tams elektronik KSM-1 User manual

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KSM-1
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Kehrschleifenmodul für
Digitalsysteme n
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Loop module for digital
controlled model railways n
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Module de boucle de
retournement pour des
réseaux numériques n
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Keerlusmodule voor
digitaalsystemen n
nAnleitung
nManual
nMode d´emploi
nHandleiding
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Art.-Nr. 21-01-050 C 21 03 24
Art.-Nr. 22-01-050 C 21 03 25 n

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Deutsch 3
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English 18
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Français 31
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Nederlands 45
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© 12/2002 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.
© 12/2002 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.
© 12/2002 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.
© 12/2002 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.n

English KSM-1
Page 18
Table of contents
How to use this manual 19
Intended use 19
Safety instructions 20
EMC declaration 21
Operation overview 22
Technical specifications 22
Choosing the power supply 23
Checking the package contents 23
Required tools and consumables 23
Safe and correct soldering 24
Assembling the kit 25
Performing a visual check 27
Functional tests and connection of the loop module 28
FAQ 28
Manufacturer's note 29
Certification 29
Conditional warranty 30
Parts list I
Printed Circuit Board (PCB) layout (Fig. 1) II
Connections (Fig. 2) III
Circuit Diagram (Fig. 3) IV
(Pages I to IV in the centre of this handbook are removeable.)

KSM-1 English
Page 19
!
How to use this manual
If you have no specialist technical training, this manual gives step-by-
step instructions for safe and correct assembly of the kit or 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 on to another person, please pass on the manual with it.
Intended use
Caution:
Integrated circuits 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.
The kit or the ready-built module can be assembled or fitted using this
manual. The ready-built module is designed for use in digital model railways
with a two-rail system. The loop Module detects short circuits which may
occur when a locomotive gets into the supervised section. In this event it
changes the polarity within the loop thus neutralizes the short circuit.
The ready-built module is designed for use in model railways. It delays
electrical switching impulses of a given length for an optional period of
time of up to 60 seconds. The module can be used e.g. for the delayed
initiation of solenoid accessories (e.g. semaphore signals, points,
bistable relays).
The kit and the ready-built module are not suitable for children under
the age of 14.
Reading, understanding and following the instructions in this manual
are mandatory for the user.
Any other use of the kit is inappropriate and invalidates any guarantees.

English KSM-1
Page 20
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 a higher voltage than designed,
§impermissibly high humidity,
§condensation of water
can cause serious injury due to electrical shock. Take the following
precautions to prevent this danger:
§Never perform wiring on a powered module.
§Only use low power for this module as described in this manual and
only use certified transformers.
§Connect transformers and soldering stations only in approved mains
sockets installed by an authorised electrician.
§Observe cable diameter requirements.
§After the condensation of water do not start working until after a
minimum of 2 hours of acclimatisation.
§Mounting the module should only be done in closed, clean, dry
rooms. Beware of humidity.
§Use only original spare parts if you have to repair the module.
Fire risk
Touching flammable material with a hot soldering iron can cause life-
threatening fire, burns and toxic smoke. Connect your soldering iron or

KSM-1 English
Page 21
soldering station only when actually needed. Use the correct soldering iron
or station and 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.
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. Life
threatening! 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.
EMC declaration
This product is developed in accordance with the European standards EN
55014 and EN 50082-1, tested corresponding to the EC - directive
89/336/EWG (EMVG of 09/11/1992, electromagnetic tolerance) and meets
legal requirements.
To guarantee the electromagnetic tolerance you must take the
following precautions:

English KSM-1
Page 22
§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 layout included with this manual.
§Use only original spare parts if you have to repair the kit or the
ready-built module.
Operation overview
In two-rail systems opposing electrical poles collide at the points into a
loop. This causes a short circuit when the points are passed by a
locomotive if no measures are taken to prevent it.
The loop module is controlled by an IC that permanently supervises the
voltage on the rails within the loop. The IC detects a short circuit which
may occur when a locomotive gets into or out of the supervised section.
The direction in which the locomotive is moving within the loop is not
significant.
When a short circuit occurs, the voltage decreases below a defined
value and the IC switches a relay to reverse the connections (and
thereby also the polarity) to the rails within the loop. This way the short
circuit is neutralized.
The rail section within the loop should be separated from the remaining
tracks. It is powered by the loop module.
The module may only be used in digital controlled two-rail model
railway.
Technical specifications
Supply voltage 16 - 24 Volt digital supply
Current consumption
(without connected devices) ca. 20 mA
Max. current loading 2 A
Protected to IP 00

KSM-1 English
Page 23
Ambient temperature in use 0 - + 60° C
Ambient temperature in storage -10 - + 80° C
Comparative humidity allowed max. 85 %
Dimensions ca. 48 x 52 mm
Weight ca. 20 g
Choosing a power supply
The module is designed for connection to 16 - 24 Volt digital supply.
Checking the package contents
Check the contents of the package for completeness:
§1 kit, containing the components listed in the parts list and a PCB, or
§1 ready-built module.
§1 manual.
Required tools and consumables
Make sure you have the following tools, equipment and materials ready
for use:
§a heat-resistant mat
§a soldering iron stand with tip-cleaning sponge
§a small side cutter and wire stripper
§a pair of tweezers and long nose pliers (not necessary for the
ready-built module)
§an electronic soldering iron (max. 30 Watt) with a fine tip
§tin solder (0,5 mm. diameter)
§wire (diameter: >0,22 mm² for all connections)

English KSM-1
Page 24
!
Safe and correct soldering
Caution:
Incorrect soldering can cause fires (through excessive heat). Avoid this
danger by reading the chapter Safety instructions again and
following the directions given.
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.
§When soldering electronic circuits never use soldering-water or
soldering grease. They contain acids that can corrode components
and copper tracks.
§Only use tin solder SN 60 Pb (i.e. 60 % tin, 40 % lead) with rosin-
based flux.
§Solder fast: long soldering can destroy components and copper
tracks, and damages through plated holes.
§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 spot 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
tin solder finds its way, then remove the soldering iron.
§Do not move the component for about 5 seconds after soldering. A
glossy and perfect soldering spot should remain.
§To make a good soldering joint you must use a clean and
deoxidised soldering tip. Clean the soldering tip with a damp piece
of cloth, a damp sponge or a piece of silicon cloth.

KSM-1 English
Page 25
§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, 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.
Assembling the kit
You can skip this part if you have a ready-built module.
Preparation
Put the sorted components in front of you on your workbench. An
explanation of the separate electronic components follows:
Resistors
A resistor "reduces" the current. Mounting orientation is of no
importance. Because resistors are very small there is no readable
information on them, but their value is given with colour rings.
Key:
Value Colour ring
470 Ωyellow - violet - brown (gold)
4,7 kΩyellow - violet - red (gold)
100 kΩbrown - black - yellow (gold)
The colour ring in brackets indicates the tolerance of the
resistor and is of no importance here.
Adjustable resistors (Trimming pots)
Adjustable resistors are a special kind of resistor, built
symmetrically. Their orientation is easy to recognise because
of their off-centre connection. Their value is easily adjusted
with a screwdriver to meet particular requirements.

English KSM-1
Page 26
Capacitors
There is a difference between “normal” capacitors and electrolytic
capacitors which have to be placed in a certain direction. They
have a very bright line at one end marked with the minus (-) sign.
That end must always be connected to minus.
Diodes
Diodes allow current to flow in one direction only and have to
be placed in that direction. The characteristic for a diode is
the ring at one end. Place them as drawn in the PCB layout.
Transistors
Transistors are in fact power switches. They have three wires
and a flat part on the body. They also have to be placed in a
certain direction. The PCB layout will help you to place the
transistor. In the layout, the flat part of the transistor is
shown.
ICs
The notch on the IC shows the mounting orientation. The PCB
layout shows this marking. Micro-Controllers are ICs which
contain an individual programm to control the circuit.
Relays
Relays are electronic change-over switches. The mounting
direction is preset by the order of the pins.
Rectifiers
Rectifiers convert alternating (a.c.) into direct (d.c.) voltage.
They should be inserted according to the polarity shown on
the PCB Layout.
Terminal strips
Terminal strips are solder-in screw-type terminals. They provide a
solder-free and safe connection of the cables to the circuit.
+
-

KSM-1 English
Page 27
!
!
Assembling the kit
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 cutter as short as possible. Next solder the IC-
socket, the rectifier and the transitors. Continue with the trimm-pot and
the capacitors. Finally solder the relay and the terminal strips.
Caution:
Electrolytic capacitors, transistors, diodes, rectifiers and ICs must be
placed 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. In any case, a wrongly connected part will
not function.
Performing a visual check
Even if you have a ready-built module you must perform a visual check
that screws, plugs and other fasteners are firm and tight to exclude
transport damage.
Caution:
Do not power up the module yet.
Damaged material and/or incorrect handling of parts can always be a
danger. After assembling the kit, perform a visual inspection.
Remove all loose parts, wire ends or drops of solder from the PCB.
Remove all sharp wire ends.
Check solder spots that are too close to each other for short circuits.
Check that all components are polarised correctly. When you have
taken all these precautions, go on to the next part.

English KSM-1
Page 28
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Functional test and
connection of the loop module
If you have purchased a ready-built module, please check all functions.
Transport damage can never be excluded.
Preparing and connecting the loop module
Start by isolating the loop completely from the remaining circuit. Both
breaks should be located as near as possible to the points.
Connect the loop module between the loop and the remaining circuit.
Follow the connections diagram (fig. 2)!
Setting the operating point
Turn the trimming pot to the left as far as possible. Turn it to the right
until the relay switches with a clicking sound. Turn it a little bit back to
the left from this position until the relay switches again with a clicking
sound.
Perform a test by driving a locomotive in and out the loop. Ultimately
when the locomotive gets out of the loop the relay must click, although
this could happen when the locomotive enters the loop. The central unit
should not switch off.
Caution:
If a component gets too hot, disconnect the mini-timer and power supply
from the mains immediately. Possible short circuit! Check the assembly!
FAQ
§Parts are getting too hot and/or start to smoke.
Disconnect the system from the mains immediately!
Possible cause: one or more components are soldered incorrectly.
àPerform a visual check.

KSM-1 English
Page 29
§When setting the trimming pot the relay does not switch.
Possible cause: one or more components are soldered incorrectly.
àPerform a visual check.
Possible cause: The IC has been inserted into the IC-socket in the
wrong direction.
àThe IC has consequently been destroyed and must be replaced.
(The programmed IC can only be purchased directly from the
manufacturer!)
§During the testing run the central unit switches off.
Possible cause: one or more components are soldered incorrectly.
àPerform a visual check.
Possible cause: The trimming pot is set incorrectly.
àSet the trimming pot according to the section "Setting the
operating point" and repeat the test.
If you cannot find the problem, please return the module for repair
(address on the cover page).
Manufacturer's note
According to DIN VDE 0869, the person who builds this kit or brings the
circuit into operation is the manufacturer of the product. If he sells the
product to another person he is responsible for passing on all the
relevant papers. Domestic appliances assembled from a kit are deemed
industrial products and must comply with health and safety regulations.
Certification
This product conforms with the EC- directive 89/336/EWG on
electromagnetic radiation and is therefore CE certified.

English KSM-1
Page 30
Conditional warranty
This product is guaranteed for two years. The warranty includes free
repair if the problem is due to material failure or incorrect assembly of
the ready-built module by us. Because we have no control over the
assembly of the kit, we can only guarantee the quality of the
components and the completeness of the kit.
Other claims are excluded. By law, we are not responsible for damages
or secondary damages in connection with this product. We retain the
right to repair, make improvements, supply spare parts or return the
purchase price.
The following invalidate the warranty:
§using an unsuitable soldering iron, solder containing liquid acids or
similar,
§if the kit is assembled and soldered poorly, or if damage is caused
by not following the instructions in this manual or the circuit
diagram,
§if the circuit has been altered and repair attempts have failed,
§if arbitrary changes in the circuit are made,
§if parts are stored incorrectly and if the wires to the switches, the
power resistors, etc. are made incorrectly,
§if parts other then the original ones delivered with this kit are used,
§if the copper tracks or soldering points are damaged,
§if parts are placed incorrectly or the circuit is connected incorrectly,
§if damage occurs due to an overload of the circuit,
§if the wrong power or current is connected,
§if damaged by other persons,
§if damaged by the wrong use or abuse of the circuit,
§if parts are damaged due to static because they were touched
before a discharge is performed.

KSM-1
Seite - Page - Page - Pagina I
Stückliste - Partslist
Nomenclature - Stuklijst
C1, C4 220 µF/25 V
C2 100 µF/25 V
Kondensatoren - Capacitors
Condensateurs - Condensatoren C3,C5 2,2 µF/25 V
Dioden - Diodes - Diodes - Diodes D1, D2, D3 1N4004 *
Zener-Dioden - Zener diodes
Diodes Zener -Zenerdiodes D6 ZD 5V1
Transistoren - Transistors Q1, Q2 BC547B
R1 100 kΩ
R2, R3 4,7 kΩ
Widerstände - Resistors
Résistances - Weerstanden R5 470 Ω
Trimmpotis - Trim pots
Potentiomètres - Trimmpotmeter R4 470 kΩ
Micro-Controller - Micro-Controller
Micro-contrôleur - Micro-controller IC1 PIC 12C508A
IC-Sockel - IC-socket
Soquet IC - IC-voetje 8-pol. 1 x
Relais RL1 2xUm
Gleichrichter - Rectifier
Redresseur - Gelijkrichter D1-4 B80 C1500
Anreihklemmen - Terminal strips
Borniers - Printkroonstenen X1, X2 2-pol.
* oder ähnlich - or similar - ou équivalent - of gelijkwaardig

KSM-1
Seite - Page - Page - Pagina II
Bestückungsplan - PCB layout
Plan d´implantation - Printplan nnnFig. 1

KSM-1 KSM-1
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Anschlußplan
Connections
Plan de raccordement
Aansluit plan
nnnFig. 2

KSM-1 KSM-1
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Schaltplan
Circuit diagram
Schéma de principe
Schakelschema
nnnFig. 3

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