MTHTrains Proto-Sound 2.0 Digital Command System User manual

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.
www.mthtrains.com PLEASE READ BEFORE USE AND SAVE FOR REFERENCE

Table of Contents
WARNING: This product is not covered by a warranty unless installed by an M.T.H.
Authorized Conversion Center.
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............................................................................... 14
Optional Front Proto-Coupler Wiring................................................... 15
Installing The Tender Harness............................................................... 16
Soldering Speaker Connections.............................................................19
Installing The Battery & Volume Pot.................................................... 20
Preparing The Locomotive For The Upgrade...................................................22
Determing The Locomotive Motor Type...............................................23
Installing The Tach Reader Bracket...................................................... 23
Installing The Flywheel Tach Tape........................................................24
Mounting The Tach Reader To The Tach Bracket.................................25
Installing The Ps-2 Harness Into The Locomotive........................................... 26
Mounting The Ps-2 Harness Connector................................................ 26
Connecting Motor, Ground & Pickup Wires........................................ 27
Installing Headlight Into RailKing Steam Engines............................... 28
Connecting The Ps-2 Harness To The Smoke Unit.............................. 29
Other Proto-Smoke Circuit Wiring Methods........................................ 30
Connecting Power To The Constant Voltage Board...............................31
Wire Management/Short Circuit Prevention......................................... 32
Testing The Ps-2 Installation...............................................................................33
Loading Proto-Sound 2.0 Files Into Locomotive...............................................34
Proto-Sound 2.0 Operation Instructions............................................................37
Conventional Operation.........................................................................37
Self-Recharging Battery.........................................................................43
Troubleshooting.....................................................................................44
Service & Warranty Information.......................................................................47
Warranty Coverage & Service Options................................................. 47
This product may be protected by one or more of the following patents: 6,019,289; 6,280,278;
6,281,606; 6,291,263; 6,457,681; 6,491,263; 6,604,641; 6,619,594; 6,624,537; 6,655,640.
©2010, M.T.H. Electric Trains®, Columbia, MD 21046
CAUTION: ELECTRICALLY OPERATED PRODUCT:
WARNING: When using electrical products, basic safety precautions should be observed, including the following:
Readthismanualthoroughlybeforeusingthisdevice.
lM.T.H. recommends that all users and persons supervising use examine the hobby transformer and other electronic equipment
periodicallyforconditionsthatmayresultintheriskoffire,electricshock,orinjurytopersons,such asdamage tothe primarycord,
plug blades, housing, output jacks or other parts. In the event such conditions exist, the train set should not be used until properly
repaired.
lDonotoperateyourlayoutunattended. Obstructedaccessoriesorstalledtrainsmayoverheat,resultingindamagetoyourlayout.
lThistrainsetisintendedforindooruse. Donotuseifwaterispresent. Seriousinjuryorfatalitymayresult.
lDonotoperatethehobbytransformerwithdamagedcord,plug,switches,buttonsorcase.
Recommended for Ages 14 and up. Not recommended for children under 14 years of age without adult supervision. As
with all electric products, precautions should be observed during handling and use to prevent electric shock.

Contents Of The Kit
A) Proto-Sound 2.0 (Ps2) board (1)
B) Ps2 plastic mounting bracket (1)
C) Tender harness (1)
D) Ps2 metal heat sink bracket (1)
E) Proto-Coupler, long (1)
F) Back-up light (1)
G) Tender Marker Light Harness w/2
LEDs (1)
H) Locomotive Harness w/Tach Reader
I) Speaker, 4 ohm 50mm diameter (1)
J) Headlight (1)
K) Tach reader brackets (2)
L) Tach tape stripes (4)
M) AA battery pack (1)
(Charge before use)
N) Screws M2 x 4 mm (2)
O) Screws 6/32 x 6 mm (3)
P) Nuts 6/32 (3)
Q) Screw 6/32 x 8 mm (1)
R) Plastic Wire Sleeve
(for wire managment) (1)
S) Shrink tubing (1)
T) Foam tape (1)
U) Wire Ties (7) (6) 4”, (1) 7”
V) Inductor (1)
W) Headlight Grommet
X) Battery Recharging Port/Harness
Y) Battery Recharging Port Hardware
(2) Screws M3 x 12, (2) Nuts M3, (2)
Spacers
Z) Locomotive Harness Spacer/Insulator
AA) Pittman Tach Reader Screws (2)
EE) Coupler Insulator
(AA)Pittman Motor Tach
Bracket Screws
(IA-0000375)
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(B)Ps-2 Plastic Mounting
Bracket (IH-0000391)
(A)Proto-Sound 2.0 Circuit Board
AE-0000010, AE-0000011
(C) Tender Wiring Harness
(BC-1000005)

(E) Proto-Coupler
(DD-0000032)
(G) Tender Marker LEDs
(CC-0000062)
(D) Ps-2 Metal
Heat Sink Bracket
(IH-0000390) (F) Tender Backup Light
(CF-0000030)
(H) Locomotive Wire
Harness w/Tach Reader
(BC-1000003)
(EE) Coupler Insulator
(ID-0000123)
(J) Locomotive Headlight
(CA-00000078)
(K) Tach Reader
Mabuchi / IDG
(IH-0000389)
Pittman
(IH-0000154)
(L) Tach Tape
(BE-0000151)
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(I) Speaker
(BF-0000034)

(X) Battery Recharging
Port & Harness
(BC-1000004)
(R) Plastic Wire Sleeve
(M) AA Battery Pack
(Charge before use)
(BG-4000003)
(Y) Recharging Port Hardware
(Spacer: ID-0000071)
(Screw: IA-0000035)
(Nut: IC-000006)
(U) Wire Ties
(W) Headlight Grommet
(IH-0000010)
(Z) Loco Harness Spacer
(BD-0000065)
(S) Shrink Tubing
(Q) 6/32 Screw x 8mm
(IA-0000050)
(O) 6/32 x 6mm Screws
(IA-0000027)
(P) Nuts
(TP-M500075)
(N) M2 Screws
(IA-0000058)
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V) Inductor
(AI-0000044)
(T) Foam Tape

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
What Is An ESD?
As ESD safe work area is an
area set aside in your workshop
that is electrically grounded and
includes anti-static mats and
grounding straps
ESD Mat
Work Only in an ESD Safe Zone Grounding Strap
PS-2 Upgrade Kit Installation Guide
6

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.
Note: If any of the above items are missing or not in working order, procure the
required parts before continuing.
Note: Before beginning installation, see discussion on page 32 on “wire
management” which should be planned as you proceed during the installation.
Part of the plastic wire tube (R) may be used for this purpose.
Make sure pickup rollers are clean & lubed and roll freely.
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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.
Follow the instructions below taking care to save the parts when noted.
Remove The Following Items From The Tender Chassis
Tender shell (save the mounting screws).
Proto-Sound 1, DCRU Reverse Unit, Mechanical Whistle, Electronic Whistle,
any other electronics and tender harnesses.
Speaker (save mounting hardware).
Existing coupler (save the “T” bar, spring, and c-clip).
Any lights including the rear back-up light and marker LEDs (if present). These
will likely be mounted inside the tender shell.
Do NOT remove the volume pot used on Proto-Sound 1 models.
Remove the old coupler by slipping off the “C”-clip from the coupler “T”-Bar.
If your locomotive does not have a volume pot, order BI-0000040 (volume pot),
IA-0000035 (screw), and ID-000071 (spacer), and IC-0000006(nut).
PS-2 Upgrade Kit Installation Guide
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Installing The PS-2 Components Into
The Tender
Required Upgrade Kit Components
Typical component arrangement on tender floor. Note position of heat sink.
A) Proto-Sound 2.0 (Ps2) board (1)
B) Ps2 plastic mounting bracket (1)
C) Tender harness (1)
D) Ps2 metal heat sink bracket (1)
E) Proto-Coupler, long (1)
F) Back-up light (1)
G) Tender Marker Light Harness w/2
LEDs (1)
I) Speaker, 4 ohm 50mm diameter (1)
M) AA battery pack (1)
O) Screws 6/32 x 6 mm (3)
P) Nuts 6/32 (3)
Q) Screw 6/32 x 8 mm (1)
R) Plastic Wire Sleeve (for wire
managment) (1)
S) Shrink tubing (1)
T) Foam tape (1)
U) Wire Ties (7) (6) 4”, (1) 7”
X) Battery Recharging Port/Harness
Y) Battery Recharging Port Hardware
(2) Screws M3 x 12, (2) Nuts M3, (2)
Spacers
EE) Coupler Insulator
50mm
27mm
100mm
60mm
18mm
30mm 39mm
PS-2 Upgrade Kit Installation Guide
9

Mounting The PS-2 Board
Remove the Ps2 Board (A) from the
sealed anti-static bag
Verify Ps2 board is securely inserted
into the plastic mounting bracket (B)
Remove the speaker (K) from the protective packaging (NOTE: be careful not
to damage the speaker cone)
Place the Ps2 board/plastic mounting bracket (A/B) in the tender to verify the
best location to mount the plastic mounting bracket (B) and the metal heat sink
bracket (C) to the tender floor. Also locate a place to put the battery pack (M)
and battery charging jack (X).
NOTE: If you are not a
participating MTH
Authorized Service Center
there is NO warranty once
the bag is opened
NOTE: Use ESD safe work
area and procedures when
handling the PS2 board.
Make sure the Ps-2 board is firmly
inserted into the plastic mounting
bracket. If not, gently push the
board into the bracket until fully
“captured” by the bracket. DO
NOT REMOVE THE BOARD
FROM THE BRACKET.
Place the components on the tender floor in the best position given the space. It
may be necessary to turn the battery pack on its side as seen above.
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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.
Drill the appropriate mounting holes as determined from positioning the Ps-2
board and other components
Remove the Ps2 board (A) with plastic mounting bracket (B), metal heat sink
bracket (D), speaker and battery from the tender and place on an ESD safe area
on your workbench.
Drill the holes as marked with the proper drill size. A 5/32” bit will be required
for the Ps2 plastic mounting bracket (B) and heat sink bracket (C). Use a 1/8”
bit for the battery charging jack mounting holes.
De-burr the holes slightly using a larger drill bit (3/8”) or a deburring tool.
Carefully remove any metal burrs resulting from drilling the mounting holes.
Loose metal burrs can damage the Ps-2 circuit board!
PS-2 Upgrade Kit Installation Guide
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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)
Apply white thermally conductive grease to the bridge rectifier on the PS2 board.
Mount the PS-2 plastic mounting bracket
Apply white thermally conductive grease to bridge rectifier & metal heat sink
bracket.
PS-2 Upgrade Kit Installation Guide
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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).
Installing The Proto-Couplers
The Proto-Coupler installs in the same location as the original engine coupler.
Install the proto-coupler (E) onto the existing tender trailing truck or coupler
mount location using the existing hardware. Be sure to route the coupler wire
harness through the tender floor.
Connect black Proto-Coupler connector to black tender harness connector on the
brown & purple wires.
Note: Use coupler insulator as required to prevent shorts from coupler solder
connections to tender truck axle.
PS-2 Upgrade Kit Installation Guide
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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. The insulator prevents
the coupler wiring from contacting and
short circuiting against the truck’s axle.
Failure to insert the insulator could
permanently damage the coupler and
Ps2 board.
Shown here is the insulator
attached to the truck and coupler.
Ensure that the part of the
insulator which protects the
coupler’s wires extends up not
down when installed.
Shown above is the
coupler unassembled.
PS-2 Upgrade Kit Installation Guide
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Tach Reader
(Bottom View)
Tach Reader
(Top View)
Pickup Roller
Leads
Ground Lead
Motor Leads
(Green) Smoke
Unit Fan Motor
(Blue) Headlight
Leads
(Red) Smoke Unit
Heating Element
Ps-2 Tender Plug
Boiler Connector
Optional Front Proto-Coupler Wiring
**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).
*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).
PIN 5
**PIN 9
Engine Harness
Tender Harness 12 Pin Connector
*
PS-2 Upgrade Kit Installation Guide
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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 Battery
Charging Jack
Ps-2 Board
2 PIN
Battery Pack
2 PIN
Ps-2 Volume
Pot Leads
Ps-2 Speaker
Leads
Ps-2 Smoke
Unit Switch
Ps-2 Tender
Harness
Ps-2 Tender
Backup Light*
Ps-2
Proto-Coupler*
Ps-2 Tender
Marker Lights
12 PIN
5 PIN
4 PIN
7 PIN
8 PIN
PS-2 Upgrade Kit Installation Guide
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PS-2 Board Connections
5 PIN
4 PIN
12 PIN
8 PIN
2 PIN
7 PIN
PS-2 Upgrade Kit Installation Guide
17

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.
Install the speaker (I) into the previous speaker mounting location using the
existing hardware.
Install the smoke unit switch (attached to the tender harness) in the tender
frame cut out using screws (N). (If one does not exist, locate the switch in the
best possible location.)
Mount the smoke unit switch into the existing switch hole on the tender floor
using srews (N).
PS-2 Upgrade Kit Installation Guide
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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. (Note if only 1 marker light is required, secure one of the
LEDs from the wire harness inside the tender.)
Ensure proper wire management by using pieces of plastic sleeve (R) to hold
various cables in place.
Ensure that the yellow speaker lead goes to the (+) speaker terminal and white
to the (-) terminal.
Solder the yellow and white wires to the speaker (I) making sure to get the polarity
correct, yellow(+) and white (-) and soldered wires do not short to speaker frame.
WARNING: If either wire shorts to the speaker frame the PS2 electronics will be
damaged.
PS-2 Upgrade Kit Installation Guide
19

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.
Insert the spacers (Y) between the recharging jack board and the tender floor to
prevent the recharging jack port from extending below the tender floor. Secure
with screws from underside of frame and nuts (Y).
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