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EnglishB-2
Table of contents
1. Why Boosters?27
2. Getting started27
3. Your B-229
4. Technical specifications30
5. Safety instructions31
6. EMC declaration33
7. Safe and correct soldering33
8. Assembling the kit35
9. Splitting your model railway layout41
10. Connecting the booster42
11. Operation44
12. Check list for troubleshooting46
13. Manufacturer's note, CE and Warranty47
Parts listI.1 / I.2
Circuit Diagram (Fig. 1)II
Printed Circuit Board (PCB) layout (Fig. 2)III.1
Drill stencil for heat sink (Fig. 3)III.2
Cut-out for housing (Fig. 4)III.2
Connections diagram (Fig. 5)IV
(Pages I to IV in the centre of this handbook are removable.)
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B-2English
1. Why Boosters?
Boosters amplify the digital signals sent from the control unit and
supply a connected track with power.
You can measure the power consumption as follows:
§ a locomotive: Gauge N: 600 mA / Gauge H0: 800 mA /
> Gauge 0: 1 A
§ a wagon light: 50 - 200 mA
§ another consumer (such as a sound module): 100 - 300 mA
§ reserve for points: 10% of the calculated sum of power
consumption
The Booster B-2 can supply 3A. If your overall power demand exceeds
the capacity of one booster you have to connect additional boosters
according to the special requirements of your layout.
2. Getting started
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 device, 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 device on to another person, please
pass on the manual with it.
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Intended use
The kit or the ready-built device can be assembled and operated with a
digital model railway using this manual.
Any other use is inappropriate and invalidates any guarantees.
The kit and the ready-built device 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.
Checking the package contents
Please make sure that your package contains:
§ one kit, containing the components listed in the parts and one PCB
or
§ one booster B-2,
§ one manual.
Required materials
For assembling the kit you need:
§ 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,
§ tin solder (0,5 mm. diameter),
In order to connect the booster you need:
§ wire. Recommended diameters: > 0,10 mm² for the connections to
the push-button switch and the central unit and > 1,5 mm² for the
connections to the transformer and the rails,
§ transformer with 16-20 V voltage and minimum 3 A current
(minimum 50 VA).
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3. Your B-2
1 Connection central unit
2 Connection push-button
3 Connection transformer
4 Connection track
5 Setting MM / DCC
6 Setting short-circuit
sensivity
5
6
7 Operation display
1 2 3 4
7
Data formats and ports
The B-2 is a multi protocol booster for your model railroad and capable
of amplifying data sent in the Motorola or the DCC format. It can be
connected either to the track port of a Motorola or DCC central unit, or
to a DCC-conforming booster port of a central unit.
Balanced track voltage
The booster B-2 is balanced, that means it keeps the power in a
connected track section constant on 18 V – independent of the actual
power consumption. This prevents changes in locomotive speeds and
the lightings´ brightness resulting from voltage variations.
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Short-circuit protection
The short-circuit protection prevents damages to the booster, vehicles
and / or tracks, due to a derailed engine, for example. The sensivity of
the short-circuit protection has to be set on a trim-pot.
When a short circuit occurs at the track output, an internal current
limiter prevents damages to components of the booster and
automatically switches off the booster. The automatic short-circuit
switch-off can be cut off by bridging the push-button for switching-on
the B-2.
When the short-circuit warning wire is connected to the central unit,
the booster sends an overload signal to the central unit in case of a
short- circuit. Most central units then switch off the booster.
4. Technical specifications
Supply voltage16-20 Volt alternating voltage (a.c.)
Input voltage12-20 Volt digital voltage
Output voltageapprox. 18 Volt digital voltage
Output currentmax. 3 A
Consumptionmax. 60 Watt
Protected toIP 00
Ambient temperature in use0 - + 60 °C
Ambient temperature in storage-10 - + 80 °C
Comparative humidity allowedmax. 85 %
Dimensions (including housing)approx. 114 x 99 x 42 mm
Weight of the circuitapprox 93 g
Weight including housingapprox 215 g
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5. 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 device.
§ Assembling and mounting the kit should only be done in closed,
clean, dry rooms. Beware of humidity.
§ Only use low power for this device 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 device.
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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 device.
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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6. 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 layout included with this
manual.
§ Use only original spare parts if you have to repair the kit or the
ready-built device.
7. 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
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.
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§ 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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8. Assembling the kit
You can skip this part if you have purchased a ready-built device.
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
10 Ωbrown - black - black (gold)
100 Ωbrown - black - brown (gold)
120 Ωbrown - red - brown (gold)
470 Ωyellow - violet - brown (gold)
1 kΩbrown - black - red (gold)
2,2 kΩ red - red - red (gold)
4,7 kΩyellow - violet - red (gold)
18 kΩbrown - grey - orange (gold)
100 kΩbrown - black - yellow (gold)
On high-power resistors the value is printed in clear text.
Trimm-potentiometers
Trimm-potentiometers (abrv. „trim-pots“) are resistors which
allow the value of resistance to be varied and so can be
adapted to the particular demands. In the middle they have a
small slot into which a small screwdriver can be put in order
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to vary the value of resistance. The value is printed on the
housing.
Depending on the mounting situation, trim-pots with a lying
or a standing housing are used. The mounting orientation is
preset by the layout of the three pins.
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.
ValueNumber
10 nF103
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 damage
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.
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Zener diodes
Zener diodes are used for limiting voltages. In contrast to
„normal“ diodes they are not damaged when the limit voltage
is exceeded.
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).
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 (SOThousing). 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.
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.
The mounting orientation of the relays which are put in a rectangular
box shaped housing is given by the layout of the pins.
Switches and push-button switches
By operating a switch or a push-button switch an electric circuit is
closed. While switches keep their status after operating (like a light
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switch), push-button switches keep their operating position only as long
as actually operated (like a bell push).
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
Start the assembly with the resistors and the diodes. First solder the
components on the solder side of the PCB and cut the excess wires with
the side cutter, as short as possible. Form the wire bridges Br1 to Br4.
Use the cut-off wires of the resistors or diodes.
Then solder the transistors and then capacitors (but not the two
capacitors C10 and C11 and the power transistors Q8 and Q9). If you
intend to mount the circuit into the housing supposed for the enclosure
of the B-2 please follow the instructions in the section "Enclosure of the
B-2".
Caution:
Electrolytic capacitors, transistors and diodes must be placed in the
right direction! If you solder them the wrong way round 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.
Then solder the relay and the capacitors C10 and C11. If you intend to
mount the circuit into the housing intended for the enclosure of the B-2
please follow the instructions in the section "Enclosure of the B-2".
Next solder the terminal strips and the solder pin. Join the terminal
strips together before soldering.
Place the power transistors Q8 and Q9 on the heat sinks as follows:
Drill a hole of 3 mm. according to the drill stencil in the two heat sinks.
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!
Caution:
De-burr the holes: not de-burring can cause injury! It is possible to
damage the insulation plates of the transistors if you do not clean up
the holes causing a short circuit.
Mount the power transistors Q8 and Q9 as follows: First place a
semiconductor insulator on the heat sink and then the transistor. Pay
attention to not mix up the two transistors when mounting. Put the
insulation bushing through the hole of the transistor. Mount the screw
and nut, but do not fasten the nut: you should be able to turn the
transistors.
Caution:
The transistors must be isolated. They must not make contact with the
heat sink!
Put the wires of the power transistors in the correct holes of the PCB
and solder them on the solder side of the PCB. Now fasten the nuts.
Performing a visual check
Perform a visual check after the assembly of the device 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.
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Performing a functional test
Caution:
Do not connect the booster to the central unit or the track yet.
Connect the booster only to the transformer for the functional test.
Connect the transformer to the mains. The LED of the booster will light
up. Check for components getting too hot.
Caution:
If a component gets too hot or the LED does not light, disconnect the
booster and transformer from the mains immediately. Possible short
circuit! After performing a successful function test, you can continue
with the remaining connections.
Enclosure of the B-2
There is a housing avalaible for the booster B-2. If you intend to use
this housing the electrolytic capacitors C6, C10 and C11 have to be bent
by 90 degrees. Bend the connecting wires before soldering in the
capacitors, as you otherwise might solder them in too close to the PCB.
Use the holes for the capacitor C11 placed at the side and not the ones
in the middle. The housing has to be cut out for the heat sink according
to fig. 4.
You may also use other housings. Be sure that the housing does not
deform when exposed to high temperatures.
Caution:
The power transistors Q8 and Q9 and their heat sink can become very
hot during operation! Never enclose the power transistors and the heat
sink in a closed housing.
If necessary you have to elongate the connection wires of the
transistors Q8 and Q9 with wire (cross section min. 1,5 mm²) in order
to mount them and the heat sink at the outside of the housing.
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9. Splitting your model railway layout
Split your model railway layout in several track sections electrically isolating
them from each other. Every section has to be supplied by a booster of its’
own. Make sure that section borders are not crossed that often. The
following divisions are useful:
§ station / engine sheds
§ the main line (if necessary in several sections)
§ the branch lines (if necessary in several sections)
The booster current into the track should be fed every 2 to 3 m as the
resistances at the track section´s borders are quite high. If the intervals
are too long there might occur problems with the short circuit
detection or the power supply of the vehicles.
At the borders between two booster-sections cut the rail transmitting
the data (with 2-rail systems) or the middle conductor (with 3-railsystems).
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10. Connecting the booster
Connect the booster to the central unit, the tracks, the power supply
and the push-button according to the following list. Follow the
connections diagram fig. 5.
Connection to the
central unit
1Short circuit
indication wire
2Mass wireMass connection
3Data wirePort "middle
4/5 Connection to the push-button
6/7 Connection to the
transformer
Connection to the
tracks
8outer conductor (earth) second conductor
9middle conductordata conductor
Page 42
Connection to a central
unit compatible to
Märklin**
PIN 1 of the booster
port
(brown)
conductor of the
tracks" (red)
Transformer with min. 50 VA
Connection to
3-rail-system
Connection to a
DCC-central unit
PIN "E"
PIN "D"
PIN "C"
Connection to
2-rail-system
B-2English
Motorola
DCC
Connecting the central unit
It is possible to connect the booster either to the track port of a
Motorola or DCC central unit or to a DCC-conforming booster port of a
central unit. Use the DCC-compatible booster port to connect the B-2 to
the central unit MasterControl.
Please note: Booster compatible to the
Märklin** or the DCC system are switched on
and off in different ways, that´s the reason why
you have to set the booster to the particular
data format. Setting is done with the jumper
that has to be inserted on the 3-pole pin socket
as shown in the diagram on the right.
Connecting the tracks
Give special attention not to cross the wires when you connect them to
the booster. It might happen that you do not notice a crossed
connection immediately. Some components cannot interpret a crossed
signal and will not work properly.
Connecting the short circuit protection
The B-2 has an integrated short-circuit switch-off. You can integrate
this by bridging the connections for the push-button that switches on
the booster with a wire. You then have to switch the booster on and off
via the central unit. In this case the central unit performs the shortcircuit switch-off as well.
When you do not want a short-circuit indication to the central unit (and
no switching-off of the booster via the central unit in case of a shortcircuit) omit the connection of the short-circuit indication wire.
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Using more boosters
Hint: Only use boosters of one type and made by one manufacturer to
avoid problems such as:
§ Problems with data transfer to the decoders.
§ Current leakage that make locomotives move by themselves when
other locomotives cross the borders between two track sections.
§ Short circuits when crossing sections.
Especially if you combine regulated and not regulated boosters in your
layout you should use rocker insulators at borders between two
separate electric circuits. Without these rocker insulators, both output
stages of both boosters are connected to each other when a locomotive
comes to a standstill with it´s current collector on the border between
two booster sections. This creates a kind of short circuit which can
bypass the short-circuit protection of the boosters and can cause
damage to the connected boosters.
Connecting several boosters B-2
It is not always possible to use several boosters and to switch on all
devices at once. In this case you can switch all push-button connections
in parallel. This allows you to switch on all electric circuits at once with
one push-button.
It is also possible to switch all short-circuit indication wires and all mass
wires of all boosters B-2 in parallel.
11. Operation
Operation display
The LED shows that the booster is in operation.
Setting the short-circuit switch-off
Turn the trimm pot with a small screwdriver to its left end, the least
sensitive adjustment.
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When everything is connected, connect the transformer and the central
unit to the power supply. The LED on the booster will light up faintly,
indicating that the booster is ready.
Put an engine on the track and choose its address on the central unit.
Push the “GO” button on the central unit and hold the push button of
the booster down. The LED will get brighter and after 1 or 2 seconds
the relay will switch on with an audible “click”. You can now release the
push button.
Turn R4 slowly to the right. When the relay disconnects and the LED
has become fainter you have reached the lower adjustment. Turn R4
back a little and go for another round with the engine. If the booster
switches off during the engine run, turn R4 back a little bit further. Do
this until the protection circuit does not switch off during the run.
Shunting the boundry between two booster sections
One should arrange track sections so that it is not necessary to halt a
train directly on the boundry between two sections. This would lead to
a connection between the outputs and damaging of the two connected
boosters. The short circuit indication does not work under these
circumstances, therefore the central unit will not switch off the booster
automatically.
Loading the boosters
The average current supplied by the booster should not exceed 3 A, as
the booster otherwise indicates a short circuit to the central unit.
Short-term excention normally does not lead to a short circuit indication
and switching off the booster by the central unit.
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12. Check list for troubleshooting
§ 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.
à Perform a visual check.
Possible cause: The connections to the track and the power supply
have been mixed up. à Alter the connections. Possibly the booster
has been damaged.
Possible cause: The insulation of Q8 and Q9 is damaged. à Check
the insulation and, if necessary, replace damaged insulation.
§ The booster does not work, the LED does not light.
Possible cause: The connector of the connecting wire to the central
unit has been inserted the wrong way round. à Alter the
connection.
Possible cause: The connection to the power supply has been
interrupted. à Check the transformer (is it connected to the
mains?). If necessary check the power supply by using a measuring
instrument.
Possible cause: The booster is defective. à Repeat the visual check
and the functional test.
§ The booster cannot be switched on.
Possible cause: A short circuit has occurred in the lead-in wire to
the tracks or on the tracks (as e.g. a locomotive is derailed).
à Eliminate the short circuit.
§ Some components connected to the booster (e.g. function or points
decoders) do not work.
Possible cause: The connecting wires to the tracks have been
crossed. à Check the connections.
§ The transistors Q 8 and Q 9 are getting too hot.
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Possible cause: There is a capacitor mounted into a track. à
Dismount the capacitor.
§ The short circuit indication does not work properly.
Possible cause: The jumper for setting the data format has been
inserted incorrectly. à Adjust the jumper settings.
Hotline
If problems with your booster occur, our hotline is pleased to help you.
(address on the cover page).
13. Manufacturer's note, CE and Warranty
Manufacturer's note
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 is developed and tested in accordance with the European
standards EN 55014-1 and EN 61000-6-3. This product conforms with
the EC- directive 2004/108/EG on electromagnetic radiation and is
therefore CE certified.
Conditions of warranty
This product is guaranteed for two years. The warranty includes the
correction of faults which can be proved to be due to material failure or
factory flaw. As we have no control over the correct and proper
assembly and mounting we can only guarantee the quality of the
components and the completeness of kits. We guarantee the function
of the parts according to the parameters in not mounted state as well
as the adherence to the technical specifications of the circuit when
assembled and connected according to the manual.
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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,
§ if the ready-built device has been altered and repair attempts have
failed,
§ if arbitrary changes in the circuit are made,
§ if components are removed or swapped, or wiring is added or
removed in any other way as layed down in the original design,
§ if parts other than the originals delivered with this kit are used,
§ if the copper tracks or soldering eyes are damaged,
§ when components are mounted incorrectly, or if the components or
the circuit are poled incorrectly, also subsequent damage resulting
from these faults,
§ if damage occurs due to an overload of the device,
§ if connected to a incorrect voltage or current,
§ if damaged by other persons,
§ if damaged by faulty operation or if damaged by careless use or
abuse,
§ if damaged by touching components before electrostatic
discharging of the hands.
The asterisks **
This manual mentions the following companies:
§ Gebr. MÄRKLIN** & Cie. GmbH
Postfach 8 60, D-73008 Göppingen
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