tams elektronik PZS-3 User manual

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PZS-3
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Pendelzugsteuerung nAnleitung
Shuttle-train control nManual
Gestion de navette nMode d´emploi
Pendeltreinsturing nHandleiding
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Art.-Nr. 21-01-095 / 22-01-095 n
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nDeutsch 3
nEnglish 29
nFrançais 53
nNederlands 77
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© 08/2007 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.
© 08/2007 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.
© 08/2007 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.
© 08/2007 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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PZS-3 English
Page 29
Table of contents
How to use this manual 30
Intended use 30
Safety instructions 31
EMC declaration 33
Operation overview 33
Technical specifications 35
Checking the package contents 36
Required tools and consumables 36
Safe and correct soldering 36
Assembling the kit 38
Performing a functional test 43
Connecting the shuttle-train control 44
Operation 46
Programming the shuttle-train control 48
FAQ 50
Manufacturer's note 51
Certification 51
Conditional warranty 51
Parts list I.1
Printed Circuit Board (PCB) layout (Fig. 1) I.2
Connections (Fig. 2-3) II-III
Circuit Diagram (Fig. 4) IV
(Pages I to IV in the centre of this handbook are removeable.)

English PZS-3
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!
How to use this manual
This manual gives step-by-step instructions for safe and correct
assembly of the kit and fitting of the ready-built 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 kit or the ready-built module on to another person, please
pass on the manual with it.
Intended use
The kit or the ready-built module can be assembled and operated using
this manual. It is designed for use in a.c. model railway layouts to
control realistic shuttle-train traffic between two terminus stations.
Any other use is inappropriate and invalidates any guarantees.
The kit and the ready-built module should not be assembled or fitted by
children under the age of 14.
Reading, understanding and following the instructions in this manual
are mandatory for the user.
Caution:
The circuit contains integrated circuits. These 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.

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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.
§Assembling and mounting the kit 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 transformers and 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.

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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.
Dangerous environments
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 kit or the ready-built 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.

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EMC declaration
This product is developed and tested in accordance with the European
standards EN 55014-1 and EN 61000-6-3 and meets the EC - directive
2004/108/EG and legal requirements.
To guarantee the electromagnetic tolerance in operation you must take
the following precautions:
§Connect the transformer only to an approved mains socket installed
by an authorised electrician.
§Make no changes to the original parts and accurately follow the
instructions, circuit diagram and PCB layut included with this
manual.
§Use only original spare parts if you have to repair the kit or the
ready-built module.
Operation overview
Please notice:
Pincipally, the shuttle-train control is not suitable for operation with
locomotives equipped with a decoder with automatic recognition of the
analogue mode.
The module controls the shuttle-train traffic between two terminus
stations of an analogue a.c. model railway layout. One additional stop
can be added in each direction of traffic between the terminus stations.
At the second terminus station points can be connected. This allows the
alternating traffic of two trains on the shuttle-train section.
The shuttle-train traffic runs automatically. The trains are slowed down
before reaching the terminus sections or the two 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.

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Independent of the automatically running shuttle-train traffic between
the terminus sections (and the two stops), extra halts can be
incorporated with external circuits at any time and place.
The traffic
§between the terminus stations
§between the terminus stations and the stops
§between the terminus stations, the stops and/or the extra halts
always 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 two terminus stations
§individually for each of the two stops
§jointly for all extra halts.
The length of the phases is adjusted at a trimmer, the settings are
saved in an IC.
The shuttle-train section has to be supplied via an analogue a.c.
transformer of it´s own. This allows the setting of the maximum driving
voltage for the shuttle-train section (and thus the maximum speed)
individually.
The 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 which position of the shuttle-train section the train is.
There are a whole range of applications for this module , e.g.:
§realising extra halts along the shuttle-train section or
§implikation 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 swiches, couplings with reed contacts or light
barriers or complex signal control circuits.

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Page 35
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 station, it remains still 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.
If the input which allows you to prolong the halt at the different stops,
is connected to earth while the train is moving, an emergency halt is
released. This prevents an accident when for instance the locomotive
has not accepted the switching impulse for the change of direction.
Technical specifications
Supply voltage for the module 16-18 Volt a.c. voltage
Supply voltage a.c. driving transformer
for the shuttle-train section of it´s own
Current consumption
(without connected loads) approx. 30 mA
Max. current per output 1 A
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. 73 x 80 mm
Weight approx. 70 g

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Checking the package contents
Check the contents of the package for completeness immediately after
unpacking:
§one kit, containing the components listed in the parts list (see
page I.1) and one PCB or
§one ready-built module,
§one manual.
Required tools and consumables
Make sure you have the following tools, equipment and materials ready
for use:
§an electronic soldering iron (max. 30 Watt) with a fine tip,
§a soldering iron stand,
§a tip-cleaning sponge,
§a heat-resistant mat,
§a small side cutter and wire stripper,
§a pair of tweezers and long nose pliers (not necessary for the
ready-built module),
§tin solder (0,5 mm. diameter),
§wire (diameter: >0,25 mm² for all connections),
§an electric light bulb for testing the module,
§if necessary, two push-button switches for programming the
module.
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

PZS-3 English
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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.
§Observe correct polarity orientation of semi-conductors, LEDs
electrolytic capacitors and integrated circuits before soldering and
ensure that the solder time does not exceed 5 seconds, otherwise
components can be damaged.
§Apply the soldering tip to the soldering spot in such a way 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
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.
§Do not move the component for about 5 seconds after soldering.
§To make a good soldering joint you 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 directly above the PCB solder side with
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 would cause faulty operation or, in the worst
case, 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.

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Assembling the kit
You can skip this part if you have purchased a ready-built module.
Preparation
Put the sorted components in front of you on your workbench. The
separate electronic components have the following special features you
should take into account to prevent mistakes in assembling:
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 colour ring in brackets indicates
the tolerance of the resistor which here is of no importance.
Value Colour rings
100 Ωbrown - black - brown (gold)
1,5 kΩ brown - green - red (gold)
4,7 kΩyellow - violet - red (gold)
330 kΩorange - orange - yellow (gold)
Trim-potentiometers
Trim-potentiometers (abrv. „trimmers“) are resistors which allow
the value of resistance to be varied and that way to be adapted to
the particular demands. In the middle they have a small slot into
which a small screwdriver can be put in order to vary the value of
resistance. The value is printed on the housing.
Depending on the mounting situation trimmers with a lying or
a standing housing are used. The mounting orientation is
preset by the layout of the three pins.

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Capacitors
Among other things capacitors are used for filtering interference
voltages or as frequency determining parts. Ceramic capacitors
are not polarized, for that reason their mounting orientation is
of no importance. Normally they are marked with a three-digit
number which indicates the value coded.
Value Number
100 nF 104
Electrolytic capacitors
Electrolytic capacitors are often used to store energy. In
contrast to ceramic capacitors they are polarized. One of the
two leads is marked with a minus sign which indicates the
mounting orientation. The value is given on the casing.
Electrolytic capacitors are available with different voltage sustaining
capabilities. Using an electrolytic capacitor with a voltage sustaining
capability higher than required is always possible.
Diodes
Diodes allow the current to pass through in one direction only
(forward direction), simultaneously the voltage is reduced by
0,3 to 0,8 V. Exceeding of the limit voltage always will destroy
the diode, and allow current to flow in the reverse 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. This is shown in the PCB layout.
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).
Light emitting diodes should always be connected via a series
resistor which limits the current and prevents failure.

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Rectifiers
Rectifiers convert alternating into direct voltage, they have
hardly no influence on the level of the voltage. They 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. The pin connections are printed on the housing.
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.
BC-Types have a housing in form of a half cylinder (SOT-
housing). The cross section is shown in the PCB Layout which
determines the mounting orientation.
The BD types have a flat housing (TO-housing) with the type
designation printed on the front side. The metallic rear is
unlabelled, on the PCB layout the rear is marked by a thick line.
Integrated circuits (ICs)
Depending on the type, ICs fulfil various tasks. They are
polarized and therefore have to be mounted in a certain
direction. 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. The mounting
orientation is shown by a semicircular or circular marking at the
end of the housing, which is also shown on the PCB layout.
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.
The mounting orientation of the sockets is preset as well. The
markings on the PCB, the socket and the IC must lie on top of
each other after mounting.

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Micro-Controler
Micro-controller are ICs, which are individually programmed
for the particular application. When leaving the
manufacturer´s works their memory is empty. The
programmed controller normally are only available from the
manufacturer of the circuit belonging to it.
Opto couplers
Opto couplers are ICs, which work similar to laser beam
switches. They combine in one housing a light emitting diode
and a photo transistor. Their task is the transmittion of
information without galvanic connection. Normally they are in
a DIL-housing with 4, 6 or 8 pins.
Voltage regulators
Voltage regulators are ICs, which convert a variable, non
regulated input voltage in a constant output voltage. They are
produced in transistor housings with three connecting pins for
input, output and earth.
With voltage reuglators in a flat TO-housing the unlabelled
metallic rear is marked by a thick line on the PCB layout.
Relays
Relays are electronic switches, depending on their position the one or
other (internal) connection is closed. Their mode of operation can be
compared to that of a push-button switch, i.e. the connection is only
closed as long as the voltage is applicated.
Relays which combine two switches in one housing are common as well
(shortly 2xUM). The switching between the two connections can be
heard clearly because of the resulting clicking sound.
The mounting orientation of the relays which are put in a rectangular
box shaped housing is given by the layout of the pins.

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!
Terminal strips
Terminal strips are solder-in screw-type terminals. They provide a
solder-free and safe connection of the cables to the circuit, which can
still be seperated any time. When several terminal strips have to be
mounted side by side, they have to be put together before mounting.
Assembling the kit
Note: The components R6 and JP1 shown on the layout, are not
required for this application and thus do not need to be inserted.
Start the assembly with the resistors and the diodes. First solder the
components on the solder side of the PCB and then cut the excess
wires with the side cutters, as short as possible.
Then insert and solder in the IC-sockets. The sockets must be mounted
according to the marking on the PCB.
Continue the assembly with the relay, the capacitors, the transistors
and the electrolytic capacitors. Then solder in the rectifier, the voltage
regulator, the trimmers and the LED.
Caution:
Relays, diodes, ICs, transistors, electrolytic capacitors, rectifiers, voltage
regulators, trimmer and the LEDs must be inserted in the right
direction! If you solder them the wrong way the affected parts can be
damaged when you connect the power. In the worst case the whole
circuit can be damaged. At the best, a wrongly connected part will not
function.
Next solder the terminal strips. Join them together before soldering.
Finally, insert the ICs into the soldered IC-sockets.
Caution:
Do not touch the ICs without first discharging yourself by touching a
radiator or other grounded metal parts. Do not bend the "legs" of the
ICs when inserting them into the sockets. Check that the markings on
the PCB, the socket and the IC show to the same direction.

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Performing a visual check
Perform a visual check after the assembly of the module and remove
faults if necessary:
§Remove all loose parts, wire ends or drops of solder from the PCB.
Remove all sharp wire ends.
§Check that solder contacts which are close to each other are not
unintentionally connected to each other. Risk of short circuit!
§Check that all components are polarised correctly.
When you have remedied all faults, go on to the next part.
Performing a functional test
Perform the functional test even if you have purchased a ready-built
module, as damages in transit cannot be excluded.
You don’t have to test all functions of the module before connecting it
to the model railway layout. The effort involved would offer no
advantages compared to testing the module after having connected it
to the model railway layout. The functional test as described should
only be carried out to test if the module basically works.
§Connect the electric light bulb to the connecting points 9 and 13.
§Connect the two connections of the driving transformer to the
connecting points 3 and 11, the polarity is of no importance. Turn
on the speed knob of the driving transformer.
§Connect the supplying transformer to the connecting points 2 and
10 and switch it on.
§The electic light bulb should slowly get brighter.
In case the bulb does not light different faults can be the reason for it.
You will find a list of possible faults and how to cure them in the
chapter „FAQ“.

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Connecting the shuttle-train control
Dividing the shuttle-train section into parts
The halts at the terminus stations and the two stops are initiated when
the train has come into the respective section and the accessory track
busy indicator has indicated the train coming in. The division of the
shuttle-train section should be done as follows:
§At least into the parts: terminus station 1 and terminus station 2.
§If neccessary into the additional parts: stop 1 and / or stop 2.
§In order to define a new part you should cut the middle conductor
at that point where the coming-in train has to start braking.
Connecting the shuttle-train section to the module
Follow the connections diagrams fig. 2 and the list below.
Make the connections between the shuttle-train section and the
connection points of the module according to the connecting diagram
and the list. You must make those connections marked grey in the list.
The other connections should be made only if required.
Connecting the power supply
Supplying transformer (= power supply
of the module)
Do not power the transformer yet!
2 and 10
Driving transformer (= power supply for the
shuttle-train section) 3 and 11
!

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Connecting the shuttle-train section
Section connection
point cutting point
Outer conductor / all sections 13
Terminus station 1 18 A
Terminus station 2 8D
Free section
If required it is possible to install "free sections" between the
terminus stations and the stops.
5B
Stop 1 (way there) and Stop 2 (way back)
It is possible to divide the section C into two parts and if
neccessary to seperate them by a "free section", in case the
two stops for the two directions are not situated at the same
place.
9 and 6 C (1, 2)
Stop 1 only (without stop 2) 9C (1)
Stop 2 only (without stop 1) 6C (2)
Additional connections
Points at terminus station 2
In case you do not use stop-points you should connect an
extra bistabile relais according to fig. 3 to the points (not
included in the package).
return line: 1
switching contacts:
14, 15
Switching input „prolonging the halting time“
(at a stop) or "emergency stop" (while
motion)
7, earth: 4
Switching input „extra halts“ 12, earth: 4
Programming input „save“ 16, earth: 4
Programming input „select“ 17, earth: 4

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Connecting points
In ordert to connect points you have to connect an additional bistable
relay according to fig. 3. The bistable relay switches on the power
supply for the one rail in terminus station 2 while switching off the
power supply for the other rail. If no bistabile relay is connected both
rails are constantly supplied with power.
Emergency stop at a terminus station
If the locomotive does not accept the impulse for changing the direction
at the terminus station, it goes on into the wrong direction. To prevent
accidents it is recommended to interrupt the middle conductor at the
point the train should not cross.
Operation
First operation and starting of new locomotives
On principle it is not possible for the shuttle-train control to set absolute
directions of motion ("way there" / "way back") for the locomotives.
When a train reaches a terminus station the module sends the impulse
for changing the actually set direction. Therefore you should keep to
the following when first starting the shuttle-train control or new
locomotives:
The train must start at a stop (not at a terminus station) or on a free
section. Depending on the position of the switching relay it goes into
the direction "there" or "back". If the train is standing at a terminus
station when first starting, it cannot be ruled out that it runs in the
wrong direction against the buffer.
If you want to integrate a second train into the shuttle-train service it
has to be set onto the switched-off rail in terminus-station 2 with
direction "terminus station 1" set.