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RAKSHA KAVACH
TROUBLESHOOTING
AND
MAINTENANCE MANUAL
STATIONARY ACDs
Stationary Troubleshooting & Maintenance Manual Version 1.1 Dt.5th February, 2008 Page 1 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
TROUBLESHOOTING AND
MAINTENANCE MANUAL
STATIONARY ACDs
Version 1.1, Date: 5th February, 2008
Stationary Troubleshooting & Maintenance Manual Version 1.1 Dt.5th February, 2008 Page 2 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Copyrights
No part of any content or document may be reproduced in any form or
incorporated into any information retrieval system, electronic or mechanical
without prior written consent from Konkan Railway Corporation Limited.
Copyright 2004 by Konkan Railway Corporation Ltd. All rights reserved.
Disclaimer
Every effort has been made to ensure that the information presented herein is
accurate and complete. This manual has also been reviewed for accuracy.
Conversely, different versions of this product have different features and
capabilities, and this manual reflects only one of those versions.
Information presented in this document is subjected to change without notice.
Reference document:
Functional Requirement Specification (FRS) of Anti Collision Device (ACD) RDSO
/ SPN / 182 / 2004 Version 1.0 with amendment 3 and upto 5th deviations
approved by Railway Board.
Intended Users
This manual is intended for use by the Installation, Troubleshooting and
Maintenance personnel looking after Stationary ACDs of the RAKSHA KAVACHTM
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
TABLE OF CONTENTS
1 ABBREVIATIONS AND DEFINITIONS .........................................................................................................5
3 INTRODUCTION TO STATION ACD...........................................................................................................14
4 STATION ACD TROUBLESHOOTING AND MAINTENANCE ...............................................................15
4.1 STATION ACD INTERFACING WIRING DIAGRAM.........................................................................................15
4.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF STATION ACD...........................16
4.3 PREVENTIVE MAINTENANCE FOR STATION ACD ..........................................................................20
4.4 MANDATORY SPARES FOR STATION ACD .......................................................................................20
5 INTRODUCTION TO MANNED LC GATE ACD........................................................................................22
6 MANNED LC GATE ACD TROUBLESHOOTING AND MAINTENANCE ............................................23
6.1 MANNED LC GATE ACD INTERFACING WIRING DIAGRAM ........................................................................23
6.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF MLCG ACD ................................24
6.3 PREVENTIVE MAINTENANCE FOR MLCG ACD................................................................................30
6.4 MANDATORY SPARES FOR MANNED LC GATE ACD......................................................................30
7 INTRODUCTION TO UNMANNED LC ACD ..............................................................................................32
8 UN-MANNED LC ACD TROUBLESHOOTING AND MAINTENANCE .................................................33
8.1 UN-MANNED LC ACD INTERFACING WIRING DIAGRAM............................................................................33
8.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF UMLC ACD ................................34
8.3 PREVENTIVE MAINTENANCE FOR UNMANNED LC ACD ..............................................................39
8.4 MANDATORY SPARES FOR UNMANNED LC ACD ...........................................................................39
9 INTRODUCTION TO ACD REPEATER.......................................................................................................41
10 ACD REPEATER TROUBLESHOOTING AND MAINTENANCE ...........................................................42
10.1 ACD REPEATER INTERFACING WIRING DIAGRAM ......................................................................................42
10.2 TROUBLESHOOTING AND MAINTENANCE PROCEDURES OF ACD REPEATER........................43
10.3 PREVENTIVE MAINTENANCE FOR REPEATER ACD .......................................................................45
10.4 MANDATORY SPARES FOR REPEATER ACD ....................................................................................45
LIST OF FLOWCHARTS
FIGURE 1: STATION ACD INTERFACING W IRING DIAGRAM .........................................................................................15
FIGURE 2: FLOWCHART FOR STATION ACD & ACD-M PROBLEMS TROUBLESHOOTING ...........................................18
FIGURE 3: FLOWCHART FOR INPUTS (CONTROL PUSH BUTTONS OF SM CONSOLE) TROUBLESHOOTING................19
FIGURE 4: MANNED LC GATE ACD INTERFACING W IRING DIAGRAM .........................................................................23
FIGURE 5: FLOWCHART FOR BOTH FLASHER AND HOOTER UNIT TROUBLESHOOTING...............................................26
FIGURE 6: FLOWCHART FOR COMMUNICATION PROBLEM TROUBLESHOOTING..........................................................27
FIGURE 7: FLOWCHART FOR SINGLE FLASHER UNIT TROUBLESHOOTING ..................................................................28
FIGURE 8: FLOWCHART FOR GATE SENSING PROBLEM TROUBLESHOOTING .............................................................29
FIGURE 9: UN-MANNED LC ACD INTERFACING W IRING DIAGRAM .............................................................................33
FIGURE 10: FLOWCHART FOR COMMUNICATION PROBLEM TROUBLESHOOTING........................................................36
FIGURE 11: FLOWCHART FOR BOTH FLASHER AND HOOTER UNIT TROUBLESHOOTING. ...........................................37
FIGURE 12: FLOWCHART FOR SINGLE FLASHER UNIT TROUBLESHOOTING ................................................................38
FIGURE 13: ACD REPEATER INTERFACING W IRING DIAGRAM ....................................................................................42
FIGURE 14: FLOWCHART FOR COMMUNICATION TROUBLESHOOTING.........................................................................44
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Abbreviation Description
ABU Autom atic Brak ing U nit
EB Em ergenc y Brak e
EMU Elec tric Mul tipl e Un it
ESD Electro Static Discharge
FSS Firs t Sto p S ign al
NB Norm al Brak e
RDSO Res earc h, Design , and Stan dards Orga ni zation
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Abbreviation Description
1.2 Definitions
Automatic Braking Unit (ABU): It is a Sub-System of Loco ACD used for
automatic application of Normal/Emergency Brakes.
ACD: Anti-Collision Device is a micro processor based control system with built-in
wireless data communication; when implemented, it acts as a non-vital safety
shield over the existing signal based train protection systems. Depending on the
application location, there are different ACDs, viz Loco ACDs, Guard ACDs for
passenger trains, Guard ACDs for Goods trains, Station ACD, LC ACD, ACD
Repeater, TID Assigning ACD and Loco Shed ACD.
ACD Guard Van: It is a Guard Van provided with a functional Guard ACD.
ACD Locomotive: It is a ‘light’ Locomotive fitted with Loco ACD or self propelled
vehicles (defined as ‘Train’ in G & SR of IR) fitted with Loco ACD.
ACD Network: It is a network of different types of ACD units, namely Loco ACD,
Guard ACD, Station ACD, Level Crossing Gate ACD, Loco shed ACD, TID
assigning ACD and Repeater ACD. Each ACD is an intelligent microprocessor
based system, which uses a GPS receiver ( for Loco and Guard ACDs ), data
radio modem for communication with other ACD units and interfaces with track
circuits and point status inputs, speedometer, self-propelled vehicles and other
external devices, on need basis
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
ACD Repeater: It is a unit installed at locations identified as Inter-ACD
communication shadow zones along with Radio antenna, Interconnecting cables,
Power supply modules, Batteries and other accessories.
ACD Territory: It is a section of Railway system in which ACD Network has been
installed and commissioned.
ACD Train: It is a train fitted with Loco ACD and Guard ACD or a DMU EMU/
MEMU having Loco ACDs at either ends or any DMU with locomotive in the
middle.
‘Cancel’ Push Button: It is a push button used on Driver’s console for
cancellation of ‘Side-Collision’ and/or ‘Train Parting’/‘Jumbling’ condition as well
as ‘SOS’ condition (which was generated by Driver through pressing of twin SOS
buttons provided on the Console). It is also used for SOS cancellation generated
by self in case of Guard ACD and Station ACD.
Dead Points & Crossing Zone (DPXZ): It is an identified ‘points and crossing
zone’ at the station where the Deviation Count Theory is not applicable due to
complex track layout or due to existence of GPS shadow zone.
Deviation Count Theory: It is a technique by which both loco and guard ACDs
automatically deduce using input from GPS receiver the change in their Track IDs
when they negotiate a point zone already pre-fed as data in the deviation count
table of that station. Accuracy & efficacy on Points on a curve, Ladder points,
Diamonds & Slips to be spelt out clearly by supplier.
DZ Station: It is a station having one or more DPXZ (s).
Emergency Brake: Emergency Brake is the brake applied by the ACD system
wherein brake pipe pressure in locomotive & its formation is reduced from 5.0
Kg/cm2 to 0 Kg/cm2 to control speed of train to desired limit.
Gate Sensing Switch: It is an electrical interface provided at the Manned LC
Gate to detect ‘open’ / ‘closed’ status of the Gate.
GPS: Global Positioning System (GPS) is a satellite-based system using which a
GPS Receiver can determine its exact location on earth. It comprises of a
constellation of 27 Earth-orbiting Satellites (24 in operation and three as backup).
The orbits are arranged so that at anytime, anywhere on Earth, at least four
satellites are visible in the sky.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
GPS Receiver: GPS Receiver receives signals from the GPS satellites, calculates
its location on earth in terms of latitudes and longitudes and provides these data
to any host CPU through a serial port at predefined regular intervals (say, once in
a second). This operation is based on a mathematical principle called trilateration.
In addition to the location data, it also provides speed, course angle of travel and
timestamp.
GPS Shadow Zone It is a track section in which the GPS Receiver does not give
output or does not give accurate and coherent output. Extent of shadow zone to
be delineated by the supplier
Goods Guard ACD: It is a portable ACD self-contained with GPS antenna, radio
antenna and battery that can be used in Guard Vans of goods trains.
IBL (Intelligent Braking Logic): It is a logic by which Loco ACD applies Normal
Brake / Emergency Brake, based on the self-calculated braking distance so as to
reduce the speed to the designed level for achieving various functionalities of
ACD Network.
ICS (Inter Cock Switch): It is a switch to disable the Loco ACD of a trailing /
banking Loco(s) in multiple / double heading / banking operations to put them in
Passive Mode. In case of DMU / EMU / MEMU, the ICS puts the Loco ACD in
Guard mode.
Jumbling: When the inter-distance between the Loco ACD and its Guard ACD
decreases by more than 100m with respect to the pre-calculated train length by
Guard ACD (when it gets attached initially to its Loco ACD), it is considered as
train jumbling.
LC ACD: It is an ACD installed at Manned or Un-Manned Level Crossings along
with radio antenna, interconnecting cables, batteries and other accessories.
Loco ACD: It is an ACD installed in a locomotive or self-propelled rail vehicle
along with Automatic Braking Unit, Driver’s consoles, Radio and GPS antenna,
Speedometer interface and interconnecting cables.
Loco Shed ACD: It is an ACD installed at Loco shed along with Radio antenna,
interconnecting cables and other accessories.
Low-comm (Low Range of Communication): When the Station ACD detects
first packet from approaching Loco / Guard ACD from a distance less than the
predefined distance, the Loco ACD / Guard ACD is termed to have low range of
communication.
Manned LC Gate ACD: It is an ACD installed at Manned Level Crossing Gate
along with radio Antenna, other accessories including interfacing with devices that
provide open/close position of the LC Gate, interconnecting cables and Power
Supply Modules and batteries.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
NB NOT OK IN ABU:“NB NOT OK IN ABU” is the signal the ACD generates,
when application of the Normal Brake fails to cause reduction in speed within time
span of 20 seconds, because of defects associated with either the ACD system or
the brake power of the train.
No-Comm: When there is no communication from Station ACD to the Loco ACD
or the Route status from Station ACD is not available the situation is called No
communication or “NO COMM”
Normal Brake: Normal Brake is the brake applied by the ACD system, wherein
brake pipe pressure in locomotive & its formation is dropped from 5.0 Kg/cm2 to
4.2 Kg/cm2 to control speed of train to desired limit.
Parting: When the inter-distance between the Loco ACD and its Guard ACD
increases by more than 100m with respect to the pre-calculated train length by
Guard ACD (when it gets initially attached to its Loco ACD), it is considered as
train parting.
Passive Mode: It is a mode assumed by Loco ACD when its locomotive is not a
leading loco. In this mode, it ceases to perform any functionality except detecting
the change in its TID.
Point Zone: It is a portion of track covering a turnout / point & crossing, including
25m-track portion in rear of either side of the end of that turnout / point & crossing
area.
Portable: It refers to a Guard ACD, which is portable as it is required to be fixed
and removed at train originating / terminating / intermediate stations.
Side Collision: When any train stops in block section it generates Side Collision
condition due to which Side Collision LED indication glows on the driver’s console
and prompts the Driver to press CANCEL button if everything is OK.
Silent Mode: It is a mode assumed by Loco ACD / Guard ACD in Station Area
when its speed is less than 3Km/h. In silent mode, the Loco ACD / Guard ACD
remains in reception state only and comes out of this mode when it perceives
collision like dangerous situation.
Sleep Mode: It is a mode assumed by Loco ACD / Guard ACD outside the ACD
territory. In this mode, they carry TID-NU and the user interface of Loco ACD /
Guard ACD shall not be active.
Sleep Zone: It is a track section of Railway system that is located outside the
ACD territory. ACD system does not provide any protection in sleep zone.
SM Console: it is a console intended for station master with Audio and Visual
Indications and push buttons.
Station ACD: It is an ACD installed in Station area along with the SM’s console,
radio antenna and other accessories including need based interfacing with
Signaling circuits and interconnecting cables.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Station Area: It is a railway section falling between either farthermost First Stop
Signal / Last Stop Signals located on both sides of the station; or outermost facing
points, if there are no stop signals at that station.
Station ID: It is a two or three character ID assigned to a Station, which may or
may not have automatic signaling, between two consecutive stations for uniquely
identifying the same
Radio Shadow Zone: It is a track section in which inter-ACD radio
communication within a distance of 3000m of a radial range is not available for a
continuous stretch of more than 200m.
Radio Communication: It is an interchange of data packets amongst various
ACDs within a pre-defined time interval, using radio waves in a simplex / half-
duplex mode at a nominated spot frequency in UHF range
TID Assigning ACD: It is an ACD used to assign TID to the passing Loco ACDs
by deriving inputs from track circuits in the TID Assigning zone. It is generally
located at stations bordering the ACD territory, prior to entering into the ACD
territory.
TID-GR: It is a TID assigned to a Group of tracks in big yards, (normally beyond
the second loop from the main lines) where train movements above the shunting
speeds are not permitted.
TID-NU: It is a neutral TID assumed by Loco ACD and Guard ACD in sleep zone.
Guard ACD also assumes initially TID-NU when it is switched ‘ON’ inside the ACD
territory and subsequently acquires the correct TID from the Loco ACD, after
attachment.
TID-SR: It is a TID assigned to an entire station yard for stations having big yards,
where train movements above the shunting speeds are not permitted.
TID-LS: It is a TID assigned to Loco ACDs of those locomotives, which enter the
Loco shed. The Loco ACD shall not apply brakes if it is carrying TID-LS. Also, it
shall not apply brakes when it is carrying TID other than TID-LS and receives a
data packet from other Loco ACD or Guard ACD, which is carrying TID-LS. All
user interfaces shall remain active for self-test of Loco ACD.
TID-S: It is a TID assigned to Loco ACD and/or Guard ACD of a rolling stock that
enter inside the siding area. All user interfaces shall remain active for self-test of
Loco ACD carrying TID-S.
TID-FS: It is a status of TID assumed by Loco ACD / Guard ACD, when it is not in
a position to identify the track on which it is located.
Track ID (TID): It is a two-digit decimal number (value between ’00’ and ‘63’) that
uniquely identifies the track on which a Loco ACD or Guard ACD is located inside
the ACD territory. It is a virtual number used in the data files of different ACDs.
Train Ahead: This is indicated on the Driver’s Console of the rear train, when it
applies the brake for the following scenario: When one train is following another
train in same direction, on the same track in the Block section.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Train Approaching: This is indicated on the Driver’s Console of the train, when it
applies the brake for the following scenario: When one train is approaching
another train in the opposite direction, on the same track in the Block section
Un-Manned LC ACD: It is an ACD installed at Un-Manned Level Crossing along
with radio Antenna, interconnecting cables and Power Supply Modules and
batteries.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
STATION ACD
TROUBLESHOOTING AND
MAINTENANCE
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
GP ANTENNA
24V/8A BATTERY RM
CHARGER CUM INPUT
POWER SUPPLY
F
STATION F
BATTERY
(24V/40AH) B
I ACD B
I
SM
CONSOLE
- -
10 12
RELAY ROOM
OF STATION
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
STATION ACD
FUNCTIONING
NOT OK
CHECK NOT OK
CHECK NOT OK OK CHECK CHECK
PHYSICAL CONNECTIONS REPLACE
24V LED VOLTAGE AT LOAD CHARGER
BETWEEN CHARGER FUSE
GLOWING TERMINALS FUSE
& ACD
OK
OK
OK NOT OK
NOT OK
NOT OK
CHECK NOT OK
CHECK REPLACE
15V LED
5A FUSE FUSE
GLOWING MAKE AC POWER
AVAILABLE
OK
CHECK REPLACE
Tx LED ACD
BLINKING OK
OK
NOT OK
CHECK
NOT OK
SM CONSOLE IN YES PHYSICAL CONNECTIONS FIX
ACD-M MODE BETWEEN ACD & CONNECTIONS
TAG BLOCK
NO
RESTART
ACD
NO ACD-OK YES
REPLACE
LED ACD - OK
ACD
GLOWING
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
S LOAD INPUT
RM
P CCU
V
BATT
MLCG
ACD
FROM
GATE SENSING BOOM SWITCH
SIGN.IN
RELAY UNIT
FLASHER - 1 FLASHER - 2
BATTERY
(16V/200AH)
GATE STATUS
INDICATION
BOX
HOOTER & HOOTER &
FLASHER FLASHER
UNIT - 1 UNIT - 2
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
PROBLEM OBSERVED IN
SL.NO. CHECK POINTS REMARKS
THE FIELD
a) Check if 16V LED is glowing. If not OK, check physical wiring between CCU,
Manned LC Gate ACD input (16V input), and battery (16V). Fix loose Check the cause
Manned LC Gate ACD not
1 connections. for fuse open and
functioning
b) Check ON/OFF switch. Check the 8A fuse in CCU. If blown, replace fuse. rectify it.
c) If problem persists, change ACD.
a) Check if 16V & 5V LEDs are glowing. If not, follow the procedures given for
problem 1.
2 Communication Problem b) Check physical connections between RM port and GP antenna. Fix loose
connections.
c) If problem persists, change ACD.
a) Check 5A in ACD and 8A fuse in CCU. If blown, replace fuse.
b) Check if 16V LED is glowing. If not, follow the procedures given for problem
Both Flasher and Hooter not 1.
3
working c) Check physical connections between Flasher units (1&2) to ACD. If not
working, replace the unit
d) If the unit is still not working, change the ACD
a) Check physical connections. Fix loose connections. If OK, change Hooter
4 Hooter not working.
unit.
a) Check physical connections. Fix loose connections. If OK, change flasher
5 Flasher not working.
unit.
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RAKSHA KAVACH™ Konkan Railway Corporation Ltd
PROBLEM OBSERVED IN
SL.NO. CHECK POINTS REMARKS
THE FIELD
a) Check physical connection between ACD and gate switch relay unit.
b) Check 6A fuse in CCU. If blown, replace it.
c) Check physical connections between switches boom A & boom B. Also check
6 Gate open/close sensing
connections between gate switching relay unit/CCU and ACD. If physical
problem.
connections are not OK, fix them.
d) If problem persists, change the gate switch relay unit. If not OK, change ACD
In switched on condition, ACD- a) Check 8A fuse. If blown replace it.
7
M LED glowing continuously b) If problem persists change the ACD
a) Check if 16V and 5V LEDs are glowing. If not, follow the procedures given for
Train is approaching towards problem 1.
8 gate, and both flasher & Hooter b) Check TX and RX LED’s. If they do not blink while the LOCO is at the gate
not working. there is a communication problem.
c) If problem persists, change ACD
Loco is passing the particular
a) Follow the procedures given for problem 6.
gate at low speed (25Kmph),
9 b) Check if TX and RX LED’s are blinking when the Loco is near the gate. If not
even when the level crossing
blinking, change the ACD.
gate is closed.
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NOT OK
CHECK
CHECK REPLACE OK
WORKING OF FLASHER
5A FUSE 5A FUSE
& HOOTER
OK NOT OK
NOT OK NOT OK
CHECK OK
OK CHECK CHECK REPLACE
WORKING OF FLASHER
16V LED 8A FUSE FUSE
& HOOTER
OK
NOT OK
CHECK NOT OK OK
CHECK
PHYSICAL CONNECTIONS FIX
WORKING OF FLASHER
BETWEEN CCU,ACD & CONNECTIONS
& HOOTER
BATTERY
OK
NOT OK
CHECK NOT OK
5V LED
OK
REPLACE FLASHER
& HOOTER UNITS
REPLACE
ACD
CHECK
NOT OK
WIRING OF FLASHER &
HOOTER
OK
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COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
GLOWING OF BLINKING OF Tx
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
CHECK PHYSICAL CHECK OK
FIX
WIRING BETWEEN CCU, BLINKING OF Tx
CONNECTIONS
ACD & BATTERY & Rx LED
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK
OK
NOT OK
REPLACE
ACD
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SINGLE FLASHER
UNIT PROBLEM
NOT OK
CHECK
PHYSICAL CONNECTION FIX
BETWEEN FLASHER CONNECTIONS
UNIT & ACD
OK
CHECK
NO
FLASHER UNIT
WORKING
REPLACE
FLASHER UNIT
YES
OK
CHECK
FLASHER
FLASHER UNIT
UNIT OK
WORKING
NOT OK
REPLACE
ACD
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CHECK
NOT OK CHECK OK
PHYSICAL CONNECTIONS FIX
GATE OPEN / CLOSE
BETWEEN ACD & GATE CONNECTIONS
SENSING
SWITCH UNIT
NOT OK
OK
CHECK PHYSICAL
CONNECTIONS BETWEEN NOT OK CHECK OK
FIX
BOOM A & BOOM B GATE GATE OPEN / CLOSE
CONNECTIONS
SWITCH RELAY UNIT INDICATOR
& CCU
OK
NOT OK
CHANGE GATE
SWITCH RELAY UNIT
CHECK OK
GATE OPEN / CLOSE
GATE OPEN / CLOSE
SENSING OK
SENSING
NOT OK
REPLACE
ACD
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UNMANNED LC ACD
TROUBLESHOOTING AND
MAINTENANCE
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S LOAD INPUT
RM
P CCU
V
BATT
UMLC
ACD
FLASHER - 1 FLASHER - 2
BATTERY
(16V/200AH)
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PROBLEM OBSERVED IN
SL. NO. CHECK POINTS REMARKS
THE FIELD
a) Check physical wiring between CCU, Un-Manned ACD input
(16V input), and battery (16V). Fix loose connections. Check the cause
Unmanned LC ACD not
1. b) Check ON/OFF switch. Check the 8A fuse in CCU. If blown, for fuse open and
functioning
replace fuse. rectify it.
c) If problem persists, change ACD.
a) Check if 16V & 5V LEDs are glowing. If not, follow the
procedures given for problem 1.
2. Communication Problem b) Check physical connections between RM port and GP
antenna. Fix loose connections.
c) If problem persists, change ACD.
a) Check 5A and 8A fuse in CCU. If blown, replace fuse.
b) Check if 16V LED is glowing. If not, follow the procedures
Both Flasher and Hooter not given for problem 1.
3.
working. c) Check physical connections between flasher units (1&2) to
ACD. If not working, replace the unit.
d) If the unit is still not working, change the ACD.
4. Hooter not working. a) Check physical connections. Change Hooter unit.
5. Flasher not working. a) Check physical connections. Change flasher unit.
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 34 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
PROBLEM OBSERVED IN
SL. NO. CHECK POINTS REMARKS
THE FIELD
a) Check if 16V and 5V LEDs are glowing. If not, follow the
Train is approaching towards procedures given for problem 1.
6. gate, and both flashers & b) Check TX and RX LED’s. If they do not blink while the LOCO
sirens not working. is at the gate there is a communication problem.
c) If problem persists, change ACD
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 35 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
GLOWING OF BLINKING OF Tx
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
CHECK PHYSICAL CHECK OK
FIX
WIRING BETWEEN CCU, BLINKING OF Tx
CONNECTIONS
ACD & BATTERY & Rx LED
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK
OK
NOT OK
REPLACE
ACD
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 36 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
NOT OK
CHECK
CHECK REPLACE OK
WORKING OF FLASHER
5A FUSE 5A FUSE
& HOOTER
OK NOT OK
NOT OK NOT OK
CHECK OK
OK CHECK CHECK REPLACE
WORKING OF FLASHER
16V LED 8A FUSE FUSE
& HOOTER
OK
NOT OK
CHECK NOT OK OK
CHECK
PHYSICAL CONNECTIONS FIX
WORKING OF FLASHER
BETWEEN CCU,ACD & CONNECTIONS
& HOOTER
BATTERY
OK
NOT OK
CHECK NOT OK
5V LED
OK
REPLACE FLASHER
& HOOTER UNITS
REPLACE
ACD
CHECK
NOT OK
WIRING OF FLASHER &
HOOTER
OK
Figure 11: Flowchart for both Flasher and Hooter Unit Troubleshooting.
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 37 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
SINGLE FLASHER
UNIT PROBLEM
CHECK NOT OK
PHYSICAL
FIX
CONNECTIONS BETWEEN
FLASHER UNIT CONNECTIONS
& ACD
OK
CHECK
NO
FLASHER UNIT
WORKING
REPLACE
FLASHER UNIT
YES
OK
CHECK
FLASHER
FLASHER UNIT
UNIT OK
WORKING
NOT OK
REPLACE
ACD
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 38 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 39 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
ACD REPEATER
TROUBLESHOOTING AND
MAINTENANCE
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 40 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 41 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
GP ANTENNA
S LOAD INPUT
RM
P CCU
V
BATT
ACD
REPEATER
BATTERY
(16V/100AH)
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 42 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
PROBLEM OBSERVED
SL. NO. CHECK POINTS REMARKS
IN FIELD
a) Check 16V & 5V LEDs. If not glowing, check physical wiring between
CCU, ACD Repeater input (16V input), and battery (16V). Fix loose
Check the cause
ACD Repeater not connections.
1. for fuse open and
functioning b) Check ON/OFF switch. Check 5A & 8A fuse in CCU. If any fuse is
rectify it.
blown, replace fuse.
c) If problem persists, replace ACD Repeater.
a) Check if 16V & 5V LEDs are glowing. If not, follow the procedures
given for problem 1.
2. Communication Problem
b) Check physical connections between RM port and GP antenna. Fix
loose connections.
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5th February, 2008 Page 43 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
COMMUNICATION
PROBLEM
NOT OK NOT OK OK
CHECK CHECK
CHECK REPLACE
GLOWING OF BLINKING OF Tx
8A FUSE FUSE
16V LED & Rx LED
OK OK
NOT OK
NOT OK
CHECK PHYSICAL CHECK OK
FIX
WIRING BETWEEN CCU, BLINKING OF Tx
CONNECTIONS
ACD & BATTERY & Rx LED
OK NOT OK
NOT OK CHECK
GLOWING OF
COMMUNICATION
5V LED
OK
OK
OK
NOT OK
REPLACE
ACD
th
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5 February, 2008 Page 44 of 45
RAKSHA KAVACH™ Konkan Railway Corporation Ltd
10.3 PREVENTIVE MAINTENANCE FOR REPEATER ACD
The following preventive maintenance measures have to be strictly
adhered for proper functioning of the Repeater ACD.
• Check battery voltage regularly
• Whenever “Battery Low” indication is reported, charge the battery
using Portable Charger and DG Set.
• Observe physical health of the unit at regular intervals
• Apply anti-corrosive liquid on battery terminals regularly
th
Troubleshooting & Maintenance Manual Version 1.1 Dt. 5 February, 2008 Page 45 of 45