BO23 User Documentation

Document number: Page:
USER DOCUMENTATION D215600-0501010102 1 of 58

Product: Order codes:
AXLE COUNTER
1. AP215600
Type:
BO23
User: Authorised by: Date:

15. 06. 2009
AXLE COUNTER BO23 OPERATING INSTRUCTIONS
Updates: Date: Prepared by / signature: Checked by / signature: Approved by / signature:

01 30.11.2006 H. Horvat I. Domladovac B. Voš!un
02 15.06.2009 H. Horvat I. Domladovac B. Voš!un
03
REVISION LOG
Document
Version Author Date Changes/history Status
number
D215600-
1 H. Horvat 30.11.2006 Document creation Closed
0501010102
D215600-
1 H. Horvat 15.06.2009 Update of chapter 3 - Installation Closed
0501010102
TABLE OF CONTENTS
1. TECHNICAL DESCRIPTION................................................................................................5
1.1 APPLICATION ...................................................................................................................5
1.2 DESCRIPTION AND DEVICE STRUCTURE.....................................................................5
1.2.1 OUTDOOR EQUIPMENT STRUCTURE................................................................................6
1.2.2 INDOOR EQUIPMENT STRUCTURE....................................................................................7
1.2.3 POWER SUPPLY ...................................................................................................................9
1.2.4 OUTPUT SIGNALS ................................................................................................................9
2. WIRING AND APPLICATION ............................................................................................10

2.1 OUTDOOR EQUIPMENT WIRING ..................................................................................10
2.2 WIRING AND SETTING THE INDOOR EQUIPMENT UNUR..........................................11
2.2.1 CONFIGURATION 1 (BO23-8A): ONE SECTION WITH UP TO 8 COUNTING POINTS ....12
2.2.2 CONFIGURATION 2 (BO23-4A-4B): TWO INDEPENDENT SECTIONS WITH UP TO 4
COUNTING POINTS ............................................................................................................13
2.2.3 CONFIGURATION 3 (BO23-3A-3B-2C): 3 INDEPENDENT SECTIONS.............................13
2.2.4 CONFIGURATION 4 (BO23-2A-2B-2C-2D): 4 INDEPENDENT SECTIONS WITH 2
COUNTING POINTS ............................................................................................................14
2.2.5 CONFIGURATION 5 (BO23-3A3B3C2D): 4 CONSECUTIVE SECTIONS ..........................14
2.2.6 CONFIGURATION 6 (BO23-2A2B2C-2D2E2F): TWO TIMES 3 CONSECUTIVE
SECTIONS WITH UP TO 2 COUNTING POINTS................................................................15
2.2.7 CONFIGURATION 7 (BO23-2A2B2C2D4E): OCCUPANCY CONTROL OF 5
CONSECUTIVE SECTIONS ................................................................................................16
2.2.8 CONFIGURATION 8 (BO23-2A2B2C2D2E3F): OCCUPANCY CONTROL OF 6
CONSECUTIVE SECTIONS ................................................................................................16
2.2.9 CONFIGURATION 9 (BO23-3A-2B-2C-2D): OCCUPANCY CONTROL OF 3
INDEPENDENT STATION SECTIONS AND SINGLE BLOCK BETWEEN STATIONS
USING RS232 SERIAL CONNECTION ...............................................................................17
2.2.10 SETTING THE POWER SUPPLY FOR COUNTING POINTS AND CONNECTION ...........18
2.2.11 SETTING THE COUNTING DIRECTION .............................................................................21
2.2.12 SAFETY RELAYS OUTPUT SIGNALS ................................................................................22
2.2.13 CONNECTION OF RELAY OUTPUTS TO DIFFERENT SIGNALLING DEVICES ..............25
2.2.14 RESETTING THE SECTION ................................................................................................26
2.2.15 CONNECTING SEVERAL INDOOR DEVICES IN RELAY ROOM FOR STATION
SECTIONS CONTROL.........................................................................................................33
2.2.16 AUXILIARY INPUTS/OUTPUTS OF BO23-UNUR INDOOR DEVICE .................................34
2.2.17 INDICATORS ON THE BO23-UNUR FRONT PANELS.......................................................35
3. INSTALLATION OF THE EQUIPMENT .............................................................................37

3.1 SENSOR ZK24 INSTALLATION ON THE RAIL...............................................................37
3.1.1 TOOLS..................................................................................................................................37
3.1.2 MOUNTING THE SENSOR AND SETTING THE HEIGHT AND SIDE DISTANCE.............37
3.1.3 VISUAL CHECK AND FINAL TIGHTENING ........................................................................38
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3.2 TRACKSIDE CONTROL UNIT VUR INSTALLATION......................................................39

3.2.1 TOOLS..................................................................................................................................39
3.2.2 ASSEMBLY PARTS PER ONE COUNTING POINT ............................................................39
3.2.3 BURYING THE VUR.............................................................................................................40
3.2.4 PROTECTION OF SENSOR CABLE AND DRAGGING THE CABLE INTO THE VUR
HOUSING .............................................................................................................................40
3.2.5 GROUNDING THE VUR’s BOX ...........................................................................................40
3.3 INSTALLATION OF THE INDOOR EQUIPMENT UNUR.................................................41

3.3.1 PREPARING THE INDOOR EQUIPMENT...........................................................................41
3.3.2 MOUNTING THE INDOOR EQUIPMENT SUBRACK..........................................................41
3.3.3 GROUNDING .......................................................................................................................41
3.3.4 WIRING THE INDOOR EQUIPMENT ..................................................................................42
3.3.5 FUNCTION AND COUNTING DIRECTION CHECK ............................................................42
3.4 DISMOUNTING AND REMOUNTING THE SENSOR DURING THE TRACK
RECONSTRUCTION .......................................................................................................42
3.4.1 TOOLS..................................................................................................................................42
3.4.2 WITH SENSOR MOUNTED ON THE CLOSER RAIL..........................................................43
3.4.3 WITH SENSOR MOUNTED ON THE MORE DISTANT RAIL .............................................43
4. MAINTENANCE .................................................................................................................44
4.1 SIX-MONTHS PERIOD MAINTENANCE – OUTDOOR EQUIPMENT ............................44
4.1.1 MECHANICAL MEASURING AND JOINT TIGHTENING ....................................................44
4.1.2 ELECTRICAL MEASURING.................................................................................................44
4.2 SIX-MONTHS PERIOD MAINTENANCE – INDOOR EQUIPMENT ................................44
4.2.1 VISUAL CHECK ...................................................................................................................44
4.2.2 ELECTRICAL MEASUREMENT...........................................................................................45
4.2.3 FUSE VALUES ON THE INDOOR EQUIPMENT.................................................................45
5. FAILURE DETECTION.......................................................................................................46
5.1 FAILURE DETECTION ON THE OUTDOOR EQUIPMENT ............................................46
5.1.1 POWER FAILURE – THE FAILURE AFTER CLOSE LIGHTNING STRIKE ........................46
5.1.2 FAILURE IN THE SENSOR CIRCUIT ..................................................................................46
5.1.3 FAILURE IN OUTPUT CIRCUITRY OF VUR .......................................................................46
5.2 FAILURE DETECTION ON THE INDOOR EQUIPMENT ................................................47
5.2.1 FAILURES CAUSED BY ATMOSPHERE DISCHARGES ...................................................47
5.2.2 FAILURE ON THE INPUT AMPLIFIER MODULE UP..........................................................47
5.2.3 MPU MICROPROCESSOR MODULE FAILURE .................................................................48
5.2.4 POWER SUPPLY FAILURE.................................................................................................48
5.2.5 RELAY OUTPUT MODULE RE FAILURE............................................................................48
6. TECHNICAL SPECIFICATIONS ........................................................................................49

6.1 OUTDOOR EQUIPMENT (VUR + sensor ZK24) .............................................................49
6.2 INDOOR EQUIPMENT BO23-UNUR...............................................................................50
6.3 SIGNAL TRANSMISSION FROM OUTDOOR TO INDOOR EQUIPMENT......................51
APPENDIX A – DIMENSION DRAWINGS............................................................................52

APPENDIX B – MOUNTING DRAWINGS ............................................................................55
APPENDIX C – MEASURING LIST PROPOSAL FOR SIX-MONTH MAINTENANCE ........57
Figure 1: Axle counter BO23 structure for 2 counting point section occupancy control ............................6
Figure 2: Sensor on mounting bracket with a clamp mounted on the rail with shields..............................6
Figure 3: Trackside control unit VUR in the box beside the track .............................................................7
Figure 4: Indoor equipment UNUR of the axle counter BO23 – positions of modules (front view) ...........8
Figure 5: Top view to opened box of trackside control unit VUR ............................................................10
Figure 6: Two examples of track configuration setup using the SW1 switch and reset mode setup
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using the J25 jumper...............................................................................................................12

Figure 7: A single section with 2 to 8 counting points controlled by one BO23-UNUR device set to
configuration 1 (BO23-8A) ......................................................................................................12
Figure 8: Example of two independent sections with 4 counting points controlled by one BO23-UNUR
indoor device set to configuration 2 (BO23-4A-4B) ................................................................13
Figure 9: Example of three independent sections controlled by one BO23-UNUR indoor device set to
configuration 3 (BO23-3A-3B-2C)...........................................................................................13
Figure 10: Two examples of 4 independent sections controlled by one BO23-UNUR indoor device
set to configuration 4 (BO23-2A-2B-2C-2D) ...........................................................................14
Figure 11: Three examples of controlling 4 consecutive sections using one BO23-UNUR indoor
device set to configuration 5 (BO23-3A3B3C2D) ...................................................................15
Figure 12: Two examples of two times 3 consecutive sections control using one BO23-UNUR device
set to configuration 6 (BO23-2A2B2C-2D2E2F) .....................................................................16
Figure 13: Example of 5 consecutive sections control (only automatic block or automatic block +
station area) using one BO23-UNUR indoor device set to configuration 7 (BO23-
2A2B2C2D4E) ........................................................................................................................16
station area) using one BO23-UNUR indoor device set to configuration 8 (BO23-
2A2B2C2D2E3F) ....................................................................................................................17
Figure 15: Example of control of 3 independent station sections and single block between stations
using serial connection between two BO23-UNUR indoor devices set to configuration 9
(BO23-3A-2B-2C-2D)..............................................................................................................17
Figure 16: Setting the power supply of counting points ..........................................................................18
Figure 17: Indoor device BO23-UNUR with connection markings (rear view) ........................................19
Figure 18: BO23-UNUR with removed ZAG2Z and KP modules (rear view) ..........................................20
Figure 19: Setting the counting direction.................................................................................................21
Figure 20: Output contacts of FREE and OCCUPIED relays for sections A, B and C ............................23
Figure 21: Output contacts for FREE and OCCUPIED relays for sections D, E and F ...........................24
Figure 22: Connection of clear / occupied relay outputs on 3 types of signalling systems .....................26
Figure 23: Digital inputs for reset of sections A, B and C on BO23-UNUR indoor device.......................28
Figure 24: Digital inputs for reset of sections D, E and F on BO23-UNUR indoor device.......................29
Figure 25: Example of connection of reset outputs from microprocessor interlocking ............................31
Figure 26: Example of safety connection of reset push buttons on the control desk ..............................32
Figure 27: Example of optimal connection of axle counters BO23 for small station control....................33
Figure 28: Auxiliary inputs/outputs of the BO23-UNUR indoor device ....................................................35
Figure 29: Position of sensor on the rail (drawing); setting the sensor’s height ......................................37
Figure 30: Setting the sensor’s side distance .........................................................................................38
Figure 31: Correct position of sensor mounted on the rail type UIC60 ...................................................39
Figure 32: Location of the control unit VUR beside the track ..................................................................40
Figure 33: Mounting the indoor equipment UNUR into the 620mm wide rack ........................................41
Figure 34: Dimension drawing – sensor ZK24 ........................................................................................52
Figure 35: Dimension drawing – trackside control unit VUR ...................................................................53
Figure 36: Dimension drawing – indoor device BO23-UNUR .................................................................54
Figure 37: Mounting the sensor ZK24 on mounting bracket on the rail – cross section..........................55
Figure 38: Mounting the sensor ZK24 on mounting bracket with shields on the rail ...............................56
Table 1: One counting point’s assemble parts of the axle counter BO23 .................................................7
Table 2: Parts for BO23 indoor equipment UNUR ....................................................................................9
Table 3: Setting the counting direction on consecutive section configurations .......................................22
Table 4: Meaning of each LED indication on the BO23-UNUR indoor device ........................................36
Table 5: Wheel flange height (according to UIC 510-2) ..........................................................................50
Table 6: Wheel flange thickness (according to UIC 510-2) .....................................................................50
Table 7: Maximal cable length from outdoor to indoor equipment ..........................................................51
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1. TECHNICAL DESCRIPTION
1.1 APPLICATION
The axle counter BO23 applies to the railway track section occupancy control wherever
the occupancy needs to be controlled; primary for vital control of the section occupancy, but
can be used in similar applications without safety significance. Examples for the application of
the axle counter BO23 are:
- Occupancy control of station sections within the station interlocking system
- Occupancy control of open railroad sections within the automatic block system
- Occupancy control of open railroad as a single block between stations
- Occupancy control of several sections in wide level crossing area for the purpose of
switching-on / switching-off the level crossing within the level crossing protection system
- Occupancy control of shunting station / marshalling yard sections within the automatic
coach shunting system etc.
The axle counter BO23 continuously controls the entrance and exit of the train axles by
it’s sensors on the counting point on each end of the section and gives the output information
that the track section is clear only if the current number of axles on the section is equal to zero
and no disturbance, error or fault is detected. In each other case the “track section occupied”
information is outputted. With the BO23 equipment the track section occupancy can be
controlled on the section with two counting points (on the open railroad section or the station
track section), on the section with 3 counting points (switch point section), on the dead end
section with one counting point, on the double slip switch point section (4 counting points) or
the multiple switch points section with maximum 8 counting points.
1.2 DESCRIPTION AND DEVICE STRUCTURE
Axle counter BO23 consists of the outdoor equipment on the track and the indoor
equipment in the station or in the block section equipment shelter near the railroad as shown
on the figure 1. The station’s relay chambers and equipment shelters where the indoor
equipment is installed are the restricted access locations and they are locked, sealed and
accessible only for signalling maintenance personnel.
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Section A
OUTDOOR Sensor ZK24 Sensor ZK24

EQUIPMENT
4 4
(sensor mounted COUNTING COUNTING
POINT 1 POINT 2
on rail and
trackside control VUR VUR
unit VUR)
TRANSMISSION
PATH
(existing 2-wire
2 2
telecommunication
twisted pairs)
BT1 BT2
INDOOR
EQUIPMENT
Indoor equipment
(power supply,
processor and BO23-UNUR
output units)
Section A Power supply,

occupancy reset
information
Figure 1: Axle counter BO23 structure for 2 counting point section occupancy control
Transmission path is not considered as a part of the axle counter because the existing
railway signalling and telecommunication cables are usually used. There is a 2-wire connection
between indoor and outdoor equipment (single 2-wire telecommunication twisted pair).
1.2.1 OUTDOOR EQUIPMENT STRUCTURE
The outdoor equipment consists of a wheel sensor ZK24 mounted on the inner side of
one rail on the mounting bracket with a clamp or mounting bracket for drilled rail, left and right
sensor shield mounted on the same rail, and the trackside control unit (VUR) in the box beside
the track. Figure 2 shows the sensor on the mounting bracket with a clamp mounted on the rail
with sensor shields. The ZK24 sensor has a double structure of wheel detection (two sensing
systems in one housing) that enables detection of direction and increases safety of the system.
Figure 2: Sensor on mounting bracket with a clamp mounted on the rail with shields
Figure 3 shows the outdoor trackside control unit VUR placed in the box on a short
column beside the track. VUR supplies and controls the sensor and sends the modulated
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signal that keeps the information from both sensing systems on the same 2-wire twisted pair to
indoor equipment. On the same 2-wire twisted pair the outdoor equipment receives the DC
power supply.
Figure 3: Trackside control unit VUR in the box beside the track
In table 1 there are one counting point’s assemble parts of the axle counter BO23
including quantity per one counting point.
Table 1: One counting point’s assemble parts of the axle counter BO23
ASSEMBLE PARTS FOR ONE BO23 COUNTING
Quantity per one
POINT (OUTDOOR EQUIPMENT COMPLETE SET Order code
counting point
AP215501)
Outdoor equipment electronic
Outdoor equipment 1 piece AP215502
module (VUR)
trackside control unit
Front panel VUR-P with
VUR – complete 1 piece AP215503
lightning protection
AP215507
1 piece VUR’s box 1 piece AP215505
VUR’s column 1 piece AP215506
Sensor cable protection tube 5 meters AP215508
Worm drive fastening ring for protection tube 2 pieces AP215509
Wheel sensor ZK24 with Sensor mounting
1 piece AP215515
mounting bracket (mounted bracket
together) AP215562, 1 piece Wheel sensor ZK24 1 piece AP215560
Sensor shield (left and right) for rail type S49 1 pair AP215513
Sensor shield (left and right) for rail type UIC60 1 pair AP215514
Each railway network region department for signalling equipment maintenance should
have at least one plastic template for sensor position adjustment on rail. Order code of the
plastic template is AP215516.
1.2.2 INDOOR EQUIPMENT STRUCTURE
The indoor equipment UNUR of the axle counter BO23 has a modular structure in 19
Eurocard subrack, 3U height (figure 4). On the first position from the left there is a
microprocessor module MPU that contains three vital microcontrollers and one diagnostic
microcontroller with display unit showing number of axles and other important data (direction,
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disturbance, errors etc.). Each vital microcontroller runs multi-structured safety program that
processes signals from the sensors, distinguishes wheel pulses from disturbances, counts
axles and gives information of occupancy of each section. Output information about occupancy
of the sections is given based on a 2-out-of-3 principle and is forwarded to relay output
modules RE. The memorized data in MPU module can be read out to a personal computer
over RS232 serial port directly or using a modem. Further to the right, there are 8 modules of
the input amplifiers UP (UP1…UP8) that supply counting points with galvanic separation and
adapts signals from counting points to microprocessor module MPU.
MPU MODEM UP UP UP UP UP UP UP UP RE RE RE ZANAP DC12

NUMBER OF AXLES ON SECTION SECTION1 SECTION1 SECTION1
(SECTION / COUNTING POINT)
ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE CLEAR CLEAR CLEAR ON
H L H L H L H L H L H L H L H L POWER
OCCUPIED OCCUPIED OCCUPIED
RESET1 RESET1 RESET1
SECTION COUNTING
+12V
POINT READY READY READY READY READY READY READY READY
SECTION
H L H L H L H L H L H L H L H L SECTION2 SECTION2 SECTION2
DIAGNOSTICS
ENTRANCE
DISTURB. CLEAR CLEAR CLEAR
OCCUP. OCCUP. OCCUP. F2A

ERROR
LINE RESET2 RESET2 RESET2

FAILURE +4...+6V +4...+6V +4...+6V +4...+6V +4...+6V +4...+6V +4...+6V +4...+6V -12V
MPU LINK
GND GND GND GND GND GND GND GND

LED-TEST
F2A
MPU MODEM UP1 UP2 UP3 UP4 UP5 UP6 UP7 UP8 RE1 RE2 RE3 ZANAP DC12
Figure 4: Indoor equipment UNUR of the axle counter BO23 – positions of modules (front view)
Relay output modules RE (RE1, RE2, RE3) gives information about occupancy of the
sections in safety relay contact form. Each module RE gives independent relay outputs for two
sections. Modules ZANAP and DC12 provide system power supply with galvanic isolation,
filters and protections. Lightning protection module ZAG2Z is fixed on the rear side of the
UNUR subrack and is easily replaced in case of burnout due to close lightning strike.
On the front panel of the microprocessor module MPU there is a LED-display showing
current number of axles on the section. In case that device controls multiple sections, the
section with displayed number of axles can be chosen using the front panel buttons. The other
RS232 connector on the front panel of the MPU module (the first one is for diagnostics on PC)
is used for serial communication with other indoor device BO23-UNUR. This kind of connection
via optical or modem communication enables processing of additional distant counting point on
very long single sections between stations.
One indoor device UNUR of the axle counter BO23 (one rack 19×3U) can process up to
8 counting points and give information about occupancy of 1 to 6 sections. Table 2 shows all
the modules and parts that indoor equipment BO23-UNUR can consist of. Each indoor device
have to contain subrack with main board and basic modules MPU, ZANAP, DC12, ZAG2Z, KP
– this all is contained in order code AP215620. According to the application several UP
modules have to be inserted to receive signals from counting points (AP215629), along with
several relay output modules RE (AP215613) and possibly modem MODD or MODL.
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Table 2: Parts for BO23 indoor equipment UNUR

Quantity per
PARTS OF INDOOR DEVICE BO23-UNUR Order code
one UNUR
Frame BO23-RACK 1 AP215621
Suback with main
Main board MP 1 AP215630
board and basic
Microprocessor module MPU 1 AP215623
modules MPU,
Module ZANAP 1 AP215625
ZANAP, DC12,
ZAG2Z, KP; order Module DC12 1 AP215624
code AP215620, 1 Lightning protection module
2 AP215633
piece ZAG2Z
Module KP (connector board) 1 AP215640
Module UP 0…8 AP215629
Module RE 0…3 AP215613
Diagnostic software BO23-Diagnostics for diagnosis on
0…1 AP215617
a personal computer
Modem MODD for diagnostic data transmission 0…1 AP215632
Modem MODL for data transmission between two MPU
0…1 AP215642
modules (MPU-Link)
Console for 620mm rack mounting 0…1 pair AP215622
1.2.3 POWER SUPPLY
The axle counter BO23 is supplied from a direct current source 18V…80V DC. When the
axle counter operates within vital safety signalling system, it is usually supplied from a
permanently charged battery power supply (24V, 36V, 48V or 60V DC).
Outdoor equipment is power supplied internally from the indoor equipment and is
galvanically isolated for each counting point and stabilised to 96V DC (on the UP module).
1.2.4 OUTPUT SIGNALS
Section occupancy output signals of the axle counter BO23 are outputted over contacts of
the safety relays on relay output module RE. The other information, such as current axle
number, direction of train movement, sensor disturbances, axle counting errors, failures and
other, that can be seen on LED-indicators of the microprocessor module MPU, can also be
monitored with a personal computer or laptop connected to RS232 port (9-pin connector
"Diagnostics") on the front panel of the MPU module of the UNUR indoor device, or remotely
using a modem and telephone line, in case the MODD diagnostic modem is inserted into
MODEM position next to MPU module.
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2. WIRING AND APPLICATION
2.1 OUTDOOR EQUIPMENT WIRING
Marks on the connection terminals of trackside control unit VUR are shown on the figure
5. The ZK24 sensor is delivered with fixed 4-wire 6-meter long sensor cable. The sensor cable
should be connected to the VUR unit terminals U+, H, U-, L as shown below:
U+ YELLOW-GREEN WIRE (Positive pole of DC power supply)

H BROWN WIRE (Current output of the sensing system H)
U- BLACK WIRE (Negative pole of DC power supply)
L BLUE WIRE (OR GRAY) (Current output of the sensing system L)
Figure 5: Top view to opened box of trackside control unit VUR
The H sensing system is located on the left and the L sensing system is located on the
right side of the ZK24 sensor housing, looking from the inner side of the track (take care of this
while setting the counting direction on indoor equipment, 2.2.11).
The cables for connection between outdoor equipment (VUR) and indoor equipment
(UNUR) have to be connected to terminals VOD1+, VOD1- (to one indoor equipment device)
and to the pins VOD2+, VOD2- (to the other indoor device, if it is used). Cable VOD1 always
has to be connected to the indoor equipment because this line is used for two applications:
transmission of the counting information from VUR to UNUR and power supply for VUR (96V-
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50% DC), which is supplied from UNUR. Output stage of cable VOD2 has a serial capacitor
(DC voltage separation) and it is not possible to use this line for supplying VUR (the line is
useful just for transmission of counting signal to another UNUR, for neighbouring section). In
case the terminals VOD2 are not used, it is necessary to connect one resistor 180 Ohm, 1/4W
between the pins VOD2+ and VOD2-. The lines VOD1 and VOD2 can be installed separately
through their own cable glands in VUR-box (there is two-wire telecommunication twisted pair
used for each line) and can be forwarded to the distribution box, either it can be installed with
one cable through the one cable gland in VUR-box (there are two two-wire telecommunication
twisted pairs used).
In case of very long distance between VUR and UNUR device (longer than the values
from the technical datasheet for telecommunication cables diameter) it is possible to supply
VUR with one local (battery) source 60V DC or with the other kind of power supply source 40V
DC to 100V DC which has to be placed not far from VUR-device. In this case maximum
distance between indoor and outdoor equipment is defined just according to maximal permitted
attenuation of the counting signal (40dB). These distances (relative to diameter of wire) are
also shown in technical data. Local power supply have to be connected to "LOCAL POWER +"
(“+” pole of power supply) and "LOCAL POWER -" (“-” pole of power supply).
2.2 WIRING AND SETTING THE INDOOR EQUIPMENT UNUR
One indoor device UNUR of the BO23 axle counter (one 19×3U subrack) can process up
to 8 counting points and output occupancy information for 1 to 6 sections. Hereafter a
description of nine possible section occupancy control configurations for single BO23 indoor
device is given. Each section occupancy control configuration has its own operating program
that runs in the microprocessor module MPU. Choosing of configuration (operating program)
for the MPU module (MPU programming) is performed during installation of the indoor device
by setting the 4-bit SW1 switch located on the rear side of the BO23-UNUR device. After
installation a sealed cover can be placed over the SW1 switch. In the indoor device subrack
any MPU module can now be inserted and after applying the power it will always start running
the operating software defined by the switch located on the rear side of the subrack. Position of
the SW1 switch is in fact a 4-bit binary number that also represents number of the track/section
configuration. Figure 6 shows two examples of the configuration setup defined by SW1 switch.
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ON DIP
EXAMPLE 1: TRACK CONFIGURATION SWITCH SW1:
CONFIGURATION SET TO "CONFIGURATION 1"
SW1
(BINARY: 0001) OR "BO23-8A" (ONE SECTION WITH UP
MSB 1 2 3 4 LSB TO 8 COUNTING POINTS)
3
RESET MODE JUMPER J25:
2
RESET MODE SET TO "MODE 0" OR "IMMEDIATE RESET"
J25
1
ON DIP
EXAMPLE 2: TRACK CONFIGURATION SWITCH SW1:
CONFIGURATION SET TO "CONFIGURATION 4" (BINARY:
SW1
0100) OR "BO23-2A-2B-2C-2D" (FOUR INDEPENDENT
MSB 1 2 3 4 LSB SECTIONS WITH 2 COUNTING POINTS EACH)
3
RESET MODE JUMPER J25:

2
RESET MODE SET TO "MODE 1" OR "PREPARATORY RESET"

J25
Figure 6: Two examples of track configuration setup using the SW1 switch and reset mode
setup using the J25 jumper
2.2.1 CONFIGURATION 1 (BO23-8A): ONE SECTION WITH UP TO 8 COUNTING POINTS
Configuration BO23-8A for controlling a single section with up to 8 counting points using
one BO23-UNUR indoor device is chosen by setting the binary number 0001 on the SW1
switch located on the rear side of the UNUR indoor device (figure 6).
To control one section with only two counting points (as on figure 1), the input amplifier
modules UP have to be inserted in first two positions UP1 and UP2, while other positions
(UP3÷UP8) are covered with blank panels. One UNUR device and the same program in MPU
module can also be used for controlling one switch point with three counting points or multiple
switch points (total of 8 counting points), as on figure 7.
SECTION A
CP1 CP2
CP3
CP4
CP5
CP6
CP7
CP8
Figure 7: A single section with 2 to 8 counting points controlled by one BO23-UNUR device set
to configuration 1 (BO23-8A)
Each of 8 counting points on figure 7 can be passed over by the vehicle simultaneously
with any other counting point; axle counter BO23 at any time monitors real current number of
axles on the section and clears the section only when all axles has left the section.
OB-R.07v2 D215600-0501010102
2.2.2 CONFIGURATION 2 (BO23-4A-4B): TWO INDEPENDENT SECTIONS WITH UP TO 4

COUNTING POINTS
Configuration BO23-4A-4B for controlling occupancy of two independent sections with up

to 4 counting points per section with a single BO23-UNUR indoor device is chosen by setting
the binary number 0010 on SW1 switch on the rear side of the indoor device (figure 6). Figure
8 shows the example of two independent sections with 4 counting points in railway station.
SECTION A SECTION B
4
CP CP
8
CP1 CP2 CP5 CP6

7
CP CP
3
Figure 8: Example of two independent sections with 4 counting points controlled by one BO23-
UNUR indoor device set to configuration 2 (BO23-4A-4B)
Each of controlled sections (section A or section B) can have less counting points (1, 2 or
3) than shown on figure 8. Simultaneous passage of the train over each two or more counting
points is allowed.
2.2.3 CONFIGURATION 3 (BO23-3A-3B-2C): 3 INDEPENDENT SECTIONS
Configuration BO23-3A-3B-2C for occupancy control of three independent sections using

switch on the rear side of the indoor device UNUR (figure 6). In this configuration first and
second section (A and B) can have up to 3 counting points and the third one (C) can have up
to 2 counting points. Figure 9 shows the example of three independent sections in railway
station.
SECTION A SECTION B
3
CP CP
6
CP1 CP2 CP4 CP5

SECTION C
CP7 CP8
Figure 9: Example of three independent sections controlled by one BO23-UNUR indoor device
set to configuration 3 (BO23-3A-3B-2C)
Each controlled section can have smaller number of counting points than shown on figure
9. Simultaneous passage of the train over several counting points is allowed.
OB-R.07v2 D215600-0501010102
2.2.4 CONFIGURATION 4 (BO23-2A-2B-2C-2D): 4 INDEPENDENT SECTIONS WITH 2

COUNTING POINTS
Configuration BO23-2A-2B-2C-2D for occupancy control of 4 independent sections using

switch on the rear side of indoor device UNUR (figure 6). Each of 4 independent sections (A,
B, C and D) can have up to 2 counting points. Figure 10 shows two examples of controlling 4
independent sections with 2 counting points inside or outside of railway station.
SECTION A
CP1 CP2
SECTION B
CP3 CP4
SECTION C
CP5 CP6
SECTION D
CP7 CP8
SECTION A SECTION C
CP1 CP2 CP5 CP6
CP3 CP4 CP7 CP8
SECTION B SECTION D
Figure 10: Two examples of 4 independent sections controlled by one BO23-UNUR indoor
device set to configuration 4 (BO23-2A-2B-2C-2D)
2.2.5 CONFIGURATION 5 (BO23-3A3B3C2D): 4 CONSECUTIVE SECTIONS
Configuration BO23-3A3B3C2D for occupancy control of 4 consecutive sections using

switch on the rear side of the indoor device UNUR (figure 6). In this configuration the first three
sections (A, B and C) can have up to 3 counting points and the fourth one (D) can have up to 2
counting points. Figure 11 shows two examples of controlling 4 consecutive station sections
and one example of controlling 4 sections of automatic block.
OB-R.07v2 D215600-0501010102
CP1 CP2
SECTION A
CP3 CP4
SECTION B
CP5 CP6
SECTION C SECTION D
CP7 CP8
SECTION A 2 SECTION C
CP CP
SECTION B 6 SECTION D
CP1 CP3 CP5 CP7 CP8
SECTION A SECTION B SECTION C SECTION D
CP1 CP3 CP5 CP7 CP8
(C
P6
)
Figure 11: Three examples of controlling 4 consecutive sections using one BO23-UNUR indoor
device set to configuration 5 (BO23-3A3B3C2D)
2.2.6 CONFIGURATION 6 (BO23-2A2B2C-2D2E2F): TWO TIMES 3 CONSECUTIVE

SECTIONS WITH UP TO 2 COUNTING POINTS
Configuration BO23-2A2B2C-2D2E2F for occupancy control of 2 times 3 consecutive

sections using one BO23-UNUR indoor device is chosen by setting the binary number 0110 on
the SW1 switch on the rear side of the indoor device UNUR (figure 6). This configuration can
be used whenever there is a need to control three consecutive sections with up to 2 counting
points; in station area or within automatic block. The first example on figure 12 shows control of
two times 3 automatic block sections using one indoor device located in station relay room.
The second example on figure 12 shows occupancy control of two times 3 sections on a
double track level crossing when axle counter BO23 is used as a train detection unit for
switching on/off the level crossing system.
OB-R.07v2 D215600-0501010102
SECTION A SECTION B SECTION C
CP1 CP2 CP3 CP4
CP5 CP6 CP7 CP8

SECTION D SECTION E SECTION F
SECTION D SECTION E SECTION F
CP5 CP6 CP7 CP8
CP1 CP2 CP3 CP4
SECTION A SECTION B SECTION C
Figure 12: Two examples of two times 3 consecutive sections control using one BO23-UNUR
device set to configuration 6 (BO23-2A2B2C-2D2E2F)
2.2.7 CONFIGURATION 7 (BO23-2A2B2C2D4E): OCCUPANCY CONTROL OF 5

CONSECUTIVE SECTIONS
Configuration BO23-2A2B2C2D4E for occupancy control of 5 consecutive sections using

switch on the rear side of the indoor device UNUR (figure 6). In case the most distant counting
point is within the maximum indoor-outdoor distance range, occupancy control of 5 consecutive
sections of the automatic block system can be performed using one BO23-UNUR indoor
device (figure 13). Some of 5 consecutive sections can be used to control station area (for
example entrance switch points, section E).
)
P8
(C
SECTION A SECTION B SECTION C SECTION D SECTION E
CP1 CP2 CP3 CP4 CP5 CP6
(C
P7
)
station area) using one BO23-UNUR indoor device set to configuration 7 (BO23-2A2B2C2D4E)
2.2.8 CONFIGURATION 8 (BO23-2A2B2C2D2E3F): OCCUPANCY CONTROL OF 6

CONSECUTIVE SECTIONS
Configuration BO23-2A2B2C2D2E3F for occupancy control of 6 consecutive sections

using one BO23-UNUR indoor device is chosen by setting the binary number 1000 on the SW1
switch on the rear side of the indoor device UNUR (figure 6). In case the most distant counting
point is within the maximum indoor-outdoor distance range, occupancy control of 6 consecutive
sections of automatic block can be performed using one BO23-UNUR indoor device (figure
OB-R.07v2 D215600-0501010102
14). Some of 6 consecutive sections can be used to control station sections (for example
entrance switch point, section F).
)
P8
(C
SECTION A SECTION B SECTION C SECTION D SECTION E
CP1 CP2 CP3 CP4 CP5 CP6 SECTION F CP7
station area) using one BO23-UNUR indoor device set to configuration 8 (BO23-2A2B2C2D2E3F)
2.2.9 CONFIGURATION 9 (BO23-3A-2B-2C-2D): OCCUPANCY CONTROL OF 3

INDEPENDENT STATION SECTIONS AND SINGLE BLOCK BETWEEN STATIONS
USING RS232 SERIAL CONNECTION
Configuration BO23-3A-2B-2C-2D for occupancy control of 3 independent station

sections and single block between stations using one BO23-UNUR indoor device is chosen by
setting the binary number 1001 on the SW1 switch on the rear side of the indoor device UNUR
(figure 6). When the operating program is set to BO23-3A-2B-2C-2D one BO23-UNUR indoor
device can control occupancy of three independent station sections (section A with 3 counting
points, section B and C with 2 counting points), together with single block between stations
with 2 counting points using RS232 serial connection to indoor device in the neighbouring
station (figure 15).
4
SECTION D
VUR
(SINGLE BLOCK BETWEEN STATIONS)
SECTION A ZK24 ZK24
4 4 4 4
VUR VUR VUR VUR
SECTION B
4 4
VUR VUR 2
2 2 2
SECTION C
4 4 2 2
VUR 2 VUR
2 2
BT1 BT2 BT3 BT4 BT5 BT6 BT7 BT8 SECTION D

MPU LINK
BT8
MPU LINK
SECTION A, B, C AND D TWO-WIRE TELECOMMUNICATION OCCUPANCY

OCCUPANCY INDOOR EQUIPMENT RS232 OR FIBER OPTIC LINK RS232 INDOOR EQUIPMENT
INFORMATION,
INFORMATION, RESET, BO23-UNUR BO23-UNUR
RESET, POWER
POWER SUPPLY
SUPPLY
MODEM OR MODEM OR
FIBER OPTIC FIBER OPTIC
CONVERTER CONVERTER
RELAY ROOM OF THE STATION A RELAY ROOM OF THE STATION B
Figure 15: Example of control of 3 independent station sections and single block between
stations using serial connection between two BO23-UNUR indoor devices set to configuration 9
(BO23-3A-2B-2C-2D)
The main purpose of this way of single block between stations occupancy control is to
avoid usage a copper wire connection to the most distant counting point when it is located
outside of the maximum indoor-to-outdoor equipment distance range (when the distance
between two stations is large) or when you simply want to avoid copper wire connection
between stations (e.g. because of lack of telecommunication pairs) and the optical cable or
similar connection is preferred. The closer counting point in this case is connected using two-
wire twisted pair directly to BO23-UNUR indoor device (on the position of 8th counting point,
receiving module UP8) same as in previous examples. Information from the further counting
point of the block between stations is received via RS232 serial connection between local
BO23-UNUR indoor device and remote indoor device in the neighbouring station that directly
OB-R.07v2 D215600-0501010102
controls further (or closer from the aspect of remote indoor device) counting point and
processes the same operating software BO23-3A-2B-2C-2D. This link is on both indoor
devices connected to connector MPU LINK located on the front panel of the MPU
microprocessor module. Communication between two indoor devices is carried out using
closed transmission system safety principle according to EN50159-1.
The length of a block between stations controlled this way is dependent only on
parameters of used telecommunication system (optical cable with related devices, type of
modem for two-wire communication, etc.) and can be long up to several tens of kilometres.
2.2.10 SETTING THE POWER SUPPLY FOR COUNTING POINTS AND CONNECTION
Each input module UP (input amplifier) that receives signals from counting points also
contains circuitry that provides galvanically isolated 96V DC power supply for counting point.
On the rear side of the main board there are jumpers which define whether the counting point
has to be power supplied or not by the UP module for each position (UP1…UP8). The indoor
device UNUR of the neighbouring section can already supply some of the counting points, so it
will not need power supply from this UNUR. Figure 16 shows the setup of jumpers J1…J16
defining power supply of certain counting point.
1
1
J2
J1
POWER SUPPLY 96V DC IS SENT TO THE COUNTING POINT

4
4
1
1
J2
J1
POWER SUPPLY 96V DC IS NOT CONNECTED TO THE

COUNTING POINT; ONLY AC SIGNAL IS RECEIVED AND THE
COUNTING POINT IS POWERED FROM ANOTHER INDOOR UNIT
4
COUNTING POINT 1 ! JUMPERS J1, J2 COUNTING POINT 5 ! JUMPERS J9, J10

Figure 16: Setting the power supply of counting points
Jumpers J1…J16 are located on the main board on the rear side of the BO23-UNUR
indoor device beneath the ZAG2Z lightning protection module. Figure 17 shows rear view of
the BO23-UNUR subrack with connection marks for transmission pairs to counting points 1…8,
main power supply and ground connection on modules ZAG2Z. Pairs for connecting counting
points BT1, BT2, BT3 and BT4 are connected to X2 and X3 connectors of one ZAG2Z module
(rear side to the right). Pairs for connecting counting points BT5, BT6, BT7 and BT8 are
connected to X2 and X3 connectors of the other ZAG2Z module (rear side to the left). To
access the jumpers J1…J16 for setting the power supply of certain counting point the ZAG2Z
module has to be temporarily removed; unscrew 4 screws M2.5 and disconnect ZAG2Z
module from the rear side connectors of the main board. Position of jumpers J1…J16 on the
main board with removed ZAG2Z modules is shown on figure 18.
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Figure 17: Indoor device BO23-UNUR with connection markings (rear view)
OB-R.07v2 D215600-0501010102
Figure 18: BO23-UNUR with removed ZAG2Z and KP modules (rear view)
OB-R.07v2 D215600-0501010102
2.2.11 SETTING THE COUNTING DIRECTION
As shown on figure 18, the jumpers for setting the counting direction for each counting
point are located on the main board at the rear side of the BO23-UNUR subrack, beneath the
ZAG2Z lightning protection module. It is necessary to remove the ZAG2Z (unscrew 4 M2.5
screws) to set the counting direction. Counting direction should be set according to figure 19,
depending on the position of ZK24 sensor on track (to which side of the sensor the related
section begins). In case the counting point is not in use it should be terminated with jumpers as
on figure 19.
COUNTING-IN COUNTING-IN COUNTING-OUT

1
COUNTING-OUT COUNTING-OUT COUNTING-IN

4
J17
H L H L
SYSTEM SYSTEM SENSOR SENSOR
3
ZK24 ZK24
SENSOR ZK24
6
L H
COUNTING-OUT COUNTING-OUT COUNTING-IN

1
COUNTING-IN COUNTING-IN COUNTING-OUT

4
J17
H L H L
SYSTEM SYSTEM SENSOR SENSOR
3
ZK24 ZK24
SENSOR ZK24
6
L H
COUNTING POINT 1 ! JUMPER J17

1
COUNTING POINT COUNTING POINT 2 ! JUMPER J18

4
NOT USED COUNTING POINT 3 ! JUMPER J19

J17
(NO OUTDOOR COUNTING POINT 4 ! JUMPER J20

EQUIPMENT COUNTING POINT 5 ! JUMPER J21
3
CONNECTED) COUNTING POINT 6 ! JUMPER J22

6

Figure 19: Setting the counting direction
The rule for setting the counting direction shown on figure 19 applies to all configurations
of the device when the independent sections are controlled; configuration 1 (BO23-8A), 2
(BO23-4A-4B), 3 (BO23-3A-3B-2C), 4 (BO23-2A-2B-2C-2D) and 9 (BO23-3A-2B-2C-2D). On
other configurations where the consecutive sections are also controlled, the rule applies only to
terminal counting points. Each counting point shared by two neighbouring sections in
configuration of single indoor equipment UNUR must simultaneously count-in axles on one
section and count-out for other section. Therefore the rule from figure 19 can only be applied to
one section, while on the other section the counting direction must be opposite to figure 19.
Table 3 shows sections (one of two neighbouring sections) on which the rule from figure 19
applies for each counting point on each configuration with consecutive sections of indoor
device BO23-UNUR.
OB-R.07v2 D215600-0501010102
Table 3: Setting the counting direction on consecutive section configurations

Counting Counting point / Related section (sections)
Configuration direction
according Counting Counting Counting Counting Counting Counting Counting Counting
to figure 19 point 1 point 2 point 3 point 4 point 5 point 6 point 7 point 8
5 Correct Section A Section A Section B Section B Section C Section C Section D Section D
3A3B3C2D Opposite - - Section A - Section B - Section C -
6 (2A2B2C- Correct Section A Section B Section B Section C Section D Section E Section E Section F
2D2E2F) Opposite - Section A Section C - - Section D Section F -
7 Correct Section A Section B Section C Section D Section E Section E Section E Section E
2A2B2C2D4E Opposite - Section A Section B Section C Section D - - -
8 Correct Section A Section B Section C Section D Section E Section F Section F Section F
2A2B2C2D2E3F Opposite - Section A Section B Section C Section D Section E - -
If the counting direction is not properly set, this will be clearly visible after passage of the
first train (wrong counting direction on the display) or while simulating the wheel passage on
the field. In that case the jumpers of that counting point must be set to opposite position (figure
19).
2.2.12 SAFETY RELAYS OUTPUT SIGNALS
Relay output signals clear/occupied for each section are formed by two safety relays on
relay output module RE. Up to three RE modules can be inserted into one BO23-UNUR indoor
device; positions RE1, RE2, RE3 (figure 4). One relay module RE gives relay outputs for 2
sections which are marked as SECTION 1 and SECTION 2 on the front panel of the RE
module. According to the application and configuration of the axle counter that is in use, 1, 2 or
3 RE modules are inserted into BO23-UNUR subrack. Each RE module can use both or only
one relay output (SECTION 1 and/or SECTION 2). Relay outputs on certain position of RE
module are fixed to sections of indoor device in the following way:
SECTION 1 position RE1 SECTION A

SECTION 2 position RE1 SECTION B
SECTION 1 position RE2 SECTION C

SECTION 2 position RE2 SECTION D
SECTION 1 position RE3 SECTION E

SECTION 2 position RE3 SECTION F
Each section is fixed to one safety relay SECTION CLEAR and one safety relay
SECTION OCCUPIED, and combination of their contacts give final outputs for occupancy /
clearance. Figure 20 shows output contacts of safety relays for occupancy / clearance of the
first three sections (A, B and C) and figure 21 shows output contacts for sections D, E and F,
with connections on the KP module (connection plate) on the rear side of the BO23-UNUR
subrack. The SECTION CLEAR relay status of each section of RE module is indicated by a
green LED (LED lights while the relay is energised), and the SECTION OCCUPIED relay
status of each section is indicated with a red LED on the front panel of the RE module.
The section is clear only when the SECTION CLEAR relay is picked-up and SECTION
OCCUPIED relay is dropped. The section is occupied by at least one axle when the SECTION
OCCUPIED relay is picked-up and SECTION CLEAR relay is dropped.
OB-R.07v2 D215600-0501010102
Section A Section A
Free Relay Occupied Relay
TCA1 TCA2 TRACK CLEAR CONTACT
X2:15 X2:11
TCA1-TCA2 (SECTION A)
SECTION A SAFETY RELAY Section A Section A
TCA3 TCA4 TRACK CLEAR CONTACT
X2:13 X5:26
CONTACT OUTPUTS
TCA3-TCA4 (SECTION A)
Section A Section A
TOA1 TOA2 TRACK OCCUPIED CONTACT
X2:14 X5:18
TOA1-TOA2 (SECTION A)
FRA1 FRA2
X5:16 X5:25 SECTION A FREE RELAY
Section A
CHANGEOVER CONTACT
Free Relay FRA3
X5:17 (AUXILIARY OUTPUT)
OCA2
X5:19 SECTION A OCCUPIED RELAY
Section A
CHANGEOVER CONTACT
OCA1 Occupied Relay OCA3
X5:28 X5:27 (AUXILIARY OUTPUT)
Section B Section B
TCB1 TCB2 TRACK CLEAR CONTACT
X9:19 X9:13
TCB1-TCB2 (SECTION B)
Section B Section B
SECTION B SAFETY RELAY

TCB3 TCB4 TRACK CLEAR CONTACT
X9:17 X9:16
CONTACT OUTPUTS
TCB3-TCB4 (SECTION B)
Section B Section B
TOB1 TOB2 TRACK OCCUPIED CONTACT
X9:20 X9:6
TOB1-TOB2 (SECTION B)
FRB1 FRB2
X9:18 X5:22 SECTION B FREE RELAY
Section B
CHANGEOVER CONTACT
Free Relay FRB3
OCB2
X5:14 SECTION B OCCUPIED RELAY
Section B
CHANGEOVER CONTACT
OCB1 Occupied Relay OCB3
Section C Section C
TCC1 TCC2 TRACK CLEAR CONTACT
X2:1 X1:5
TCC1-TCC2 (SECTION C)
Section C Section C
SECTION C SAFETY RELAY

TCC3 TCC4 TRACK CLEAR CONTACT
X1:7 X5:12
CONTACT OUTPUTS
TCC3-TCC4 (SECTION C)
Section C Section C
TOC1 TOC2 TRACK OCCUPIED CONTACT
X1:10 X5:3
TOC1-TOC2 (SECTION C)
FRC1 FRC2
X5:1 X5:11 SECTION C FREE RELAY
Section C
CHANGEOVER CONTACT
Free Relay FRC3
OCC2
X1:8 SECTION C OCCUPIED RELAY
Section C
CHANGEOVER CONTACT
OCC1 Occupied Relay OCC3
AXLE COUNTER BO23-UNUR

Connector Plate KP (rear side)
Figure 20: Output contacts of FREE and OCCUPIED relays for sections A, B and C
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Section D Section D
TCD1 TCD2 TRACK CLEAR CONTACT
X9:4 X8:8
TCD1-TCD2 (SECTION D)
SECTION D SAFETY RELAY Section D Section D
TCD3 TCD4 TRACK CLEAR CONTACT
X9:2 X9:1
CONTACT OUTPUTS
TCD3-TCD4 (SECTION D)
Section D Section D
TOD1 TOD2 TRACK OCCUPIED CONTACT
X9:5 X8:1
TOD1-TOD2 (SECTION D)
FRD1 FRD2
X9:3 X5:8 SECTION D FREE RELAY
Section D
CHANGEOVER CONTACT
Free Relay FRD3
OCD2
X5:4 SECTION D OCCUPIED RELAY
Section D
CHANGEOVER CONTACT
OCD1 Occupied Relay OCD3
Section E Section E
TCE1 TCE2 TRACK CLEAR CONTACT
X4:6 X3:5
TCE1-TCE2 (SECTION E)
Section E Section E
SECTION E SAFETY RELAY

TCE3 TCE4 TRACK CLEAR CONTACT
X3:7 X4:10
CONTACT OUTPUTS
TCE3-TCE4 (SECTION E)
Section E Section E
TOE1 TOE2 TRACK OCCUPIED CONTACT
X4:7 X3:9
TOE1-TOE2 (SECTION E)
FRE1 FRE2
X3:11 X4:11 SECTION E FREE RELAY
Section E
Free Relay
CHANGEOVER CONTACT
FRE3 (AUXILIARY OUTPUT)
X3:10
OCE2
X3:8 SECTION E OCCUPIED RELAY
Section E
CHANGEOVER CONTACT
OCE1 Occupied Relay OCE3
Section F Section F
TCF1 TCF2 TRACK CLEAR CONTACT
X7:12 X7:6
TCF1-TCF2 (SECTION F)
Section F Section F
SECTION F SAFETY RELAY

TCF3 TCF4 TRACK CLEAR CONTACT
X7:10 X7:9
CONTACT OUTPUTS
TCF3-TCF4 (SECTION F)
Section F Section F
TOF1 TOF2 TRACK OCCUPIED CONTACT
X7:13 X6:9
TOF1-TOF2 (SECTION F)
FRF1 FRF2
X7:11 X7:3 SECTION F FREE RELAY
Section F
Free Relay
CHANGEOVER CONTACT
FRF3 (AUXILIARY OUTPUT)
X7:2
OCF2
X6:1 SECTION F OCCUPIED RELAY
Section F
CHANGEOVER CONTACT
OCF1 Occupied Relay OCF3

Figure 21: Output contacts for FREE and OCCUPIED relays for sections D, E and F
In normal operation, the axle counter can shortly be in a transition phase when both
SECTION CLEAR and SECTION OCCUPIED relays are dropped; this happens when the first
axle of train enters the section, or when the last axle of train leaves the section. Though it is
OB-R.07v2 D215600-0501010102
possible for this phase to last longer in case the train stops with its first or last axle in the area
above the sensor, the maximal transition phase time (both relays dropped) can be calculated
when using a minimal train speed of 1km/h:
Transition phase when the first axle enters the section <0.5 seconds
Transition phase when the last axle exits the section <0.5 seconds
Some types of disturbances or errors can also lead to condition with both output relays
dropped; the more often case is to have a short disturbance that can be cleared by resetting
the section. The status with both SECTION CLEAR and SECTION OCCUPIED relays picked-
up is possible only in case of a major failure.
Because of mechanical sloth of the relays and time necessary to process the signal in the
microprocessor module MPU, there is a small delay in occupying the section after the first axle
enters the section, or delay in clearing when the last axle exits the section. The maximal delays
are as follows:
Delay in occupying the section after physical occupation <100ms

Delay in clearing the section after physical clearing <100ms
The exception of this is section D in configuration 9 (BO23-3A-2B-2C-2D) because the

information about one of its counting points is transferred via serial connection RS232 over
modem or optical cable from another indoor device. The maximal delay for section D in
configuration 9 is as follows:
Delay in occupying the section after physical occupation <1s

Delay in clearing the section after physical clearing <2s.
2.2.13 CONNECTION OF RELAY OUTPUTS TO DIFFERENT SIGNALLING DEVICES
Figure 22 shows the connection of safety relay output contacts for "track clear" and " track
occupied" information of section (A) with three types of station interlocking or automatic block
systems. The first case on figure 22 is a typical connection to relay signalling system that
usually contains two repeating relays, one for section clear (usually designated as GFM or GL
by German manufacturers) and the other for section occupied (usually designated as GBM or
GP by German signalling system manufacturers). For additional safety, it is recommended to
connect both positive and negative pole of repeating relay coil power supply over the " track
clear" and " track occupied" output contacts of BO23 axle counter (as on figure 22).
On microprocessor interlocking systems, two digital inputs are always used; separate
input for "track clear" and separate for "track occupied" signal for each section. With regards to
additional safety advantages that microprocessor signalling systems usually have (e.g. current
control on digital inputs with small tolerances) it is enough to connect only one branch with
"section free" and "section occupied" relay contacts that are closed in basic state (no train) to
the "track clear" digital input, and one branch with "section free" and "section occupied" relay
contacts that are open in basic state to the "track occupied" digital input, as in example 2 on
figure 22. There are also signalling systems that send coded signal to output contacts of the
axle counter and receive it back on their antiparalel optocoutpler digital inputs. In that case the
"track clear" and "track occupied" outputs of the BO23 axle counter should be connected as in
example 3 on figure 22. The level crossings systems are also connected to the axle counter
BO23 relay outputs as in one of these three examples.
OB-R.07v2 D215600-0501010102
RELAY INTERLOCKING
Section A Section A OR AUTOMATIC BLOCK
TCA1 TCA2 EQUIPMENT
+
X2:15 X2:11
Interlocking Section A Section A Track clear
power supply Free Relay Occupied Relay relay (GFM)
TCA3 TCA4
-
X2:13 X5:26
Section A Section A
TOA1 TOA2
X2:14 X5:18
Track occupied
AXLE COUNTER BO23-UNUR relay (GBM)
Connector plate KP (rear side)
Section A relay output contacts
MICROPROCESSOR
Section A Section A INTERLOCKING OR
TCA1 TCA2 BLOCK EQUIPMENT
+
X2:15 X2:11 Track
Interlocking
Clear
power supply
digital
- input
Section A Section A
TOA1 TOA2
X2:14 X5:18 Track
AXLE COUNTER BO23-UNUR Occupied
Connector plate KP (rear side) digital
Section A relay output contacts input
MICROPROCESSOR
FRA1 FRA2 INTERLOCKING OR
X5:16 Section A X5:25 BLOCK EQUIPMENT
Free Relay FRA3
X5:17 Coded signal
OCA2 output
Section A X5:19
OCA1 Occupied Relay OCA3
X5:28 X5:27
AXLE COUNTER BO23-UNUR Track Track
Coded signal
Connector plate KP (rear side) Occupied Clear

input
Section A relay output contacts
Figure 22: Connection of clear / occupied relay outputs on 3 types of signalling systems
2.2.14 RESETTING THE SECTION
Figures 6, 17 and 18 shows position of J25 jumper for setting the section reset mode on
the main board on the rear side of the BO23-UNUR indoor device. There are two possible
reset modes:
OB-R.07v2 D215600-0501010102
A. Immediate (or direct) section reset – for this mode of reset the jumper J25 on the rear
side of UNUR must be closed on pins 1 and 2 (figure 6).
Applying the voltage on reset inputs or pressing the indented RESET button on the front
panel of RE module will clear the section in about 1s in case all the conditions for clearing
the section are met. In this case the personnel resetting the section must be
absolutely sure that there is no train on the section (according to railway
regulations).
B. Preparatory section reset– for this mode of reset the jumper J25 on the rear side of
UNUR must be closed on pins 2 and 3 (figure 6).
Applying the voltage on reset inputs or pressing the indented RESET button on the front
panel of RE module will reset the number of axles on the section to zero, SECTION
OCCUPIED relay will drop (in case it was picked-up), but the SECTION CLEAR relay will
not jet pick-up; the section will not be clear until the next train occupies the section by
regular counting-in of the axles and leaves the section by regular counting-out ("sweep
train"). Only after this procedure the section will become clear, i.e. the SECTION CLEAR
relay will pick-up.
In case the railway regulations set additional requirements for section reset, such as
passage of at least two axles of the "sweep train" with entrance and exit on different counting
point in preparatory reset mode, or such as disabling the reset if the last action on the section
was counting-in of the axles in immediate (direct) reset mode, it is recommended to contact the
manufacturer regarding the delivery of the MPU module with another version of operating
software (different than standard version), that already contains additional requirements for
section reset function.
Each section contains two digital inputs for reset: single reset RSTS and common reset
RSTT, as it is shown on figures 23 and 24. For each reset digital input there is a rule that it will
be activated in case there is a voltage higher than 14V DC connected between + and –
terminals (for example RSTSA+, RSTSA-) and will be deactivated in case the voltage is lower
than 4V DC. So, there is a hysteresis between 4…14V, which reduces the influence of EMC
disturbances on reset inputs activation. The main condition for section reset is that both
RSTS and RSTT must be activated simultaneously and that the time period of activation
of both inputs is greater than 100ms. When the station interlocking or automatic block
system resets the section, the section reset pulse duration must be taken care of in the
following way:
Duration of active state of RSTS reset input: 100ms < RSTS < 5s
Duration of active state of RSTT reset input: 100ms < RSTT < 5s
Time period while both RSTS and RSTT inputs are active: min. 100ms
If the immediate reset mode is set on main board of the indoor device, the section will
become clear when both RSTS and RSTT inputs deactivate (<4V), after both of them have
been active for at least 100ms simultaneously. To reduce the EMC influences, each reset
pulse (RSTS, RSTT) must last for at least 100ms continuously; i.e. if the section is reset
directly by the push buttons on the command table, each button must be pressed for at least
0.1s. Basically, there is no maximal limit for duration of pressing the push button, the buttons
can be pressed longer than 5 seconds, and the section will clear only after both buttons are
released.
OB-R.07v2 D215600-0501010102
RSTSA+ Section A Section A

SINGLE RESET
DIGITAL INPUT
(SECTION A)
X2:20 Occupied Relay Reset Relay
RSTZA1
Reset Relay
AUXILIARY OUTPUT CONTACTS

X2:17
Section A
Logic high >14V
Free Relay
SECTION A RESET RELAY

Logic low <4V
Section A
RSTSA- RSTZA2
X2:7 X2:12
RSTRA1
COMMON RESET
RSTTA+ X2:9
DIGITAL INPUT
Section A
(SECTION A)
X2:19 Reset Relay RSTRA2

Logic high >14V X2:18
Logic low <4V
RSTMA1
RSTTA- X2:16
Section A
X2:8 RSTMA2
Reset Relay
X2:10
RSTSB+ Section B Section B

SINGLE RESET
DIGITAL INPUT
(SECTION B)

RSTZB1
Reset Relay
X9:12

Section B
Logic high >14V
Free Relay
SECTION B RESET RELAY

Logic low <4V
Section B
RSTSB- RSTZB2
X9:10 X9:14
RSTRB1
COMMON RESET
RSTTB+ X9:15
DIGITAL INPUT
Section B
(SECTION B)
X9:11 RSTRB2
Reset Relay
Logic low <4V
RSTMB1
RSTTB- X9:9
Section B
X5:21 RSTMB2
Reset Relay
X9:8
RSTSC+ Section C Section C

SINGLE RESET
DIGITAL INPUT
(SECTION C)

RSTZC1
Reset Relay

X2:3
Section C
Logic high >14V

Free Relay
Logic low <4V SECTION C RESET RELAY

Section C
RSTSC- RSTZC2
X1:1 X1:6
RSTRC1
X1:3
COMMON RESET
RSTTC+
DIGITAL INPUT
Section C
(SECTION C)
X2:5 RSTRC2
Reset Relay
Logic low <4V
RSTMC1
RSTTC- X2:2
Section C
X1:2 RSTMC2
Reset Relay
X1:4

Figure 23: Digital inputs for reset of sections A, B and C on BO23-UNUR indoor device
OB-R.07v2 D215600-0501010102
RSTSD+ Section D Section D

SINGLE RESET
DIGITAL INPUT
(SECTION D)
RSTZD1
Reset Relay

X8:7
Section D
Logic high >14V
Free Relay
SECTION D RESET RELAY

Logic low <4V
Section D
RSTSD- RSTZD2
X8:5 X8:9
RSTRD1
COMMON RESET
RSTTD+ X8:10
DIGITAL INPUT
Section D
(SECTION D)
X8:6 RSTRD2
Reset Relay
Logic low <4V
RSTMD1
RSTTD- X8:4
Section D
X5:7 RSTMD2
Reset Relay
X8:3
RSTSE+ Section E Section E

SINGLE RESET
DIGITAL INPUT
(SECTION E)

RSTZE1
Reset Relay

X4:4
Section E
Logic high >14V
Free Relay
SECTION E RESET RELAY

Logic low <4V
Section E
RSTSE- RSTZE2
X3:1 X3:6
RSTRE1
X3:3
COMMON RESET
RSTTE+
DIGITAL INPUT
Section E
(SECTION E)
X4:2 RSTRE2
Reset Relay
Logic low <4V
RSTME1
RSTTE- X4:5
Section E
X3:2 RSTME2
Reset Relay
X3:4
RSTSF+ Section F Section F

SINGLE RESET
DIGITAL INPUT
(SECTION F)

RSTZF1
Reset Relay

X6:3
Section F
Logic high >14V

Free Relay
Logic low <4V SECTION F RESET RELAY

Section F
RSTSF- RSTZF2
X6:5 X7:7
RSTRF1
COMMON RESET
RSTTF+ X7:8
DIGITAL INPUT
Section F
(SECTION F)
X6:4 RSTRF2
Reset Relay
Logic low <4V
RSTMF1
RSTTF- X6:6
Section F
X7:4 RSTMF2
Reset Relay
X6:7

Figure 24: Digital inputs for reset of sections D, E and F on BO23-UNUR indoor device
Nevertheless, it is recommended for each reset input to always be active in period shorter
than 5s, because in the operating software there is a safety action for cases when there is a
failure in station interlocking or automatic block system and >14V appears continuously on
certain reset input. In these cases, the possibility of accidental section reset is much higher
OB-R.07v2 D215600-0501010102
because accidental pressing of only one pushbutton (instead of two) can reset the section.
Because of that, in cases when only one reset input is active the axle counter BO23 runs the
following safety actions:
- If RSTS is not active and only RSTT is activated for longer than 5s: section remains clear if
it was clear, but further clearing once it is occupied or it was occupied is disabled
- If RSTT is not active and only RSTS is activated (longer than 100ms): the section remains
clear if it was clear, but further clearing once it is occupied or it was occupied is disabled
The common reset input RSTT of each section can be connected in parallel to one
common reset output from the station interlocking, while the single reset input RSTS must
always be controlled by the separate reset output for each section from the station interlocking.
Activation of single reset input RSTS on relay output module RE activates the safety relay
SECTION RESET (figures 23 and 24) that has a yellow state indication LED on the front panel
of the RE module. Auxiliary outputs of the SECTION RESET relay, combined with auxiliary
outputs of SECTION FREE and SECTION OCCUPIED relays can be used in safety circuit for
section reset by station interlocking.
Figure 25 shows the example of connecting section reset digital outputs of a high safety
level microprocessor signalling system to the axle counter BO23. This type of signalling system
continuously monitors status of its digital outputs and there is no possibility to have
simultaneous activation of two single reset outputs for different sections. Therefore, a
connection schematic diagram is rather simple; common reset output is connected in parallel
to all inputs for common reset RSTT on axle counters and single reset output for each section
is connected to single reset input RSTS of the section on the axle counter. In case a
preparatory reset is required for the station or automatic block, it is not necessary to connect a
common reset output, but only single reset output to single reset input RSTS of the proper
section on the axle counter (as on figure 25) and the common reset input RSTT is for each
section connected in parallel to single reset input RSTS (for example for section A: RSTSA+ is
connected to RSTTA+ and RSTSA- is connected to RSTTA-).
Figure 26 shows an example of fail-safe connection of reset pushbuttons form the control
table in station. Relay station interlocking systems mostly use common and single pushbutton
for section reset. Sometimes relay interlocking systems have a special relay group for reset by
pushbuttons, mostly designed for particular type of axle counter, i.e. for defined impedance on
the reset input of the axle counter. The logic of such relay group is similar to logic in schematic
diagram on figure 26. The main purpose of such connection is to disable the reset by
accidental pressing of only one push button, to disable accidental reset of two sections when
two single reset buttons and common reset button are pressed simultaneously, and to disable
reset of any section in case of permanent short-connection (failure) on each push button.
OB-R.07v2 D215600-0501010102
Fail-safe control of
the digital output
SAFETY DIGITAL OUTPUTS OF MICROPROCESSOR INTERLOCKING FOR RESETTING THE SECTIONS

RSTTA+
X2:19
Common reset DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION A
Fail-safe control of RSTTA-
the digital output X2:8
RSTSA+
X2:20
Single reset of the DIGITAL INPUT FOR
certain section (A) SINGLE RESET OF
THE SECTION A
RSTSA-
X2:7
RSTTB+
X9:11
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION B
Fail-safe control of RSTTB-
RSTSB+
X5:20
certain section (B) SINGLE RESET OF
THE SECTION B
RSTSB-
X9:10
RSTTC+
X2:6
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION C
Fail-safe control of RSTTC-
RSTSC+
X2:5
certain section(C) SINGLE RESET OF
THE SECTION C
RSTSC-
X1:2
INDOOR EQUIPMENT UNUR

OF AXLE COUNTER BO23
+ -
Internal DC power 14V...80V Connector plate KP
Figure 25: Example of connection of reset outputs from microprocessor interlocking
The axle counter BO23 in its operating software already has safety action (section clearing
disable) in case of permanent voltage on any reset input, so there is no need for additional
(external) protection in case of permanent short-connection on the common reset pushbutton.
The R1 and R2 (figure 26) can be calculated with regards to power supply voltage, input
resistance of digital inputs for single reset and the fact that the digital input is activated in case
of voltage >14V and deactivated in case of voltage <4V.
OB-R.07v2 D215600-0501010102
Electromechanical counter
of the reset pulses Common RSTTA+
+ reset X2:19
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION A
Common
push button Minus pole RSTTA-
for section of power supply X2:8
DIGITAL INPUT FOR SINGLE RESET
reset Single RSTSA+ OF THE SECTION A
reset (A) X2:20
Reset Relay
OPERATOR'S CONTROL DESK IN THE STATION (MAY BE PART OF THE RELAY INTERLOCKING)
Section A
Single push
button for
certain
section RSTSA-
reset (A) X2:7
Section A Section A
Reset Relay Occupied Relay
RSTZA1
X2:17
Free Relay
Section A
RSTZA2
X2:12
Plus pole RSTMA1
of power X2:16 Section A
R1 Reset Relay
RSTMA2
X2:10
R2
RSTTB+
X9:11
DIGITAL INPUT FOR
COMMON RESET
ON THE SECTION B
RSTTB-
X5:21
DIGITAL INPUT FOR SINGLE RESET
Single RSTSB+ OF THE SECTION B
reset (B) X5:20
Reset Relay
Section B
Single push
button for
certain
section RSTSB-
reset (B) X9:10
Section B Section B
Reset Relay Occupied Relay
RSTZB1
X9:12 Free Relay
Section B
RSTZB2
X9:14
RSTMB1
X9:9 Section B
RSTMB2 Reset Relay
X9:8
+ -
INDOOR EQUIPMENT UNUR
Main DC
OF AXLE COUNTER BO23
power supply + -
Connector plate KP
Figure 26: Example of safety connection of reset push buttons on the control desk
Calculated values of the R1 and R2 resistors are for example in case of 60V DC power
supply +20% / -10%:
- For power supply 60V DC +20% / -10%: R1=39k", 0.25W R2=11k", 0.25W
For application of connection as on figure 26 with some other DC power supply voltages
contact manufacturer for calculation of R1 and R2 resistor values.
OB-R.07v2 D215600-0501010102
2.2.15 CONNECTING SEVERAL INDOOR DEVICES IN RELAY ROOM FOR STATION

SECTIONS CONTROL
In case the BO23-UNUR indoor devices for controlling the whole station (or part of a
station / automatic block) are located in the same relay room (if possible on the same
chassis/rack), connection to outdoor devices can be optimised to use less telecommunication
pairs and minimal number of UP modules. Sometimes number of power supply DC12 module
can also be reduced. The number of receiving UP modules should not be greater than the
number of counting points, as shown on figure 27. Each counting point (control unit VUR with
ZK24 railwheel sensor) is connected to relay room using only one 2-wire twisted pair, no matter
if it belongs to only one section (terminal counting point) or two neighbouring sections.
VUR VUR
K3
ZK
4
42
4
2 4
ZK
K2A S1 S2 K2 S3 S4 K2B
ZK24 ZK24 ZK24 ZK24 ZK24 ZK24 ZK24 ZK24
24
ZK
4 4 4 4 4 4 4 4
VUR VUR VUR VUR VUR 4 VUR VUR VUR
K1 VUR K1B
4
S5 ZK24
ZK
ZK24
VUR
24
4 4
VUR VUR
2 2 2 2 2 2 2 2 2 2 2 2 2 2
BT1 BT3 BT4 BT5 BT6 BT7 BT8 BT3 BT5 BT7 BT8 U+ U+ BT2 BT3 BT8
MAIN DC
POWER
+ NAP+ BO23-UNUR FOR CONTROL OF NAP+ BO23-UNUR FOR CONTROL OF U- U- BO23-UNUR FOR CONTROL OF
SECTIONS K2A,S1,S2,K1 +12V SECTIONS K2,S3,S4,K2B +12V +12V SECTIONS S5,K1B,K3
- NAP- CONFIGURATION: 5 (BO23-3A3B3C2D) NAP- CONFIGURATION: 5 (BO23-3A3B3C2D) 0V 0V CONFIGURATION: 3 (BO23-3A-3B-2C)
H4 L4 H6 L6 H8 L8 H1 L1 H4 L4 H6 L6 -12V -12V H1 L1 H2 L2 H3 L3 H4 L4 H7 L7 H8 L8
2
2
2 2
2
STATION RELAY ROOM
Figure 27: Example of optimal connection of axle counters BO23 for small station control
When counting point (ZK24+VUR) belongs to two neighbouring sections there are three
possible cases: when UNUR is set to one of configurations for controlling consecutive sections
and both neighbouring sections are controlled by the same UNUR (for example K2A and S1),
when one section belongs to one UNUR and the other section to another UNUR (such as S2
and K2), and the case when UNUR is set to one of the configurations for controlling
independent sections and both neighbouring sections are controlled by the same UNUR (such
as S5 and K1B). In last two cases it is necessary to connect auxiliary outputs H and L from
receiving UP module of certain counting point to auxiliary inputs H and L of counting point that
belongs to neighbouring section on the same or different UNUR (figure 27) and not to insert
the UP module of this counting point. Length of wires used for this interconnection should
not be more than 15m. Terminals of the auxiliary inputs/outputs H and L on connection plate
KP on the rear side of the indoor device are shown on figure 28. In case input module UP is
inserted into position for certain counting point (for example UP3), belonging terminals H and L
(H3, L3) on connector plate KP are used exclusively as output (for sending signal to
neighbouring section) and in case when input module UP is not inserted into position,
belonging terminals H and L (H3, L3) on connector plate KP are used exclusively as inputs (for
receiving signal from neighbouring section). In case signals H and L are connected from one
UNUR to another, the plus (+) pole of their internal system power supplies +12V must also be
connected together (terminals X11:3 on connector plates KP) as on figure 27.
OB-R.07v2 D215600-0501010102
In case the rack of the BO23-UNUR indoor device contains relatively small number of
inserted UP and RE modules, the internal system power supply can be connected from
another indoor device with also relatively small number of modules. Internal system power
supply ±12V (X11:3, X11:4, X11:5 on KP) and filtered main power supply U+, U- (X11:2, X11:1
on KP) should be connected in this case (figure 27). In this case module DC12 is not inserted
in one of these two subracks. Total number of all UP and RE modules should not be greater
than 11 when connecting the internal system power supply from one subrack to another.
2.2.16 AUXILIARY INPUTS/OUTPUTS OF BO23-UNUR INDOOR DEVICE
Terminal list on the connector plate KP of outputs H1…H8 and L1…L8 from receiving
UP modules, that are also inputs for the MPU microprocessor module when the UP module of
a certain counting point is not inserted, is shown on figure 28. Terminals for internal system
power supply ±12V and filtered main DC power supply U+, U- that can be used for
interconnection to another UNUR device are also shown. Some terminals on the X11 and X2
connectors of the connector plate KP are short-connected together (figure 28) and can be used
as auxiliary terminals for the interconnecting purposes.
Each counting point has one auxiliary optocoupler digital output that gives information
about direction of the last train passage over the counting point (outputs DIR1+, DIR1-, DIR2+,
DIR2-, … DIR8+, DIR8- on figure 28). Output transistor of the optocoupler on these outputs is
permanently open (switched-off) or permanently closed (switched-on), depending on the
direction of the last wheel that passed over the counting point. The transistor is closed in case
the direction was toward the section (entering the section), and open in case the axle was
exiting the section. On counting points that are common for two neighbouring sections, this rule
applies to section in which the counting direction is correct according to table 3. The maximal
current on optocoupler transistor is 50mA DC and overvoltage protection must be used
when using inductive loads (such as reverse diode in parallel to relay coil) are
connected to direction outputs DIR1…DIR8.
Figure 28 also shows 6 auxiliary optocoupler digital inputs ENFRA*…ENFRF*, one per
each section (A…F), that are used to disable picking-up of the SECTION FREE relay. When
there is no voltage on the input ENFR* (<5V) the relay output SECTION FREE operates
normally. When the voltage on ENFR* is 18V…32V DC towards ENFR-, relay SECTION FREE
is disabled to pick-up. The maximal voltage permanently connected to ENFRA*…ENFRF*
inputs is 32V DC.
OB-R.07v2 D215600-0501010102
RECEIVED SIGNALS H, L FROM THE COUNTING POINT

X10:1 H1 Counting DIR1+
Direction on
INPUTS/OUTPUTS FOR THE INTERCONNECTION OF

X10:32
L1 point 1
OUTPUTS FOR MOVEMENT DIRECTION OF THE LAST

X10:2 counting DIR1-
point 1 X10:31

Direction on X10:30
X10:4 L2 point 2 counting DIR2-
point 2 X10:29

Direction on X10:28
point 3 X10:27
TRAIN PASSAGE
Direction on X10:26
point 4 X10:25

Direction on X10:24
point 5 X10:23

Direction on X10:22
point 6 X10:21

Direction on X10:20
point 7 X10:19

Direction on X10:18
point 8 X10:17
(activation: min. 18V, max. 32V DC towards ENFR-)
ENFRA*
AUXILIARY INPUTS FOR TRACK CLEARANCE
X10:39 U+ X11:2
FILTERED MAIN
Section A
clearance DC POWER
U- X11:1
SUPPLY
disabling
ENFRB*
X10:38 Section B +12V X11:3 INTERNAL
clearance SYSTEM
0V X11:5
disabling POWER
ENFRC* -12V X11:4 SUPPLY
X10:37 Section C
DISABLING
clearance X11:6
TERMINALS FOR AUXILIARY
disabling
ENFRD* X11:7
SHORT-CONNECTED
INTERCONNECTION
X10:36 Section D X11:8

clearance X12:1
disabling
ENFRE* X12:2
X10:35 Section E X12:3
clearance X12:4
disabling
ENFRF* X12:5
X10:34 Section F X12:6
clearance X12:7
ENFR- disabling
X10:33 X12:8

Connector plate KP (rear side)
Figure 28: Auxiliary inputs/outputs of the BO23-UNUR indoor device
2.2.17 INDICATORS ON THE BO23-UNUR FRONT PANELS
Figure 4 is a front view of the BO23-UNUR indoor device that shows all indicators (display,
LEDs) on front panels of modules with matching indication colours. Table 4 explains the
meaning of each LED indication.
OB-R.07v2 D215600-0501010102
Table 4: Meaning of each LED indication on the BO23-UNUR indoor device

LED Meaning of indication
Module designation /
colour ON OFF Blinking
SECTION Direction of the last train movement over Direction of the last train
ENTRANCE / the counting point was entrance (toward movement over the counting point -
yellow the section). was exit (from the section).
Pulses on at least one of the sensors or
DISTURBANCE transmission lines on the section that are No disturbance on the outdoor
-
/ red not evaluated as a wheel (such as pulse devices of certain section.
on only one sensor channel).
Internal error detected on at
least one of MPU
Error in axle counting on the section
MPU microcontrollers. This error
ERROR / red (negative axle number or >999). LED is No error in axle counting.
in some cases can
off only after section reset.
disappear after power off
and power on.
Different status on one of three vital Communication with distant
microcontrollers in stationary state or indoor device disconnected
error on one of microcontrollers. If all All three vital microcontrollers work (MPU LINK – cable
FAILURE / red microcontrollers are correct and one has properly and have the same data disconnected, error on
different data status LED goes off after status in stationary state. modem…).
reset of section(s) with different data Indication possible only on
status. configuration 9.
Sensor channel H or L activated by the Rectified input signal of channels
Train passing over the H or
ACTIVE (H, L) wheel, or has dropped-away, or rectified H and L from the counting point is
L channel on the counting
/ red input signal is <3.3V or >8V, or outdoor >3.3V (with hysteresis >1.8V) and
point.
UP device / UP module failure. <8V DC.
Rectified input signal of channel H or L Rectified input signal of channel H Train passing over the H or
READY (H, L)
from the counting point is within allowed or L from the counting point is out L channel on the counting
/ green range 4V…6V DC. of the range 4V…6V DC. point.
Output safety relay SECTION CLEAR of
SECTION (1 the section 1 or 2 on relay module is Output safety relay SECTION
or 2) CLEAR / picked-up (section A or B on RE1, CLEAR of the section 1 or 2 on
green section C or D on RE2, section E or F on relay module is dropped.
RE3).
SECTION (1 Output safety relay SECTION
RE or 2) OCCUPIED of the section 1 or 2 on Output safety relay SECTION
relay module is picked-up (section A or OCCUPIED of the section 1 or 2
OCCUPIED / B on RE1, section C or D on RE2, on relay module is dropped.
red section E or F on RE3).
Safety relay RESET on single
RESET (1 or Safety relay RESET on single reset input
reset input for section 1 or 2 is
2) / yellow for section 1 or 2 is picked-up.
dropped.
POWER / Main DC power supply within normal Main DC power supply outside
yellow range 18V…80V DC. normal range 18V…80V DC.
ZANAP Internal system power supply +12V DC Failure on internal system power
+12V / yellow within normal range supply +12V DC.
Internal system power supply -12V DC Failure on internal system power
-12V / yellow within normal range supply -12V DC.
DC/DC converter main-to-internal power Failure on BO23-UNUR power
DC12 ON / yellow supply (module DC12) works properly. supply or no power supply.
The MPU module display shows current number of axles on section chosen with the
SECTION push button (default: section A). By pressing the SECTION button, the display
shows letter (A…F) of the section currently being displayed on the display and LEDs SECTION
ENTRANCE, DISTURBANCE and ERROR. If the SECTION button is pressed and hold longer
than 2 seconds, indication switches to next section alphabetically (after section F comes
section A), depending on configuration set by the SW1 switch on the main board (for example
on configuration BO23-4A-4B only sections A and B can be displayed). Pressing the
COUNTING POINT push button, the display shows counting point of the section that was last
passed by the train. Pressing the LED TEST, all LED segments of the display and all LEDs on
the MPU module turn on.
OB-R.07v2 D215600-0501010102
3. INSTALLATION OF THE EQUIPMENT
3.1 SENSOR ZK24 INSTALLATION ON THE RAIL
3.1.1 TOOLS
- Open-end spanner 24mm with torque regulation
- Socket drive spanner 24mm with torque regulation
- Open-end spanner 30mm (if shields are also mounted)
- Plastic template for position setting
- Vernier callipers
3.1.2 MOUNTING THE SENSOR AND SETTING THE HEIGHT AND SIDE DISTANCE
Release the nut (pos. 1 on figure 29) that comes to the outer side of rail (the opposite
side from sensor) and put the clamp on the rail foot in the way that sensor comes on the inner
side of the rail. Pull the clamp with sensor along the rail to get it in a symmetrical position
between two sleepers, make sure that sensor is parallel to the rail and tighten the nut (1) using
the spanner 24 up to the torque of 30 Nm. If the sensor has to be mounted on the rail profile
smaller than UIC60 (i.e. UIC54, S49, etc.), the 24mm long metal tube has to be put before the
nut and spring washer. If the sensor has to be mounted on the rail type UIC60 or similar profile,
the 24mm long metal tube has to be removed (as on figure 29). After fixing the clamp to the
rail, sensor is further needed to be brought to the correct vertical and side position regarding
the rail head. Put the plastic template on the sensor (figure 29). If the 2mm thick plate on the
template doesn't fit between the sensor and the rail head, release the nut beside the sensor
and move the sensor a little aside from the rail so that 2mm thick plate comes between the
sensor and the rail head.
Figure 29: Position of sensor on the rail (drawing); setting the sensor’s height
Release the nut beneath the plate with sensor and move the sensor vertically until the
upper plate of the plastic template touches the rail top or is less than 1mm away from the rail
top. Surface of the T-profile console for vertical positioning has 1mm step teeth so the optimal
teeth position has to be found; the plastic template has to touch the rail top or to be less than
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1mm away from the rail top, but the template also has to fit on the sensor with it's complete
surface (figure 29). Make sure that teeth on the T-profile console fit correctly among the teeth
on the clamp. Using vernier callipers check if the distance between the upper plate of the
template and the rail top is less than 1mm. After that tighten the nut beneath the plate with
sensor (pos. 2 on figure 29) using the spanner 24 up to the torque of 80 Nm and the height
between the rail top and the sensor top is adjusted to 40mm with ±1mm tolerance. Template's
part that defines this height is 39mm high, but since the rail is mounted with a slope 1:20 to the
sleeper (drawing on figure 29), the top point of the sensor will be 40mm below the rail top.
If the passage of a train is expected very soon, plastic template has to be removed
from the sensor. Leaving the template on sensor during the passage of a train can result
in death or serious injury of people!
Figure 30: Setting the sensor’s side distance
Release the nut beside the sensor (pos. 3 on figure 29) and move the sensor towards
the rail until the 2mm thick plate on the plastic template touches the side of the rail head (it can
be visually checked from above through the hole on the template) with one side, and the side
of the sensor with the other side (figure 30). Sensor must not fit the template too tight; the
template should be easily removed and placed back on the sensor. Tighten the nut (3) beside
the sensor using the spanner 24 up to the torque of 80 Nm and the sensor's side distance from
the rail head is adjusted to 2mm with tolerance +1/-0.5mm.
3.1.3 VISUAL CHECK AND FINAL TIGHTENING
After position adjustment of the sensor, it is necessary to visually check the position of
the sensor once again. Take a side and a top look at the sensor to check without template
whether the sensor is parallel to the rail (figure 31) and whether the distance between sensor
and the rail head is approximately 2 mm on each part of the sensor. The nut (1) that comes to
the outer side of rail should be finally tightened up to the torque of 90 Nm. Once again, check
the tightness of all three nuts using spanner 24 to the following torque values:
! The nut (3) for sensor horizontal (side) position adjustment: 80 Nm
! The nut (2) for sensor vertical position adjustment: 80 Nm
! The nut (1) for main fixing of clamp to the rail foot: 90 Nm.
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Figure 31: Correct position of sensor mounted on the rail type UIC60
3.2 TRACKSIDE CONTROL UNIT VUR INSTALLATION
3.2.1 TOOLS
- Open-end spanner 27mm
- Open-end or ring spanner 8mm
- Screwdriver 6mm
- Screwdriver 8mm
- Crimp tool for bigger terminals (25 to 50mm²)
- Wire strippers or cutters
- Scrapers or knife
- Wire cable for dragging the sensor cable through the protecting tube, 6m at least
- Hoe, shovel, pitchfork
3.2.2 ASSEMBLY PARTS PER ONE COUNTING POINT

- Trackside control unit VUR in the box on the column
- Protecting tube with inner diameter Ø13mm for sensor cable, minimum 3m, maximum
5m
- Fastening ring for fastening the protecting tube on the cable gland – 2 pieces to protect
sensor cable (this doesn’t include possible protection of power supply or
telecommunication cable)
- Crimp terminals M16, 25 to 50mm²
- Earth bonding strap or cable, 25mm², 35 mm² or 50 mm²
- Welding tool for connection of earth bonding strap or cable to the rail
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3.2.3 BURYING THE VUR
The trackside control unit VUR on a column should be buried in the ballast with at least
200mm of column above the ballast. The distance between the closer rail and VUR can be
from 1m up to 3.5m, depending on the circumstances and railway regulations (figure 32).
Figure 32: Location of the control unit VUR beside the track
The control circuitry VUR should be turned that way so the cable gland of the sensor
cable (contacts U+, H, U-, L) is faced toward the track. If it is possible, make sure that the
housing of the VUR is not beneath the level of the rail.
3.2.4 PROTECTION OF SENSOR CABLE AND DRAGGING THE CABLE INTO THE VUR
HOUSING
Sensor cable is mechanically protected with a special protecting tube. Cut a piece of
protecting tube long enough to cover the distance between the cable gland on the sensor and
the cable gland on the VUR box beneath the U+, H, U-, L contacts. Drag the sensor cable
through the tube and plug the tube end on the cable gland on sensor. Put two fastening rings
(worm drives) on the tube and fasten the one on the sensor end using a spanner 8mm Now,
drag the cable through the cable gland on the VUR housing under the U+, H, U-, L connectors
till the protecting tube fits into its place on the cable gland. While pulling the sensor cable to fit
the protecting tube as good as possible on the cable gland, tighten the cable gland using a
spanner 22mm to fix the sensor cable on its position. Pull the protecting tube over the cable
gland and fasten the remaining fastening ring on the tube using a spanner 8mm. In the box,
connect the sensor cable on U+, H, U-, L terminals as described in 2.1.
The telecommunication cables (that transmit the information to the indoor equipment)
can also be protected the same way as sensor cable. Length of protecting tube on
telecommunication cable depends on the circumstances on the field.
3.2.5 GROUNDING THE VUR’s BOX
Beneath the VUR’s box there is a M16 screw for grounding. Over the M16 crimp
terminal the grounding cable 25mm², 35 mm² or 50 mm² has to be fixed to the M16 screw. The
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other end of the grounding cable has to be connected to the rail on which the sensor ZK24 is
mounted, or to the rail which is grounded (by welding, or clamp, or screw, etc.).
3.3 INSTALLATION OF THE INDOOR EQUIPMENT UNUR
3.3.1 PREPARING THE INDOOR EQUIPMENT
It is advised to make the preparations of the indoor equipment in the workshop to

reduce the quantity of work that needs to be done on the field. First of all, plug in the module
set depending on the use of the axle counter device (see 2.2). If the exact location of every
ZK24 sensor is already known or at least there is a precise schematic diagram, so the exact
location of each ZK24 sensor is known, counting direction jumpers (J17…J24) and counting
points power supply jumpers (J1…J16) can be set on the main board beneath the lightning
protection module ZAG2Z, on the rear side of the BO23-UNUR. Also, the SW1 switch for
configuration selection as well as J25 for reset mode can be set (see 2.2.).
3.3.2 MOUNTING THE INDOOR EQUIPMENT SUBRACK
The case of the indoor equipment is a standard 19 Eurocard subrack with the height of
3U (U=44.5mm) with possibility of installing into the standard 19 (482.6mm) rack cases and
fastening with 4 M6 screws. For installing into an older type of railway case with 620mm width
it is necessary to fix the adjusting console on each side of the indoor equipment UNUR. The
area of at least 5mm beneath and above the case should be clear to enable the airflow and
cooling of the device (figure 33).
Figure 33: Mounting the indoor equipment UNUR into the 620mm wide rack
Fasten the indoor equipment with consoles on it on the 620mm wide case using four
M8×20mm on each side. Each screw should have two washers M8, one spring washer M8 and
one nut M8. To tighten them use two spanners 13mm.
3.3.3 GROUNDING
On the rear side of the BO23-UNUR indoor device, there are two lightning protection
modules ZAG2Z. Each lightning protection module has terminals X4:1, X4:2 provided for
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grounding (figure 17). For better protection from lightning overvoltage, on each ZAG2Z module
one of the terminals X4:1 or X4:2 should be grounded to the nearest ground using isolated
1mm² wire. If the chassis (rack) is grounded, this connector can be connected to the closest
suitable place on the chassis, or even on the subrack if there is a good galvanic connection to
chassis. If the chassis (rack) is not grounded and local regulations prohibit ground connections
to the equipment on chassis using isolated wire, the grounding terminal on ZAG2Z can also be
connected to the closest place on chassis or UNUR subrack, but this kind of connection
doesn't guarantee the same level of protection against lightning as when ZAG2Z is connected
to proper ground.
3.3.4 WIRING THE INDOOR EQUIPMENT
If counting direction jumpers (J17…J24), counting point power supply jumpers

(J1…J16), reset mode jumper (J25) and SW1 switch for configuration selection are already set,
after mounting the subrack, telecommunication pairs from outdoor equipment can be
connected (according to 2.2). The main power supply should be connected last. In case that it
is necessary to connect the main power supply wires under voltage, remove both fuses on the
ZANAP module and return them after connecting. After the main power has been connected it
is necessary to reset the device (before that make sure that no train is on the section!) and
check the equipment function and counting direction.
3.3.5 FUNCTION AND COUNTING DIRECTION CHECK
The quick check of indoor equipment function while there is no train on the section can
be made using two short cables with Ø2mm plugs. One side of each cable plug together into
the black GND socket on the UP module. The other end of the cable should be plugged into
the red H and L sockets. With proper order, depending on the location of sensors on the track,
it is possible to count in and count out an axle (it is necessary in one moment to have both
cables plugged in to simulate the pulse overlap). It is good to do this kind of a check with every
UP module (for each counting point).
The proper function of the whole axle counter device can only be checked by going on
every single counting point and passing over the sensor with metal template. The template is
made to simulate the wheel flange of the smallest wheel (Ø330mm) with the lowest wheel
flange height (25mm) and thickness (20mm). Using a mobile communication contact the
person near the indoor equipment and check if the counting and counting direction are
accurate. The negative number on the display indicates that the counting direction is not
properly set. In that case, only resetting the device can clear the section. The wheel passage
simulation using the template is performed only in case of low railway traffic density on the
section; correct function of the axle counter section can be checked by observing the axle
counter function during the passage of the first following train.
3.4 DISMOUNTING AND REMOUNTING THE SENSOR DURING THE TRACK

RECONSTRUCTION
3.4.1 TOOLS
- Open-end spanner 30mm (if the sensor shields are mounted)
- Hammer
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- Plastic template for positioning the sensor

- Vernier callipers
- Ballast removing tool (a small shovel)
3.4.2 WITH SENSOR MOUNTED ON THE CLOSER RAIL
Remove the ballast under the mounting bracket and clear approximately 250mm of
space under the rail. Release the nut on the out side of the rail (spanner 24mm), loose the
claw using a hammer and remove the whole mounting bracket with sensor on it from the
bottom part of the rail. Other two nuts on the bracket do not need releasing. Slip the
mounting bracket with sensor on it beneath the rail. During the reconstruction, sensor can be
put aside the track together with its protecting tube. Also, using a spanner 30mm remove the
sensor shields from the rail (if mounted).
After the track has been serviced, mount the shields back on the rail. Slip the sensor
back under the rail the same way it was removed and mount it on the rail. Tighten the main nut
of the clamp on the outer side of the rail using a spanner 24mm. With the plastic template on
the sensor check the side position and height of the sensor. If needed because of the rail
exploitation wear, lower the T-profile console with sensor for one tooth (as in 3.1.2).
3.4.3 WITH SENSOR MOUNTED ON THE MORE DISTANT RAIL
The procedure is the same as in 3.4.2 except that the ballast needs to be removed
under the closer rail (not the distant one with sensor mounted on it). After removing the ballast,
slip the bracket with sensor under the closer rail toward the trackside control unit VUR.
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4. MAINTENANCE
4.1 SIX-MONTHS PERIOD MAINTENANCE – OUTDOOR EQUIPMENT
4.1.1 MECHANICAL MEASURING AND JOINT TIGHTENING
On each counting point a plastic template should be placed over the sensor to check the
height of the sensor from the top of the rail (as in 3.1.2.), and side distance of the sensor. The
template is plastic and it does not influence the sensor, so this check can be done with axle
counter in function. In the most cases the template fits gently between the sensor and the rail
head, so it is not necessary to change the side distance of the sensor. Because of the rail
exploitation wear, sometimes it is necessary to lower the sensor. In that case, lower the sensor
for one tooth on the T-profile console of the sensor bracket. The need for lowering the sensor
is dependent on density of traffic on the track.
All three nuts on the mounting bracket should be tightened using spanner 24mm. Also,
nuts on the sensor shields should be tightened using spanner 30mm (if shields are mounted).
Take care not to pass with a metal objects (spanners, screwdrivers…) in the area
40mm above the sensor to avoid sensor activation.
4.1.2 ELECTRICAL MEASURING
Remove the top cover of the outdoor equipment VUR and check if both green LED's
light (H READY and L READY) with no wheel above the sensor (figure 5). Check the DC
voltage on the sensor terminals H, U- and L, U- and power supply contacts VOD1+, VOD1-.
Check the AC voltage on the power supply contacts VOD1+, VOD1- and VOD2+, VOD2-. For
reference list with tolerance for these values check the six-months checklist in Appendix C.
Using an ohmmeter check the connection of every terminal with the box (ground). This
needs to be done because every terminal is over-voltage protected with 3-stage lightning
protection to the ground. If in last six months any element of lightning protection was burnt
because of the close lightning strike, the resistance will be less than 1 M" between the
terminal and the box. In that case, the front panel VUR-P (AP215503) that contains the
lightning protection (beneath the panel) should be replaced. It is advised to replace the whole
electronic module VUR together with the front panel because of the shorter replacement time.
The control panel on the replaced module can be then replaced in the workshop. Electronic
module is fixed to the box with 5 screws M6.
4.2 SIX-MONTHS PERIOD MAINTENANCE – INDOOR EQUIPMENT
4.2.1 VISUAL CHECK
On the MPU module, when the indication is set to a certain section (see 2.2.17), no red
LED should light (DISTURBANCE, ERROR, FAILURE) and the display should indicate right
number of axles (000 if the section is clear). On part of one of the RE modules belonging to the
selected section, there green LED SECTION CLEAR should light if there is no train, or red
LED SECTION OCCUPIED should light if there is a train on the section. Such visual check
should be carried out for each section in configuration of indoor device BO23-UNUR (by setting
the indicated section with push button SECTION, see 2.2.17).
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On all UP modules, there green LEDs H and L READY should light, and ZANAP and
DC12 should have yellow LEDs POWER, +12V, -12V and ON turned on (figure 4). The device
works properly only if combination of LEDs lights as described in case of occupancy or
clearance of section (the transition phase during entrance or exit of the train is not considered).
If the red LED FAILURE lights on microprocessor module MPU, there is a possibility that
one of the three vital microprocessors doesn't have the same data. In this case, reset sections
one by one on the indoor device until the red LED FAILURE turns off. If the LED is still on, turn
the main power supply of the indoor device off and on. If red LED FAILURE remains lighting,
the MPU module should be replaced with a proper one.
During each periodical check, press the LED-TEST on the MPU module to check if all
LEDs and display segments work properly.
4.2.2 ELECTRICAL MEASUREMENT
On each UP module a negative pole of the voltmeter should be plugged in the black
socket (GND). Plug the positive pole into red socket H to measure the rectified DC voltage
from the counting point that sends the status of H system of the sensor. After that, plug the
positive pole into red socket L to measure the rectified DC voltage from the counting point that
sends the status of L system of the sensor. Referent values with tolerances are given in
measuring list for six-months period check in the appendix C.
Using the ohmmeter on the rear side of each of the lightning protection modules ZAG2Z,
measure resistance towards the ground (figure 17) on each of 8 terminals of inputs (+, -) for 4
counting points and each of 2 terminals of the main power supply (NAP+, NAP-). If the
resistance is less than 1 M" towards the ground, some of protection elements on ZAG2Z
module have burned out and the ZAG2Z module should be replaced.
4.2.3 FUSE VALUES ON THE INDOOR EQUIPMENT
On the indoor device UNUR of the BO23 axle counter, quick blow 20×5mm fuses are used.
Value of each fuse is marked on the front panel near the fuse housing. Exception from this are
ZAG2Z lightning protection modules on the rear side of indoor device; on each ZAG2Z module
there are 10 quick blow ceramic 20×5mm fuses; value of each fuse is marked on figure 17
(F2A and F6.3A). In total, two types of fuses are used:
- F2A, order code AP215536 (10 pcs pack), 18 pcs per device
- F6.3A, order code AP215547 (10 pcs pack), 4 pcs per device.
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5. FAILURE DETECTION
Failure detection on BO23 axle counter is much simpler if the device is connected to a
personal computer in local maintenance center via modem and telephone line. This is
described in a separate document about remote control of the axle counter BO23. This
document only explains failure detection without checking the MPU microprocessor module
memory.
5.1 FAILURE DETECTION ON THE OUTDOOR EQUIPMENT
After coming on the failed counting point, remove the top cover of the VUR and check if
both green LEDs H READY and L READY light.
5.1.1 POWER FAILURE – THE FAILURE AFTER CLOSE LIGHTNING STRIKE
If none of the LEDs lights (neither green nor red) there is a possibility of a power failure.
Check the DC voltage between VOD1+ and VOD1-. It should be between 48V DC and 96V
DC. If there is no such voltage, the short circuit check between each terminal and the box
(ground) should be made as described in 4.1.2. If any of lightning protection elements was
burnt during the lightning there will be the short circuit between the terminal and the ground
(box) and the front panel VUR-P (AP215503) should be replaced. It is advised to replace the
whole electronic module VUR together with the front panel because of the shorter replacement
time. The front panel on the replaced module can be then replaced in the workshop.
If no terminal has the connection towards the box and VUR doesn’t get the power supply
voltage, the twisted pair to indoor equipment on VOD1+, VOD1- is probably broken.
5.1.2 FAILURE IN THE SENSOR CIRCUIT
If the VUR have the power supply 48V…96V DC between VOD1+ and VOD1-, and one of
the green LEDs doesn't light, check for any kind of metal objects on the sensor and if its
position on the rail is proper. Then, check the DC voltage between U+, U- terminals. If the
voltage is not within 24V DC ±5%, disconnect the sensor cable and check the voltage again. If
the voltage is still not within the mentioned range and the VUR power supply is proper
48V…96V DC measured between VOD1+, VOD1- terminals, the VUR should be replaced. If
the voltage is within 24V DC ±5%, the sensor should be replaced. If the sensor power supply is
proper 24V DC ±5%, check the DC voltage between sensor terminals H, U- and L, U-. If the
voltage is not within 4V DC ±10% and the sensor is properly mounted on the rail, the ZK24
sensor should be replaced.
5.1.3 FAILURE IN OUTPUT CIRCUITRY OF VUR
If the voltage between the U+, U- and H, U- and L, U- terminals are within the proper
range, check the AC voltage on the output signals on the VOD1+, VOD1- and the VOD2+,
VOD2- terminals. In both cases the voltage should be within 1.1V AC ±15%. If not, the failure is
in the electronic module VUR and it should be replaced.
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5.2 FAILURE DETECTION ON THE INDOOR EQUIPMENT
5.2.1 FAILURES CAUSED BY ATMOSPHERE DISCHARGES
Atmosphere discharges (lightning strikes) up to 500m in circle from the device can cause
high voltage in the transmission lines that could damage over-voltage protection on the ZAG2Z
module of the indoor equipment UNUR, or over-voltage protection placed beneath the front
panel VUR-P of the outdoor equipment VUR. In both cases, failure is manifested as
impossibility to clear the axle counter by resetting. On the lightning protection module ZAG2Z
there is a quick blow ceramic fuse F2A per each wire of the transmission line for each counting
point, as well as one F6.3A for each wire of the main power supply. If some of the fuses
towards the twisted pairs for counting points has blown, there will be no receiving signal on the
respective UP module, neither the power supply for the counting point 96V DC (if the counting
point is power supplied from the indoor unit UNUR) on it's twisted pair. In this case, only the
blown fuse is replaced and over-voltage protection elements on module ZAG2Z are checked
according to 4.2.2.
If no fuse has blown, but over-voltage protection elements have been burnt on module
ZAG2Z or beneath the front panel of the trackside control unit VUR, it is possible that there is
no 96V DC power supply to counting point, because transmission line towards the counting
point can be short-connected on the ZAG2Z module or on VUR control unit. Counting point
power supply circuitry on module UP is trying to set power supply voltage for that counting
point at value of 96V DC but it continuously fails because somewhere on the transmission line
is a short circuit. By measuring the resistance between the connection pins and ground (earth),
detection of over-voltage protection failure on the indoor equipment UNUR on the ZAG2Z
module according instructions 4.2.2, or detection of over-voltage protection failure of the
outdoor equipment VUR of the counting point with no signal (detection of lightning protection
failure according to 4.1.2) should be obtained. Extreme damaging of protection elements on
the ZAG2Z module of indoor equipment can cause that the main fuse of the axle counter DC
power supply in the relay room blows. By replacement of the ZAG2Z module, axle counter
should work properly if over-voltage protection beneath the front panel of the trackside control
unit VUR on some counting point is not damaged.
5.2.2 FAILURE ON THE INPUT AMPLIFIER MODULE UP
If any of the green LEDs (H or L) on the UP module doesn't light, DC voltage check on
the related red socket toward black one GND should be performed; the voltage should be in
range +4V DC to +6V DC. If the voltage is out of that range, AC signal from the outer device
should be checked. For each counting point, the voltage on the ZAG2Z module (on the rear
side) between pins BT+ and BT- (figure 17) should be in range of 12 mV AC to 1100mV AC. If
received AC signal is in that range for certain counting point and voltage on the related socket
H, L (red toward black) is out of range (+4V DC to +6V DC) and can not be adjusted to that
range, UP module is faulty and should be replaced. If the voltage on the H and L sockets is in
range, outputs H and L of the UP module (on the KP connection plate, figure 28) toward the
MPU module should be checked. The voltage on each H or L output toward the 0V (X11:4)
should be 12V DC ±10%. If one of the above mentioned UP module outputs is not in the range
of 12V DC ±10% (while voltage on the front sockets is in range), replacement of the UP
module should be considered.
On the UP module, there is also a converter for counting point power supply (96V DC). If
the counting point is supplied by the indoor device and there is no 96V DC on the transmission
line terminals on the ZAG2Z module (also check with transmission pair disconnected), and if
the ZAG2Z module (according to 4.2.2.) is working properly, the UP module should be
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replaced because of possible failure on its counting point power supply circuit.
5.2.3 MPU MICROPROCESSOR MODULE FAILURE
Failure states on the microprocessor MPU module are indicated by permanent or blinking
FAILURE LED, or blinking ERROR LED (see 2.2.17). Table 4 shows all the necessary actions
in case of some failure indication; in most cases, resetting all sections should help. If not,
BO23-UNUR main power supply should be switched off and on again. If there is still failure
indication, MPU module should be replaced.
5.2.4 POWER SUPPLY FAILURE
On power supply protection module ZANAP three yellow LEDs should light: POWER,
+12V and –12V. If just one of those doesn't light, the certain fuse beside that LED should be
checked and replaced if necessary. If still one or more yellow LEDs don't light, yellow DC12
LED "ON" on main power supply module DC12 should be checked if it lights. If yellow LED
POWER doesn't light on the ZANAP module, main DC power supply between NAP+, NAP- on
ZAG2Z should be checked if within 18V…80V DC. If the main power supply is proper and
yellow LED POWER on ZANAP lights and yellow LED ON doesn't light on DC12 module,
DC12 module should be replaced.
After device power supply failure, or after the main power supply is switched off and on
again, yellow LED POWER on the ZANAP module and yellow LED "ON" on DC12 module will
light, but for the first 10 seconds all other modules will not have the power supply. After 10
seconds, if there is no failure (such as short-connection), internal system power supply ±12V
will start and indications on other modules will light. After each time of switching the power
supply on, all sections are occupied and should be reset. If internal system supply tries to start
±12V each 10 seconds but fails every time, there is a short-circuit on one of the modules, and
one by one should be removed and after 10 seconds checked if the device manages to start
internal power supply ±12V. This way, the module with a short-circuit can be detected.
5.2.5 RELAY OUTPUT MODULE RE FAILURE
If any of safety relays SECTION CLEAR, SECTION OCCUPIED or RESET for some of
the sections is not picked-up (respective LED on the RE module doesn't light) when all
conditions are met for picking-up of the relay, RE module should be replaced. If both SECTION
CLEAR and SECTION OCCUPIED relays are picked-up at the same time, RE module should
also be replaced.
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6. TECHNICAL SPECIFICATIONS
6.1 OUTDOOR EQUIPMENT (VUR + sensor ZK24)
Power supply (VOD1+, VOD1-): 40V DC to 120V DC
Sensor power supply (U+, U-): 24V DC ±5%
Power dissipation (VUR + ZK24): max. 3.6W
Total power dissipation with

telecommunication cable losses: max. 7.2W
Output current of inactive state of

sensor ZK24: output H: 8mA DC ±2%
output L: 8mA DC ±2%
Output current of active state of

sensor ZK24: output H: 2mA DC ±2%
output L: 2mA DC ±2%
Side distance of drop-away from rail

detection of sensor ZK24: 5 to 15mm on the whole temperature range, for all rail
types
Operating temperature range: -40°C to +80°C
Relative humidity: up to 100%
Water and dust protection: IP65 for trackside control unit VUR
IP68 for sensor ZK24
Vibration and shocks resistance: tested according to EN 50125-3

- Sensor ZK24 - vertical axis: vibrations 5… 2000Hz, 28g r.m.s., shocks 200g / 6ms
- Sensor ZK24 - transversal axis: vibrations 5… 2000Hz, 14g r.m.s., shocks 100g / 6ms
- Sensor ZK24 - longitudinal axis: vibrations 5… 2000Hz, 5g r.m.s., shocks 36g / 6ms
Electrical connection: signal – screwdriver terminal blocks, M4 crimp

terminals
rail ground – M16 screw, crimp terminal for 35 to 50
mm² wire
Minimal rail wheel diameter: 300mm
Wheel flange height: according to UIC 510-2 (table 5)
Wheel flange thickness: according to UIC 510-2 (table 6)
Rail profile: S45…S49…UIC54…UIC60 (other profiles on demand)
Dimensions of VUR case (D × W × H): 200 × 230 × 110 mm
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Dimensions of VUR case on column

(D × W × H): 250 × 250 × 645 mm
VUR weight without column: 5.32kg
Column weight: 5.9kg
Sensor ZK24 weight (without cable): 1.72kg
Weight of the sensor with mounting

bracket and cable: 6.05kg
Sensor shield weight: 6.78kg (UIC60); 6.3kg (S49)
Table 5: Wheel flange height (according to UIC 510-2)

Wheel diameter 330mm to 630mm 630mm to 760mm >760mm
Min. 32mm Min. 30mm Min. 28mm
Wheel flange height
Max. 36mm Max. 36mm Max. 36mm
Table 6: Wheel flange thickness (according to UIC 510-2)

Wheel diameter 330mm to 840mm >840mm
Min. 27.5mm Min. 22mm
Wheel flange thickness
Max. 33mm Max. 33mm
6.2 INDOOR EQUIPMENT BO23-UNUR
Power supply: 18V to 80V DC
Stabilized counting point power supply: 96V DC ±2%, 8W, galvanically isolated
Total power dissipation (8 counting

points, power supplied): at 24V DC: 66W
at 48V DC: 65W
at 60V DC: 66W
at 80V DC: 72W
Operating temperature range: -30°C do +70°C
Axle counting capacity: 999 axles with indication (internal counting up to

32767 axles)
Microprocessor module configuration: 2-out-of-3
Maximal number of counting points: 8 local + 1 remote via remote indoor device (RS232)
Maximal number of track sections: 6 sections
Output signals: relay – safety relay contacts

serial interface – RS232
OB-R.07v2 D215600-0501010102
Maximal current switching on safety

relay output contacts: 6A
Maximal voltage switching on safety

relay output contacts: 440V
Maximal current on optocoupler

output transistors: 50mA
Maximal collector-emitter voltage

on optocoupler outputs: 75V
Maximal saturation voltage

on optocoupler outputs: 1V
Reset inputs voltage: reset activation: 14…80V DC

reset deactivation: <4V DC
ENFRA…ENFRF inputs voltage: activation: 18…32V DC

deactivation: <5V DC
Maximal train speed: for wheel diameter >840mm: 250km/h

for wheel diameter 630 to 840mm: 220km/h
for wheel diameter <630mm: 150km/h
Train passage memory: last 10000 passages (date, time, number of axles,
occupation, direction, location, disturbances, errors,
failures) – inerasable with power off
Subrack dimensions (W × D × H): 483 × 240 × 133 mm (Eurocard 19, 3U height)
6.3 SIGNAL TRANSMISSION FROM OUTDOOR TO INDOOR EQUIPMENT
Maximal loop resistance: 700"
Maximal permitted
signal rejection up to 5 kHz: 40dB
Cable type: Screened signal cable or telecommunication cable

(twisted pair)
Number of conductors per

counting point: 2 wires
Table 7: Maximal cable length from outdoor to indoor equipment

Conductor diameter (mm) 0.8 0.9 1.2 1.4
Cable length with VUR power supplied from UNUR (km) 9.5 12.5 21.8 30.4
Cable length with VUR power supplied locally (km) 21 27.7 42 49
OB-R.07v2 D215600-0501010102
APPENDIX A – DIMENSION DRAWINGS
Figure 34: Dimension drawing – sensor ZK24
OB-R.07v2 D215600-0501010102
Figure 35: Dimension drawing – trackside control unit VUR

OB-R.07v2 D215600-0501010102
Figure 36: Dimension drawing – indoor device BO23-UNUR
OB-R.07v2 D215600-0501010102
APPENDIX B – MOUNTING DRAWINGS
Figure 37: Mounting the sensor ZK24 on mounting bracket on the rail – cross section
OB-R.07v2 D215600-0501010102
Figure 38: Mounting the sensor ZK24 on mounting bracket with shields on the rail
OB-R.07v2 D215600-0501010102
APPENDIX C – MEASURING LIST PROPOSAL FOR SIX-MONTH

MAINTENANCE
MEASURING LIST FOR SIX-MONTHS CHECK OF THE OUTDOOR EQUIPMENT OF AXLE

COUNTER BO23
DATE _________________________
COUNTING POINT __________________________________________________
Reference value with

Measured signal Terminals Measured value
tolerance
Supply voltage for the
U+, U- 24V DC ±5%
sensor ZK24
Voltage of the H sensing
H, U- 4V DC ±10%
system of the sensor ZK24
Voltage of the L sensing
L, U- 4V DC ±10%
system of the sensor ZK24
DC power supply voltage VOD1+, VOD1- 48V…98V DC
AC signal for the first
VOD1+, VOD1- 1100mV AC ±15%
transmission line*
AC signal for the second
VOD2+, VOD2- 1100mV AC ±15%
transmission line*
VOD1+, box No connection, >1 M"
VOD1-, box No connection, >1 M"
LOCAL
No connection, >1 M"
POWER+, box
LOCAL
No connection, >1 M"
Short circuit from terminal to POWER-, box
ground (box) check** VOD2+, box No connection, >1 M"
VOD2-, box No connection, >1 M"
U+, box No connection, >1 M"
U-, box No connection, >1 M"
H, box No connection, >1 M"
L, box No connection, >1 M"
* Measure with AC voltmeter with min. 2% accuracy for 5 kHz AC signal

** Measure with ohmmeter or with multimeter in diode-check mode
Sensor’s vertical position from the top of the rail (40±1mm): _____________mm
Sensor’s horizontal position from the side edge of the rail head (2+1/-0.5mm): __________mm
- mechanical parameters check visually using the plastic template
OB-R.07v2 D215600-0501010102
MEASURING LIST FOR SIX-MONTHS CHECK OF THE INDOOR EQUIPMENT OF AXLE

COUNTER BO23
DATE ________________
SECTION A ______________ SECTION B ______________ SECTION C ____________
SECTION D ______________ SECTION E ______________ SECTION F ____________
Reference value with Measured

Measured signal Terminals
tolerance value
H, GND on UP1 4V…6V DC
L, GND on UP1 4V…6V DC
Rectified input signals,
channel H and channel L of
the sensor on counting points
1…8 H, GND on UP5 4V…6V DC
BT1+, ground No connection, >1 M"
BT1-, ground No connection, >1 M"
Lightning protection module
ZAG2Z terminal connection
to the ground for counting
points 1…4*
NAP+, ground No connection, >1 M"
NAP-, ground No connection, >1 M"
Lightning protection module BT6-, ground No connection, >1 M"
ZAG2Z terminal connection BT7+, ground No connection, >1 M"
to the ground for counting BT7-, ground No connection, >1 M"
points 5…8* BT8+, ground No connection, >1 M"
NAP+, ground No connection, >1 M"
NAP-, ground No connection, >1 M"
* Measure with ohmmeter or with multimeter in diode-check mode
OB-R.07v2 D215600-0501010102

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USER DOCUMENTATION D215600-0501010102 1 of 58

User: Authorised by: Date:

AXLE COUNTER BO23 OPERATING INSTRUCTIONS

Updates: Date: Prepared by / signature: Checked by / signature: Approved by / signature:

2. WIRING AND APPLICATION ............................................................................................10

3. INSTALLATION OF THE EQUIPMENT .............................................................................37

3.2 TRACKSIDE CONTROL UNIT VUR INSTALLATION......................................................39

3.3 INSTALLATION OF THE INDOOR EQUIPMENT UNUR.................................................41

6. TECHNICAL SPECIFICATIONS ........................................................................................49

APPENDIX A – DIMENSION DRAWINGS............................................................................52

using the J25 jumper...............................................................................................................12

1.2 DESCRIPTION AND DEVICE STRUCTURE

OUTDOOR Sensor ZK24 Sensor ZK24

Section A Power supply,

1.2.1 OUTDOOR EQUIPMENT STRUCTURE

1.2.2 INDOOR EQUIPMENT STRUCTURE

MPU MODEM UP UP UP UP UP UP UP UP RE RE RE ZANAP DC12

DISTURB. CLEAR CLEAR CLEAR

OCCUP. OCCUP. OCCUP. F2A

LINE RESET2 RESET2 RESET2

GND GND GND GND GND GND GND GND

Table 2: Parts for BO23 indoor equipment UNUR

1.2.3 POWER SUPPLY

1.2.4 OUTPUT SIGNALS

2. WIRING AND APPLICATION

2.1 OUTDOOR EQUIPMENT WIRING

U+ YELLOW-GREEN WIRE (Positive pole of DC power supply)

Figure 5: Top view to opened box of trackside control unit VUR

2.2 WIRING AND SETTING THE INDOOR EQUIPMENT UNUR

RESET MODE JUMPER J25:

RESET MODE SET TO "MODE 1" OR "PREPARATORY RESET"

2.2.1 CONFIGURATION 1 (BO23-8A): ONE SECTION WITH UP TO 8 COUNTING POINTS

2.2.2 CONFIGURATION 2 (BO23-4A-4B): TWO INDEPENDENT SECTIONS WITH UP TO 4

Configuration BO23-4A-4B for controlling occupancy of two independent sections with up

CP1 CP2 CP5 CP6

2.2.3 CONFIGURATION 3 (BO23-3A-3B-2C): 3 INDEPENDENT SECTIONS

Configuration BO23-3A-3B-2C for occupancy control of three independent sections using

CP1 CP2 CP4 CP5

2.2.4 CONFIGURATION 4 (BO23-2A-2B-2C-2D): 4 INDEPENDENT SECTIONS WITH 2

Configuration BO23-2A-2B-2C-2D for occupancy control of 4 independent sections using

CP1 CP2 CP5 CP6

CP3 CP4 CP7 CP8

2.2.5 CONFIGURATION 5 (BO23-3A3B3C2D): 4 CONSECUTIVE SECTIONS

Configuration BO23-3A3B3C2D for occupancy control of 4 consecutive sections using

CP1 CP3 CP5 CP7 CP8

SECTION A SECTION B SECTION C SECTION D

CP1 CP3 CP5 CP7 CP8

2.2.6 CONFIGURATION 6 (BO23-2A2B2C-2D2E2F): TWO TIMES 3 CONSECUTIVE

Configuration BO23-2A2B2C-2D2E2F for occupancy control of 2 times 3 consecutive

SECTION A SECTION B SECTION C

CP1 CP2 CP3 CP4

CP5 CP6 CP7 CP8

SECTION D SECTION E SECTION F

CP5 CP6 CP7 CP8

CP1 CP2 CP3 CP4

SECTION A SECTION B SECTION C

2.2.7 CONFIGURATION 7 (BO23-2A2B2C2D4E): OCCUPANCY CONTROL OF 5

Configuration BO23-2A2B2C2D4E for occupancy control of 5 consecutive sections using

CP1 CP2 CP3 CP4 CP5 CP6

2.2.8 CONFIGURATION 8 (BO23-2A2B2C2D2E3F): OCCUPANCY CONTROL OF 6

Configuration BO23-2A2B2C2D2E3F for occupancy control of 6 consecutive sections

CP1 CP2 CP3 CP4 CP5 CP6 SECTION F CP7

2.2.9 CONFIGURATION 9 (BO23-3A-2B-2C-2D): OCCUPANCY CONTROL OF 3