tams elektronik PZS-2 Series User manual

tams elektronik
Manual
PZS-2
Item no. 51-02025 | 51-02026 | 51-02027
Shuttle-train control
for analogue d.c. model railwa la outs
tams elektronik
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tams elektronik
English PZS-2
Table of 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. Functional test..........................................................................23
8. Connecting the PZS-2................................................................24
8.1. Schema............................................................................24
8.2. Dividing the shuttle-train section into parts.........................25
8.3. Connecting the power suppl .............................................25
8.4. Connecting the shuttle-train section to the PZS-2................27
9. Operation.................................................................................30
10. Programming the PZS-2.............................................................33
11. Check list for troubleshooting.....................................................36
12. Guarantee bond........................................................................38
13. EU declaration of conformit ......................................................39
14. Declarations conforming to the WEEE directive...........................39
© 01/2015 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.
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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 shuttle-train control PZS-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 PZS-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 PZS-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 20) and one PCB or
one read -built module or
one read -built module 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).
For testing the module ou need an electric light bulb.
In order to connect the module ou need wire. Recommended
diameters: > 0.25 mm² for all connections.
It is recommended to connect two push-buttons when programming
the module (e.g. push-buttons item no. 85-5212x, x=1,2,3,6,7).
When connecting points at terminus station 2, ou need for switching
the points:
a bistable rela 12 V (e.g. item no. 84-61111) or
a rela print RL-2 (e.g. 72-00055 as a kit or 72-00056 as a read -
built module).
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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.
Dangerous 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.
ther 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
Traffic between two terminus stations
The module controls the shuttle-train traffic between two terminus
stations of an analogue d.c. model railwa la out. At the second
terminus station points can be connected. This allows the alternating
traffic of two trains on the shuttle-train section. One additional stop can
be added in each direction of traffic between the terminus stations.
The shuttle-train traffic runs automaticall . The trains are slowed down
before reaching the terminus sections or the two stops as soon as a
track bus indicator integrated into the module indicates the train
coming into the respective section. The further course (braking, halting
and accelerating) is time controlled.
Extra halts
Independent of the automaticall running shuttle-train traffic between
the terminus sections (and the two stops), extra halts can be
incorporated with external circuits at an time and place.
Settings for the automatic operation
The traffic
between the terminus stations
between the terminus stations and the stops
between the terminus stations, the stops and/or the extra halts
alwa s runs in four phases: acceleration, normal speed, braking and
halt. The length of the phases acceleration, braking and halt can be
programmed
individuall for each of the two terminus stations
individuall for each of the two stops
jointl for all extra halts.
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The length of the phases is adjusted at a trimmer, the settings are
saved in an IC.
Manual operation
The halt at the terminus stations, the stops and the extra halts can be
prolonged b connecting the corresponding input of the module to
earth. Then the train stops at the next station, stop or halt as long as
the input is connected to earth (at least so long as programmed for the
particular halt). This allows intervention in the automatic shuttle-train
traffic via a switch or an external extra circuit.
The alread mentioned extra halts are released as soon as the
corresponding input of the module is connected to earth. This can be
done at an time, regardless in which position of the shuttle-train
section the train is. There are a whole range of applications for this,
e.g.:
effectuating extra halts along the shuttle-train section or
effectuating of signal stops or
triggering exact halts at defined positions (e.g. at the end of a
platform).
To trigger additional halts, several external circuits can be used, e.g.
manuall released swiches, couplings with reed contacts or light
barriers or complex signal control circuits.
vercurrent protection
A fuse integrated in the PZS-2 interrupts the current circuit with
overload or when a short circuit occurs on the rails and thus protects
the module from damage. The fuse is designed as a self-closing fuse
which heats with overload and re-activates the module automaticall
after cooling.
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Power supply
The module has to be supplied via a transformer not in use as driving
transformer. Note: Driving transformers providing an additional output
for further accessories are not suitable to suppl both rails and module,
as the internall contain onl one transformer. Note: It is possible to
suppl the module via a transformer used to suppl other accessories
as the rails (e.g. lighting).
When connecting the module to a transformer in use as driving
transformer, short circuits occur within the PZS-2 which ma damage it
irreparabl . The integrated fuse is without effect on these short circuits.
The seperate suppl of module and rails has the advantage that the
driving voltage can be set individuall . E.g. the maximum driving
voltage for the shuttle-train traffic (and the maximum speed with full
speed) can be (pre-) set individuall .
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Example for a shuttle-train
traffic controlled by a PZS-2
In order to use the PZS-2 it is
sufficient to connect the two
terminus stations. All other
extensions are optional.
B connecting a second rail at
terminus station 2 it is possible to
run two trains alternatingl . In
order to switch between the two
rails an extra bistable rela (not
included in the package) has to be
mounted.
The additional stops 1 (outward
bound) and 2 (return) are
independent of each other. This
allows a different routeing for
outward and return journe (which
is not obligator ).
Extra halts (e.g. at signals or
further stops) can be mounted at
an point of the route. To release
the stop ou need a switch or
another external circuit switching
against earth.
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5. Technical specifications
Caution:
The PZS-2 must not be supplied via a transformer in use as a driving
transformer! Further information see chapter 4. section "power
suppl ".
Suppl voltage for the module 12 - 18 Volt d.c. or a.c. voltage
Suppl voltage
for the shuttle-train section
d.c. driving transformer
Current consumption of the
module
approx. 30 mA
Max. current for the rails 1.000 mA
Predected 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. 60 g
approx. 108 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:
120 brown - red - brown (gold)
1,5 k brown - green - red (gold)
4,7 kellow - violet - red (gold)
330 k orange - orange - ellow (gold)
Trimm-potentiometers
Trimm-potentiometers (abrv. "trimm-pots") are resistors
which allow the value of resistance to be varied and that
wa to be adapted to the particular demands. In the
middle the have a small slot into which a small
screwdriver can be put in order to var the value of
resistance. The maximum value is printed on the housing.
Depending on the mounting situation trimmpots with a
l ing or a standing package are used.
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Ceramic capacitors
Among other things ceramic capacitors are used for
filtering interference voltages or as frequenc determining
parts. Ceramic capacitors are not polarized.
Normall the are marked with a three-digit number which
indicates the value coded.
The number 104 corresponds to the value 100 nF.
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.
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.
The diode t pe is printed on the package.
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Light emitting diodes (LEDs)
When operated in the forward direction the LEDs light.
The are available in several different versions (differing in
colour, size, form, luminosit , maximum current, voltage
limits).
Light emitting diodes should alwa s 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.
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.
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. BD 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 BD t pes)
are called basis, emitter and collector (abbreviated with the
letters B, E, C in the circuit diagram).
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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.
pto 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.
Voltage regulators
Voltage regulators are ICs, which convert a variable, non
regulated input voltage in a constant output voltage. The
are produced in transistor packages with three connecting
pins for input, output and earth.
The package forms of voltage regulators depend on their
t pe. In use are e.g. voltage regulators in flat TO
packages.
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Fuses
Fuses interrupt a current circuit, when the current exceeds
a certain strength of current for a set time. In this wa
the protect the circuit from damage due to overheating,
resulting from an excess current flowing for a longer
period. Excess current can be caused b overload or a
short circuit.
Terminal strips
Terminal strips are solder-in screw-t pe terminals. The provide a
solder-free and safe connection of the cables to the circuit, which can
still be separated an time.
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PCB layout and parts list
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Resistors R21, R22, R33, R34 120 
R3, R7, R12, R14, R15, R16 1,5 k
R2, R4, R5, R6, R8, R9, R10,
R11, R13
4,7 k
R17, R18, R19, R31, R32 330 k
Trimm-pots R1, R29, R30 470 k
Diodes D1- D20 1N400x, x=2...7
LEDs LED1 LED 3 mm
Rectifiers B1 B80C800
Ceramic
Capacitors
C1, C2, C3, C6, C7, C8, C10,
C11
100 nF
Electrol tic
capacitors
C12, C13, C14, C15 2,2 µF/25 V
C4, C5 100 µF/25 V
C9 220 µF/25 V
C16 470 µF/25 V
Transistors T1, T2 BC547
Q3, T3, T4, T5 BD679
Q1, Q2 BD680
ICs IC1 PIC 16F627 A-I/P
Opto couplers OK1, OK2 PC827
IC sockets IC1 18-pol.
OK1, OK2 8-pol.
Voltage
regulators
IC2 7805
Fuses F1 1 A
Terminal strips X1 2 x 9 poles
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