tams elektronik FCS-3 User manual

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FCS-3 n
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Busmodul
für Faller* Car-System n
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Bus module compatible
to the Faller* Car-System n
nAnleitung
Module pour autobus
du Faller* Car-System nManual
nMode d´emploi
Busmodule voor
het Faller* Car System nHandleiding
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Art.-Nr. 22-01-071-3 n
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nDeutsch 3
nEnglish 19
nFrançais 33
nNederlands 47
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© 07/2005 Tams Elektronik GmbH
Alle Rechte, insbesondere das Recht
der Vervielfältigung und Verbreitung
sowie der Übersetzung vorbehalten.
Vervielfältigungen und Reproduktionen
in jeglicher Form bedürfen der
schriftlichen Genehmigung durch die
Tams Elektronik GmbH.
Technische Änderungen vorbehalten.
© 07/2005 Tams Elektronik GmbH
All rights reserved. No part of this
publication may be reproduced or
transmitted in any form or by any
means, electronic or mechanical,
including photocopying, without prior
permission in writing from Tams
Elektronik GmbH.
Subject to technical modification.
© 07/2005 Tams Elektronik GmbH
Tout droits réservés, en particulier les
droits de reproduction et de diffusion
ainsi que le traduction. Toute
duplication ou reproduction sous
quelque forme que ce soit nécessite
l´accord écrit de la societé Tams
Elektronik GmbH.
Sous réserve de modifications
techniques.
© 07/2005 Tams Elektronik GmbH
Alle rechten voorbehouden. Niets uit
deze publicatie mag worden
vermenigvuldigd opgeslagen of
openbaar gemaakt, zonder
voorafgaande schriftelijke toestemming
van Tams Elektronik GmbH.
Technische wijzigingen voorbehouden.
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FCS-3 English
Seite 19
Table of contents
How to use this manual 19
Intended use 20
Safety instructions 20
EMC declaration 22
Summary of operation 23
Technical specifications / Circuit Diagram(Fig. 1) 24
Checking the package contents 25
Required tools and materials 25
Safe and correct soldering 26
Special features of the additional components 27
Mounting the FCS-3 28
FAQ 31
Manufacturer's note 31
Certification 31
Conditional warranty 32
Connections (Fig. 2) II
(Page II in the centre of this handbook is removeable.)
How to use this manual
If you have no specialist technical training, this manual gives step-by-
step instructions for safe and correct fitting of the module, and
operation. Before you start, we advise you to read the whole manual,
particularly the chapter on safety instructions and the FAQ chapter. You
will then know where to take care and how to prevent mistakes which
take a lot of effort to correct.
Keep this manual safely so that you can solve problems in the future. If
you pass the module on to another person, please pass on the manual
with it.

English FCS-3
Seite 20
!
Intended use
Caution:
Integrated circuits are very sensitive to static electricity. Do not touch
components without first discharging yourself. Touching a radiator or
other grounded metal part will discharge you.
The module can be used according to the specifications of this manual
in a vehicle compatible to the Faller* Car-System. The stored software
is designed for controlling a bus in scheduled services.
The module is not suitable for children under the age of 14.
Reading, understanding and following the instructions in this manual
are mandatory for the user.
Any other use is inappropriate and invalidates any guarantees.
Safety instructions
Mechanical hazards
Cut wires can have sharp ends and can cause serious injuries. Watch
out for sharp edges when you pick up the PCB.
Visibly damaged parts can cause unpredictable danger. Do not use
damaged parts: recycle and replace them with new ones.
Electrical hazards
§Touching powered, live components,
§touching conducting components which are live due to malfunction,
§short circuits,
§connecting the circuit to another voltage than specified,
§impermissibly high humidity,
§condensation build up
can cause serious injury due to electrical shock. Take the following
precautions to prevent this danger:
§Never perform wiring on a powered module.

FCS-3 English
Seite 21
§Mounting the module should only be done in closed, clean, dry
rooms. Beware of humidity.
§Only use low power for this module as described in this manual and
only use certified transformers.
§Connect soldering irons only in approved mains sockets installed by
an authorised electrician.
§Observe cable diameter requirements.
§After condensation build up, allow a minimum of 2 hours for
dispersion.
§Use only original spare parts if you have to repair the kit or the
ready-built module.
Fire risk
Touching flammable material with a hot soldering iron can cause fire,
which can result in injury or death through burns or suffocation.
Connect your soldering iron or soldering station only when actually
needed. Always keep the soldering iron away from inflammable
materials. Use a suitable soldering iron stand. Never leave a hot
soldering iron or station unattended.
Thermal danger
A hot soldering iron or liquid solder accidentally touching your skin can
cause skin burns. As a precaution:
§use a heat-resistant mat during soldering,
§always put the hot soldering iron in the soldering iron stand,
§point the soldering iron tip carefully when soldering, and
§remove liquid solder with a thick wet rag or wet sponge from the
soldering tip.

English FCS-3
Seite 22
Dangerousenvironments
A working area that is too small or cramped is unsuitable and can cause
accidents, fires and injury. Prevent this by working in a clean, dry room
with enough freedom of movement.
Other dangers
Children can cause any of the accidents mentioned above because they
are inattentive and not responsible enough. Children under the age of
14 should not be allowed to work with this module.
Little children can swallow small components with sharp edges, with
fatal results! Do not allow components to reach small children.
In schools, training centres, clubs and workshops, assembly must be
supervised by qualified personnel.
In industrial institutions, health and safety regulations applying to
electronic work must be adhered to.
EMC declaration
This product is developed in accordance with the European standards
EN 55014 and EN 50082-1, tested corresponding to the EC - directive
89/336/EWG (EMVG of 09/11/1992, electromagnetic tolerance) and
meets legal requirements.
To guarantee the electromagnetic tolerance you must take the
following precautions:
§Make no changes to the original parts and accurately follow the
instructions, circuit diagram and connections diagrams included
with this manual.
§Use only original spare parts if you have to repair module.

FCS-3 English
Seite 23
Summary of operation
The module is particularly designed for the use in vehicles compatible
to the Faller* car system, that are run with two accumulator batteries. It
has six in- and outputs for the connection of LEDs, motor and reed
contacts. Additional white LEDs for the front lighting can be connected
to the additional output. It is not necessary to use all light-outputs. The
in- and outputs are controlled from the software stored in the IC. The
software is designed for controlling a bus in scheduled services.
The voltage of 2,4 V that is provided by the vehicle accumulator batteries,
is doubled by the module. This enables white LEDs to be connected,
which normally need a voltage of more than 2,4 V. Red and yellow LEDs
may be connected directly via series resistors to the accumulator
batteries, provided they are not to be controlled by the software.
Front lighting
Additional to the six in- and outputs controlled by the software there
can be connected up to two additional white LEDs for the front lighting
to the additional output. These LEDs are not controlled by the software
and light as soon as the module is supplied with voltage.
N.B. In contrast to the LEDs connected to the outputs controlled by the
software these should be connected via series resistors. Otherwise the
connected LEDs are damaged and the circuit may not work as intended.
Back lighting
It is possible to connect two red LEDs to one output of the module for
the back and stop lights. While breaking and some seconds after
stopping, the back lights are switched brighter.
Flashing lights
The LEDs for the flashing lights on the right and the left can be
switched in series from two outputs of the module. Switching on or off
the flash lights while the vehicle is turning right or left is not possible.
When the bus halts more than 10 seconds at a stop, the module
interprets the stop as bus stop. The LEDs for the flash light are

English FCS-3
Seite 24
switched to „warning light“ until the drive on signal, but max. up to one
minute. If the bus does not receive the signal to drive on during one
minute, the flashing lights and the back lights are switched off (current
saving mode). While starting after at halt at the bus stop the flash
lights on the left are switched on for a short time.
At stops where flash lighting is not desired (e.g. at traffic lights or
priority roads), the bus should get the signal to drive on in less than 10
seconds. After such a (short) stop the flash lights on the left are not
swiched on.
Driving of the motor
The reed contact that is in the vehicle, and the additional reed contact
should be connected to the module. The module then influences the
motor: After a stop it starts gently. When crossing the stop with the
first reed contact the vehicle brakes gently and finally stops when
crossing the stop with the second reed contact. If the reed contacts are
not connected to the module, controlling the back lights and the flash
lights at a stop is not possible.
Technical specifications
Supply voltage 2 to 3 Volt D.C.
Current consumption
(without connected loads) approx. 4 mA
Max. total current 80 mA
Max. current per output 20 mA
Protected to IP 00
Ambient temperature in use 0 - + 60 °C
Ambient temperature in storage -10 - + 80 °C
Comparative humidity allowed max. 85 %
Dimensions approx. 12 x 18 x 2,1 mm
Weight approx. 0,5 g

FCS-3 English
Seite 25
Fig. 1:
Cicuit Diagram
Checking the package contents
Check the contents of the package for completeness after unpacking:
§one module,
§additional components: one resistor 10 kΩ, one diode 1N4148, one
transistor BC 327, one reed-contact,
§one manual.
Required tools and materials
Make sure you have the following tools and materials ready for use:
§an electronic soldering iron (max. 30 Watt) with a fine tip,
§a soldering iron stand,
§a tip-cleaning sponge and a heat-resistant mat,
§a small side cutter and wire stripper,
§a pair of tweezers,
§tin solder (0,5 mm. diameter),
§enamelled copper wire or thin connecting wire,
§LEDs for the lights,
§if necessary: series resistors for the front lights.

English FCS-3
Seite 26
!
Safe and correct soldering
Caution:
Incorrect soldering can cause dangers through fires and heat. Avoid
these dangers by reading and following the directions given in the
chapter Safety instructions. If you have had training in soldering you
can skip this chapter.
§Use a small soldering iron with max. 30 Watt. Keep the soldering tip
clean so the heat of the soldering iron is applied to the solder point
effectively.
§Only use electronic tin solder with flux.
§When soldering electronic circuits never use soldering-water or
soldering grease. They contain acids that can corrode components
and copper tracks.
§Solder quickly: holding the iron on the joints longer than necessary
can destroy components and can damage copper tracks or
soldering eyes.
§Apply the soldering tip to the soldering spot in such a way that the
wire and the soldering eye are heated at the same time.
Simultaneously add solder (not too much). As soon as the solder
becomes liquid take it away. Hold the soldering tip at the spot for a
few seconds so that the solder flows into the joint, then remove the
soldering iron.
§The joint should be held still for about 5 seconds after soldering.
§To make a good soldering joint you should use a clean and
unoxidised soldering tip. Clean the soldering tip with a damp piece
of cloth, a damp sponge or a piece of silicon cloth.
§After soldering check (preferably with a magnifying glass) tracks for
accidental solder bridges and short circuits. This would cause faulty
operation or, in the worst case, permanent damage. You can
remove excess solder by putting a clean soldering tip on the spot.
The solder will become liquid again and flow from the soldering
spot to the soldering tip.

FCS-3 English
Seite 27
Special features of the additional components
Resistors
Resistors reduce current. Their mounting orientation is of no
importance. The value of resistors for smaller power ratings
(under 5 W) is indicated through colour rings. Every colour
stands for another figure. The added resistor has a value of
10 kΩ (colour rings brown - black – orange – gold).
Diodes
Diodes allow the current to pass through in one direction only
(forward direction). The diode type is printed on the body.
Diodes must be mounted in a given direction. The negative
end is marked with a ring.
Transistors
Transistors are current amplifiers which convert low signals
into stronger ones. They have three contacts. As they are
polarized, they have to be mounted in a certain direction. Die
BC-Types have a housing in form of a half cylinder (SOT-
housing). The three connecting points are called basis (B),
collector (C) and emitter (E).
Light emitting diodes (LEDs)
When operated in the forward direction the LEDs light. They
are available in several different versions (differing in colour,
size, form, luminosity, maximum current, voltage limits). The
longer lead of wired LEDs is always the anode (positive pole).
With SMD-LEDs the cathode normally is shown by a mark on
the housing.
Light emitting diodes should always be connected via a series
resistor which limits the current and prevents failure. With
circuits designed for the connection of LEDs the series
resistors are often integrated on the circuit board.

English FCS-3
Seite 28
!
Reed contacts
Depending on their version reed contacts fulfill the task of a
closer or a change-over switch. They respond to a magentic
field, thus making possible contactless switching operations.
They consist of a glass bulb filled with a protective gas.
Sealed in the glass bulb are two or three reeds made of a
magnetic material. When bending the legs the glass bulb they
can be easily damaged through mechanical strain.
Mounting the FCS-3
Preparation
Open the housing of the vehicle. Locate the position for the module.
Disconnect all connections from the accumulator batteries, the motor and
the mounted reed contact except for the lead-in wire to the charging
contact. Follow the connection diagram fig. 2 (page II in the centre of this
handbook) and the special features of the addional components.
In many vehicles the resistor R7 shown in the connection diagram is
mounted into the lead-in wire to the motor. The resistor has to be
connected to the plus pole of the accumulator battery if not yet
mounted that way. If there is no resistor, R7 is not applicable.
Connection to the supply voltage
Connect the connecting point X2 to the plus pole of the accumulator
battery and the minus pole of the accumulator battery to the existing
switch S of the vehicle. Connect the second pole of the switch to the
connecting point X1.
Caution:
The module should not be connected the wrong way round. Otherwise
it will be destroyed when put into operation.
Connection of the existing reed contact
The existing reed contact has three connecting points, one at side A
and two at side B. Connect the connecting point at side A to the
connecting point X2 and the plus pole of the accumulator battery.

FCS-3 English
Seite 29
!
In order to check which one of the two connecting points of side B you
have to connect to the module, connect temporarily the minus pole of the
motor to the minus pole of theaccumulator battery and the plus pole of
the motor to one of the two connecting points at side B of the reed
contact. If the motor does not run with this connection, you have to
connect this connecting point to the connecting point X8 and the
enclosed resistor R10. If the motor runs with this connection, you have
to connect the other connecting point to the connecting point X8 and
the enclosed resistor R10. Finally disconnect the temporary connections
of the motor. Connect the second side of the resistor R10 to the
connecting point X3.
Connection of the additional reed contact
The additional reed contact has to be mounted as far as possible in front
of the vehicle. Connect the enclosed reed contact to the connecting points
X3 and X9.
Caution:
Reed contacts are sensitive to stress. Therfore be careful when bending
the legs in oder not to destroy the glass bulb.
Connection of the motor
Connect the enclosed diode 1N4148 to the connections of the motor.
Observe the polarity of the diode. Then connect the minus pole of the
motor to the connecting point X1. Next connect the collector (C) of the
enclosed transistor BC 327 to the plus pole of the motor, the basis (B)
to the connecting point X4 and the emitter (E) to the resistor R7. If
there is no resistor R7, connect the emitter directly to the plus pole of
the accumulator battery.
Connection of the LEDs for the flash lights
The two LEDs for the flash lights on the left or the right have to be
connected in series, i.e. the anode (+) of the one LED has to be connected
to the cathode (-) of the other LED. Next connect the disconnected anode
with connecting point X5 (flash lights on the right) or X7 (flash lights on the
left) and the disconnected cathode with connecting point X3.

English FCS-3
Seite 30
!
Connection of the LEDs for the stop and back lights
The two LEDs for the stop and back lights have to be connected in series,
i.e. the anode (+) of the one LED has to be connected to the cathode (-)
of the other LED. Next connect the disconnected anode with connecting
point X6 and the disconnected cathode with connecting point X3.
Connection of the diodes for the front light
You may connect up to two white LEDs for the front lighting to the
voltage output of the module. These LEDs are not controlled by the
stored software. They light as soon as the module is connected to the
power supply. Follow the connection diagram fig. 2!
Connect the anodes (+) of the LEDs to the soldering point X2 and the
cathodes (-) to the soldering point X3.
Caution:
The LEDs for the front light, which are connected to the voltage output
must be operated via series resistors! Otherwise the connected LEDs
are damaged and the circuit may not work as intended.
Computation of the series resistors for the front light LEDs
In order to spare the accumulator batteries it is recommended to
restrict the input of the LEDs for the front lighting to approx. 10 mA.
This guarantees as well a sufficient brightness. In this case you can
determine the series resistor from the following formula:
R = (UB- UF) / I = (4,8 - UF) / 0,01
R: necessary series resistor [Ohm]
UB: voltage at the voltage output of the circuit [V]
UF: forward voltage of the LED [V]
I: Current through the LED [A]
Example for a LED with UF= 4 V:
R = (4,8 – 4,0) / 0,01 = 80 Ohm
As the calculated value in this example does not correspond to a
commercial resistor we choose the next lower value, that means a
resistor of 68 Ohm.The input of the LED then is ca. 12. mA.

FCS-3 English
Seite 31
!
FAQ
§Parts are getting very hot and/or start to smoke.
Disconnect thesystem from the mains immediately!
Possible cause: The connections to the power supply are connected
the wrong round.
àCheck the connection. In this case the module is probably
damaged irreparably.
§The LEDs do not light / flash.
Possible cause: The LEDs are connected the wrong round.àCheck
the connections.
Possible cause: The power supply is interrupted. àCheck the
connections.
§The vehicle does not drive.
Possible cause: The wrong connecting point at side B of the existing
reed contact was used.àCheck the connection.
§The vehicle drives backwards.
Possible cause: The connections of the motor are connected
reverse. àCheck the connections.
If you cannot find the problem, please return the module for repair
(address on the cover page).
Manufacturer's note
According to DIN VDE 0869, the person who assembles and/or mounts
a circuit in its’ casing is the manufacturer of the product. If he sells the
product to another person he is responsible for passing on all the
relevant papers and his name and address.
Certification
This product conforms with the EC- directive 89/336/EWG on
electromagnetic radiation and is therefore CE certified.

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Seite 32
Conditions of warranty
This product is guaranteed for two years. The warranty includes the
correction of faults which can be proved to be due to material failure or
factory flaw. We guarantee the function of the parts according to the
parameters in not mounted state as well as the adherence to the
technical specifications of the circuit when assembled and connected
according to the manual.
Other claims are excluded. By law, we are not responsible for damages
or secondary damages in connection with this product. We retain the
right to repair, make improvements, supply spare parts or return the
purchase price.
The following invalidate the warranty:
§using an unsuitable soldering iron, solder containing liquid acids or
similar,
§if damage is caused by not following the instructions in this manual
or the connection diagram(s)
§if the module has been altered and repair attempts have failed,
§if arbitrary changes in the circuit are made,
§if additional components are added which are not described in the
manual,
§if the copper tracks or soldering eyes are damaged,
§if damage occurs due to an overload of the module,
§if connected to a incorrect voltage or current,
§if damaged by other persons,
§if damaged by faulty operation or if damaged by careless use or
abuse,
§if damaged by touching components before electrostatic
discharging of the hands.
* "Faller" is a registered and protected trade mark of Gebrueder Faller
GmbH, Guetenbach, Germany.

English FCS-3
Page II.1
Fig. 2: Connections

FCS-3 English
Page II.2
Connection Table
X1 Connection to „-” of the accumulator batteries
X2 Connection to „+”of the accumulator batteries /
front lighting
X3 Voltage output (-) of the circuit
X4 Motor control
X5 Right indicator
X6 Braking and reversing lights
X7 Left indicator
X8 Existing reed contact
X9 Secondary reed contact
External Components
D2 Additional Diode (1N4148)
G1, G2 Existing chargable batterries
LED1*, LED2* White LEDs for front lighthing
LED3*, LED4* Yellow LEDs fort he right indicator
LED5*, LED6* Red LEDs for braking and reversing lights
LED7*, LED8* Yellow LEDs for left indicator
MMotor
Q1 Ydditional Transistor (BC 327)
R7 Existing resistor
R8*,R9* Additional resistors for LED1 and LED2
R10 Additional resistor 10 kΩ
RK1 Existing reed contact
RK2 Additional reed-contact
SExisting switch
* Not supplied.

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