Maintenance Handbook On DC Track Circuit Ver2

CAMTECH/S/2004/DCTC/2.
D.C. TRACK CIRCUIT

1.
Introduction
Track Circuit is a low powered electrical circuit
in which running rails are used as a part. With
the help of track circuit, one can easily identify
whether the particular section is clear or
occupied by a train/vehicles or Track Circuit is
in failed condition.
The advantages of DC track circuit are :
It is very simple to maintain.
It is highly reliable for effective and safe

running of trains.
A DC track circuit has mainly two ends i.e. feed

end and relay end as shown in fig. no. 1.
A track circuit gives two indications.
Yellow/White/No light indication When track circuit portion is clear i.e.

when line is unoccupied.
Red indication - When track circuit

portion is occupied by a vehicle or track
circuit is in fail condition.
D.C. Track Circuit Ver 2.0
March 2004
CAMTECH/S/2004/DCTC/2.0
2.
Requirements
Permanent Way Requirements
Glued joints or insulation joints of approved
type are to be provided for defining
boundary of track circuit. In all future works
of track circuiting, glued insulated joints is
to be preferably been provided.
Insulated joints wherever provided is to be
maintained as square joints. Where
staggering can not be avoided the distance
between staggered joints shall not exceed the
minimum wheel based of the vehicles.
Rail ends of insulated joints shall be square
and true. All rough edges and burrs shall be
removed from bolts holes. Battered ends
shall be put right and the gap between the
rails is to be equal to the thickness of the end
post.
Fish bolts at the joints must be kept tight and
the sleepers well packed in the vicinity of
the joints.
Proper drainage should be ensured so as to
avoid flooding of tracks during rains,
particularly in the yards where watering of
coaches is done and in the water columns
and ash pits. It would be desirable to provide
washable concrete aprons on platform lines
at originating stations, in track circuited
areas.
March 2004
Ballast shall be kept clean throughout the

track circuited section should be taken do
see that the ballast is kept clear off the rails
and rail fastenings. The clearance from the
foot of the rail should not less than 50 mm.
Well screened ballast right up to the
formation level shall be provided.
Rail ends shall be kept free from brake-dust,
sand, rust, other foreign materials etc. all
rough edges and burrs at rail ends must be
removed.
To avoid crushing of end posts of insulated
rail joints due to creep at least one rail length
in either side of insulated joint should be
provided with anti creep devices.
Rail screws should preferably be used in
place of dog spikes at insulated joints.
Wooden sleepers concrete sleepers or any
other approved type insulated sleepers shall
be provided for track circuiting. Concrete
sleepers where used shall have a minimum
resistance of 500 ohms between insert-toinsert.
Where short welded rail panels are used,
SWR shall not but against insulated joints.
Two rails lengths of 13 meters/12 meters
shall be interposed to isolate short welded
rail from insulated joint. This standard
length of rails shall be anchored effectively
to arrest movement in either direction.
In case of turnouts and crossings, insulated
stretchers, insulated gauge ties plates and
March 2004
insulated crossings plates shall be provided

as per approved drawings.
GEN liners shall be provided in the trackcircuited area using concrete sleepers.
3.
Types of track circuits

A closed type track circuit shall be provided to
prove the clearance of rail track.
Double rail track circuit
Double rail track circuit is to be provided on
non RE areas, as for as practicable.
In double rail track circuit both the running
rails are insulated from adjoining sections by
insertion of block joints.
Insulation
joints
TR
+
Double Rail Track circuit

(Figure 1)
March 2004
Single rail track circuit

In RE area, generally single rail track
circuit is used where one of the rails is
reserved for the traction return current.
This rail is referred to as the un-insulated
rails.
Any connection from the OHE mast or
other structure shall be made only to the
un-insulated rails.
Similarly, connections for the return
current at feeding points as well as from
booster
transformers
and
return
conductors shall be made only to the uninsulated rail.
Other rail carries positive polarity of DC
rack circuit. This positive polarity rail is
insulated from either side.
March 2004
Insulation
Joint
6 Amp Fuse
Choke
TR
Single Rail Track Circuit

(Figure 2)
As far as practicable, the rail adjacent to

the O.H.E mast shall be utilised as the
insulated rail. However, this may not
always be possible, particularly in yards
where there are a large number of points
and crossings or where the O.H.E masts
March 2004
are not always on the same side or where

track circuits are staggered.
In single rail track circuits, in the event
of a break in the un-insulated rails, very
heavy current will flow through the
track relay as well as the equipment at
the feed point. To avoid this the uninsulated rails of the adjacent tracks shall
be cross-bonded at intervals of not more
then 100 mts. In case the track circuit is
less then 100 mts. The cross bonding
shall be provided on the un-insulated rail
at either end of the track circuit.
March 2004
Insulation
Joint
Break
Traction
Return current
6 Amp Fuse
Un insulated
rail
Choke
TR
+
Single Rail Track Circuit with Breakage on

Un insulated Rail
(Figure-3)
To avoid this the un-insulated rails of the

adjacent tracks shall be cross-bonded at
intervals of not more than 100 mts. In
case the track circuit is less than 100 mts.
The cross bonding shall be provided on
the un-insulated rails at either end of the
track circuit.
March 2004
In case of adjacent track circuits, the

return rail shall be staggered as shown in
fig. Below.
2T
1T
Traction Bond
Adjacent Track Circuit

(Figure-4)
4.
Length of track circuits
4.1
Minimum length
The length of the track circuit shall not be less
then the maximum wheel base of any vehicle,
except in marshalling yards.
Track circuits shall cover at least two rail
lengths (Min.26 meters)
4.2
Maximum length
As per SEM pera 17.15.5 the maximum length
of track circuit under different track parameters
are given in the table below.
RE/Non
RE area
Sleeper
Section
yard
Block
Mini.
Ballast
TSR
in
Ohms
Max.
length
of
Type
of
track relay
to be used
March 2004
10
section
Non RE
track
circuit
Block
resista
nce in
Ohms
per
Km
4
0.5
1000
QT type 4 or
9 Ohms or
shelf
type
relay
-Do-
Wooden/
PSC
Non RE
Yard
0.5
670
RE
Wooden/
PSC
Wooden
Block
0.50
450
RE
RE
RE
RE
Wooden
PSC
PSC
PSC
Yard
Block
Yard
Yard
2
4
2
2
0.5
0.5
0.5
0.5
450
450
350
750
QT 9 Ohms
AC immune
or shelf type
9 Ohms AC
immune
-Do-Do-DoQBAT
in
cunjuct-ion
with QSPA1
with B type
choke
at
relay end.
(Table - 1)
5.
Description & working (Closed Type)
March 2004
11
Track circuit is designed to know whether

the portion of rail (track circuited) is clear
or occupied by a train.
A D.C. track circuit has two ends i.e. feed
end and relay end. Both the ends are
insulated by a Nylon joint or glued joint.
Feed end is connected to power source and
relay end is connected to track relay. Track
relay will be in de-energised position under
following conditions:
A vehicle occupies any part of the
track circuit or
It is short-circuited by any means.
Otherwise track relay will be in
energised position.
Since it is a vital safety circuit, hence
installation is to be made according to the
approved interlocking plan.
6.
Specification of equipment required for DC

track circuit in RE area.
March 2004
S.
NO.
1
2
3
4
12
Equipment
Specification No.
Track feed
charger
B type
choke
F type
resistance
AC
Immunized
track relay
IRS-89/93
Secondary
cells 40 AH
IRS-65/83
RE/S&T/ALD/SPEN/128
BRS 939 A
BRS 966 A/BS 1659
WITH RE
SPECIFICATION.
IS-1651
(Table - 2)
7.
Main parts
Non- RE Area
Following are the main parts of a DC track
circuit.
Relay
Relay must conform to British Standard
Specification No.1659, unless otherwise
specially permitted. The approved type
issue relays are:
Shelf type
Q series type
March 2004
13
The resistance of the track relay should

be 9 ohm for the length of track circuits
up to and less than 100 Mtrs.
The resistance of the track relay should
be 2.25 Ohm for a length of track circuit
above 100 Mtrs. if the track is laid on
wooden sleepers and 9 Ohm if laid on
concrete sleepers.
Track Feed
Power supply given to DC track circuit at feed
end:
Approved type of primary cells or lead acid
secondary cells shall be used.
Where primary cells are used, two batteries
in parallel shall be used to increase
reliability.
Where secondary cell(s) is/are used, they
shall be used with battery charger/solar
panels of adequate capacity.
Separate feed shall be provided for each
track circuit.
The polarity of a DC track circuit must
differ with adjacent DC track circuit as
shown in fig. no.5
March 2004
14
01 T
01 AT
FEED
END
+
RELAY
END
+ FEED END
RELAY
END
Track Feed and Relay Arrangement with

Adjacent DC Track Circuit
(Figure-5)
Adjustable Resistance
Ohms
0-15 Ohms and 0-25
This resistance is used at power source and feed

end voltage is adjusted according to the
condition of ballast and pickup voltage of track
relay.
March 2004
15
Cables
The cable from feed location/cabin to feed end
junction box and relay end junction box to relay
location should preferably be made of copper
conductors of min. 2.5 Sq.mm. cross-section.
Bond wires
A straight track portion of welded rails does not
need any props to enhance its conductivity. But
if smaller panels or individual rails are to be
included, the ordinary fish plated and bolted
joints themselves cannot give good electrical
continuity. In such cases, the rails are to be
connected with continuity Rail bonds.
Bond wires shall be of an approved type
or 8 SWG GI bond wires may be used
for rail bonds.
These bond wires are fitted with channel
bond pins, which have grooves to hold
the wires.
It is desirable to used bond wire clips to
secure the bond wired.
March 2004
16
Object of track bonding

The objectives of track bonding are:
To provide a path for traction return current,
which ensures that no component of the
track/traction return network rises above 25
Volt to remote earth, under normal traction
load conditions and 430Volt under traction
short circuit conditions.
To ensure that protective equipment operates
satisfactorily.
To minimize damage to installations due to
traction short circuit.
To maintain correct operation of track circuits.
Bonding of single rail track circuits
The track circuit rail must be series bonded in
order to ensure that defective bonding can not
cause a wrong side failure of the track circuit.
Accordingly, the bonding arrangement of the
track circuit rail must ensure that the
conductive path between the track circuit feed
connection and the relay or receiver end
connection is interrupted in the event of a
disconnection.
Because of traction return considerations, it is
not possible for the traction return rail to be
series bonded. It is therefore essential to avoid
bonding disconnection to minimize the risk of
loss of train shunt.
March 2004
17
Insulation Rail Joint

Two types of insulated joints are presently in
use.
Nylon insulated rail joints [Supplied by S&T
dept.]
Glued joints [Supplied by Engg. dept.]
For one Nylon insulation joint, following
insulation components are required :
Bushes
End post
Channel side plate LH
Channel side plate RH
8 nos.
1 no.
2 nos.
2 nos
Insulation Rail Joint

Two types of insulated joints are presently in
use :
Nylon insulated rail joints [Supplied by S&T
dept.]
Glued joints [Supplied by Engg. dept.]
March 2004
18
For one Nylon insulation joint, following

insulation components are required:
Bushes
End post
Channel side plate LH
Channel side plate RH
Nylon insulating plate
Steel backing plate
8 nos.
1 no.
2 nos.
2 nos
4 nos.
4 nos.
Maintainer shall select suitable insulation

components with care, as these are available in
various sizes to suit Rail sections of 90 R, 52
kg., 60 Kg. etc.
Track lead junction box

Track Circuit is provided with two track lead
junction boxes, one at feed end insulation joint
and another at relay end insulation joint.
Jumpers are used for connecting track feed to
rails from feed end junction box. Similarly
jumpers are used for connecting rails to relay
end junction box.
Cable from power source and feed end jumpers
are terminated in feed end junction box.
Similarly cable from track relay and relay end
jumpers are terminated in relay end junction
box.
March 2004
19
Main parts of DC track circuit on RE area

In RE area, all parts are similar to NON-REs
track circuit except choke & relay.
Choke B type 0-3 Ohm, impedance 120 Ohm.

This is used for the safety of track circuit. This
prevents damage to the feed source at the time
of a caternary snap resulting in heavy currents in
un-insulated rail.
Relay
S.
N
O.
TYPE OF
TRACK
RELAY
Relay must be AC immunised.

Track relay resistance must be 9 ohms
only for any length of track circuit.
The permissible lengths for different
types of track relays are shown in table I
AC
IMM.
OF
TRACK
RELAY
50 V
TYPE OF
SLEEPER
MAX.
LENGTH
POSSI-BLE
Wooden
450 m
ACI Shelf
type or QTA2
type.
QBAT type
80 V
Wooden
ACI shelf
type or
QTA2.
50 V
Wooden
750 m
(with relay
end choke)
200 m
Wooden
300 m
REMARKS
A 10 V induced
voltage drop is
considered in 90 m
long rail length @
600 Amp. current.
-doThe voltage drop
will be more @
800 Amp. In S/L
& 1000 Amp. in
D/L track circuits.
March 2004
S.
N
O.
TYPE OF
TRACK
RELAY
20
AC
IMM.
OF
TRACK
RELAY
80 V
TYPE OF
SLEEPER
MAX.
LENGTH
POSSI-BLE
Wooden
450 m
QBAT type
ACI shelf
type or QTA2
type.
50 V
Wooden
Concrete
450 m
350 m
QBAT type
80 V
Concrete
350 m
REMARKS
800 Amp. in S/L

& 1000 Amp. in
D/L track circuits.
The workable
length is restricted
to a lesser value
due to 0.6/Km.
Ballast Resistance
minimum
permitted.
-do-
(Table - 3)
Length of DC track circuit is restricted

depending upon rail return current with
caternary current restricted to 300 amps. on
single track section and 600 amps on double
track section. Length of DC track circuit shall be
restricted depending upon the use of type of
relay and sleepers.
The length of DC single rail track circuit in AC
electrified area with AC immune 9 ohms shelf
type relay shall not exceed 450 meters where
wooden sleepers are used and 350 meters where
concrete sleepers are used. The length of track
circuit can be extended up to 450 meters when
QTA2 plug in relay used.
Restriction on the track circuit length due to use
of concrete sleepers can be relaxed up to 450
meters by CSTE of Railway if adequate ballast
resistance can be consistently obtained.
March 2004
8.0
21
In view of increased AC immunity due to the

presence of biased magnetic arrangement,
QBAT relays can be used up to a maximum
length of track circuit of 750 meters using one
B type choke and the relay end, under
minimum ballast resistance of 2 Ohms/km.
Operation of track circuit with this type of relay
will required four cells delivering 8.8 volts
QBAT relays shall be used in conjunction with
QSPA relays confirming to BRS 933A.
As an interim measure, length of DC track
circuit may be retained at the existing level at
higher caternary current of 800 amps. on single
track section and 1000 amps. on double track
section by providing B type 120 Ohms
impedance choke in series with track relay.
Audio frequency track circuit shall be used on
sections where caternary current exceed 300
amps. on single track section and 600 amps. on
double track section.
D.C. Track Circuit Parameters
The performance of a D.C. track circuit depends
upon the parameters explained below :
Ballast resistance
This is the total resistance of various

leakage paths across the track circuit rails
offered by ballast and sleepers.
March 2004
The ballast resistance of the dc track

circuit should be as high as possible. Its
value also changes for track circuit
situated in different areas as below :
AREA
22
BALLAST Resistance
Block section
Station section
D/rail track circuit
with concrete sleeper
S/rail track circuit
with concrete sleeper
4 ohm/km
2 ohm/km
1 ohm/km
0.6 ohm/km
( In RE area )
Train shunt resistance
This is the maximum value of resistance,

when applied across the track, drops the
track relay. The min. permissible value is
0.5 Ohm for DC track circuit.
Maximum permitted voltage at relay
terminal under maximum ballast
resistance condition shall not be more
than 250% of relay pickup value for shelf
type relays and 300% for plug in type
relays.
The permitted voltage under minimum
ballast condition shall be 125 % of relay
pick up value.
March 2004
23
The maximum permitted relay terminal

voltage with 0.5 Ohm TSR (Train Shunt
Resistance) shall be less than 85% of
drop away value of relay.
Rail resistance
The resistance of rail and bonding per

1000 mtrs. of track should not exceed 0.5
Ohm for track circuits longer than 700
Mtrs.
A rail and bond resistance up to 1.5 ohm
per 1000 meters of track may be allowed
for length of track circuit less than 700
Mtrs.
Minimum length of Track Circuit :

Double rail track circuit on non-RE area
shall not exceed 1300 Mtrs. on wooden
sleepers and 670 Mtrs. on concrete
sleepers.
March 2004
9.0
Intallation
Track Feed
24
Track feed equipment and secondary

cells shall be installed in separate
location box & as near as possible to the
track.
Separate track feed shall be used for each

track circuit.
The no. of secondary cells required for

track circuit shall be selected as per
length of track circuit/type of
sleeper/type of relay.
The track feed charger cell selector knob

shall be kept in a position of no. of cells
selected.
The rating of the fuse at feed end shall

be decided depending upon no. of cell
selected.
The track feed equipment wiring shall be

done with 7/0.37 cable.
Slow to pick up repeater relay (QSPA1)

shall be used in conjunction with plugin-type track relays i.e. QTA1/QTA2
relays.
March 2004
25
The QSPA1 relay used in conjunction

with plug-in-type track relay having no
back contact, shall be kept in location
box and it shall be kept in relay room, if
track relay is having back contact.
In the case of short track circuit (up to 50

m.), the track relay and QSPA1 relay
shall be kept in track feed location box
and beyond 50 m. a separate location
box shall be used.
Connect all the spare contacts in parallel

to the loaded contacts.
Insulation joints
Select the correct insulation components

as per Rail section i.e. 90 R, 52 Kg. & 60
Kg. etc.
Check that track circuit rail section is
welded or not, if not than provide rail
joint bonding. These bonding are
provided by drilling 7.2 MM. holes in the
rail webs closer to the fish plate joints on
either ends and on rail joints. The bond
wires are inserted into the holes along
with channel pins which are having
grooves to hold the wires.
March 2004
26
Insulation joint must be located

according to the approved interlocking
plan.
The ends of rails, where insulation joint
are fitted, must be square and smooth.
There should not be any burr or rough
edge which can damage the insulation
material.
The gap between the rails where the end
post is provided must be maintained
properly. Fig. no. 5 & 6 are example of
improper gaps, which results in crushing
of insulation material frequently.
Holes must be proper in accordance with
fish plate hole i.e. oblong holes crush the
bushes.
Jumper connections must be so made
that the whole of track circuit is in
series as shown in fig. no.3.
The insulated rail joint shall be installed
at least one rail length in advance of the
signal.
In case of turnouts and crossings,
insulated stretchers, gauge tie plates and
crossing plate shall be provided.
The distance between the Track Circuit
termination and fouling mark shall not
be less than 3.0 Mtrs.
Insulated rail joints shall be as for as
possible not be provided on the outer rail
in curves.
March 2004
27
Steel backing plate of 4 MM. thickness

with bends shall be used at ends to
prevent damage to insulating plate.
In case, the top edge of the Nylon end

post protrudes above, the top of the rail
surface, it shall be made in level with the
rail surface by cutting off the extra
portion of the end post.
RELAY
END
01 T
01 AT
-
FEED
END
+
FIG. NO. 6
Increase the track circuit length by 7'

beyond fouling mark in BG and 5.5 in
MG in point track circuits.
March 2004
28
Where DC track circuit are adjacent, the

polarity on adjacent the rail should be
opposite.
Relays
Relay end should be located at the

entering end of train where ever possible.
Where relays are likely to be subjected to

vibration they shall be mounted on shock
absorbers.
Shelf type relays must be housed with

antitilting arrangement.
All the contacts of the track relay shall
be loaded as far as possible. Where spare
contacts and available, they shall be
connected in parallel to the loaded
contacts
Connections between track relay and

track repeating relay must be made in
accordance with approved wiring
diagram.
The regulating resistance shall be

adjustable and of an approved type. It
must have markings to show the value of
resistance introduced in the circuit.
March 2004
10.0
29
Failsafe adjustment of track circuit

Select the required track relay and calculate
and record 250%, 125 % of Pick Up value
and 85 % DA value of the relay
VF
IF
VR
CHOKE
{R-3 OHM,
Z-120 OHM}
REGULATING
RESISTANCE
+ A= Ammeter,
Relay
V= Voltmete r,
IR
T R
TR= Track
FIG.NO. 7
Find out the minimum permitted value of

ballast resistance for the given track
circuit length by formula given below
and shown in fig. no. 4 :
VF+VR
Ballastresistance=-----------------2 ( IF-IR )
Connect the relay directly to cell with

regulating resistance in series. (Cell
voltage must be 2.2 Volts)
Connect a resistance equivalent to min.
ballast resistance across the relay and
adjust the regulating resistance so that
March 2004
30
the voltage across the relay is just above

125 % of rated pick up value.
Now disconnect the equivalent ballast

resistance connected and take reading
across the relay without changing the
value of regulating resistance and the
voltage shall not be more than 250 % of
rated pick up voltage, if voltage is high,
increase the value of regulating
resistance and ensure the voltage is not
exceeding 250 % limit.
Shunt the relay with 0.5 Ohm TSR and
check the voltage at relay terminal, it
shall be less than 85 % of DA (drop
away) value of the relay.
Now disconnect the relay and power
supply and connect the same without any
alteration in regulating resistance to the
rails at the respective end i.e. relay to the
relay end and power to the feed end.
Test the track circuit with 0.5 Ohm shunt
and check up the relay voltage which
should be less than 85 % of DA (drop
away) value and relay is in dropped
condition.
Measure and record the actual value of
voltage and working current.
If the track relay voltage is less than 125
% of rated pick up value it means ballast
resistance is less than minimum required
value and if it is impossible to improve
March 2004
31
the value of ballast resistance than split

the track circuit.
Dead section
By any means the dead section should

not be longer than the minimum distance
between the wheel of a four wheeler
vehicle. So that the vehicle must shunt
adjacent live portion of track circuit
while being on dead section.
In BG section, the distance between two
axle of a four wheeler is 6 m. ( 20' ) and
in
MG/NG sections, it is 3.6 m. (12').
The dead section may be due to:
Creep (in curved portion mainly)
Cross over out of square
A track portion is excluded of

adjacent track circuits due to level
crossing or bridge/culvert or a rail
portion where tramline crosses the
track.
Glued joint
Before installation insulation of glued joint must
be tested. Glued joint should be kept in dry
wooden sleepers.
March 2004
32
Insulation test in dry condition
The value of resistance shall not be less than 25

Mega ohms when a meggering voltage of 100 V
DC is applied across the joint and resistance is
calculated by dividing the voltage by current..
Insulation test in wet condition

Wet sand can be applied on the joint for 24 hr.
and thereafter the value of resistance shall not be
less than 3 Kilo ohm when obtained with
application of 100V DC megger.
Precaution
Joint must be well packed 10 sleepers on

either side of glued joint.
No damage shall be caused to the joint

while inserting in the track.
Working of Trap circuit
If a dead section in excess of 10.8 mtrs. (36 feet)

occurs, such as on girders bridges, a special trap
circuit should be provided as shown in fig no.7.
Suppose the train is entering from left & it is
trapped in the dead section, BTR which has
March 2004
33
dropped cannot pick up since ATR has already

picked up and CT is unoccupied, hence CTR is
also in picked up position.
Similarly, for the train coming from right
direction and is trapped in the dead section, BTR
which has dropped cannot pick up since CTR
already picked up & AT is unoccupied.
AT
TB
BT
DEAD
SECTION
BT
TB
ATR
TN
BTR
ATR
CT
TN
BTR
CTR
CTR
FIG.NO. 8
Cut section arrangement of track circuits

Where cut section track circuits are installed, the
track relays concerned, when de-energised shall
open the track feed and shunt the track circuit as
shown in figure below.
March 2004
34
2T
1T
1TR
2TR
1TR
+ -
FIG.NO. 9
Termination of track circuit

For track circuited points or lines in a station, track
circuit termination shall be provided sufficiently
before the fouling mark so as to avoid infringement
to the standard dimension by any portion of vehicle.
The distance track circuit termination and fouling
mark shall not be less than 3 meters.
Loading of track relay contacts
All the contracts of track relay shall be loaded as far
as possible. Where spare contacts are available, they
shall be connected in parallel to the loaded contacts.
Measurement of stray direct current before
installation of DC single rail track circuits
Before installing a DC track circuit in areas, which
are to be AC electrified, stray direct current tests
March 2004
35
shall be carried out so as to ensure that DC track

relay shall not operate with the stray currents.
These test shall be carried out only on non
electrified sections.
If there are already existing track circuit in the
area, these shall be disconnected do safe guard
against false readings being recorded in case of
leakage of block joints.
The length of track required being track
circuited should be insulated by means of block
joints on either end of the rails. The rail joints in
the track circuited length may or may not be
beyond for purpose of these tests.
Selecting a suitable earth, which shall not
exceed 5 Ohms in resistance test shall be carried
out.
A suitable type of Milli Voltmeter and
millimeter shall be used for recording voltages.
These stray current and real earth voltage
measurements shall be recorded in accordance
the diagram for measurements indicated below.
X1
Fig No.10
March 2004
36
For measurement of stray current set up the

circuit as shown above and measure current
simultaneously.
X1
R
Fig No. 11
Where 9 ohms, 4 ohms or 2.25 ohms relays are

used, use 9 ohms, 4 ohms or 2.25 ohms
resistance and measure the voltage once at X
and next at X1.
These measurements shall be recorded at
different periods of the day one in the
morning, one in the afternoon and one in the
evening. These tests shall be extended for three
days.
Where stray current / voltages are observed the
length of the direct current track circuit shall be
cut down so as not exceed the following limits
for each length of track circuit.
The rail earth voltage as measured across 09
ohms, 4 ohms or 2.25 ohms shall not exceed
0.1 volt.
March 2004
37
The total stray current as measured shall not

exceed 100mA. Where all track circuit to be
installed on the line are less than 100 meters
long., the highest acceptable figure stray
current 10mA.
11.0
Maintenance
Insulation joint
Every joint must be tested by maintainer

to ensure high resistance. If the value of
I.R. is below 5 Mega ohm, such joint
should be marked and insulation must be
replaced on priority as it may fail
intermittently.
Sleepers edge from insulation joint must

be 4.5 " so that dog spikes/pandrol clip
may not short the insulation.
Remove accumulation of brake-dust, dirt,

other foreign matter and formation of burrs
from insulated joints.
Ensure provision of anti-creep devices

on either side of the insulated joint,
specially which are in block section and
near by long welded rail (LWR).
Interpose two-rail length of 13m/12m to
isolate SWR from insulated joint.
March 2004
38
Ensure tightness of fish plate bolts and

proper packing of ballast in the vicinity of
the joint.
Ensure proper drainage to prevent joint

being flooded with rainwater.
Ensure sound condition of gauge tie

plate insulation, stretcher bar insulation,
D type insulation and rodding insulation.
Ensure no leakage of current on account

of muddy portion between feed end and
relay end. If leakage is more then advise
to PWI for deep/shallow screening of
ballast.
For glued joints on wooden sleepers,

ensure provision of dog spikes. The
spikes should not protude below the
sleeper.
Insulation rail joint

Before opening an insulated rail joint, the
components required for replacement,
confirming to the rail section, shall be kept
ready by the side of the track.
For replacement of an end post when there is
no gap at the insulated pail joint, loosen the
rail fastening and pull back the rail sand
insert end post between the rail ends.
March 2004
39
It is imperative that when an insulated rail

joint is provided at least three sleepers on
either side of the insulated rail joint shall be
packed properly.
Fish bolts shall be kept tight. Nuts shall be
tightened several times during the first two
weeks after installation/replacement, until all
components of an insulated rail joint are
firmly set.
A metal flow is seen often at the rail table at
the joints. Such metal flow of metal forms a
lip and creates sharp burrs at the rail ends.
Projections formed at the rail ends shall be
chiseled without damaging the end post so
that these do not bridge the rail expansion
gap and cause a short circuit.
Brake block dust, which may accumulate on
the head and sides of the end post and top
surfaces of the fish plate, shall be brushed
off frequently so that the possibility of
electrical conductivity being established
between the rail ends is eliminated.
Special type pandrol clips (J types) shall be
provided at nylon insulated joints/ glued
joint to avoid touching of pandrol clip with
the fish plate.
Periodic coating by insulating varnish/epoxy
over the nylon insulated joint/glued joint to
avoid shorting due to brake dust shall be
done.
A faulty insulated joint may be detected by
taking the voltage readings across the track
March 2004
40
relay terminals and noting if this reading

changes when the adjacent track circuit feed
is shunted or disconnected. Any change in
the voltage reading will indicate a faulty
insulated joint.
Bond wires
Bond must be checked for rigid

connection with rail to avoid the
possibility of high resistance.
To avoid failures, two bond wires (in

parallel) may be provided.
Bonds shall be painted with alluminium

paint, where bond corrosions are
excessive.
On every visit maintainer should ensure

that the bond wire has rigid connections
with rails.
Ballast
Ballast must be maintained clean

throughout the track circuited section
and care should be taken to see that
clearance of ballast from the foot of the
rail shall not be less than 50 MM. Ballast
shall be kept free from vegetation.
March 2004
41
The ballast resistance of the track with

both rails insulated should not be less
than 2.0 Ohm/Km. with wooden sleepers
and 1.0 Ohm./Km. with concrete
sleepers in non-RE area and 0.6
Ohm/Km. with concrete sleepers in RE
area.
In case of concrete sleepers. ensure

provision of rubber pads & availability of
insulated liners up to 97%.
Drainage
Special attention shall be paid during the
rains to track drainage. Defects, if any, shall
be reported to the Permanent Way Inspector.
All cases of defective valves of overhead

water pipes in track circuited area shall be
reported to the Inspector of Works.
Relay
Maintained pick up and drop away values
within the limits specified by the
manufacturer.
Relays shall be inspected visually every two
years and the following visual checks
conducted.
Movement of armature and contact
carriage
Wiping of contacts
Arcing of contact if any
March 2004
42
Pitting or charging of contacts

Dust on contacts
Electroplating
Corrosion, rusting of components
Presence of fungus, if any
Charring of cover neat contacts (for plug
in relays)
Correctness of label
Presence of seal
The relay that is any way defective should
be changed at once and sent to shops
together with a brief report stating the nature
of the defects. On no account should any
attempt be made by the line staff to rectify
the relay.
Track relays of all type shall be periodically
over hauled every 10 years subject to a max.
of 12 years. The duration may be reduced
depending on local conditions, decided by
CSTE.
Check for arcing of contacts, corrosion,

presence of fungus after every sixmonth.
Ensure no moisture/ leakage of water

near by track relay.
Track charger and battery
On every visit maintainer should put the

charger in off position for one hour &
March 2004
43
then check insulation joint, bond wires

etc.
Check the current & voltage at feed end

and relay end with & without charger as
shown in Fig. no. 8 & 9, ensure that it is
with in limit i.e. less than 250% of PU
value.
Check the battery connection, specific

gravity and voltage.
Joint inspection of track by ST and permanent

way inspector
The track-circuited portion of the track shall be
jointly inspected by SSE/Signal and SSE/Pway at
least once in six months. This is and addition to
routine inspections to be carried out by each branch.
The condition of rail and insulation at the rail joints,
ballast and sleepers, abnormal collection of brake
dust, rusting of the rail and drainage of the yard
shall be particularly noted. It shall be ensured that
percentage of missing liners for track circuit length
not to exceed 3% maintenance work found
necessary on insulation joints after such inspection
should be carried out jointly.
March 2004
44
Train Shunt
A train shunt test shall be taken every quarter and
every time the track circuit adjusted or any
alteration is made.
Shunt test shall be taken not only at relay end but
also at other parallel portions of the track, such as
turnouts and cross over.
Track circuit test card
Test cards shall be easily accessible for inspection
by officials.
Test cards shall be kept up to date in accordance
with the instructions given on the card. Reading
shall be recorded every six months.
March 2004
1.
3.
5.
7.
9.
11.
13.
15.
17.
19.
21.
45
_____________Railways
Signal and Telecommunication Department
TRACK CIRCUIT TEST RECORD CARD
Station of section of line
2. Track circuit no.
Type of relay
4. Date installed
PU volts
6. DA volts
PU current
8. DA current
Resistance of relay
10. Length of track circuit (M)
Length of leads from feed end to 12. Length of leads relay to track
track (M)
Type of ballast
14. Type of track feed
Type of track feed conductor
16. Size of conductor to relay
Type of sleeper and condition
18. Type of insulated joints
No. of ASH pint in track
20. No. of L/xing in track
No. of insulated joints in track
VF + VR
Ballast Resistance=
Rail Resistance=
VF - VR
( I F + IR )
1/
2
22. Date
24. Condition of ballast wet/damp/
dry
26. Drainage of track good, fair or
bad
28. Condition of bonds and jumpers
30. Condition of track battery
Track feed end
31. Feed resistance
33. VF voltage at rails
Relay end
35. VR voltage at rails
37. IR current at relay terminals
39. Rail
resistance
and
bond
resistance
41. Pick up shunt value
( IF - IR )
Current at Relay =
Voltage at Relay terminals
Resistance of relays
23. Weather
25. Percentage of ballast clear of rails
27. Condition of rail surface
29. Condition of insulated joints
32. Voltage at battery of track feed voltage

34. IF current at rails
36. Voltage at relay terminals
38. Ballast resistance
40. Drop shunt value
42. Signature of section engineer/ signal
Signature of senior section engineer
/Signal
Station_______________________
(Table - 4)
March 2004
12.0
46
Uses of track circuit in signalling circuit
To indicate occupied / unoccupied

condition of a track.
To prevent reception/dispatch of a train

in an occupied section.
To put back a signal to its ON position

immediately after passage of train.
To prevent operation of a point under

wheels.
To lock the route in the face of an

approaching train.
To prove the arrival of a train.
To control the aspects of a signal in an

automatic signalling area.
To achieve one slot one train system of

working.
To assist effective working of an axle

counters by suppressing counting of
trolley wheels.
Prewarn facility to gate man at the time

of train approaching to gate.
March 2004
13.0
47
To close and open the level crossing gate

automatically.
To introduce automatic block working.
To provide
arrangement.
To introduce
signalling.
To introduce directional sequential

arrival of a train in RRI area.
Red
lamp
protection
Intermediate
block
Do's and Don'ts

DO's
Check all safety parameters and record

the exact values in track history card.
Check insulation joint regularly and at

the same time see its previous value. If
changing, then replace such insulation
joint promptly.
Check the due date of overhauling of

each track relay and send them timely for
overhauling.
March 2004
48
T R
FIG.NO. 13
Megger the track circuit tail cable after

every six months and if the value is less
than 1 mega ohm then such cable should
be replaced promptly.
March 2004
49
Measure the stray current, as shown in

the fig. no.10 by disconnecting the feed.
If stray current persist then try any one
method.
Interchange the positive and

negative connections of the rails,
so that stray voltage becomes
opposite to the track feed.
Interchange the feed and relay

ends of the track circuit. Stray
voltage may disappear.
Splitting the track circuit, so that

value of stray voltage will be
negligible.
Check the bond wire connections to

avoid high resistance, which are causes
of voltage drop.
Prefer to provide track lead junction box

vertically to avoid water accumulation in
the junction box as shown in fig. no. 8.
Apply glue/epoxy on the rail and fish

plate of those joints, which are shorting
due to iron filings and iron powder.
March 2004
50
At the time of replacing the insulation

joint apply quick drier paint on the rail
and fish plate.
Try to replace the insulation joint when

the temp. is between 200 -350 C.
At insulation joint pandrol clip should be

opposite in direction so that pandrol
clips small portion should be towards
fishplate or use J Pandrol clip to avoid
touching of pandrol clip with the fish
plates.
DON'T
Bypass the regulating resistance at any

time.
Tamper with the track relay at the time of

track circuit failure.
Disturb the antitilting arrangement of

track relay.
Forget to give disconnection memo to

on-duty ASM/CASM at the time of
attending failure.
Adjust the track circuit beyond the limit

of track circuit parameters given earlier.
March 2004
51
Forget to clean the insulation joint on

every visit.
Permit relay end voltage to be lesser than

125 % of pick up voltage of relay.
March 2004

Maintenance Handbook On DC Track Circuit Ver2

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Maintenance Handbook On DC Track Circuit Ver2

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CAMTECH/S/2004/DCTC/2.

D.C. TRACK CIRCUIT

It is very simple to maintain.

It is highly reliable for effective and safe

A DC track circuit has mainly two ends i.e. feed

Yellow/White/No light indication When track circuit portion is clear i.e.

Red indication - When track circuit

D.C. Track Circuit Ver 2.0

D.C. Track Circuit Ver 2.0

Ballast shall be kept clean throughout the

insulated crossings plates shall be provided

Types of track circuits

Double Rail Track circuit

D.C. Track Circuit Ver 2.0

Single rail track circuit

D.C. Track Circuit Ver 2.0

Single Rail Track Circuit

As far as practicable, the rail adjacent to

D.C. Track Circuit Ver 2.0

are not always on the same side or where

D.C. Track Circuit Ver 2.0

Single Rail Track Circuit with Breakage on

To avoid this the un-insulated rails of the

D.C. Track Circuit Ver 2.0

In case of adjacent track circuits, the

Adjacent Track Circuit

Length of track circuits

D.C. Track Circuit Ver 2.0

Description & working (Closed Type)

D.C. Track Circuit Ver 2.0

Track circuit is designed to know whether

Specification of equipment required for DC

D.C. Track Circuit Ver 2.0

D.C. Track Circuit Ver 2.0

The resistance of the track relay should

D.C. Track Circuit Ver 2.0

Track Feed and Relay Arrangement with

0-15 Ohms and 0-25

This resistance is used at power source and feed

D.C. Track Circuit Ver 2.0

D.C. Track Circuit Ver 2.0

Object of track bonding

Insulation Rail Joint

Insulation Rail Joint

D.C. Track Circuit Ver 2.0

For one Nylon insulation joint, following

Maintainer shall select suitable insulation

Track lead junction box

D.C. Track Circuit Ver 2.0

Main parts of DC track circuit on RE area

Choke B type 0-3 Ohm, impedance 120 Ohm.

Relay must be AC immunised.

D.C. Track Circuit Ver 2.0

800 Amp. in S/L

Length of DC track circuit is restricted

D.C. Track Circuit Ver 2.0

In view of increased AC immunity due to the

This is the total resistance of various