tams elektronik KSM-2 User manual

tams elektronik
Manual
KSM-2
Item no. 49-01125 | 49-01126 | 49-01127
Loop module
for digital model railroad la outs
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tams elektronik
English KSM-2
Contents
1. Getting started............................................................................3
2. Safet instructions.......................................................................5
3. Safe and correct soldering...........................................................7
4. Operation overview.....................................................................9
5. Technical specifications..............................................................13
6. Assembling the kit.....................................................................14
7. Connecting the KSM-2...............................................................23
8. Check list for troubleshooting.....................................................27
9. Guarantee bond........................................................................29
10. EU declaration of conformit ......................................................30
11. Declarations conforming to the WEEE directive...........................30
© 10/2015 Tams Elektronik GmbH
All rights reserved. No part of this publication ma be reproduced or
transmitted in an form or b an means, electronic or mechanical,
including photocop ing, without prior permission in writing from Tams
Elektronik GmbH.
Subject to technical modification.
Remark: RailCom® is the registered trademark of the Lenz Elektronik
GmbH, Hüttenbergstraße 29, D-35398 Gießen. To increase the text´s
readabilit we have refrained from refering to this point in each
instance.
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1. Getting started
How to use this manual
This manual gives step-b -step instructions for safe and correct
assembl of the kit and fitting and connecting of the read -built
module, and operation. Before ou start, we advise ou to read the
whole manual, particularl the chapter on safet instructions and the
checklist for trouble shooting. You will then know where to take care
and how to prevent mistakes which take a lot of effort to correct.
Keep this manual safel so that ou can solve problems in the future. If
ou pass the kit or the read -built module on to another person, please
pass on the manual with it.
Intended use
The loop module KSM-2 is designed to be operated according to the
instructions in this manual in model building, especiall with model
railwa s. An other use is inappropriate and invalidates an guarantees.
The KSM-2 should not be assembled or mounted b children under the
age of 14.
Reading, understanding and following the instructions in this manual
are mandator for the user.
Caution:
The KSM-2 contains integrated circuits. These are ver sensitive to
static electricit . Do not touch components without first discharging
ourself. Touching a radiator or other grounded metal part will
discharge ou.
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Checking the package contents
Please make sure that our package contains:
one kit, containing the components listed in the parts list
( page 18) and one PCB or
one read -built module with a jumper put onto JP1 or
one read -built module with a jumper put onto JP1 in a housing
(complete unit),
a CD (containing the manual and further information).
Required materials
For assembling the kit ou need:
an electronic soldering iron (max. 30 Watt) or a regulated soldering
iron with a fine tip and a soldering iron stand,
a tip-cleaning sponge,
a heat-resistant mat,
a small side cutter and wire stripper,
as necessar a pair of tweezers and long nose pliers,
electronic tin solder (0,5 mm. diameter).
In order to connect the module ou need wire. Recommended
diameters: > 0,25 mm² for all connections.
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2. Safet instructions
Mechanical hazards
Cut wires can have sharp ends and can cause serious injuries. Watch
out for sharp edges when ou pick up the PCB.
Visibl damaged parts can cause unpredictable danger. Do not use
damaged parts: rec cle and replace them with new ones.
Electrical hazards
Touching powered, live components,
touching conducting components which are live due to malfunction,
short circuits and connecting the circuit to another voltage than
specified,
impermissibl high humidit and condensation build up
can cause serious injur due to electrical shock. Take the following
precautions to prevent this danger:
Never perform wiring on a powered module.
Assembling and mounting the kit should onl be done in closed,
clean, dr rooms. Beware of humidit .
Onl use low power for this module as described in this manual and
onl use certified transformers.
Connect transformers and soldering irons onl in approved mains
sockets installed b an authorised electrician.
Observe cable diameter requirements.
After condensation build up, allow a minimum of 2 hours for
dispersion.
Use onl original spare parts if ou have to repair the kit or the
read -built module.
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Fire risk
Touching flammable material with a hot soldering iron can cause fire,
which can result in injur or death through burns or suffocation.
Connect our soldering iron or soldering station onl when actuall
needed. Alwa s keep the soldering iron awa 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 accidentall touching our skin can
cause skin burns. As a precaution:
use a heat-resistant mat during soldering,
alwa s put the hot soldering iron in the soldering iron stand,
point the soldering iron tip carefull when soldering, and
remove liquid solder with a thick wet rag or wet sponge from the
soldering tip.
angerous environments
A working area that is too small or cramped is unsuitable and can cause
accidents, fires and injur . Prevent this b working in a clean, dr room
with enough freedom of movement.
Other dangers
Children can cause an of the accidents mentioned above because the
are inattentive and not responsible enough. Children under the age of
14 should not be allowed to work with this kit or the read -built
module.
Caution:
Little children can swallow small components with sharp edges, with
fatal results! Do not allow components to reach small children.
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In schools, training centres, clubs and workshops, assembl must be
supervised b qualified personnel.
In industrial institutions, health and safet regulations appl ing to
electronic work must be adhered to.
3. Safe and correct soldering
Caution:
Incorrect soldering can cause dangers through fires and heat. Avoid
these dangers b reading and following the directions given in the
chapter Safety instructions.
Use a small soldering iron with max. 30 Watt or a regulated
soldering iron.
Onl use electronic tin solder with flux.
When soldering electronic circuits never use soldering-water or
soldering grease. The contain acids that can corrode components
and copper tracks.
Insert the component connecting pins into the PCB´s holes as far as
possible without force. The components should be close to the
PCB`s surface.
Observe correct polarit orientation of the parts before soldering.
Solder quickl : holding the iron on the joints longer than necessar
can destro components and can damage copper tracks or soldering
e es.
Appl the soldering tip to the soldering spot in such a wa that the
part and the soldering e e are heated at the same time.
Simultaneousl add solder (not too much). As soon as the solder
becomes liquid take it awa . Hold the soldering tip at the spot for a
few seconds so that the solder flows into the joint, then remove the
soldering iron.
Do not move the component for about 5 seconds after soldering.
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To make a good soldering joint ou must 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.
Cut the wires after soldering directl above the soldering joint with a
side cutter.
After placing the parts, please double check for correct polarit .
Check the PCB tracks for solder bridges and short circuits created b
accident. This would cause fault operation or, in the worst case,
damage. You can remove excess solder b putting a clean soldering
tip on the spot. The solder will become liquid again and flow from
the soldering spot to the soldering tip.
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4. Operation overview
Loop problems
At the loop points in two-rail-s stems, different polarities meet with
each other. As soon as a vehicle bridges the differentl polarized
sections when driving in or out the terminal loop a short circuit occurs.
In digital la outs loop modules generall have to adapt the polarit
within the terminal loop to the one outside. In case the polarit outside
the terminal loop would be altered, different polarities would meet with
each other at the transition to the next booster section. Thus the
problem would be misaligned onl .
Fig. 1: Short circuit problem at the loop points
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Mode of operation of the KSM-2
The loop module KSM-2 changes the polarit within the loop before a
short cicuit occurs – independentl of the locomotive´s direction of
travel or the data format used to control the locomotive.
For that purpose transition zones are added between the la out and the
inside of the terminal loop. Integrated track bus modules detect the
direction of travel and position of the locomotive in the transition zones
and in the section within the loop. As long as onl one of the two track
bus indicators in the transition zones detects "bus ", the locomotive is
about to drive into the loop. When the section within the loops detects
"bus " as well, the locomotive is going to drive out of the loop.
Procedure
Phase 1: The two transition zones are switched currentless initiall .
Phase 2: After a locomotive has come into one of the two transition
zones, the integrated track bus indicator sends a bus message to a
micro controller on the printed circuit board. The micro controller
controls a rela which sets the "right" polarit within the loop. There is
no short circuit occuring as the locomotive is within the transition zones
which initiall is currentless.
Phase 3: After having set the polarit within the loop "properl " the two
interruptions at the initiall currentless transition zone are closed b an
integrated switch and the transition zone is supplied with current.
As a rule, the short interruption of the power suppl at the locomotive
´s front axle when coming into the initiall currentless transition zone
has no visible effects on the locomotive´s driving characteristics.
Phase 4: Shortl after the locomotive has left the transition zone (and
there is not sent a "bus "-message from this zone an longer), the
transition zone is switched currentless again.
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Fig. 2: Procedure
Track busy indicator conducted to the outside
The track bus indicator integrated into the KSM-2 which supervises the
section within the loop, is conducted to the outside of the module and
can be integrated into the rest of the la out´s control s stem. As it is
galvanicall separated from the rest of the circuit, digital feed back
modules (e.b. s88 modules) can be connected directl .
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Using the KSM-2 in RailCom supervised layouts
It is impossible to connect a RailCom detector directl to the inside of
the terminal loop. As the RailCom detector is an electric load, it would
create a permanent bus indication when connected directl to the
track section. This would invalidate the loop module´s function.
The KSM-2 has a special connection for a RailCom detector which
allows to link the terminal loop to a la out supervised b RailCom.
esigning a layout with the KSM-2
The rails in the loop´s inside have to be at least as long as the longest
train to pass the terminal loop. Additionall , two transition zones which
are at least half as long as the longest locomotive have to be added
between the points and the loop´s inside.
Due to priniciple onl one train is permitted to pass the terminal loop at
once.
The maximum current of all vehicles in the loop is 3 A (including motor
current of the locomotive, carriage lightings, other accessories).
Use with a turntable
With turntables different polarities possibl occur at the transitions
between bridge and the other parts of the la out after turning the
bridge. Loop modules can solve this problem.
However, loop modules of the t pe of the KSM-2 needing additional
transition zones are not suitable for use with turntables.
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5. Technical specifications
Data formats all
Suppl voltage 12 – 24 V a.c. or d.c. voltage
Caution:
The KSM-2 must not be supplied b a transformer in use to suppl
the digital s stem!
Current consumption (without
connected devices)
approx. 100 mA
Max. current of all vehicles in the loop 3 A
Protected to IP 00
Ambient temperature in use 0 ... +60 °C
Ambient temperature in storage -10 ... +80 °C
Comparative humidit allowed max. 85 %
Dimensions of the PCB
Dimensions including housing
approx. 72 x 82 mm
approx. 100 x 90 x 35 mm
Weight of the assembled board
Weight including housing
approx. 57 g
approx. 105 g
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6. Assembling the kit
You can skip this part if ou have purchased a read -built module or device.
Preparation
Put the sorted components in front of ou on our workbench.
The separate electronic components have the following special features
ou should take into account in assembling:
Resistors
Resistors reduce current.
The value of resistors for smaller power ratings is indicated
through colour rings. Ever colour stands for another
figure.
Carbon film resistors have 4 colour rings. The 4th ring
(given in brackets here) indicates the tolerance of the
resistor (gold = 5 %).
Value: Colour rings:
330 orange – orange – black (gold)
470 ellow - violet - brown (gold)
1 kbrown - black - red (gold)
2,2 k red - red - red (gold)
4,7 kellow - violet - red (gold)
47 kellow - violet - orange (gold)
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Electrolytic capacitors
Electrol tic capacitors are often used to store energ . In
contrast to ceramic capacitors the are polarized. The
value is given on the package.
Electrol tic capacitors are available with different voltage
sustaining capabilities. Using an electrol tic capacitor with
a voltage sustaining capabilit higher than required is
alwa s possible.
iodes and Zener diodes
Diodes allow the current to pass through in one direction
onl (forward direction), simultaneousl the voltage is
reduced b 0,3 to 0,8 V. Exceeding of the limit voltage
alwa s will destro the diode, and allow current to flow in
the reverse direction.
Zener diodes are used for limiting voltages. In contrast to "normal"
diodes the are not destro ed when the limit voltage is exceeded.
The diode t pe is printed on the package.
Rectifiers
Rectifiers convert alternating into direct voltage. The have
four pins: two for the input voltage (a.c. voltage) and two
for the output voltage (d.c. voltage). The pins for the
output voltage are polarized.
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Transistors
Transistors are current amplifiers which convert low signals into
stronger ones. There are several t pes in different package forms
available. The t pe designation is printed on the component.
Transistors for a low power rating (e.g. BC t pes) have a
package in form of a half z linder (SOT-package).
Transistors for a high power rating (e.g. BT t pes) have a
flat package (TO-package), which is in use in different
versions and sizes.
The three pins of bipolar transistors (e.g. BC and BT t pes)
are called basis, emitter and collector (abbreviated with the
letters B, E, C in the circuit diagram).
Integrated circuits (ICs)
Depending on the t pe, ICs fulfil various tasks. The most
common housing form is the so-called "DIL"-housing, from
which 4, 6, 8, 14, 16, 18 or more "legs" (pins) are
arranged along the long sides.
ICs are sensitive to damage during soldering (heat,
electrostatic charging). For that reason in the place of the
ICs IC sockets are soldered in, in which the ICs are
inserted later.
Microcontrollers
Microcontrollers are ICs, which are individuall programmed for the
particular application. The programmed controllers are onl available
from the manufacturer of the circuit belonging to it.
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Opto couplers
Opto couplers are ICs, which work similar to laser beam switches. The
combine in one housing a light emitting diode and a photo transistor. Their
task is the transmission of information without galvanic connection. The
are in a DIL-housing with at least 4 pins.
Relays
Rela s are electronic switches, depending on their position the one or
other (internal) connection is closed. The mode of operation of
monostable rela s can be compared to that of a push-button switch,
i.e. the connection is onl closed as long as the voltage is applicated.
Bistable rela s keep their status after switching – comparable to a
switch.
Rela s which combine two switches in one housing are common as well
(shortl 2xUM). The switching between the two connections can be
heard clearl because of the resulting clicking sound.
Screw terminals
Screw terminals provide a solder-free and safe connection of the cables
to the circuit, which can still be separated an time.
Terminal strips are available as single or double row versions with 2 or
3 poles (resp. 2x2 or 2x3 poles). Connections with an number of poles
can be created b linking several terminal strips. In order to fix them
the connecting cables are inserted and screwed (similar to a lustre
terminal).
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Parts list
Resistors R4, R7, R8 330 
R5, R9, R10, R11, R12,
R13, R14, R17, R18
470 
R23 1 kW
R2, R3, R15 2,2 kW
R1, R6, R19, R20 4,7 kW
R16 47 kW
Diodes D16 1N400x, x=2...7
D15, D17 1N4148
D13, D14 1N540x
Zener diodes D1 5V6
Rectifiers D1-4 B80C
Electrol tic
capacitors
C3, C4, C6 2,2 µF / > 10 V
C1, C2, C5 100 µF / > 25 V
Transistors T5, Q1, Q2 BC547B
T1, T2, T3 BT136
Micro-Controlers IC1 PIC12F508P
Opto couplers OK1, OK2, OK3 MOC3012M
OK4 PC817
OK5 PC827
IC-sockets OK1, OK2, OK3 6-pole
OK5, IC1 8-pole
Rela s RL1 2xUm 5V monostable
Pin strips JP1 2-pole
Jumper JP1 2-pole
Terminal strips X1 – X5 1x2-pole (1 unit)
1x3-pole (3 units)
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Fig. 3: PCB la out
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Assembly
Proceed according to the order given in the list below. First solder the
components on the solder side of the PCB and then cut the excess
wires with the side cutter. Follow the instructions on soldering in
section 3.
Caution:
Several components have to be mounted according to their polarit .
When soldering these components the wrong wa round, the can be
damaged when ou connect the power. In the worst case the whole
circuit can be damaged. At the best, a wrongl connected part will not
function.
1. Resistors Mounting orientation of no importance.
2. Diodes
Zener
diodes
Observe the polarit !
The negative end of the diodes is marked with a
ring. This is shown in the PCB la out.
3. Opto
coupler
Solder the opto coupler OK4 directl onto the PCB
(without socket).
4. IC sockets Mount the sockets that wa , the markings on the
sockets show in the same direction as the
markings on the PCB board.
5. Rectifiers Observe the polarit ! The pin connections are
printed on the housing. The longer connecting pin
is the positive pole.
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