SOUND SYSTEM FOR LARGE-SCALE MODEL RAILROADS

Transcription

1 S O U N D T R A X X SOUND SYSTEM FOR LARGE-SCALE MODEL RAILROADS 461 OWNER'S MANUAL

2 ACKNOWLEDGMENTS In the process of recording the many locomotive sounds used in the creation of SoundTraxx Sound Systems, we'd like to gratefully acknowledge the assistance of the following groups and organizations: The Cumbres & Toltec Scenic Railroad Box 789, Chama, NM (505) The Durango & Silverton Railroad Main Street, Durango, CO (970) The East Broad Top Railroad & Coal Co. P.O. Box 158, Rt. 994, Rockhill Furnace, PA (814) The Georgetown Loop Railroad P.O. Box 27, Georgetown, CO (303) The Leadville, Colorado & Southern P.O. Box 916, Leadville, CO (719)

3 Notice The information in this document is subject to change without notice. Throttle Up! dba SoundTraxx shall not be liable for technical or editorial errors or omissions contained herein; nor for incidental or consequential damages resulting from the furnishing, performance or use of this material. This document contains information protected by copyright. No part of this document may be photocopied or reproduced in any form without the prior written consent of SoundTraxx. Product names mentioned herein may be trademarks and/or registered trademarks of their respective companies. SoundTraxx, Auto-Exhaust and Hyperlight are trademarks of Throttle Up! Corp Throttle Up! Corp. All Rights Reserved.

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5 TABLE OF CONTENTS ALL ABOARD! 2 SIERRA FEATURES AND SPECIFICATIONS 2 Sierra Features 2 Steam Sound Features 2 Lighting Features 2 Kit Contents 3 Orientation 3 IMPORTANT STEPS FOR A SUCCESSFUL INSTALLATION 4 INSTALLATION 4 Step 1. Select Your Locomotive 6 Step 2. Plan the Installation 6 Step 3. Fit the Speaker 8 Step 4. Modify the Tender Body and Floor 8 Step 5. Install the Lighting Effects (Optional) 10 Step 6. Install the Magnetic Sensor Switch (Optional) 11 Step 7. Install the Coupler Clank Sensor Switch (Optional) 12 Step 8. Install the Recharging Jack (Optional) 13 Step 9. Install the Remote Mounted Volume Control Switch (Optional) 13 Step 10. Install and Wire the Sound Module 14 Step 11. Test the Installation 17 Step 12. Customize the Locomotive Sounds 17 OPERATING SOUNDTRAXX SIERRA 26 Operating Notes 26 Charging the Battery 28 TROUBLESHOOTING 29 SERVICE AND WARRANTY 31 APPENDIX A - OPTIONS AND ACCESSORIES 33 APPENDIX B - SIERRA SETUP CHECKLIST 35

6 ALL ABOARD! Congratulations on the purchase of your SoundTraxx Sierra sound module. Properly installed, Sierra will provide all the pleasures of high quality, digital onboard sound coupled with ease of use and incredible flexibility. With the proper tools, basic modeling skills and common sense, equipping a locomotive with sound is not difficult. It may, however, be a new experience for you, and you will find that successive installations will go more quickly than the first. SoundTraxx Sierra has some unique features and capabilities. We strongly encourage even the most skilled and experienced modeler to read this manual thoroughly as it contains instructions and information designed to provide optimum, trouble free performance. SIERRA FEATURES AND SPECIFICATIONS Sierra is designed to be installed onboard a locomotive in conjunction with a speaker to provide the ultimate in realistic sound. Sierra integrates a full featured digital sound system, and special Hyperlight lighting effects into a single, compact electronic module. SoundTraxx Sierra is available with prototype-specific sound and lighting effects for a multitude of North American and foreign locomotives. Depending on the effect, the sounds are generated continuously, automatically in response to some other action, or as controlled by the user. Sierra Features The Sierra Sound Module is compatible with: Power packs Digital Command Control Radio Control Sierra is a compact 2.81"L X 1.28"W X.53"D. Most kits come with a rechargeable battery which measures 2" X 1.9" X 1" and a speaker which measures 3" in diameter. Steam Sound Features The Steam models provide high quality digital sounds specific to its prototype. All sounds are polyphonic; one sound will never interrupt another! Each Sierra module includes: Steam Exhaust Chuff Whistle Bell Firebox Blower Dynamo Airpump Cylinder Blowdown (Hiss) Boiler Pop Valve Fireman Fred Coupler Clank Adjustable Volume Control 1 Watt Audio Amplifier Auto-Exhaust allows chuff to be synchronized using an exhaust cam sensor or track voltage. Lighting Features Each Sierra also comes equipped with two lighting outputs that can be programmed to be: Constant Intensity Lighting Mars Light Intelligent Firebox Flicker - synchronizes with sound of firebox door opening and closing. Lighting outputs specifications: 100mA current sink capability 2

7 Kit Contents Before proceeding with your installation, take a moment to familiarize yourself with the following components which are included with your Sierra sound system ) SoundTraxx Sierra CIrcuit Board 3) Magnetic Reed Switch for cam synchronization (1) 2) Speaker (prewired) 4) Wheel or Axle Magnets (2) 5) 6V gel cell battery (prewired) 6) Power Switch 7) Hookup Wire Figure 1 - Kit Contents 1. SoundTraxx Sierra circuit board 2. Speaker (size varies with model) 3. Magnetic reed switch for exhaust synchronization 4. Two miniature magnets for wheel or axle mounting, to be used in conjunction with the magnetic reed switch. 5. Pre-wired 6 volt gel cell rechargeable battery 6. Power Switch 7. Hookup wire Orientation It may be helpful to start by familiarizing yourself with the layout and location of key components on the Sierra circuit board. 1. TERMINAL BLOCK CONNECTORS Used to connect Sierra to speaker, track, sensors and remote switches. 2. VOLUME (-) KEY Used for decreasing the volume and for making adjustments during the setup procedure. 3. VOLUME (+) KEY Used for increasing the volume and for saving and selecting during the setup procedure. 4. INDICATOR LEDs Used as status and setup indicators 5. BATTERY RECEPTACLE. Receptacle for the connector on the prewired battery harness Figure 2 - Sierra Board Orientation 4 3

8 IMPORTANT STEPS FOR A SUCCESSFUL INSTALLATION It will be a great temptation to begin connecting wires immediately. Before you install your Sierra sound module, there are some simple precautions you should take. First, finish reading this Owner s Manual! The Sierra circuit board should be handled carefully in a static-free environment. To discharge static electricity, touch a grounded water pipe or bare sheet metal surface before handling the circuit board. Work in a clean, well lit area on a nonconductive surface. Metal scraps and dirt can get onto Sierra's circuitry and cause shorts. Never, ever make connections to the sound module while it is powered. Doing so makes for an accident waiting to happen. Make sure all electrical connections are insulated. Avoid using electrical tape if possible as it tends to unravel over time. We recommend using heat shrinkable tubing instead. Never allow the speaker outputs to become shorted together. Never allow the battery wires to become shorted together. Do not bend the battery terminals. Doing so may rupture the battery seals and allow corrosive liquids to leak. Do not exceed the ratings for which the module is designed. Take your time and have fun! INSTALLATION 11 Easy Steps to Steam Sound Installing the Sierra sound module generally requires the following steps: 1. Select the Locomotive Choose a locomotive appropriate to the module purchased and your installation skills. 2. Plan the Installation Determine locations of the circuit board, battery, speaker, magnets, lamps and connectors. 3. Modify the Tender Body and Floor Modify the tender to accept the speaker and circuit board 4. Install the Lighting Effects (optional) Modify locomotive to accept miniature lamps. 5. Install the Exhaust Sensor Switch (optional) Install magnets and mount the sensor switch. 6. Install and Wire the Coupler Switch (optional) Modify the coupler and mount the coupler clank sensor switch. 7. Install the Remote Mounted Volume Control Switch (optional) 4

9 8. Install the Battery Charging Kit (optional) 9. Install and Wire the Sound Module Mount the module and connect the lamps, motor, speaker, etc. 10. Test the Installation 11. Customize the Sound Effects Fine tune the performance and sound effects. Tools and Materials You Will Need In addition to the common hand tools found on most modeler s workbenches, you should have at your disposal: Low wattage (under 25 watts!) soldering iron Rosin Core Solder X-acto knife Miniature screwdriver set Diagonal cutters High speed motor tool (such as a Dremel) Double sided tape Silicone RTV 5-minute epoxy Optional Items for the Perfect Installation We also recommend the following items to ease your installation: Microconnectors SoundTraxx offers microconnectors to facilitate easy separation of items from the locomotive. SoundTraxx sells P.N , an easy to handle 2-pin microconnector. Individual connector pins are also available (SoundTraxx P.N , 10-pack of micro-mini connector pins) which will allow you to disguise the connecting wires as air and water lines but require great care when reconnecting them so as not to miswire the module. Wiring Aids We recommend you use insulative and shrink tubing to insulate your connections. SoundTraxx sells P.N , which contains an assortment of heat shrink tubing suitable for this purpose and P.N which provides a length of Teflon tubing. Electrical tape will unravel with time and is not recommended! Microbulbs If you intend to take advantage of the special lighting effects and wish to use 1.5 Volt microbulbs for this purpose, SoundTraxx offers P.N with a diameter of 1.3mm. P.N has a diameter of 2.2mm for use in larger scales. Both are also available in economical six packs. Heavy Duty Battery This heavy duty rechargeable battery (P.N ) provides approximately twice the number of operating hours. It measures 2" X 1.65" X 1.97". Remote Mounted Volume Control Switch We also offer a switch which can be used to customize the sound system and control the overall volume of Sierra without accessing the circuit board directly. This switch P.N can be mounted in a convenient to reach, but out-of-sight location. 5

10 Battery Charging Kit The Battery Charging kit P.N , allows Sierra's battery to be conveniently recharged from household current, ensuring that Sierra is ready to go before each operating session. Since the locomotive is stationary during the recharging, it also saves excess wear and tear on the engine and ensures maximum operating time. Trigger Switches Trigger switches (P.N ) sense magnets placed in the roadbed, and can be used to activate Sierra's bell, whistle and hiss effects at predetermined locations on your layout. One trigger switch is required per effect and includes one magnet. Firebox Lighting Kit SoundTraxx also offers a firebox lighting kit, P.N containing one yellow and one orange LED, pre-wired and ready to install. Coupler Sensor Switch The coupler clank sensor switch is used to trigger the sound of the coupler clank when coupling to a boxcar or another engine. Speakers Sierra comes with it's own speaker, usually designed to fit a particular locomotive. Other speaker sizes are available if your particular installation requires a larger or smaller speaker. Remember, larger is always better! See Appendix A. Step 1. Select your Locomotive If this is the first time you have installed sound in a locomotive, then we suggest you choose your locomotive carefully. A few simple precautions will ensure that your first effort produces a great sounding locomotive instead of an intimidating ball of wires: - Do pick a smooth running locomotive that runs well. A smooth running mechanism is vital for good throttle control and enhances the realism of the sound. Dirty, worn out or binding mechanisms will have trouble starting smoothly and will destroy the illusion created by the Auto-Exhaust feature if they barely lurch along at half throttle. - Do pick a locomotive with a reasonably large, rectangular tender. The larger the tender, the more room you will have for installation of the module, battery and speaker. It will also allow you to use a larger speaker, giving both better volume and sound fidelity. - Do start with an engine that is sound-ready if possible, such as an engine with predrilled speaker holes, for example. The simpler you can make your first installation, the better. - Don t pick a noisy engine, or one which experiences some arcing or sparking when in operation. The best sound will come from locomotives powered with can motors. Older, open-frame motors may produce an offensive, interference sound. Step 2. Plan the Installation You should give some thought to where the installation of the various Sierra components will be within the locomotive before you get started. Figure 3 shows a typical installation. The decision most critical to the success of your installation will be where to put the speaker. Obviously, the where of speaker installation will depend on the size and type of the locomotive. But when considering the speaker s location, remember that the volume of the speaker will be 6

11 greatly enhanced when the speaker is fitted into a small airtight enclosure with the front of the speaker open to surrounding air. The reason for this is simple: in order to generate any appreciable sound, the speaker must develop air pressure. Without an enclosure, any pressure developed by the front of the speaker is canceled by an opposite pressure behind the speaker. The enclosure isolates the front and back surfaces of the speaker, thereby increasing the sound pressure and hence, the volume. Headlight Recharging Jack Firebox Light Sierra Module Speaker Magnets Sensor Left Rail Pickup Right Rail Pickup 6V Battery Figure 3 - Typical Sound Installation Additionally, the enclosure must be sized proportionally to the speaker such that the volume of air enclosed is several times larger than the speaker diameter. If an enclosure is too small, it will interfere with the speaker operation and although it cannot be made too large, there is a point of diminishing return. As a rule of thumb, for small speakers, the minimum for the length, width and height should be equal to the speaker diameter. Thus the smallest enclosure for a 3" speaker would be 3" X 3" X 3". As this is only a general guideline, exceptions can and must be made in many circumstances. HOWEVER, the use of a proper speaker enclosure cannot be over emphasized and failure to use one is almost always the cause for poor sound quality. Fortunately, most steam engines have a tender and with a little work, the tender itself becomes a great speaker enclosure. The speaker can face up through the coal bunker or down through the floor. Either way will produce equally good sound. You will also want to use the largest speaker possible to get the best bass response. Larger diameter speakers can be trimmed down in width so they will fit within the tender shell. By building an internal baffle, they can also be mounted at an angle although this may compromise the available space for the Sierra sound module in all but the largest of tenders. In small tenders, the speaker should be mounted forward in the coal bunker area, where higher walls are available to cover the speaker magnet. For other locomotives, the speaker enclosure need not be fancy and can be fabricated from sheet styrene, bass wood, and even cardboard in a pinch! The cardboard tube center of a roll of paper towels usually produces excellent results. The Sierra sound module is best suited for installation in the tender, although it will fit in the boiler of larger locomotives. Boiler installation has the advantage of requiring considerably less wires that have to be routed between the engine and tender. It will usually come at the expense of some boiler weight and possible reduction in traction. It is normal for the Sierra module to get warm after periods of extended operation and its built-in thermal overload protection will automatically shut down the audio amplifier if it gets too warm. 7

12 Therefore, it is important to install Sierra in a location where it can dissipate the most heat. Avoid placing the module near heat sources such as the motor or lights. You will also need to decide how you will synchronize the exhaust chuff. SoundTraxx Sierra provides two means for synchronization. The first method is to use a magnetic sensor switch in conjunction with 2 or 4 magnets mounted on an axle or the inside face of a driver wheel. As the wheel rotates, the magnets pass by the sensor switch, producing a chuff. This will give the most precise synchronization and even produce a wheel slip effect if the locomotive is accelerated too quickly! In a pinch, the magnetic sensor switch can be used with a tender axle, although the synchronization effect will not be exact unless the tender wheel diameter is an exact multiple of the locomotive driver diameter. The other method of exhaust synchronization is Sierra s Auto-Exhaust feature which produces chuffs in proportion to the throttle setting. This method is recommended for those locomotives where the magnetic sensor would be difficult to install. Next, you will need to consider which lighting effects you will use. Sierra provides for two lighting outputs which can be used for controlling lightbulbs or LEDs. The outputs may be customized as follows: As a conventional on/off output, they may drive additional bulbs for a constant intensity headlight, cab light, marker lights or number boards. As a Mars light, they may be used to simulate the famous warning beacon found in front of the modern steam engines used by railroads such as the Southern Pacific, Union Pacific and Nickel Plate Roads. As a firebox light, they may be used to simulate the flickering glow from the firebox. As a 'smart' firebox light, they may be used to produce a firebox flicker effect that turns on only when the sound of the firebox door opening has been activated and turns off when the doors close. Each Hyperlight output can be independently programmed so it is possible to use one output as a Mars light and the other bulb for the firebox. Finally, you will need to consider installation of any of Sierra's optional accessories such as the charging jack, coupler clank sensor switch, etc. After you have fully read the installation manual, we suggest reviewing Step 10 on wiring the module and draw yourself a schematic similar to Figure 3 showing all connections between Sierra and the various subcomponents. This will also help you determine which connector is best suited for your needs, should you decide to use one. Step 3. Modify the Tender Body and Floor Depending upon your choice of tender, you will probably be mounting the speaker facing down on the tender floor or facing up in the coal bunker. In either case, a certain amount of body work may be necessary to accommodate the speaker, battery and sound module. This may include removing weights, mounting brackets, internal bracing and other structural features. Although some models come with speaker holes predrilled, in other locomotives you may need to cut an opening in the tender shell or floor for the speaker. A series of small holes can be easily drilled and will work as well as one large hole provided the open area is at least one half the area of the speaker cone. In either case, there should be no openings outside or larger than the 8

13 speaker cone itself. Tender Body Modifications On tenders with low side walls, the speaker is often best mounted facing up in the coal bunker so as to provide adequate clearance for the sound module which will be mounted against the tender floor. In some cases, it may even be necessary to add a wooden retaining wall to build up height. The simplest tenders have a flat deck across the coal bunker and are the easiest to deal with. Simply mark or scribe the speaker outline onto the tender deck and using a jeweler s saw, cut out a circular opening about 1/16" inside the outline marks. Remove all sharp edges and burrs. The speaker is then disguised by covering the opening with a acoustically transparent coal load. The coal load can be fabricated by contouring a piece of fine screen mesh or polyurethane foam to represent a coal load and then covering it with a thin layer of scale coal cemented in place with a thin wash of diluted white glue. Remove inside walls and slope sheet if needed. Cut hole diameter to slightly less than speaker diameter. Perforate coal load with #55 drill. Styrene in sub-deck Optional wooden retaining boards to build up height. Cross section of plastic tender with molded coal load. Opening in deck should be slightly smaller than speaker diameter Figure 4 - Tender Shell Modifications Plastic tenders often have a molded coal load already in place. Unfortunately, the inside surface of such tenders are contoured to match the coal load and do not provide a flat mounting surface for the speaker. In such cases, the modeler has two options. The first is to cut out and remove the coal load entirely and replace it with a flat sheet of 0.060" or thicker styrene and then proceed as described above for the flat decked tenders. Alternatively, a sub-deck can be fabricated from 0.060" sheet styrene such that it fits below the coal load tightly against the tender sides. Cut a large circular opening appropriate for the speaker diameter into the styrene sheet and then glue the sub-deck to the inside of the tender shell. Perforate the coal load by drilling a series of small holes (use a #50-#60 drill) at random angles between the coal nuggets. This way, the sound will be allowed to escape yet the speaker remains relatively invisible regardless of viewing angle. The more realistic tenders will have fuel bunkers that prototypically extend to the tender floor. For 9

14 larger tenders with such a feature, the speaker is best mounted on the tender floor. For smaller tenders, the slope sheet and interior walls will interfere with the speaker and it will usually be necessary to remove and replace them with sheet brass or styrene to create a flat decked tender. Tender Floor Modifications If you are mounting the speaker to the tender floor, first determine the exact speaker location within the tender and verify that there is adequate clearance between the tender body and speaker magnet. Use a marker or scribe to note the location of the speaker on the tender floor and then drill three rows of holes (see Figure 5) in the pattern shown to provide an opening for the sound to escape. A drill approximately.250" is a good size. Space the holes as best you can, taking into consideration the tender underbody detail. Although the spacing is not critical, you should attempt to provide at least this much of an opening. If necessary, use more holes of a smaller diameter. Keep all the holes within the expected cone area of the speaker. Take care not to place holes at the outer edge of the speaker assembly itself. Once you have drilled your holes, remove all burrs and uneven edges. Make sure there are no metal burrs or edges projecting up - the speaker floor should be smooth, with nothing to physically interfere with the speaker s ability to lay completely flat on the tender floor, such as solder joints, screw bosses, and mounting studs. Speaker Cone Area Figure 5 - Tender Floor Modifications Secure the Speaker in Place Once body work is complete and the speaker has been fitted in place, it must be secured tightly to the enclosure. For the best sound, an airtight seal is needed around the speaker edge and we have found the best way to hold the speaker in place is to use silicone RTV - it provides the airtight seal needed and unlike epoxy or other hard glues, allows the speaker to be readily removed in the future. Be careful that you don t get any RTV onto the speaker cone itself as this will severely distort the sound quality! Step 4. Install the Power Switch Select a discreet but easy to access location for mounting the power switch. Drill a 1/4" diameter hole for the switch and secure with the included nut and washer. Remember to insulative the switch on brass locomotives! Step 5. Install the Lighting Effects (Optional) Headlights, Backup Lights and Mars Lights Drill out the headlight castings to accept any lights you intend to use, including the tender backup light. If you are using SoundTraxx s 1.5V, 1.3mm microbulbs, P.N , a #53 twist drill makes a perfect hole. If you are using the larger, 2.5mm microbulbs, P.N , a #41 twist drill works well. Test fit the microbulb for adequate hole clearance and enlarge the hole if necessary. Next, paint the headlight castings reflector surface with white or silver paint and allow to dry. Install the light bulbs and secure in place using tape or a flexible glue that does not bond well to 10

15 glass such as white glue, rubber cement or RTV. Epoxy or ACC glues will make bulb replacement very difficult and are not recommended. As a final touch, install a lens using white glue to hold it in place. You may wish to use a commercially available lens such as those offered by MV Lenses or make your own. A lens can be easily fabricated from a sheet of clear styrene or alternatively, molded from a drop of clear epoxy that is allowed to flatten and harden on a non-stick surface. Firebox Lights The Firebox Lighting Kit comes with a pair of pre-wired orange and yellow LEDs. The firebox lights should be mounted between the locomotive frame rails in the general vicinity of the ash pan. The idea is that the LEDs are never directly visible but rather casts a gentle glow into the cab or onto the ground below if mounted in the ashpan. The LEDs may be held in place with tape or silicone RTV. If you are using the Smart Firebox Flicker effect, you may wish to modify the locomotive s firebox door so it is slightly open and then mount the LEDs directly behind it. In this manner, when Fireman Fred puts a few scoops of coal into the fire, the cab will fill with a soft orange glow. Step 6. Install the Magnetic Sensor Switch (Optional) If you are intending to synchronize the steam exhaust chuff directly to the drive wheels, you will need to install the magnets and reed switch which come with your Sierra sound system. Otherwise, if you are planning to use Sierra s Auto-Exhaust feature, you may skip this step. Begin by selecting the magnet pattern appropriate for your engine. For conventional 2 cylinder engines, four chuffs per wheel revolution is prototypically correct. However, keep in mind that most large scale trains are run faster than scale Magnets Magnets speeds and using 4 magnets per axle revolution is probably not going to give the desired results. Conventional Articulated We find that using 2 magnets per axle will produce a more pleasing sound. Sierra is supplied with two magnets; additional magnets can be purchased from SoundTraxx as P.N or Radio Shack P.N Articulated Steam Locomotives Articulated engines come in two flavors, simple and compound. On simple articulated engines, the cylinders on the front and rear are the same size. On compound engines, one set of cylinders is considerably larger than the second set. For compound articulated engines, 4 chuffs per driver revolution is correct. Install the same as for regular locomotives. For simple articulated engines, spacing the magnets unevenly will provide an 'interesting' exhaust cadence. Geared Locomotives Geared engines require a larger number of chuffs due to multiple cylinders and gearing of the drive wheels. Due to the large number of contacts required for each wheel revolution, it is usually impractical to achieve the prototypically correct number of exhaust chuffs per revolution. It is usually preferable to use the Auto-Exhaust feature. Install the Magnets The magnets may be mounted to the axle or locomotive drive wheel. First, trial fit the magnets 11

16 for adequate clearance between the wheel and the locomotive frame. Space the magnets as far apart as possible, but do not locate them so close to the edge of the wheel flange that they cause interference with track features such as guard rails and turnout frogs. Once you are satisfied with the magnets' location, they can be secured in place with 5-minute epoxy. Install the Sensor Switch Caution: The switch sensor is made of glass and can be broken if mishandled. Do not bend the sensor's leads or make solder connections within 1/8" of the glass body. If you do need to bend the leads, hold the lead with a pair of needle-nose pliers between the switch body and the bend point. Then bend the lead as needed. Solder connections should be made as far from the switch body as possible using only a minimal amount of heat. The magnetic sensor switch should be installed so that it floats 3/8" or less from the surface of the magnet. You will probably want to attach the black connecting wires before installing. Cut the black wire in half and strip and tin each end. Solder one wire to each lead of the sensor switch. Once the leads are attached, temporarily mount the sensor switch in place with adhesive tape. Once your system is wired, you may find that the sensor's location will have to be adjusted to get reliable pickup. Once you are satisfied with the switch location, permanently attach it using 5-minute epoxy. Reed switch should be 3/8" or less from magnets as shown Mount one magnet on each side of axle Mount magnets on inside of driver wheels Reed switch should be 3/8" or less from magnets as shown Figure 6 - Magnet and Sensor Installation Step 7. Install the Coupler Clank Sensor Switch (Optional) If you wish to take advantage of the coupler clank sound effect, you have a little more work to do! Otherwise, you may skip this step. In order to use the coupler clank sound effect, you need to install the coupler sensor in such a way that the switch is depressed when you actually couple to a car or other engine. To do this, you need to modify the coupler so that there is some forward/backward movement. Although there are many different couplers, the principle for installation is the same. Following Figure 7, remove the coupler and elongate the mounting hole with a small round jewelers file so that the coupler will now move slightly back and forth. Take a moment to also remove any burrs that might interfere with movement. Reattach the coupler and tighten the mounting screw just to the point where it contacts the coupler shank. A small metal washer between the screw and the coupler will ensure that the coupler stays in place. The coupler must move easily and be free of binds. A dry graphite lubricant will also help free up sticky couplers. Mount the switch so that when the coupler is moved back towards the tender, the switch is depressed and when it is moved away from the tender, no contact is made. You can epoxy the switch in place or use the mounting tab and a small screw. It's nice to mount the switch on the underside of the coupler where it can't be seen, although the 12

17 switch may be mounted on top if necessary. Drill a small hole in the tender floor for the coupler sensor wires to pass through. Remove screw and file hole about 1/16" as shown Mount Coupler Clank Sensor so that switch will depress when coupler is moved Figure 7 - Modifying the Coupler Step 8. Install the Charging Jack (Optional) The optional battery charger allows Sierra's battery to be conveniently recharged without having to run your train. To use the battery charger you must first wire the charging jack into the battery wire harness. Referring to Figure 8, cut the battery wire harness in half and strip the insulation from the ends of each wire. Connect and solder the two black wires to the jack's A terminal. Connect and solder the red wire from the battery to the jack's B terminal. Finally, connect and solder the remaining red wire to the jack's C terminal. Insulate the soldered connections to prevent accidental shorts. BLACK RED B - + 6V Battery A BLACK Charging Jack C RED 3-pin connector Figure 8 - Installing the Charging Jack The jack should be mounted in a discreet but convenient location such as under a water hatch and will fit into a 1/4" diameter hole. Caution: The jack must be mounted to a nonconductive surface as the mounting nut is also the sound system's ground. Do not mount the jack directly to the body of a brass or metal locomotive as a short circuit may result. For such locomotives, you will need to fasten the jack to a bracket or panel fashioned from a nonconductive material such as sheet styrene. Step 8. Install the Remote Mounted Volume Control Switch (Optional) The Remote Mounted Volume Control Switch will allow you to customize the sound effects and adjust the volume of the sound system from outside the locomotive. The switch should be mounted in a discreet but accessible location such as underneath the tender. Drill a 1/4" hole at the desired location, insert the switch and thread the switch's mounting nut in place. 13

18 Step 9. Install and Wire the Sound Module Begin by determining the placement of the sound module. Keep in mind that you want to be able to have easy access to the two buttons, LEDs and the battery connector. Once you have determined the optimum location, secure the board in place using double sided foam tape. Be sure the board cannot come into contact with metal or other conductive surfaces. Temporarily refit the body shell to ensure that adequate clearance still exists. Wiring the sound module is done by way of two terminal blocks on the circuit board. Simply loosen the screw on the top of the block, insert the stripped end of the wire, tighten the screw and your connection is made! When wiring the sound module, trim all wires to reduce unnecessary lead length. This will not only give your installation a neater appearance but also prevent wires from interfering with the drive mechanism and getting pinched between the frame and body shell. Magnet triggers on drive wheel Exhaust Trigger Switch Bell Trigger Switch WhistleTrigger Switch Hiss Trigger Switch CouplerTrigger Switch Speaker - Speaker Left-hand Rail Pickup Right-hand Rail Pickup GREEN Light 2 Light 1 Remote Volume Control RED Power On/Off Switch Not used Optional Recharging Jack 6V Battery - + To Terminal 8 Figure 9 - Master Wiring Diagram Referring to the master wiring diagram (Figure 9), begin with the speaker connections. BE ABSOLUTELY SURE THAT THERE ARE NO SHORT CIRCUITS. Speaker Connections 1. Connect one speaker wire to terminal 9 and the other speaker wire to terminal 10. Lighting Outputs (Optional) Each Sierra is equipped with two function outputs that are intended to drive headlight, backup light or special effect lights. Each output is rated for 100mA. Do not exceed this rating! To wire the optional firebox lights (P.N ): 1. Connect the RED wire of each light to terminal 4. 14

19 2. Connect the BLACK wire of one light to terminal Connect the BLACK wire of the other light to terminal 6. The Sierra lighting outputs may be used with 6 volt incandescent lamps, 1.5 volt microbulbs or LEDs. If you are using Sierra to drive 6V lamps, each bulb can be directly wired to the effect outputs as shown in Figure 10. If you are using Sierra to drive 1.5V microbulbs, you need to wire a small current-limiting resistor in series with each of the lamps to prevent them from burning out. A 300 ohm, 1/4W resistor is recommended for use with SoundTraxx P.N or microbulbs, however, you may need to adjust this value to get the desired brightness. Lower resistances will increase the brightness of the lamp. Sierra may also be used with LEDs, which also require a resistor, typically about 1/4W, 220 ohms. Note that LEDs are sensitive to polarity. Note: LEDs are not recommended for use with the Mars Hyperlight effect. Pin 4 Light Effect ohm Resistor Light Effect ohm Resistor LED 6V Bulb LED 6V Bulb Pin 5 Pin 6 Figure 10 - Wiring the Effect Lights Exhaust Sensor Switch Connections (Optional) 1. Connect one lead of the exhaust sensor switch to pin 11, and the other lead to pin 12. Remote Volume Control Switch (Optional) If you have installed the Auxiliary Volume Control Switch, wire it as follows: 1. Connect the switch's BLACK wire to terminal Connect the switch's YELLOW wire to terminal Connect the switch's GREEN wire to terminal 3. Coupler Clank Sensor Switch (Optional) If you have installed the Coupler Clank Sensor Switch, wire it as follows: 1. Connect one switch wire to terminal Connect the other switch wire to terminal 12. Sound Effect Trigger Switches (Optional) The Sound Effect Trigger Switches are wired between terminal 12 and terminals 13-15, depending on which sound effect you want activated: 1. For a 5-second bell, connect a Trigger Switch between terminals 12 and For a grade crossing whistle, connect a Trigger Switch between terminals 12 and For a cylinder blowdown, connect a Trigger Switch between terminals 12 and

20 Track and Battery Connections Caution: Do not perform this step until you have first reviewed the previous steps and double checked your wiring! Be sure Sierra is securely mounted and there are no wire scraps or other debris on the circuit board. The power switch should be wired into the battery wire harness at this time. After a To Battery (+) period of inactivity, Sierra will automatically To Sierra's green shut itself down to conserve power; battery plug however, it will continue to put a slight drain on the battery and will eventually Not Used discharge it. The power switch will allow No Connection you to completely cut power to the sound system between operating sessions. Figure 11 shows a bottom view of the power switch connections and an overall wiring diagram is shown in Figure Connect the green wire from terminal 7 to the locomotive's right hand rail pickup (engineer side). 2. Cut the red wire into two pieces. Wire one piece from terminal 8 to the power switch as shown in Figures 11 and 12. Connect the other piece of red wire from the power switch to the locomotive's left hand rail power pickup (fireman side). 3. Cut the battery BLACK - + 6V Battery RED To Left Track Pickup To Sierra Terminal #8 Not Used No Connection Figure 11 - Bottom View of DPDT Switch Charging Jack To Left Track Pick-up BLACK RED To #8 on Sierra board Figure 12 - Wiring the Power Switch and the Battery Charging Jack 3-pin connector Not used DPDT Switch harness's red wire in the middle. If you have installed the charging jack, cut the red wire at a point between the charging jack and the three-pin connector plug. Connect the two red battery wires to the power switch as shown in Figures 11 and Plug the battery's three-pin connector into the socket on the Sierra circuit board. Caution: Use your finger to hold the socket firmly against the circuit board when plugging in the connector to prevent the socket from ripping off the circuit board. The connector goes in one way so check that it is aligned properly before plugging it in. It is a snug fit and once plugged in, it is difficult to remove. If it is necessary to remove the connector later, use one finger to hold the socket firmly against the circuit board, while using your other hand to grasp the connector and gently wiggle it from side to side as you pull the connector straight out. Be very careful as excessive force may pull out the wires or rip the mating connector off of the circuit board. Using Sierra with DCC or an RC Receiver Sierra can be set up such that the whistle, bell and cylinder blowdown sound effects may be controlled remotely using Radio Control or as an auxiliary function using a Digital Command Control (DCC) decoder. These installations require additional effort that is beyond the scope of this manual. Technical Note 6 describes how to interface Sierra to a typical Radio Control system such as the Aristo Train Engineer or Locolinc. Technical Note 7 describes how to wire Sierra to a typical DCC decoder. Both bulletins are available free upon request. 16

21 Step 10. Test the Installation Before you close up your locomotive, turn on power to the Sierra circuit board. You should observe the F1 and F2 LEDs light up and hear the firebox box and airpump sound running in the background for a few seconds and then turn back off. If nothing happens, the battery is most likely in need of recharging first (see page 29). Now you are ready for the test track. We recommend your test track be fused with a fast-blo fuse appropriately rated for your locomotive. Place the locomotive on the track and slowly turn up your throttle to about 1 volt or so. If all is well, you will hear the firebox blower and airpumps running in the background. If there is no sound, double check your wiring to the track pickups. As you turn up the throttle further to about three volts, you will hear the dynamo spool up and two short whistle toots and then the bell will start ringing. The fire box lights should now be glowing brightly. As the locomotive begins moving you should hear the exhaust chuffs if you have installed the exhaust sensor switch. Otherwise, you will need to complete the setup section to activate the exhaust sound. Tap the coupler sensor switch (if installed) and you will hear the sound of couplers coming together. This completes the basic checkout. If you are having problems, the troubleshooting section lists common ailments and likely cures. Step 11. Customizing the Locomotive Sounds The final installation step (At last!) is customizing the Sierra module s locomotive sounds. Individual properties such as sound volume, bell ring rate, exhaust synchronization and much, more can be adjusted to suit your needs. Sierra has been shipped pre-programmed so you can begin using your locomotive immediately without requiring any adjustments. Table A summarizes Sierra s default operating characteristics as shipped. Table A. SoundTraxx Sierra Default Operating Characteristics Audio Volume = 50% Start Voltage = 1.0 volts Bell On Voltage = 2 volts Bell Off Voltage = 4 volts Whistle Sensitivity = 3 Filter Rate = 10 Exhaust Synchronization Source = Sensor Switch Whistle = Voltage Controlled Bell = Voltage Controlled Hiss = Voltage Controlled Exhaust Type = Conventional Dynamo Sound = On Airpump = Single Fireman Fred Sound = On Pneumatic Grease Gun Sound = On Blower Draft = On Pop Valve = On Lighting Effect 1 = Firebox Flicker Lighting Effect 2 = Smart Firebox Flicker 17

22 After awhile, you will probably want to make some adjustments, such as changing the voltage at which the bell will turn on and off. The following paragraphs describe Sierra's customizable sound options. Once the adjustments have been made, they will be permantently remembered even after the power has been turned off. Sierra can be modified as often as necessary by simply reprogramming it according to the instructions. All the changes that you make will be made by way of two buttons on the circuit board. As you see in Figure 12, the buttons are identified as Volume (+) and Volume (-). As you make your adjustments you will be aided by the use of the two LEDs, labeled in the illustration as F1 (GREEN) and F2 (RED). Volume Adjustment The two buttons usually serve as the master volume control. Press and release the Volume (+) button and the overall volume of the sound Figure 13 - Customizing Sierra will increase by one level. Press and release the Volume (-) button and the overall volume will decrease by one level. There are 16 volume levels. If you installed the remote volume control switch, simply flip it one way to increase the volume and the other way to decrease the volume. In Operations Mode, the LEDs indicate whatever lighting effect has been selected. Setup Procedure The Setup Procedure is used to customize the different sound and lighting effects. During the setup procedure, you will have both visual (by way of the LEDs) and audible cues to help you through the process. Take your time reading through the setup process first, as there are 20 different items which can be customized and it can be intimidating if you let it. Take your time! Everything can be done or undone and our Reset allows you to start over if you get lost the first time through. Remember, once you have the sound customized the way you want, Sierra will remember the settings, so you won't have to do it again unless you want to change something. To activate the Setup Mode press and hold the Volume (-) key until you hear a short toot and the F1 LED blinks. Then release the (-) key and proceed to Step 1. Sierra allows you to go directly to a particular Setup Step if you wish (i.e., this morning you wish to turn off the dynamo). Hold the Volume (-) button down, until the number of toots and blinks corresponds to the Setup Step number. In other words, if you hold the Volume (-) button until you hear 6 short toots, while the LED blinks 6 times, you will have reached Setup Step 6 (see Figure 13). Once the desired Setup Step has been reached, the Volume (-) button should be released. Changes are now made using the Volume (+) button. Once the changes have been made, pressing the Volume (-) key once will lock your changes into memory and returns you to operations mode. Sierra will also exit the setup mode if no key has been pressed for 60 seconds. If you have installed the optional remote volume control switch, you may also use it to make the sound adjustments by holding the lever in the Volume (-) position until you get to the desired step, and then flipping the lever to the Volume (+) position to make changes. Before you get started,we suggest you use a checklist for how you want the locomotive to sound and use it as a reminder as you go along. We've provided one for you at the rear of this manual F2 F1 Volume (+) Volume (-)

23 (see Appendix B). Read through the following steps first, determining those items that you wish to customize and making notes on the checklist. Now that you are armed with your checklist, let's start to customize our locomotive sounds! Press and hold Volume (-) key for 2 seconds. Setup Procedure Whistle Toots F1 LED will blink once Continue holding Volume (-) key to go to next step Release Volume (-) key to change F1 LED will blink once Setup Step 1 Continue to next Setup Step Press Volume (+) to change Return to Normal Operation Whistle Toots F1 LED will blink once Press Volume (-) for 2 seconds Press Volume (-) and release Continue holding Volume (-) key to go to next step Release Volume (-) key to change F1 LED will blink twice Setup Step 2 Continue to next Setup Step Press Volume (+) to change Return to Normal Operation Whistle Toots F1 LED will blink once Press Volume (-) for 2 seconds Press Volume (-) and release Etc. Etc. Figure 14 - The Setup Procedure Exhaust Features Take a look at your checklist and Setup Step 1. The default for this Step is sensor switch synchronization. If you wish to use the Auto-Exhaust instead, you must change this parameter. Setup Step 1 - Synchronization Source To change the synchronization source to Auto-Exhaust, enter Setup Mode Step 1, by pressing and 19

24 holding the Volume (-) key until F1 blinks once and you hear a short toot. Release the Volume (-) key. Press the Volume (+) key to select Auto-Exhaust. Pressing the Volume (+) again will toggle between sensor switch synchronization (F2 LED on) and Auto-Exhaust (F2 LED off). If this is the only parameter you wish to change, simply press and release the Volume (-) key. If you wish to make other changes, press and hold the Volume (-) key for 2 seconds until you hear a short toot signifying that you have entered the next programming step, in this case Step 2. Release the Volume (-) key and make your changes with the Volume (+) key as outlined in Setup Step 2, below. Setup Step 2 - Exhaust Type This allows you to change the type of exhaust between Conventional Exhaust and Articulated Exhaust. The default value is Conventional Exhaust. This should be used for all engines (including shays) other than articulated. From within Setup Step 2, press the Volume (+) key. This will select Articulated Exhaust. Pressing the Volume (+) key again toggles between Conventional Exhaust (F2 LED On) and Articulated Exhaust (F2 LED off). Once you have made the adjustment, press and release the Volume (-) key to exit or press and hold the Volume (-) key for 2 seconds until you hear a short toot and proceed to Step 3. Setup Step 3 - Start Voltage This sets the track voltage level at which point the locomotive begins to move so that the Auto-Exhaust mode can determine when chuffing should start. If you have elected to use sensor switch synchronization, you can skip this step. The current start voltage setting can be visually verified by turning up the throttle and noting the point at which the F2 LED begins to flash. This is where the voltage is greater than the currently programmed value. If the LED goes out, the track voltage is less than the current value. The start voltage is set by increasing the throttle to the point where the locomotive just begins to move and the pressing the Volume (+) key. This sets the start voltage to the present level. Once you have made the adjustment, press and release the Volume (-) key to exit or press and hold the Volume (-) key for 2 seconds until you hear a short toot and proceed to Step 4. Setup Step 4 - Chuff Rate This allows you to change the rate of the exhaust chuff. If you have elected to use magnetic sensor switch synchronization, you can skip this step. With the locomotive running, press the Volume (+) key until the rate of the chuff increases to the appropriate rate for your locomotive. F1 LED: Blinks 1X every two seconds F2 LED: On = Exhaust Sensor Switch (default) Off: = Auto-Exhaust Audio Cue: Exhaust Chuffing Volume (+) to change F1 LED: Blinks 2X every two seconds F2 LED: On = Conventional Exhaust (default) Off = Articulated Exhaust Audio Cue: Exhaust Chuffing Volume (+) to change F1 LED: Blinks 3X every two seconds F2 LED: On = Track voltage at program value Flashing = Voltage > program value Off: = Voltage < program value Audio Cue: None Volume (+) to set at current level F1 LED: Blinks 4X every two seconds F2 LED: Flashes at exhaust chuff rate Audio Cue: Exhaust chuff Volume (+) to increase Volume (-) to decrease Because this adjustment can take a few seconds to set up, the 60 second auto-exit will not be activated as long as there is more than 1 volt on the track. Using the Volume (-) key will decrease the rate of chuff while in this mode. To save your selection, decrease the throttle to less than 1 20