tams elektronik PZS-3 User manual

Manual
PZS-3
Item no. 51-02035 | 51-02036 | 51-02037
Shuttle-train control
for analogue a.c. model rail ay layouts
tams elektronik
n n n

English PZS-3
Table of contents
1. Getting started............................................................................3
2. Safety instructions.......................................................................5
3. Safe and correct soldering...........................................................7
4. Operation overvie .....................................................................9
5. Technical specifications..............................................................13
6. Assembling the kit.....................................................................14
7. Functional test..........................................................................23
8. Connecting the PZS-3................................................................24
8.1. Schema............................................................................24
8.2. Dividing the shuttle-train section into parts.........................25
8.3. Connecting the po er supply.............................................25
8.4. Connecting the shuttle-train section to the PZS-3................27
9. Operation.................................................................................30
10. Programming the PZS-3.............................................................33
11. Check list for troubleshooting.....................................................36
12. Guarantee bond........................................................................38
13. EU declaration of conformity......................................................39
14. Declarations conforming to the WEEE directive...........................39
© 01/2015 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, ithout prior permission in riting from Tams
Elektronik GmbH.
Subject to technical modification.
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PZS-3 English
1. Getting started
How to use this manual
This manual gives step-by-step instructions for safe and correct
assembly of the kit and fitting and connecting of the ready-built
module, and operation. Before you start, e advise you to read the
hole manual, particularly the chapter on safety instructions and the
checklist for trouble shooting. You ill then kno here to take care
and ho to prevent mistakes hich take a lot of effort to correct.
Keep this manual safely so that you can solve problems in the future. If
you pass the kit or the ready-built module on to another person, please
pass on the manual ith it.
Intended use
The shuttle-train control PZS-3 is designed to be operated according to
the instructions in this manual in model building, especially ith model
rail ays. Any other use is inappropriate and invalidates any guarantees.
The PZS-3 should not be assembled or mounted by children under the
age of 14.
Reading, understanding and follo ing the instructions in this manual
are mandatory for the user.
Caution:
The PZS-3 contains integrated circuits. These are very sensitive to
static electricity. Do not touch components ithout first discharging
yourself. Touching a radiator or other grounded metal part ill
discharge you.
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English PZS-3
Checking the package contents
Please make sure that your package contains:
one kit, containing the components listed in the parts list
( page 20) and one PCB or
one ready-built module or
one ready-built module in a housing (complete unit),
a CD (containing the manual and further information).
Required materials
For assembling the kit you need:
an electronic soldering iron (max. 30 Watt) or a regulated soldering
iron ith a fine tip and a soldering iron stand,
a tip-cleaning sponge,
a heat-resistant mat,
a small side cutter and ire stripper,
as necessary a pair of t eezers and long nose pliers,
electronic tin solder (0,5 mm. diameter).
For testing the module you need an electric light bulb.
In order to connect the module you need ire. Recommended
diameters: > 0.25 mm² for all connections.
It is recommended to connect t o push-buttons hen programming
the module (e.g. push-buttons item no. 85-5212x, x=1,2,3,6,7).
When connecting points at terminus station 2, you need for s itching
the points:
a bistable relay 12 V (e.g. item no. 84-61111) or
a relay print RL-2 (e.g. 72-00055 as a kit or 72-00056 as a ready-
built module).
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PZS-3 English
2. Safety instructions
Mechanical hazards
Cut ires can have sharp ends and can cause serious injuries. Watch
out for sharp edges hen you pick up the PCB.
Visibly damaged parts can cause unpredictable danger. Do not use
damaged parts: recycle and replace them ith ne ones.
Electrical hazards
Touching po ered, live components,
touching conducting components hich are live due to malfunction,
short circuits and connecting the circuit to another voltage than
specified,
impermissibly high humidity and condensation build up
can cause serious injury due to electrical shock. Take the follo ing
precautions to prevent this danger:
Never perform iring on a po ered module.
Assembling and mounting the kit should only be done in closed,
clean, dry rooms. Be are of humidity.
Only use lo po er for this module as described in this manual and
only use certified transformers.
Connect transformers and soldering irons only in approved mains
sockets installed by an authorised electrician.
Observe cable diameter requirements.
After condensation build up, allo a minimum of 2 hours for
dispersion.
Use only original spare parts if you have to repair the kit or the
ready-built module.
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English PZS-3
Fire risk
Touching flammable material ith a hot soldering iron can cause fire,
hich can result in injury or death through burns or suffocation.
Connect your soldering iron or soldering station only hen actually
needed. Al ays keep the soldering iron a ay 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,
al ays put the hot soldering iron in the soldering iron stand,
point the soldering iron tip carefully hen soldering, and
remove liquid solder ith a thick et rag or et sponge from the
soldering tip.
angerous environments
A orking area that is too small or cramped is unsuitable and can cause
accidents, fires and injury. Prevent this by orking in a clean, dry room
ith 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 allo ed to ork ith this kit or the ready-built
module.
Caution:
Little children can s allo small components ith sharp edges, ith
fatal results! Do not allo components to reach small children.
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PZS-3 English
In schools, training centres, clubs and orkshops, assembly must be
supervised by qualified personnel.
In industrial institutions, health and safety regulations applying to
electronic ork must be adhered to.
3. Safe and correct soldering
Caution:
Incorrect soldering can cause dangers through fires and heat. Avoid
these dangers by reading and follo ing the directions given in the
chapter Safety instructions.
Use a small soldering iron ith max. 30 Watt or a regulated
soldering iron.
Only use electronic tin solder ith flux.
When soldering electronic circuits never use soldering- ater or
soldering grease. They contain acids that can corrode components
and copper tracks.
Insert the component connecting pins into the PCB´s holes as far as
possible ithout force. The components should be close to the
PCB`s surface.
Observe correct polarity orientation of the parts before soldering.
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 ay that the
part 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 a ay. Hold the soldering tip at the spot for a
fe seconds so that the solder flo s into the joint, then remove the
soldering iron.
Do not move the component for about 5 seconds after soldering.
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English PZS-3
To make a good soldering joint you must use a clean and unoxidised
soldering tip. Clean the soldering tip ith a damp piece of cloth, a
damp sponge or a piece of silicon cloth.
Cut the ires after soldering directly above the soldering joint ith a
side cutter.
After placing the parts, please double check for correct polarity.
Check the PCB tracks for solder bridges and short circuits created by
accident. This ould cause faulty operation or, in the orst case,
damage. You can remove excess solder by putting a clean soldering
tip on the spot. The solder ill become liquid again and flo from
the soldering spot to the soldering tip.
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PZS-3 English
4. Operation overvie
Traffic between two terminus stations
The module controls the shuttle-train traffic bet een t o terminus
stations of an analogue a.c. model rail ay layout. At the second
terminus station points can be connected. This allo s the alternating
traffic of t o trains on the shuttle-train section. One additional stop can
be added in each direction of traffic bet een the terminus stations.
The shuttle-train traffic runs automatically. The trains are slo ed do n
before reaching the terminus sections or the t o stops as soon as a
track busy 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 automatically running shuttle-train traffic bet een
the terminus sections (and the t o stops), extra halts can be
incorporated ith external circuits at any time and place.
Settings for the automatic operation
The traffic
bet een the terminus stations
bet een the terminus stations and the stops
bet een the terminus stations, the stops and/or the extra halts
al ays runs in four phases: acceleration, normal speed, braking and
halt. The length of the phases acceleration, braking and halt can be
programmed
individually for each of the t o terminus stations
individually for each of the t o stops
jointly for all extra halts.
The length of the phases is adjusted at a trimmer, the settings are
saved in an IC.
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English PZS-3
Manual operation
The halt at the terminus stations, the stops and the extra halts can be
prolonged by 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 allo s intervention in the automatic shuttle-train
traffic via a s itch or an external extra circuit.
The already mentioned extra halts are released as soon as the
corresponding input of the module is connected to earth. This can be
done at any time, regardless in hich position of the shuttle-train
section the train is. There are a hole 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.
manually released s iches, couplings ith reed contacts or light
barriers or complex signal control circuits.
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PZS-3 English
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 supply both rails and module,
as they internally contain only one transformer. Note: It is possible to
supply the module via a transformer used to supply other accessories
as the rails (e.g. lighting).
When connecting the module to a transformer in use as driving
transformer, short circuits occur ithin the PZS-3 hich may damage it
irreparably.
The seperate supply of module and rails has the advantage that the
driving voltage can be set individually. E.g. the maximum driving
voltage for the shuttle-train traffic (and the maximum speed ith full
speed) can be (pre-) set individually.
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English PZS-3
Example for a shuttle-train
traffic controlled by a PZS-3
In order to use the PZS-3 it is
sufficient to connect the t o
terminus stations. All other
extensions are optional.
By connecting a second rail at
terminus station 2 it is possible to
run t o trains alternatingly. In
order to s itch bet een the t o
rails an extra bistable relay (not
included in the package) has to be
mounted.
The additional stops 1 (out ard
bound) and 2 (return) are
independent of each other. This
allo s a different routeing for
out ard and return journey ( hich
is not obligatory).
Extra halts (e.g. at signals or
further stops) can be mounted at
any point of the route. To release
the stop you need a s itch or
another external circuit s itching
against earth.
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5. Technical specifications
Caution:
The PZS-3 must not be supplied via a transformer in use as a driving
transformer! Further information see chapter 4. section "po er
supply".
Supply voltage for the module 12 - 18 Volt d.c. or a.c. voltage
Supply voltage
for the shuttle-train section
a.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 humidity allo ed 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. 66 g
approx. 114 g
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English PZS-3
6. Assembling the kit
You can skip this part if you have purchased a ready-built module or device.
Preparation
Put the sorted components in front of you on your orkbench.
The separate electronic components have the follo ing special features
you should take into account in assembling:
Resistors
Resistors reduce current.
The value of resistors for smaller po er ratings is indicated
through colour rings. Every 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:
100 bro n - black - bro n (gold)
1,5 k bro n - green - red (gold)
4,7 kyello - violet - red (gold)
330 k orange - orange - yello (gold)
Trimm-potentiometers
Trimm-potentiometers (abrv. "trimm-pots") are resistors
hich allo the value of resistance to be varied and that
ay to be adapted to the particular demands. In the
middle they have a small slot into hich a small
scre driver can be put in order to vary the value of
resistance. The maximum value is printed on the housing.
Depending on the mounting situation trimmpots ith a
lying 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 frequency determining
parts. Ceramic capacitors are not polarized.
Normally they are marked ith a three-digit number hich
indicates the value coded.
The number 104 corresponds to the value 100 nF.
Electrolytic capacitors
Electrolytic capacitors are often used to store energy. In
contrast to ceramic capacitors they are polarized. The
value is given on the package.
Electrolytic capacitors are available ith different voltage
sustaining capabilities. Using an electrolytic capacitor ith
a voltage sustaining capability higher than required is
al ays possible.
iodes
Diodes allo the current to pass through in one direction
only (for ard direction), simultaneously the voltage is
reduced by 0,3 to 0,8 V. Exceeding of the limit voltage
al ays ill destroy the diode, and allo current to flo in
the reverse direction.
The diode type is printed on the package.
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Light emitting diodes (LE s)
When operated in the for ard direction the LEDs light.
They are available in several different versions (differing in
colour, size, form, luminosity, maximum current, voltage
limits).
Light emitting diodes should al ays be connected via a
series resistor hich 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. They have
four pins: t o for the input voltage (a.c. voltage) and t o
for the output voltage (d.c. voltage). The pins for the
output voltage are polarized.
Transistors
Transistors are current amplifiers hich convert lo signals into
stronger ones. There are several types in different package forms
available. The type designation is printed on the component.
Transistors for a lo po er rating (e.g. BC types) have a
package in form of a half zylinder (SOT-package).
Transistors for a high po er rating (e.g. BD types) have a
flat package (TO-package), hich is in use in different
versions and sizes.
The three pins of bipolar transistors (e.g. BC and BD types)
are called basis, emitter and collector (abbreviated ith the
letters B, E, C in the circuit diagram). T
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Integrated circuits (ICs)
Depending on the type, ICs fulfil various tasks. The most
common housing form is the so-called "DIL"-housing, from
hich 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 hich the ICs are
inserted later.
Microcontrollers
Microcontrollers are ICs, hich are individually programmed for the
particular application. The programmed controllers are only available
from the manufacturer of the circuit belonging to it.
Opto couplers
Opto couplers are ICs, hich ork similar to laser beam s itches. They
combine in one housing a light emitting diode and a photo transistor. Their
task is the transmission of information ithout galvanic connection. They
are in a DIL-housing ith at least 4 pins.
Voltage regulators
Voltage regulators are ICs, hich convert a variable, non
regulated input voltage in a constant output voltage. They
are produced in transistor packages ith three connecting
pins for input, output and earth.
The package forms of voltage regulators depend on their
type. In use are e.g. voltage regulators in flat TO
packages.
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Relays
Relays are electronic s itches, depending on their position the one or
other (internal) connection is closed. The mode of operation of
monostable relays can be compared to that of a push-button s itch,
i.e. the connection is only closed as long as the voltage is applicated.
Bistable relays keep their status after s itching – comparable to a
s itch.
Relays hich combine t o s itches in one housing are common as ell
(shortly 2xUM). The s itching bet een the t o connections can be
heard clearly because of the resulting clicking sound.
Terminal strips
Terminal strips are solder-in scre -type terminals. They provide a
solder-free and safe connection of the cables to the circuit, hich can
still be separated any time.
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PCB layout and parts list
Note: The components R6 and JP1 sho n on the layout, are not
required for this application and thus do not need to be inserted.
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Resistors R21, R22, R33, R34 100 W
R3, R12, R14, R15, R16 1,5 kW
R2, R4, R5, R6, R10, R11, R13 4,7 kW
R17, R18, R19, R31, R32 330 kW
Trimm-pots R1, R29, R30 470 kW
Diodes D1- D20 1N400x, x=2...7
LEDs LED1 LED 3mm
Transistors T1, T2 BC547
T3, T4 BD679
Q1 BD680
Ceramic
Capacitors
C1, C2, C3, C6, C7, C8, C10,
C11, C13, C14, C15
100 nF
Electrolytic
capacitors
C4, C5 100 µF/25 V
C9 220 µF/25 V
C16 470 µF/25 V
C17, C18 470 µF/50 V
Rectifiers B1, B2 B80C800
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
Relais RL1 monostable
2 x Um 5 V
Terminal strips X1 2 x 9 poles
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