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MTHTrains Proto-Sound 2.0 Digital Command System Installation Manual

Steam locomotive upgrade kit
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STEAM LOCOMOTIVE UPGRADE KIT
INSTALLATION MANUAL
4th Edition
Compatibility
This Proto-Sound 2.0 Steam Locomotive Upgrade Kit is compatible with any AC or DC
Powered locomotive equipped with a DC can motor and motor flywheel. The locomotive
must be large enough to house the electronics. The instructions herein are generic in
nature and will not provide the installer with specific installation details for specific
locomotives. Consult the individual item's operator's manual for specific instructions on
how to disassemble the locomotive prior to installing the upgrade kit.
WARNING: This product is not covered by a warranty unless installed by an M.T.H.
Authorized Conversion Center.
PLEASE READ BEFORE USE AND SAVE FOR REFERENCE
www.mthtrains.com

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Summary of Contents for MTHTrains Proto-Sound 2.0 Digital Command System

  • Page 1 Consult the individual item’s operator’s manual for specific instructions on how to disassemble the locomotive prior to installing the upgrade kit. WARNING: This product is not covered by a warranty unless installed by an M.T.H. Authorized Conversion Center. PLEASE READ BEFORE USE AND SAVE FOR REFERENCE www.mthtrains.com...

  • Page 2: Table Of Contents

    Table of Contents Contents Of The Kit.................... 3 Required Tools..................6 Locomotive Inspection & Review............... 7 Preparing The Tender For The Upgrade............8 Installing The Ps-2 Components Into The Tender........... 9 Mounting The Ps-2 Board..............10 Installing The Proto-Coupler..............13 Coupler Installation................

  • Page 3: Contents Of The Kit

    Contents Of The Kit N) Screws M2 x 4 mm (2) A) Proto-Sound 2.0 (Ps2) board (1) O) Screws 6/32 x 6 mm (3) B) Ps2 plastic mounting bracket (1) P) Nuts 6/32 (3) C) Tender harness (1) Q) Screw 6/32 x 8 mm (1) D) Ps2 metal heat sink bracket (1) R) Plastic Wire Sleeve E) Proto-Coupler, long (1)
  • Page 4 (E) Proto-Coupler (DD-0000032) (D) Ps-2 Metal Heat Sink Bracket (F) Tender Backup Light (IH-0000390) (CF-0000030) (EE) Coupler Insulator (ID-0000123) (G) Tender Marker LEDs (CC-0000062) (I) Speaker (BF-0000034) (H) Locomotive Wire Harness w/Tach Reader (BC-1000003) (J) Locomotive Headlight (CA-00000078) (L) Tach Tape (K) Tach Reader (BE-0000151) Mabuchi / IDG...
  • Page 5 (N) M2 Screws (O) 6/32 x 6mm Screws (IA-0000058) (IA-0000027) (M) AA Battery Pack (Charge before use) (P) Nuts (BG-4000003) (TP-M500075) (R) Plastic Wire Sleeve (Q) 6/32 Screw x 8mm (IA-0000050) (S) Shrink Tubing (T) Foam Tape (U) Wire Ties V) Inductor (AI-0000044) (X) Battery Recharging...

  • Page 6: Required Tools

    Required Tools Soldering iron ESD safe work area White thermally conductive grease Screw drivers, Philips #2 & #00 Wire cutters Drill Drill bits (1/8”, 5/32”) Drill bit (3/8” or ½”) or de-burring tool Allen key (1.5 mm for Pittman motor flywheel set screw) Electrical Tape Razor Saw...

  • Page 7: Locomotive Inspection & Review

    Inspection & Review Before beginning the installation, Inspect the engine and tender to be upgraded and verify the following are in good working order: Pick-up rollers Motor w/flywheel Smoke unit Speaker mounting hardware Volume pot Coupler mounting hardware, “T” bar, spring, c-clip Constant voltage lighting board and connected bulbs.

  • Page 8: Preparing The Tender For The Upgrade

    Preparing The Tender For The PS-2 Upgrade Before you can install the Ps2 components into your tender, any existing sound boards or reversing units must be removed. The Ps2 Kit contains all the necessary electronics your locomotive requires to operate. Some existing mounting brackets may be utilized during the installation of the Ps2 components.

  • Page 9: Installing The Ps-2 Components Into The Tender

    Installing The PS-2 Components Into The Tender Required Upgrade Kit Components A) Proto-Sound 2.0 (Ps2) board (1) P) Nuts 6/32 (3) B) Ps2 plastic mounting bracket (1) Q) Screw 6/32 x 8 mm (1) C) Tender harness (1) R) Plastic Wire Sleeve (for wire D) Ps2 metal heat sink bracket (1) managment) (1) E) Proto-Coupler, long (1)

  • Page 10: Mounting The Ps-2 Board

    Mounting The PS-2 Board NOTE: If you are not a participating MTH Remove the Ps2 Board (A) from the Authorized Service Center sealed anti-static bag there is NO warranty once the bag is opened Verify Ps2 board is securely inserted into the plastic mounting bracket (B) NOTE: Use ESD safe work area and procedures when...
  • Page 11 Mounting The PS-2 Board Cont’d Once you have determined the best locations for mounting the plastic bracket (B), metal heat sink bracket (D), battery pack (M), and battery charging jack (X), mark the tender floor locations using a pencil or silver marker so you can drill the holes in the proper locations.
  • Page 12 Mounting The PS-2 Board Cont’d Mount the plastic mounting bracket (B) containing the PS2 board (A) using the 2 of the screws (O) and nuts (P) Mount the PS-2 plastic mounting bracket Apply white thermally conductive grease to the bridge rectifier on the PS2 board. Apply white thermally conductive grease to bridge rectifier &...

  • Page 13: Installing The Proto-Coupler

    Mounting The PS-2 Board Cont’d Secure the metal heat sink bracket (D) to the bridge rectifier using screw (Q) Note, if screw is too long, cut it down so it does not hit the relay Apply thermal conductive grease to the metal heat sink bracket surface that contacts the frame and mount to the tender frame using screw (O) and nut (P).

  • Page 14: Coupler Installation

    Coupler Installation A plastic insulator, item EE in the parts list of your Proto-Sound 2.0 Upgrade Kit has been included with the rest of your Ps2 Upgrade Kit parts. This insulator should be inserted between the coupler and the spring, washer and the C clip that holds the coupler to the T-Bar and truck bolster.

  • Page 15: Optional Front Proto-Coupler Wiring

    Optional Front Proto-Coupler Wiring *If front proto-coupler is desired purchase a coupler DD-0000032 and give up Headlight Control. Power headlight as it was powered prior to PS2 upgrade. Use the headlight connector (Blue) to control the front proto-coupler. Move the purple wire in the tender 12 pin connector from pin 5 location (purple wire next to green wire) to pin 9 location (between brown and blue wires).

  • Page 16: Installing The Tender Harness

    Installing The Tender Harness, Speaker, Switches & Lights *Note: If tender has harness to connect an auxillary tender, connect the back- up light and coupler connectors to the harness. Use switch to select light/coupler operation in tender or auxillary tender. PS-2 Upgrade Kit Installation Guide...
  • Page 17 PS-2 Board Connections 5 PIN 7 PIN 4 PIN 12 PIN 2 PIN 8 PIN PS-2 Upgrade Kit Installation Guide...
  • Page 18 Installing The Tender Harness, Speaker, Switches & Lights Attach tender harness (C) to the PS2 board (A) noting the connectors all should fit in their respective locations. See previous pages for locations. Take care to insert the correct plug into the correct connector on the Ps-2 board. Each plug is polarized and has a different number of pins.

  • Page 19: Soldering Speaker Connections

    Install the rear back up light (F) with green connector and marker lights (G) with yellow connector as required in the model. Connect the backup light green connector and marker light yellow connector to the green and yellow Ps2 harness connectors, respectively.

  • Page 20: Installing The Battery & Volume Pot

    Installing The Battery And Volume Pot Plug the 2 pin battery pack connector into the Ps-2 board. The battery pack connector comes pre-mounted to the recharging port (X) and battery pack cable. It plugs into the Ps2 Circuit board as indicated by the arrow. Mount the 2 pin battery recharging jack (X) to tender floor as shown below.
  • Page 21 Solder the red, blue and gray volume pot wires to the volume pot. Red to the center terminal and blue and gray to the outside terminals. Place the double-sided foam tape (T) on the tender floor in the proper location established previously. Secure the AA rechargeable battery pack (M) using double-sided foam tape.

  • Page 22: Preparing The Locomotive For The Upgrade

    Preparing The Locomotive For The Ps2 Upgrade Remove The Following Items From The Engine Note: Do not remove the Boiler (save the mounting screws). constant voltage board & bulbs connected to it. Headlight bulb and wire harness plug from These will be reused later the constant voltage board if present.

  • Page 23: Determing The Locomotive Motor Type

    Determine Engine Motor Type Verify which type of motor is present (Pittman or Mabuchi) If the motor is a Pittman model (the Pittman name is printed on the motor label), remove the flywheel by loosening the set screw with the Allen Key. Identify which type of motor the The flywheel on the Pittman motor locomotive is equipped with.

  • Page 24: Installing The Flywheel Tach Tape

    Installing Tach Reader Bracket Small Mabuchi Motor Large Mabuchi Motor Some Mabuchi motors are larger than others and will require that the tach reader bracket be modified in Spread the Tach Reader bracket order to fit around the motor. Cut the apart and slip between the flywheel bracket straps as shown.

  • Page 25: Mounting The Tach Reader To The Tach Bracket

    Mounting Tach Reader To Tach Reader Bracket Insert the tach reader into the tach reader bracket. The gap between the optical sensor and flywheel should be 0.5 mm (0.022”) – 1.5 mm (0.060”); 0.75mm (0.030”) is optimum. If the gap is too small, remove the tach reader spacer as detailed below.

  • Page 26: Installing The Ps-2 Harness Into The Locomotive

    Installing The Ps-2 Harness Into The Locomotive Mounting Harness Connector Mount the 10-pin connector to the back of the chassis using the screws that held the previous 4-pin connector in place. It may be necessary to use the spacer (Z) as a shim if the connnector doesn’t properly line up with the opening at the back of the boiler.

  • Page 27: Connecting Motor, Ground & Pickup Wires

    Connecting Motor, Ground & Pickup Wires Solder the yellow and white wires to the motor. (Note if the engine starts out in the reverse direction, you will later need to reverse the yellow and white wires to the motor. This will not be tested until installation is complete - see page 30) Connect the red wire to the pick-up roller using the existing wire nut.

  • Page 28: Installing Headlight Into Railking Steam Engines

    Installing The Headlight Into RailKing Steam Engines On RailKing steam locomotives, the headlight is usually a screw based bulb inserted into a bracket mounted to the chassis. This bulb must be replaced and the screw base bracket drilled out with a 3/8” Drill Bit. Insert the headlight bulb grommet (W) into the drilled out hole followed by the headlight bulb (J).

  • Page 29: Connecting The Ps-2 Harness To The Smoke Unit

    Connecting The Ps-2 Harness To The Smoke Unit Solder Gray and Green wires to the smoke unit fan motor. If the smoke green wire unit motor terminals are hooked up gray wire backward, the impeller will spin in reverse and fail to pump out the smoke. When properly wired, most impellers should rotate clockwise.

  • Page 30: Other Proto-Smoke Circuit Wiring Methods

    Other Proto-Smoke Circuit Wiring Methods Please keep in mind the objective when modifying Original ProtoSound fan driven smoke unit is to place the heating elements in parallel and isolate the heating elements from the smoke unit circuit board components. Please see the picture below showing one other style found in RK Allegheny, Big Boy, and Challengers.

  • Page 31: Connecting Power To The Constant Voltage Board

    Connect Power To The Constant Voltage Board Use one of the previous red power wires to provide track power to the locomotive’s original constant voltage board (if present). The constant voltage board is used to power all lights in the boiler EXCEPT the headlight. Locate the engine’s constant voltage board power pickup wire as shown.

  • Page 32: Wire Management/Short Circuit Prevention

    Wire Management/Short Circuit Protection Route the wires around the motor and chassis such that the wires will not be pinched when the boiler is installed. NOTE: The wires may need to be cut and spliced together to shorten the length of the wires. Use the shrink tubing (S) supplied in the kit for this purpose whenever necessary.

  • Page 33: Testing The Ps-2 Installation

    Testing The Ps-2 Upgrade Installation Connect the tender (without the tender shell on) to the engine (chassis only) by inserting the tender harness into the 10 pin plug at the rear of the engine. Apply 12 volts of power (in conventional mode) to the engine and tender. If you have a Z4000 look at the current display.

  • Page 34: Loading Proto-Sound 2.0 Files Into Locomotive

    Loading The Ps-2 Sound File Into The Upgraded Engine Before your upgraded locomotive will play locomotive sounds, the Ps-2 circuit board needs to be programmed with the appropriate Ps-2 Conversion File for your engine type. Programming can only be accomplished with the M.T.H. DCS Digital Command System and the free DCS Loader Program.
  • Page 35 STEP 1: The Ps2 upgrade kit utilizes the 3volt Ps2 board. To find a 3volt sound file, go to www.mthtrains.com and select “Service”. Then select “Product Files and Documents” from the available options. First, select “Service” Then, click on “Product Files and Documents”...
  • Page 36 STEP 3: Select the engine sound file from the results list. Remember to select a 3volt production file, or the Ps2 Upgrade Sound File (if available). Right click and save the sound file to your computer. Use the DCS Loader Program to load the sound file into your engine.

  • Page 37: Conventional Operation

    Conventional PS-2 Operation The Throttle knob controls how fast your train will travel. Turn the throttle knob up ½-way, until the engine and caboose lights shine bright. Activating Features Throttle - To increase or decrease track voltage, and therefore train speed, turn the throttle control knob.

  • Page 38: Proto-Sound 2.0 Operation Instructions

    Proto-Sound® 2.0 Operating Instructions This manual contains the operating instructions for Proto-Sound 2.0 in conventional mode only. Instructions for accessing DCS command mode features accompany the DCS Remote Control System equipment. Activating Proto-Sound® 2.0 Conventional Mode Features Proto-Sound® 2.0 features are activated by sequences of Bell and Horn button pushes described below.
  • Page 39 Passenger/Freight Announcements (PFA) Your engine is equipped with a sound package of passenger station or freight announcements that you can play when you pull into a station. Each sequence described below will play as long as it is left on, randomly generating sounds, but be sure to allow approximately 30 seconds between the button pushes described below to allow the PFA sufficient time to run through each sequence.
  • Page 40 Tips on Using PFA • You can terminate PFA at any time by turning off power to the track for 15 seconds. • You do not have to be in Forward to use PFA. At the conclusion of the full sequence, the train will pull away from the station in whatever direction you were going when you activated the feature.
  • Page 41 Front Coupler: To fire the front coupler (if your engine has one), quickly tap the Bell button once followed by four quick taps of the Horn button, allowing approximately ½ second to lapse between each quick button press. The sound of the lift bar and air line depletion will play, and the knuckle will be released.
  • Page 42 Locking Locomotive Into a Direction You can lock your engine into a direction (forward, neutral, or reverse) so that it will not change directions. To do this, put the engine into the direction you want (or into neutral to lock it into neutral), run it at a very slow crawl (as slowly as it will move without halting), and quickly but firmly tap the Horn button once followed by three quick taps of the Bell button, allowing approximately ½...

  • Page 43: Self-Recharging Battery

    Self Charging Battery Back-up The special rechargeable 2.4v self-charging battery recharges continuously during train operation and should last for up to five years. The battery is a dry battery that should not leak or cause any damage to your engine. Depending upon when your engine was built, it may need to be charged right out of the box.

  • Page 44: Troubleshooting

    Troubleshooting Proto-Sound® 2.0 Problems Although Proto-Sound 2.0 has been designed and engineered for ease of use, you may have some questions during initial operation. The following table should answer most questions. If your problem cannot be resolved with this table, contact M.T.H.
  • Page 45 Cab Chatter Remedy Sometimes the Cab Chatter sounds Cab Chatter plays only in neutral at don’t play. random intervals. Lock-out Remedy I can’t get the engine to run after I The engine is locked into the neutral power up the transformer. It sits still position.
  • Page 46 Remedy Once in PFA, the engine doesn’t go So that PFA effects can be as realistic into reverse. as possible, Proto-Sound 2.0 disables the reversing unit whenever PFA is enabled. This way the engine remains still at its stop as the operator cycles through the PFA sequences.

  • Page 47: Service & Warranty Information

    Service & Warranty Information How to Get Service Under the Terms of the Limited Warranty When you suspect an item is defective, please check the operator's manual for standard operation and trouble-shooting techniques that may correct the problem. Additional information may be found on the M.T.H.

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