tams elektronik RailCom RCD-2 User manual

Manual
RCD-2
Item no. 45-01025 | 45-01026 | 45-01027
2-fold RailCom detector
with inte rated 2-fold track occupancy indicator
and 8 switchin outputs
tams elektronik
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Contents
1. Gettin started ...........................................................................3
2. Safety instructions.......................................................................6
3. Safe and correct solderin ...........................................................8
4. Back round information: RailCom...............................................10
5. Operatin mode of the RCD-2....................................................12
6. Technical specifications..............................................................14
7. Assemblin the kit ....................................................................15
8. Connectin the RCD-2...............................................................24
9. Pro rammin the RCD-2............................................................29
10. Check list for troubleshootin .....................................................36
11. Guarantee bond........................................................................38
12. EU declaration of conformity......................................................39
13. Declarations conformin to the WEEE directive...........................39
© 07/2013 Tams Elektronik GmbH
All ri hts reserved. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic or mechanical,
includin photocopyin , without prior permission in writin from Tams
Elektronik GmbH.
Subject to technical modification.
Remark: RailCom® is the re istered trademark of the Lenz Elektronik
GmbH, Hüttenber straße 29, D-35398 Gießen. To increase the text´s
readability we have refrained from referin to this point in each
instance.
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1. Gettin started
How to use this manual
This manual ives step-by-step instructions for safe and correct
assembly of the kit and fittin and connectin 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
checklist for trouble shootin . 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 RailCom detector RCD-2 is desi ned to be operated accordin to
the instructions in this manual with di ital model railways. Any other
use is inappropriate and invalidates any uarantees.
The RCD-2 should not be assembled or mounted by children under the
a e of 14.
Readin , understandin and followin the instructions in this manual
are mandatory for the user.
Caution:
The RCD-2 contains inte rated circuits. These are very sensitive to
static electricity. Do not touch components without first dischar in
yourself. Touchin a radiator or other rounded metal part will
dischar e you.
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Checking the package contents
Please make sure that your packa e contains:
one kit, containin the components listed in the parts list and one
PCB or
one ready-built module or
one ready-built module in a housin (complete unit),
one jumper for pro rammin the address,
3 distortion resistors (1 piece 120 W, 2 pieces 4,7 kW),
a CD (containin the manual and further information).
Required materials
For assemblin the kit you need:
an electronic solderin iron (max. 30 Watt) or a re ulated solderin
iron with a fine tip and a solderin iron stand,
a tip-cleanin spon e,
a heat-resistant mat,
a small side cutter and wire stripper,
as necessary a pair of tweezers and lon nose pliers,
electronic tin solder (0,5 mm. diameter).
In order to connect the module you need wire. Recommended
diameters:
data bus: > 0,1 mm². It is recommended to use twin wire (e. . LiYz,
2x0,19 mm², red-brown, item no. 73-30037);
connections to the rails and the booster: > 0,25 mm²;
connections to the inte rated track occupancy indicator: > 0,1 mm²;
connection of downstream circuits to the switchin outputs:
> 0,1 mm²
connections to the detector´s power supply: > 0,25 mm².
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As a power supply for the RCD-2 you cannot use the transformer
supplyin the di ital control. It is recommended to use a separate
transformer for the supply of all RailCom components on your layout
(12 – 18 V d.c. or a.c. volta e.)
If you intend to display and / or transfer the read-out data to a PC, you
need external display devices resp. a PC interface, e. .
sin le display device RCA-1 (item no. 45-02016);
24-fold display device RCA-24 (item no. 45-02247);
PC interface RC-Link (item no. 45-02257 with USB interface or 45-
02267 with V24 interface).
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2. Safety instructions
Mechanical hazards
Cut wires can have sharp ends and can cause serious injuries. Watch
out for sharp ed es when you pick up the PCB.
Visibly dama ed parts can cause unpredictable dan er. Do not use
dama ed parts: recycle and replace them with new ones.
Electrical hazards
Touchin powered, live components,
touchin conductin components which are live due to malfunction,
short circuits and connectin the circuit to another volta e than
specified,
impermissibly hi h humidity and condensation build up
can cause serious injury due to electrical shock. Take the followin
precautions to prevent this dan er:
Never perform wirin on a powered module.
Assemblin and mountin 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 solderin 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 ori inal spare parts if you have to repair the kit or the
ready-built module.
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Fire risk
Touchin flammable material with a hot solderin iron can cause fire,
which can result in injury or death throu h burns or suffocation.
Connect your solderin iron or solderin station only when actually
needed. Always keep the solderin iron away from inflammable
materials. Use a suitable solderin iron stand. Never leave a hot
solderin iron or station unattended.
Thermal danger
A hot solderin iron or liquid solder accidentally touchin your skin can
cause skin burns. As a precaution:
use a heat-resistant mat durin solderin ,
always put the hot solderin iron in the solderin iron stand,
point the solderin iron tip carefully when solderin , and
remove liquid solder with a thick wet ra or wet spon e from the
solderin tip.
angerous environments
A workin area that is too small or cramped is unsuitable and can cause
accidents, fires and injury. Prevent this by workin in a clean, dry room
with enou h freedom of movement.
Other dangers
Children can cause any of the accidents mentioned above because they
are inattentive and not responsible enou h. Children under the a e of
14 should not be allowed to work with this kit or the ready-built
module.
Caution:
Little children can swallow small components with sharp ed es, with
fatal results! Do not allow components to reach small children.
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In schools, trainin centres, clubs and workshops, assembly must be
supervised by qualified personnel.
In industrial institutions, health and safety re ulations applyin to
electronic work must be adhered to.
3. Safe and correct solderin
Caution:
Incorrect solderin can cause dan ers throu h fires and heat. Avoid
these dan ers by readin and followin the directions iven in the
chapter Safety instructions.
Use a small solderin iron with max. 30 Watt or a re ulated
solderin iron.
Only use electronic tin solder with flux.
When solderin electronic circuits never use solderin -water or
solderin rease. They contain acids that can corrode components
and copper tracks.
Insert the component connectin pins into the PCB´s holes as far as
possible without force. The components should be close to the PCB
´s surface.
Observe correct polarity orientation of the parts before solderin .
Solder quickly: holdin the iron on the joints lon er than necessary
can destroy components and can dama e copper tracks or solderin
eyes.
Apply the solderin tip to the solderin spot in such a way that the
part and the solderin 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 solderin tip at the spot for a
few seconds so that the solder flows into the joint, then remove the
solderin iron.
Do not move the component for about 5 seconds after solderin .
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To make a ood solderin joint you must use a clean and unoxidised
solderin tip. Clean the solderin tip with a damp piece of cloth, a
damp spon e or a piece of silicon cloth.
Cut the wires after solderin directly above the solderin joint with a
side cutter.
After placin the parts, please double check for correct polarity.
Check the PCB tracks for solder brid es and short circuits created by
accident. This would cause faulty operation or, in the worst case,
dama e. You can remove excess solder by puttin a clean solderin
tip on the spot. The solder will become liquid a ain and flow from
the solderin spot to the solderin tip.
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4. Back round information: RailCom
Feedback with RailCom
RailCom is a standard for bi-directional communication in di ital model
railway layouts controlled in DCC-format. It allows e. . the feedback of
the address and the CV values from RailCom decoders to the di ital
control unit or to special receivers (so-called detectors).
To transfer the RailCom messa es special RailCom boosters supplyin
the so-called RailCom cutout have to be used.
ata transfer between RailCom components
The RailCom standard is the basis of the communication between
RailCom compatible decoders and RailCom detectors, which allows you
to use detectors and decoders of different manufacturers to ether. On
the other hand, a manufacturer specific data bus is used to
communicate between detectors, display devices and PC interfaces.
That is the reason why the use of detectors, display devices and PC
interfaces of one manufacturer is mandatory.
The data bus used by Tams Elektronik for the communication between
detectors, display devices and PC interfaces allows you
to control up to 24 separate track sections and
to connect up to 32 RailCom devices (detectors RCD-1, RCD-2 or
RCD-8, display devices RCA-1 or RCA-24, PC interfaces RC-Link).
In order to assi n the detectors, display devices and PC interfaces to
each other, they et addresses between 1 and 24.
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Example for the data transfer in the Tams specific data bus








There are five different detectors connected to the data bus, all
to ether controllin 13 separate track sections. In order to display
and exploit the data there are used:
four sin le display devices RCA-1 displayin the data from one
section each,
one 24-fold display device RCA-24, displayin the data from all 13
track sections,
one RailCom PC interface RC-Link.
Bus line
For technical reasons, there are two wires with a diameter of minimum
0,10 mm² mandatory as a bus line for the communication between
detectors, display devices and PC interfaces (lines A and B). In order to
minimise the vulnerability towards disturbances from other cables, the
two wires should be twisted. It is recommended to use twin wire (e. .
LiYz, 2x0,19 mm², red-brown, item no. 73-30037)
The bus line has to be looped throu h from one to the other device.
When connectin them the lines A and B always have to be assi ned to
the correspondin connection points A and B of the devices.
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5. Operatin mode of the RCD-2
Supervising track sections with RailCom
The RailCom detector RCD-2 picks up the RailCom si nals from maximum
two track sections separated from each other. These are possibly:
Addresses of the vehicle decoders in the rail section. The decoder´s
address is sent permanently.
CV-values of the vehicle decoders in the rail section. The CV-values are
sent only after a read out command (i.e. sent by the control unit).
isplaying and transferring the data
There is no display for the RailCom feedback si nals inte rated in the
RCD-2. In order to display the received data special RailCom display
devices have to be connected (e. . sin le display device RCA-1 or 24-
fold display device RCA-24). These display devices can be mounted in
those places of the railway layout where needed.
In addition to display devices or instead of display devices, units passin on
data to a PC (e. . RC-Link) or to the di ital control unit can be connected.
The RCD-2 verifies the si nals it receives and sends the "clean" si nals
via a Tams specific databus to the downstream devices.
Integrated track occupancy indicator
There is an inte rated track occupancy indicator for each of the two
track sections of the RCD-2 which is able to detect also loads not
sendin a RailCom si nal. The messa es "track occupied" are displayed
in assi ned display modules (e. . RCA-1 or RCA-24) or transferred by
an interface (e. . RC-Link) to a PC.
The two outputs of the inte rated track occupancy indicators have been
carried to the outside and thus can be used for the connection of
conventional feedback modules. This allows you to inte rate the track
sections into a conventional feedback system controllin only the busy
condition of the track sections (e. . s88).
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etection of the rerailing direction
In 2-rail systems the detector detects the direction in which the
locomotive has been rerailed. This information is of importance e. .
when the locomotive´s direction has to be detected in invisible sections
or serves as a basis for a PC software. The rerailin direction is
displayed in assi ned display devices (e. . RCA-1 or RCA-24) or
transferred by an interface (e. . RC-Link) to a PC
Integrated switching outputs
The RCD-2 has 8 switchin outputs for the connection of downstream
circuits which can be assi ned to the controlled track sections accordin
to your needs. This allows you to release switchin operations
dependin on the locomotives´addresses pullin into a rail section.
Examples are switchin succeedin points or releasin announcements
at the station for particular locomotive addresses.
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6. Technical specifications
Attention: As a power supply for the RCD-2 you should not use the
transformer supplyin the di ital control. If possible you should use a
separate transformer supplyin only the RailCom components on your
layout.
Supply volta e 12 - 18 Volt d.c.
or a.c. volta e
Di ital format DCC
Feedback lo RailCom
Number of sections controlled by
RailCom 2
Number of outputs of track occupancy
indicators
max. current / output
2
100 mA
Number of switchin outputs
max. current / switchin output
max. Strom for switchin outputs
8
300 mA
500 mA
Current consumption without connected
loads approx. 100 mA
Protected to IP 00
Ambient temperature in use 0 ... +60 °C
Ambient temperature in stora e -10 ... +80 °C
Comparative humidity allowed max. 85 %
Dimensions of the PCB (approx.)
Dimensions includin housin (approx.)
72 x 82 mm
100 x 90 x 35 mm
Wei ht of the assembled board (approx.)
Wei ht includin housin (approx. )
75
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7. Assemblin 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 workbench.
The separate electronic components have the followin special features
you should take into account in assemblin :
Resistors
Resistors reduce current.
The value of resistors for smaller power ratin s is indicated
throu h colour rin s. Every colour stands for another
fi ure.
Carbon film resistors und eini e Arten von
Drahtwiderständen have 4 colour rin s. The 4th rin ( iven
in brackets here) indicates the tolerance of the resistor
( old = 5 %).
Value: Colour rin s:
220 red - red - brown ( old)
560 reen - blue - brown ( old)
820 rey - red - brown ( old)
1 kbrown - black - red ( old)
2,2 k red - red - red ( old)
4,7 kyellow - violet - red ( old)
10 kbrown - black - oran e ( old)
33 koran e - oran e - oran e ( old)
270 kred - violet - yellow ( old)
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Metal film resistors have 5 colour rin s. The 5th rin ( iven
in brackets here) indicates the tolerance of the resistor
(brown = 1 %).
Value: Colour rin s:
1,5 brown - reen – black - silver (brown)
Ceramic capacitors
Amon other thin s ceramic capacitors are used for
filterin interference volta es or as frequency determinin
parts. Ceramic capacitors are not polarized.
Normally they are marked with a three-di it number which
indicates the value coded.
Value: Number:
10 nF 103
100 nF 104
Electrolytic capacitors
Electrolytic capacitors are often used to store ener y. In
contrast to ceramic capacitors they are polarized. The
value is iven on the casin .
Electrolytic capacitors are available with different volta e
sustainin capabilities. Usin an electrolytic capacitor with
a volta e sustainin capability hi her than required is
always possible.
iodes
Diodes allow the current to pass throu h in one direction
only (forward direction), simultaneously the volta e is
reduced by 0,3 to 0,8 V. Exceedin of the limit volta e
always will destroy the diode, and allow current to flow in
the reverse direction. The diode type is printed on the body.
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Light emitting diodes (LE s)
When operated in the forward direction the LEDs li ht. They
are available in several different versions (differin in colour,
size, form, luminosity, maximum current, volta e limits).
Li ht emittin diodes should always be connected via a
series resistor which limits the current and prevents failure.
Transistors
Transistors are current amplifiers which convert low si nals into
stron er ones. There are several types in different packa e forms
available. The type desi nation is printed on the component.
Transistors for a low power ratin (e. . BC and BS types)
have a packa e in form of a half zylinder (SOT-packa e).
Transistors for a hi h power ratin (e. . BD types) have a
flat packa e (TO-packa e), which is in use in different
versions and sizes.
The three pins of bipolar transistors (e. . BC and BD types)
are called basis, emitter and collector (abbreviated with the
letters B, E, C in the circuit dia ram). The three pins of the
field effect transistors (e. . BS types) are called "source",
" ate" and "drain" (abbreviated with the letters S, G, D in
the circuit dia ram).
Integrated circuits (ICs)
Dependin on the type, ICs fulfil various tasks. The most
common housin form is the so-called "DIL"-housin , from
which 4, 6, 8, 14, 16, 18 or more "le s" (pins) are
arran ed alon the lon sides.
ICs are sensitive to dama e durin solderin (heat,
electrostatic char in ). For that reason in the place of the
ICs IC sockets are soldered in, in which the ICs are
inserted later.
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Microcontrollers
Microcontrollers are ICs, which are individually pro rammed for the
particular application. The pro rammed controller are only available
from the manufacturer of the circuit belon in to it.
Opto couplers
Opto couplers are ICs, which work similar to laser beam switches. They
combine in one housin a li ht emittin diode and a photo transistor. Their
task is the transmittion of information without alvanic connection. They are
in a DIL-housin with at least 4 pins.
Voltage regulators
Volta e re ulators are ICs, which convert a variable, non
re ulated input volta e in a constant output volta e. They
are produced in transistor packa es with three connectin
pins for input, output and earth.
The packa e forms of volta e re ulators depend on their
type. In use are volta e re ulators in SOT packa es (half
cylinder shaped) and in flat TO packa es.
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 separated any time.
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Parts list
Carbon film
resistors
R13, R21 220 W
R10, R15, R24, R26 560 W
R22 820 W
R3, R11, R12, R14, R17 1 kW
R1, R4 2,2 kW
R5, R7, R8, R16 4,7 kW
R6, R9, R19, R20, R27, R28 10 kW
R31 33 kW
R23 270 kW
Metal film resistors R2, R25 1,5 W
Capacitors C1 10 nF
C3, C5, C6, C7, C15, C16, C34 100 nF
Electrolytic
capacitors
C2, C4 100 µF
C14 220 µF
C17 470 µF
Diodes D4, D5, D6, D7, D14 1N400x, x=2..7
D3, D8, D9, D11 1N540x, x>1
LEDs LED1 3 mm
Transistors for a
low power ratin
Q1, Q5, Q9, Q10 BC547B
Q7, Q8 BC557B
Q4, Q6, T1, T2 BS170
Transistors for a
hi h power ratin
Q3 BD679
ICs IC2 SN75176
IC3 ULN2004AN
IC9 LM339N
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Micro-Controler IC1 MEGA162P
Photocoupleurs OK2 PC827
IC-sockets IC1 40-pole
IC2, OK2 8-pole
IC3 16-pole
IC9 14-pole
Volta e re ulators IC 4 7805
Terminal strips X3 1 x 3-pole
Double terminal
strips
X1, X2, X5 2 x 9-pole
Solder pin JP1 2-pole
Not assembled R18, C12, C13, Q2, SV1, SV3,
X4
Distortion resistors RS1 120 W
RS2, RS3 4,7 kW
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