggle switches
switch2
(1-Top & 2 Bottom)
1. Push switch 1 to the left
(“Adjust“) for at least 0.5 seconds
2. Release and allow both switches
in neutral position for maximum
2 seconds
3. Push switch 1 to the right (“Test“) for at least 0.5
seconds
4. Repeat Step 2
5. Repeat Steps 1 to 3 with switch 2
19
12. Setting of the DIP switches
The DIP switch position “OFF” corresponds to the binary
value “0” and “ON” corresponds to the binary value “1”.
DIP switches of the AEB

On the circuit board of the AEB, the DIP switches for the
double usage, for the ID of AEB and for the direction
inversion must be set.
Channel 1 Channel 1
Channel 2 Channel 2
(Double usage) (ID & Direction inversion)
The DIP switches for channel 1 & channel 2 must be set
identically. The DIP switches for the double usage of a wheel
sensor RSR180 are on the left side of the circuit board of AEB.
Counting from top to bottom
Channel 1 - First 3 DIP rows
Channel 2 - Last 3 DIP rows
20
DIP switches of AEB for double usage (Channel 1 & 2)

Channel DIP DIP Setting Function
row switches
Channel 1 DIP 101 OFF OFF No function

1 2 DIP 102 OFF OFF No function
3 DIP 103 ON ON Analogue double usage
disabled (condition when
delivered)
OFF OFF Analogue double usage
enabled
Channel 4 DIP 201 OFF OFF No function
2 5 DIP 202 OFF OFF No function
6 DIP 203 ON ON Analogue double usage
disabled (condition when
delivered)
OFF OFF Analogue double usage
enabled
The double usage may only be enabled with the wheel
sensor RSR180
The DIP switches for the ID of the AEB and for direction
inversion are on the right side of the circuit board of the
AEB.
21
DIP switches for ID of AEB and direction inversion

(Channel 1 & 2)
Channel DIP Switch No. Possible Function

Settings
0 (LSB) OFF/ON ID of the AEB
Channel 1 OFF/ON (ID 1 to 4095)
1/ 2 OFF/ON
Channel 3 OFF/ON
2 4 OFF/ON
5 OFF/ON
6 OFF/ON
7 OFF/ON
8 OFF/ON
9 OFF/ON
10 OFF/ON
11 (MSB) OFF/ON
12 OFF No function
13 OFF No function
14 OFF No direction inversion
ON Direction inversion
15 OFF No function
DIP 0 (DIP no. 0 to 11 set to “OFF”) is not allowed as an
ID of the AEB.
22
DIP switches of the COM

On the circuit board of the COM, the DIP switches for the ID
of COM and further functions must be set. These DIP
switches are on the left side of the circuit board of COM.
The DIP switches for channel 1 & channel 2 of the COM

must be set identically.
DIP 0 (DIP no. 0 to 11 set to “OFF”) is not allowed as an ID of
the COM.
With DIP switch with DIP no. 12, a protection against
broadcast storm can be activated or deactivated.
In case of non-redundant communication, 1 COM per CAN
segment may be configured as configuration server, in case
of redundant communication, the 2 redundant COM boards
may be configured as configuration servers.(DIP No. 13).
23
DIP switches for ID of AEB and further functions
(Channel 1 & 2)
Channel DIP Switch Possible Function
No. Settings
0 (LSB) ON/OFF ID of the COM
Channel 1/ 1 ON/OFF (ID 1 to 4095)
Channel 2 2 ON/OFF
3 ON/OFF
4 ON/OFF
5 ON/OFF
6 ON/OFF
7 ON/OFF
8 ON/OFF
9 ON/OFF
10 ON/OFF
11 (MSB) ON/OFF
12 OFF No protection against
broadcast storm
ON Protection against
broadcast storm
13 OFF No configuration server
ON Configuration server
14 OFF Master COM
ON Slave COM
15 OFF No redundant operation
ON Redundant operation
24
13. Local Diagnostics – AEB for troubleshooting
Sys1 / Sys2 red LED

Slow blinking
 Wrong connection of wheel sensor cable
 Wire break / wire shortcut on wheel sensor
cable
 Overcurrent
 AEB not yet adjusted
Fast blinking
 Wrong adjustment procedure
 Internal error of AEB
Short blinking
 Sensor current drift
B1 and / or B2- Operation Status
LED off
 CAN bus error free communication
LED lit
 Faulty communication on CAN bus due to
defective PSC or defective AEB or CAN bus
cabling not correct
25
A1 and/or A2 – Operation status
LED off
 Track section clear or no track section
configured.
 In case of counting head control DP sensitized
(i.e. starts counting).
LED lit
 Track section occupied
 In case of counting head control DP sensitized
(i.e. starts counting) and track section
occupied.
LED flashing slowlysensor current drift

 Track section faulty requiring reset
 Communication error requires check the path
between AEB and DP.
LED short flashingsensor current drift

 Counting head control DP desensitized (i.e.
do not count)
LED shortly goes offsensor current drift

 Counting head control DP desensitized (i.e.
do not count) and track section occupied.
26
14. LED Diagnostics – IO-EXB for troubleshooting
After Power up -
Reset required
“P” - Partial Traversing –

Identify cause of error
and / or carry out reset
“C” - Communication
Error – Reset not
necessary
“E” – Error - Investigate

cause
“F” - Wait for Sweep

(pilot) train
27
15. Measurements at a glance
Measurement at AEB
Sensor current
280 to 500mV ± 20 mV
(2.8 – 5 mA ± 0.2 mA)
Measurement at BSI
12 - 28 V DC
V
Measurements at TLJB (GAK)
12 - 14 V DC
28
16. Reset operation
A reset is required in the following cases:
 During or after commissioning.
 After a power-up of axle counting system.
 After an error of the axle counting system.(e.g. track
section (FMA) is in occupied status after a communication
error even if communication error is rectified.)
 After checking and/or maintaining of axle counting system.
The following conditions must be met when carrying out a
reset of the FAdC:
 No wheel sensor must be damped or traversed.
 No axles must be in the track section (FMA).
 No wheel sensor errors, no board errors and no
communication errors must be present.
 The reset may only be carried out under the conditions
specified by railways.
Reset operation with the toggle switches on the
front panel of the AEB
This type of reset is possible only when the front panel
elements of the AEB are not configured as “disabled” in the
configuration word “Toggle switches of the AEB”. The type
of reset operation is also defined in this configuration word.
To reset track section1 (FMA1):
1. Push toggle switch 1 to the left (“Adjust”) and within 2
seconds push toggle switch 2 to the right (“Test”).
2. Keep toggle switch 1 & 2 for at least 0.5 seconds in the
respective position.
3. Release both toggle switches within 0.5 seconds.
29

1. Push toggle switch 2 to the left (“Adjust”) and within 2
seconds push toggle switch 1 to the right (“Test”).
2. Keep toggle switch 1 & 2 for at least 0.5 seconds in the
respective position.
Reset operation with the toggle switches on the

front panel of the IO-EXB
This type of reset is possible only when the front panel
elements of the IO-EXB are not configured as “disabled” in
the configuration word “Toggle switches of the AEB”. The
type of reset operation is also defined in this configuration
word.

1. Push both toggle switches to the left (“Section A”)
within 0.5 seconds.
2. Keep both toggle switches in this position for at least
0.5 seconds.

1. Push both toggle switches to the left (“Section B”)
within 0.5 seconds.
2. Keep both toggle switches in this position for at least
0.5 seconds.
3. Release both toggle switches within 0.5 seconds
30
17. Steps in Components Replacement

Wheel Sensor Physical alignment at track side & AEB
adjustment at indoor
BSI Replace and do AEB adjustment
AEB DIP switch setting & AEB Adjustment
COM DIP switch setting & swap CF card
PSC, IO-EXB Replace item
18. Do’s & Don’ts
Do
 Always carry out “Adjustment of AEB” and testing after
any work done / disturbance in the sensor connection. At
site check measurements “A” and “B” for sensor
alignment.
 Check Nuts and bolts of sensor and rail claw in every
maintenance round and tighten if found loose.
 Always ensure that Wheel sensor cables for connection
between TLJB and RSR-180 are visible and not buried
under ballast or mud.
Don’t
X Don’t touch the module components & repair module on
your own.
X Don’t remove/modify axle counting system interface
wirings or cables without authorization.
X Don’t use blower for cleaning the dust or use vacuum
cleaner inside the housing.
X Don’t remove RJ45 cable when axle counting system is
ON.
31
Notes
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32
Disclaimer
The information given in this pocketbook does not
supersede any existing provisions laid down in
Signal Engineering Manual, Railway Board and
RDSO publications. This document is not statutory
and instructions given in it are for the purpose of
guidance only. If at any point contradiction is
observed, then S.E.M., Rly. Board/RDSO guidelines
or Zonal Rly. instructions may be followed.
Quality Policy
To develop safe, modern and cost effective Railway
technology complying with Statutory and
Regulatory requirements, through excellence in
Research, Designs & Standards and Continual
improvements in Quality Management System to
cater to growing demand of passenger and freight
traffic on the Railways.
INDIAN RAILWAYS
Centre for Advanced Maintenance Technology
Maharajpur, Gwalior (M.P.) Pin Code – 474 005

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GOVERNMENT OF INDIA

Frauscher Advanced Counter

Contact person: Director (S & T)

Sr. Description Page

2 Brief description of outdoor 2

5 Tools and Measuring instruments 10

6 Mounting instructions for Wheel 12

12 Setting of the DIP switches 20

13 Local Diagnostics – AEB for 25

17 Steps in Components Replacement 31

18 Do’s & don’ts 31

Power Supply Board PSC

Overvoltage protection board BSI

Input/Output Board IO-EXB

 The Input/Output Board IO-EXB can only be used in

Status – Power Status of board

 It consists of 2 Ethernet connectors (configurable)

Board racks BGT

Rear side of BP- Rear side of BP-

Cabling Scheme – Block Diagram

5. Tools and Measuring instruments

 Socket spanner SW19, SW17, hexagon allen 6 mm

 Ring spanner SW36/Friction

 Steel tape measure

Tools and Measuring instruments……

 Plumb bob for level measurement (2

 Multi-meter: Range 1000 mV

 Testing plate PB200.

6. Mounting instructions for Wheel Sensor RSR 180

7. Adjustment of Wheel Sensor RSR 180

Bolt for Adjustment of A

8. Measurements in TLJB when wheel sensor

 Voltage between wires 3 and 4 - 12 V to 14 V DC.

If voltage is less than 12 V DC, the loop resistance must be

The maximum loop resistance of the cable from the TLJB to

2 Move (pull) the PB200 constantly in

10. Adjustment of AEB

When & Why?

11. Coding of AEB

DIP switches of the AEB

DIP switches of AEB for double usage (Channel 1 & 2)

Channel 1 DIP 101 OFF OFF No function

DIP switches for ID of AEB and direction inversion

Channel DIP Switch No. Possible Function

DIP switches of the COM

The DIP switches for channel 1 & channel 2 of the COM

13. Local Diagnostics – AEB for troubleshooting

Sys1 / Sys2 red LED

B1 and / or B2- Operation Status

LED flashing slowlysensor current drift

LED short flashingsensor current drift

LED shortly goes offsensor current drift

“P” - Partial Traversing –

“E” – Error - Investigate

“F” - Wait for Sweep

To reset track section2 (FMA2):

Reset operation with the toggle switches on the

To reset track section1 (FMA1):

To reset track section2 (FMA2):

17. Steps in Components Replacement

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