tams elektronik
Manual
KSM-3
Item no. 49-01135 | 49-01136
Loop module
for digital model railroad layouts
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English KSM-3
Table of contents
1. Getting started............................................................................3
2. Safety instructions.......................................................................5
3. Safe and correct soldering...........................................................7
4. Operation overview.....................................................................9
5. Technical specifications..............................................................13
6. Assembling the kit.....................................................................14
7. Connecting the KSM-3...............................................................24
8. Check list for troubleshooting.....................................................28
9. Guarantee bond........................................................................30
10. EU declaration of conformity......................................................31
11. Declarations conforming to the WEEE directive...........................31
© 10/2015 Tams Elektronik GmbH
All rights reserved. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic or mechanical,
including photocopying, without prior permission in writing from Tams
Elektronik GmbH.
Subject to technical modification.
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1. Getting started
How to use this manual
This manual gives step-by-step instructions for safe and correct
assembly of the kit and fitting and connecting of the ready-built
module, and operation. Before you start, we advise you to read the
whole manual, particularly the chapter on safety instructions and the
checklist for trouble shooting. 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 loop module KSM-3 is designed to be operated according to the
instructions in this manual in model building, especially with model
railways. Any other use is inappropriate and invalidates any guarantees.
The KSM-3 should not be assembled or mounted by children under the
age of 14.
Reading, understanding and following the instructions in this manual
are mandatory for the user.
Caution:
The KSM-3 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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Checking the package contents
Please make sure that your package contains:
one kit, containing the components listed in the parts list
( page 19) and one PCB or
one ready-built module or
one ready-built module in a housing (complete unit),
a CD (containing the manual and further information).
Required materials
For assembling the kit you need:
an electronic soldering iron (max. 30 Watt) or a regulated soldering
iron with a fine tip and a soldering iron stand,
a tip-cleaning sponge,
a heat-resistant mat,
a small side cutter and wire stripper,
as necessary a pair of tweezers and long nose pliers,
electronic tin solder (0,5 mm. diameter).
In order to connect the module you need wire. Recommended
diameters:
connection of the rails:
gauges Z and N: > 0,75 mm²
other gauges: > 1,5 mm²
connection of the points: > 0,25 mm²
When using motor-run points, you need an addtional adapter for
motor-run points AMW-1 (item-no. 72-00076).
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2. 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 and connecting the circuit to another voltage than
specified,
impermissibly high humidity and condensation build up
can cause serious injury due to electrical shock. Take the 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.
Caution:
Little children can swallow small components with sharp edges, with
fatal results! Do not allow components to reach small children.
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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.
3. 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.
Use a small soldering iron with max. 30 Watt or a regulated
soldering iron.
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.
Insert the component connecting 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 soldering.
Solder quickly: holding the iron on the joints longer than necessary
can destroy components and can damage copper tracks or soldering
eyes.
Apply the soldering tip to the soldering spot in such a 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.
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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 soldering joint 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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4. Operation overview
Loop problems
At the loop points in two-rail-systems, different polarities meet with
each other. As soon as a vehicle bridges the differently polarized
sections when driving in or out the terminal loop a short circuit occurs.
In digital layouts loop modules generally have to adapt the polarity
within the terminal loop to the one outside. In case the polarity outside
the terminal loop would be altered, different polarities would meet at
the transition to the next booster section. Thus the problem would be
dislocated only.
Fig. 1: Short circuit problem at the loop points
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Mode of operation of the KSM-3
As soon as a locomotive bridges the sectioning point between
differently poled sections inside and outside the loop, the KSM-3
changes the polarity within the terminal loop. The response time is
extremely short, as the KSM-3 already detects the voltage drop at the
switchover to a short-circuit. In consequence, the KSM-3 is able to react
within milliseconds before the voltage breaks down due to the short
circuit.
The sensitivity for the polarity reversal depends on the applicated
voltage and for that reason has to be set via a trimm-pot individually.
In order to allow the precise setting a LED on the KSM-3 lights up as
soon as the sensitivity has been set optimally (for the particular layout).
That way you safely prevent wheels, current collectors and rails from
damages and make sure locomotives pass the sectioning point without
jerking.
Integrated switching of the points
The KSM-3 has an additional output for the connection of coil driven
points. In order to connect motor-run points, you need an addtional
The points are switched automatically as soon as the locomotive
reaches one of the two sectioning points (simultaneously with altering
the polarity). The two sectioning points are assigned to a particular
correct position of points. That way externally switching the points does
not interfere with the safe procedure.
Procedure
Phase 1: According to the current position of points the locomotive runs
clockwise or counter-clockwise through the terminal loop. When the
train is intended to run in a specific direction through the loop, the
points can be set accordingly from the outside.
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adapter for motor-run points AMW-1 (item-no. 72-00076).
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Phase 2: When the train running into the loop arrives at the sectioning
point behind the points, the polarity within the loop is altered (if
necessary).
Phase 3: When the train running out of the loop arrives at the
sectioning point before the points, the polarity within the loop is altered
and at the same time the points are set properly for the train to run out
of the terminal loop.
Fig. 2: Procedure
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Designing a layout with the KSM-3
The rails in the loop´s inside between the two sectioning points have to
be at least as long as the longest train to pass the terminal loop.
The circuit also works properly when there are several trains within the
loop at the same time provided that there are not two locomotives
passing the sectioning points simultaneously. This allows branching rails
within in terminal loop, for example.
The maximum current of all vehicles in the loop is 8 A (including motor
current of the locomotive, carriage lighting, other accessories).
Use with a turntable
With turntables different polarities possibly meet at the transitions
between bridge and the other parts of the layout after turning the
bridge. The KSM-3 can solve this problem. For that purpose you have to
connect the bridge like the loop´s inside.
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5. Technical specifications
Data format all
Voltage supply
via the rails
Current consumption
(without connected devices)
ca. 20 mA
Max. current of all vehicles in the
loop
8 A
Additional outputs 1 (for the connection of coil
driven points)
Max. current: 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 of the PCB
Dimensions including housing
approx. 48 x 52 mm
approx. 70 x 60 x 25 mm
Weight of the assembled board
Weight including housing
approx. 37 g
approx. 54 g
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6. Assembling the kit
You can skip this part if you have purchased a ready-built module or device.
Preparation
Put the sorted components in front of you on your workbench.
The separate electronic components have the following special features
you should take into account in assembling:
Resistors
Resistors reduce current.
The value of resistors for smaller power ratings is indicated
through colour rings. Every colour stands for another
figure.
Carbon film resistors have 4 colour rings. The 4th ring
(given in brackets here) indicates the tolerance of the
resistor (gold = 5 %).
Value: Colour rings:
150 brown - green - brown (gold)
4,7 k yellow - violet - red (gold)
22 k red - red - orange (gold)
Trimm-potentiometers
Trimm-potentiometers (abrv. "trimm-pots") 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 maximum value is printed on the housing.
Depending on the mounting situation trimmpots with a lying or a
standing package are used.
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Ceramic capacitors
Among other things ceramic capacitors are used for
filtering interference voltages or as frequency determining
parts. Ceramic capacitors are not polarized.
Normally they are marked with a three-digit number which
indicates the value coded. The number 224 corresponds to
the value 220 nF.
Electrolytic capacitors
Electrolytic capacitors are often used to store energy. In
contrast to ceramic capacitors they are polarized. The
value is given on the package.
Electrolytic capacitors are available with different voltage
sustaining capabilities. Using an electrolytic capacitor with
a voltage sustaining capability higher than required is
always possible.
Diodes and Zener 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.
Zener diodes are used for limiting voltages. In contrast to "normal"
diodes they are not destroyed when the limit voltage is exceeded.
The diode type is printed on the package.
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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).
Light emitting diodes should always be connected via a
series resistor which limits the current and prevents failure.
With circuits designed for the connection of LEDs the
series resistors are often integrated on the circuit board.
Rectifiers
Rectifiers convert alternating into direct voltage. They have
four pins: 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.
Transistors
Transistors are current amplifiers which convert low signals into
stronger ones. There are several types in different package forms
available. The type designation is printed on the component.
Transistors for a low power rating (e.g. BC types) have a
package in form of a half zylinder (SOT-package).
Transistors for a high power rating (e.g. BD types) have a
flat package (TO-package), which is in use in different
versions and sizes.
The three pins of bipolar transistors (e.g. BC and BT types)
are called basis, emitter and collector (abbreviated with the
letters B, E, C in the circuit diagram).
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Integrated circuits (ICs)
Depending on the type, ICs fulfil various tasks. The most
common housing form is the so-called "DIL"-housing, from
which 4, 6, 8, 14, 16, 18 or more "legs" (pins) are
arranged along the long sides.
ICs are sensitive to damage during soldering (heat,
electrostatic charging). For that reason in the place of the
ICs IC sockets are soldered in, in which the ICs are
inserted later.
Microcontrollers
Microcontrollers are ICs, which are individually programmed for the
particular application. The programmed controllers are only available
from the manufacturer of the circuit belonging to it.
Relays
Relays are electronic switches, depending on their position the one or
other (internal) connection is closed. The mode of operation of
monostable relays can be compared to that of a push-button switch,
i.e. the connection is only closed as long as the voltage is applicated.
Bistable relays keep their status after switching – comparable to a
switch.
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.
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Screw terminals
Screw terminals provide a solder-free and safe connection of the cables
to the circuit, which can still be separated any time.
Terminal strips are available as single or double row versions with 2 or
3 poles (resp. 2x2 or 2x3 poles). Connections with any number of poles
can be created by linking several terminal strips. In order to fix them
the connecting cables are inserted and screwed (similar to a lustre
terminal).
Plug-in units consist of a 2-, 3-, 4- or more pole box header to be
soldered on the PCB and an appropriate plug-in part into which the
connecting cables have to be inserted and srewed.
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Parts list
Resistors R5 150
R2, R3, R4, R6, R7, R9 4,7 k
R1 22 k
Trim pots R8 10 k (standing)
Diodes D1, D2, D3, D6, D7 1N400x, x=2...7
Zener diodes D4 5V6
LEDs D5 3 mm (green)
Rectifiers D1-4 B80C1500
(or similar)
Capacitors 220 nF C3
Electrolytic
capacitors
C5 2,2 µF / 25 V
C1, C2 100 µF / 25 V
C4 220 µF / 25 V
Transistors Q2 BC337
Q1 BC547B
T1, T2 BD679
Micro-Controllers IC1 PIC12F1571-I/P
IC-sockets IC1 8-pole
Relais K1 2xUm, 8 A, 5V
monostable
Terminal strips X1, X2 1x2-pole
Plug-in units S2 3-pole box header
3-pole plug-in part
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Fig. 3: PCB layout
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Assembly
Proceed according to the order given in the list below. First solder the
components on the solder side of the PCB and then cut the excess
wires with the side cutter. Follow the instructions on soldering in
section 3.
Caution:
Several components have to be mounted according to their polarity.
When soldering these components the wrong way round, they 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.
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1. Resistors Mounting orientation of no importance.
2. Diodes, Zener
diodes
Observe the polarity!
The negative end of the diodes is marked with
a ring. This is shown in the PCB layout.
Solder the diode D6 and D7 that way, their
bodies are standing upright on the PCB.
3. Ceramic
Capacitors
Mounting orientation of no importance.
4. IC sockets Mount the sockets that way, the markings on
the sockets show in the same direction as the
markings on the PCB board.
5. Transistors Observe the polarity!
The cross section of transistors for a low
power rating in SOT-packages is shown in the
PCB layout.
With transistors for a high power rating in TO
packages (e.g. BD types) the unlabelled back
side is marked in the PCB layout by a thick
line.
6. Rectifiers Observe the polarity! The pin connections are
printed on the housing. The longer connecting
pin is the positive pole.
7. Electrolytic
capacitors
Observe the polarity! One of the two leads
(the shorter one) is marked with a minus sign.
8. Relays The mounting orientation is given by the
layout of the pins.
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9. Light emitting
diodes (LEDs)
Observe the polarity!
With wired LEDs the longer lead is always the
anode (positive pole).
10.
Srew terminals
Terminal strips and box header of the plug-in
unit.
11. Trimmpotentiometers
The mounting orientation is preset by the
layout of the three pins.
12. ICs in DILhousing
Insert the ICs into the soldered socket.
Do not touch the ICs without first discharging
yourself by touching a radiator or other
grounded metal parts.
Do not bend the "legs" when inserting them
into the sockets. Check that the markings on
the PCB, the socket and the IC show to the
same direction.
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.
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7. Connecting the KSM-3
Isolating the terminal loop from the layout
First isolate the loop completely from the rest of the layout. Arrange the
two isolating points as near to the points as possible.
Fig. 4: Sections of the terminal loop
Connections
There are two terminal strips for the connection of the rails and a plugin unit (consisting of a box header and an appropriate plug-in part) for
the connection of the points soldered to the module which are used to
insert and screw on the connecting wires.
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Fig. 5: Connections
X1 Inside of the loop
1 inner rails →
2 outer rails→
X2 Layout outside the loop
1 inner rails →
2 outer rails→
X3
1 Position of points 1 →
2 voltage supply→
3 Position of points 2→
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Optional: coil driven points (or motor-run points plus AMW-1)
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Connecting points
Connecting points to the KSM-3 is optional. You can do without when
you do not intend to switch the points automatically.
Each of the two isolating points is assigned firmly to one position of
points. If the position is "branch" or "straight" depends on the particular
mounting situation.
For that reason you have to check after having connected them if the
points switch "correctly", when the locomotive passes the isolating
points on its way out of the loop. If not, you have to interchange the
connections of the points (X3-1 and X3-3).
Setting the sensitivity for the polarity reversal
Proceed accurately when setting the sensitivity for the polarity reversal
in order to make sure the KSM-3 already reacts at the beginning of the
voltage drop and alters the polarity within the loop as quickly as
possible. If the inevitably occuring short circuit lasts too long, wheels,
rails and current collectors possibly corrode or locomotives passing the
sectioning point possibly jerk. With a very high current the short circuit
interruption of the booster possibly reacts.
First set the trimm-pot by use of a small screwdriver as far to the left as
possible. Then turn it
1. slowly to the right, until the LED lights up or flashes
2. further to the right, until the LED goes out or the relay
switches (audible by a clicking sound)
3. carefully back to the left, until the LED lights up or flashes
again or the relay stops to switch
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Connecting a turntable
You can use the KSM-3 in combination with a turntable.
Fig. 6:
Connecting
a turntable
X1 Rails of the bridge. The assignment of the connections 1 and
2 is of no importance.
X2 Rail output of the booster
1 connection for "inner" rails →
2 connection for "outer" rails→
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8. 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 In case you have mounted the module from a kit, perform a
visual check (à section 6.) and if necessary, remedy the faults.
Otherwise send in the module for repair.
When setting the trimming pot the relay does not switch.
Possible cause: one or more components are soldered incorrectly.
Perform a visual check.
Possible cause: The IC has been inserted into the IC-socket in the
wrong direction. The IC has consequently been destroyed and
must be replaced. (The programmed IC can only be purchased
directly from Tams Elektronik!)
During the testing run the central unit switches off.
Possible cause: one or more components are soldered incorrectly.
Perform a visual check.
Possible cause: The trimming pot is set incorrectly. Set the
trimming pot according to the section "Setting the operating point"
and repeat the test.
When the train is driving out of the loop the points are switched
incorrectly.
Possible cause: The connections X3-1 and X3-3 have been assigned
incorrectly. Interchange the connections.
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Hotline: If problems with your module occur, our hotline is pleased to
help you (mail address on the last page).
Repairs: You can send in a defective module for repair (address on the
last page). In case of guarantee the repair is free of charge for you.
With damages not covered by guarantee, the maximum fee for the
repair is the difference between the price for the ready-built module
and the kit according to our valid price list. We reserve the right to
reject the repairing of a module when the repair is impossible for
technical or economic reasons.
Please do not send in modules for repair charged to us. In case of
warranty we will reimburse the forwarding expenses up to the flat rate
we charge according to our valid price list for the delivery of the
product. With repairs not covered by guarantee you have to bear the
expenses for sending back and forth.
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9. Guarantee bond
For this product we issue voluntarily a guarantee of 2 years from the
date of purchase by the first customer, but in maximum 3 years after
the end of series production. The first customer is the consumer first
purchasing the product from us, a dealer or another natural or juristic
person reselling or mounting the product on the basis of selfemployment. The guarantee exists supplementary to the legal warranty
of merchantability due to the consumer by the seller.
The warranty includes the free correction of faults which can be proved
to be due to material failure or factory flaw. With kits we guarantee
the completeness and quality of the components as well as the function
of the parts according to the parameters in not mounted state. We
guarantee the adherence to the technical specifications when the kit
has been assembled and the ready-built circuit connected according to
the manual and when start and mode of operation follow the
instructions.
We retain the right to repair, make improvements, to deliver spares or
to return the purchase price. Other claims are excluded. Claims for
secondary damages or product liability consist only according to legal
requirements.
Condition for this guarantee to be valid, is the adherence to the
manual. In addition, the guarantee claim is excluded in the following
cases:
if arbitrary changes in the circuit are made,
if repair attempts have failed with a ready-built module or device,
if damaged by other persons,
if damaged by faulty operation or by careless use or abuse.
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10. EU declaration of conformity
This product conforms with the EC-directives mentioned below
and is therefore CE certified.
2004/108/EG on electromagnetic. Underlying standards: EN 55014-1
and EN 61000-6-3. 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, connection diagrams and PCB layout included with this
manual.
Use only original spare parts for repairs.
2011/65/EG on the restriction of the use of certain hazardous
substances in electrical and electronic equipment (ROHS). Underlying
standard: EN 50581.
11. Declarations conforming to the WEEE directive
This product conforms with the EC-directive 2012/19/EG on
waste electrical and electronic equipment (WEEE).
Don´t dispose of this product in the house refuse, bring it to the next
recycling bay.
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Information and tips:
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http://www.tams-online.de
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Warranty and service:
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Tams Elektronik GmbH
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Fuhrberger Straße 4
DE-30625 Hannover
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fon: +49 (0)511 / 55 60 60
fax: +49 (0)511 / 55 61 61
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e-mail: modellbahn@tams-online.de
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