ZTC 505 User manual

The ZTC System is only intended for controlling model railways by
experienced modellers over the age of 14 .
It should only ever be operated by young persons under
competent adult supervision.
COPYRIGHT 2004
ZTC Controls Ltd.
24 Chilkwell St. Glastonbury.
Somerset BA6 8DB, England
Tel: [phone] Fax: [phone]
E Mail: [e-mail]
Web Site: www.ztccontrols.com
Issue 1.01
WARNING
If you fail to read the installation instructions properly it is possible
that you could accidentally damage your ZTC unit. Such damage is
NOT covered by our guarantee. So to prevent avoidable and
potentially expensive mistakes, please take the time to read these
instructions before attempting to install your equipment

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Table of Contents
INTRODUCTION ...................................................................................................................5
1.0 Connecting Power to the ZTC 505...................................................................................8
1.1 Transformer Required ..................................................................................................8
1.2 Powering Up.................................................................................................................9
1.3 Fast Track Start-Up......................................................................................................9
ZTC 505 Controls and Panel Features ................................................................................10
Key to 505 Controls and Panel Features……………………………………………………....11
2.0 ZTC 505 Control Features .............................................................................................11
2.1 Keypad buttons ..........................................................................................................12
2.2 Command Keys ......................................................................................................12
2.3 Number Keys..........................................................................................................12
2.4 Enter Keys..............................................................................................................12
2.5 Entering Keypad Commands..................................................................................12
2.6 Command Key Look-up Table ................................................................................13
2.7 Loco controls..............................................................................................................13
2.8 Reverser Lever .......................................................................................................13
2.9 Regulator Lever ......................................................................................................13
2.10 Brake Handle........................................................................................................14
2.11 All Stop Button......................................................................................................14
3.0 Liquid Crystal Display (LCD) ......................................................................................14
3.1 Power Mode Indicators ..............................................................................................15
3.2 Current Indicator ........................................................................................................15
3.3 Overload ....................................................................................................................15
4.0 System Parameters .......................................................................................................16
4.1 Setting System Parameters .......................................................................................16
4.2 Scale and Gauge Settings......................................................................................16
5.0 Operating Our ZTC 505 .................................................................................................17
5.1 Loco Control Mode.....................................................................................................17
5.2 Changing Loco Control Mode.................................................................................18
5.3 Controlling a Locomotive Without a Decoder Installed...............................................18
5.4 Controlling Another Loco............................................................................................18
5.5 Switching Control Between Running Locos ...............................................................19
5.6 Loco Command Roster ..............................................................................................19
5.7 Saving Loco Parameters ........................................................................................19
5.8 Automatic Recall of Loco Roster on Start-up..........................................................20
5.9 Deleting the Saved Loco Roster .............................................................................20
5.10 Operating Decoder Functions ..................................................................................20
5.11 Double Heading and Multiple Units ..........................................................................21
Note:- A break can only be done by the controller that is driving the group .....................21
6.0 Slave Controllers ...........................................................................................................21
6.1 Slave Controller Assignment......................................................................................21
6.2 Setting up a Slave Controller and its Slave Number ..................................................22
7.0 What You Need to Know About Loco Decoders ............................................................23

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7.1 Configurable Variables (CV) ......................................................................................23
7.2 Programming Track....................................................................................................24
7.3 First Time Loco Decoder Programming .....................................................................24
7.4 Programming Mode....................................................................................................24
7.5 Programming Locomotive Decoders ..........................................................................25
7.6 Verifying the Existing Value of a CV .......................................................................25
7.7 Resetting Loco Decoders to Factory Settings.........................................................25
7.8 ZTC 203, 205, 206, 213, 214, 215, 216, 217, 218, 226, 227 and 251…………...………25
7.9 ZTC 4000 Plug and Play Range Based on Standard Decoders………………………….26
7.10 CV 1 Locomotive Address or Number ................................................................26
7.11 CV 2 Start Voltage................................................................................................26
7.12 CV 3 and CV 4 Loco Acceleration and Deceleration ............................................27
7.13 CV 5 Max speed ...................................................................................................27
7.14 CV 6 Mid Step Speed ...........................................................................................27
7.15 CV 9 Output PWM Frequency ..............................................................................28
7.16 CV 12 Power Source Conversion .........................................................................29
7.17 CV 29 Basic Configuration Register .....................................................................30
7.18 CV 65 Kick Pulse..................................................................................................30
8.0 Advanced CV Options ...................................................................................................30
8.1 Changing Binary Bit Fields.........................................................................................30
Use the ZTC 114 Decoder Slide Rule to assist in this type of calculation. .......................31
8.2 CV 12 Feature Table..................................................................................................31
8.3 CV 29 Feature Table..................................................................................................32
8.4 Extended Addressing .............................................................................................32
9.0 Accessory Decoders......................................................................................................33
9.1 Accessory Decoder Addresses ..................................................................................33
9.2 Operating Points with Accessory Decoders ...............................................................34
9.3 Operating Signals with Accessory Decoders .............................................................34
9.4 Multiple Aspect Signal Operation ...............................................................................34
9.5 Operating Other Accessories with Accessory Decoders ............................................35
9.6 Route Setting .............................................................................................................35
9.7 Setting up Accessory Presets.................................................................................35
9.8 Time Delays............................................................................................................36
9.9 Reviewing a Route .................................................................................................36
9.10 Editing Route ........................................................................................................37
9.11 Operating an Accessory Preset Route .................................................................37
10.0 Test and Calibration.....................................................................................................38
10.1 Testing the Controls .................................................................................................38
10.2 Calibrating the Controls............................................................................................38
10.3 Transformer Test......................................................................................................39
10.4 LED Test ..................................................................................................................39
11.0 Installation ...................................................................................................................40
11.1 Power Input..............................................................................................................40
11.2 Input Terminals.....................................................................................................41
11.3 Optional DC Power Input......................................................................................41
11.4 Recommended Track Wiring Gauge ........................................................................42
11.5 Wiring the ZTC 505 Outputs to the Track(s). ...........................................................43
11.6 Multiple Track Feeds ............................................................................................44
11.7 The Programming Track ..........................................................................................44
11.8 Connecting Accessory Decoder Modules ................................................................44

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11.9 Points & Turnouts.....................................................................................................44
11.10 Large Layouts – Isolating Track Sections ..............................................................45
11.11 Power Boosting ......................................................................................................45
12.0 Reverse Loops .........................................................................................................46
13.0 Over Temperature Protection...................................................................................46
14.0 Software Upgrades ......................................................................................................47
15.0 Alternative Decoder Programming Modes ...................................................................47
15.1 Direct Mode..............................................................................................................47
15.2 Physical Register Mode ...........................................................................................47
15.3 Loco Address Verification ........................................................................................48
15.4 Loco Address Programming.....................................................................................48
16.0 System Parameters..................................................................................................48
16.1 Loco Speed Indicator ...............................................................................................48
17.0 Troubleshooting ...........................................................................................................49

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INTRODUCTION
Controlling a model railway with a simple variable resistance, or voltage, regulator has been
the classic way of doing things since the introduction of the electric train set at the
beginning of the 20th century. Now there is the ZTC 505 Digital Controller, with RealFeel™
controls that look and perform like the real controls of a traditional locomotive.
Running a Railway
Varying the voltage on the track to control a train is quite satisfactory for a simple layout.
However, when it comes to larger layouts with a number of running lines and multiple train
operation, you need a lot of switching and wiring to block sections to get the power from
multiple controllers to the right parts of the track. Add a reverse loop or whatever, and
running one train alone can become quite complex. Running many engines, some on the
same track, becomes practically impossible using conventional DC.
What’s on the Track?
With Digital Command & Control or DCC for short, power is on all of the track all of the time.
DCC power is a low voltage digital AC signal. The actual regulation of the loco speed goes
on in the loco itself. A decoder fitted inside the loco, converts the AC power to run the DC
motor of the loco.
So to control a loco, instead of varying the track voltage, a command is sent along the track
to the loco to tell it what speed it should be going at. This remote control means that you
can have as many trains in operation as you like without having to use block section
switching.
Simple Wiring
This then greatly simplifies the wiring, especially for complex layouts. Since independent
control of locos on the same track is possible, you can have much more realistic operations
with double heading, banking and shunting.
More movements
The most important benefit of digital operation is to not have to make numerous track
section switching actions every time you want to move anything. You can now have more
enjoyment by letting out as many locos as you could wish whenever you want to.
More Benefits
There are many other benefits of going DCC. The control is much smoother than you would
expect from a conventional controller, with very slow loco speeds being easy to achieve.
You can also remotely operate auxiliary functions for each loco, such as lights, sound ,
smoke effects or even electric couplers if you have them.
Accessories
You can control far more than the locos, if you desire. A remote controlled device, called an
accessory or stationary decoder, can be used to operate everything else on your layout
from the Master Controller. Also, points, signals and other motorised accessories can be
easily called-up from the keyboard, rather than relying on banks of electrical switches.
Complexity of wiring is substantially reduced.

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Control
The controller in a DCC layout does much more than the old-fashioned boxes with a knob.
It can handle a number of locos simultaneously, up to at least 12.
You can start controlling any loco at once without having to switch power to the track. After
keying in a loco number, the controller will allow you to move a particular engine and run it
right up to another stationery loco, couple up, and go off double headed or as a multiple
unit. Similarly, you can bank or shunt realistically. But beware, you might be in danger of
having the worst prototypical accident - the head on collision!
Better Controls
This is where RealFeel comes into its own. The regulator lever is much better for controlling
locomotives than rotary knobs. The controller also has a built-in memory to retain your set-
up preferences.
The FWD and REV indicators are provided to show present loco direction before control is
seized or when inertia causes a lag in direction response.
Multiple Train Control
One ZTC 505 can command up to 12 locos in motion at any one time from up to 9,999
different loco numbers. A roster is maintained of the currently running engines so that only
one button press is needed to swap between each one.
Additional slave controllers can be plugged into the rear of the master unit so that other
locos can be simultaneously operated. These slaves can either be further ZTC 505 units or
one or more of the Slave Hand Controllers. In this way, Up to 15 additional friends can help
operate the railway and make it much more fun. Extension leads and sockets (ZTC 309)
allow remote operation from 3 to 300 metres away!
Locomotive (Loco) decoders
A locomotive decoder has to be fitted inside each loco or its tender to operate in digital
mode. The exception is that DCC does allow a single loco without any decoder ‘chip’ to be
run on the system as if it had one. The function of these ‘chips’ is to receive the signals sent
along the track and control the power to the DC motor of the loco according to the
commands decoded. The power control is on-board the loco not in the controller. However,
converted locos will still run on any conventional pure DC controlled layout. These will also
be able to operate on other layouts powered by other manufacturers’ DCC controllers.
The decoders can be set-up for their loco addresses and all other characteristics from the
keyboard of the ZTC 505 by using the programming output connected to a short stub of
track. There are no links or conductive paint needed. With 9,999 numbers to choose from,
even the biggest loco collections can be catered for. The memory inside the decoder
storing the address and set-up characteristics is non-volatile and will remember its settings
for more than 10 years and yet can be re-programmed as many times as necessary.
ZTC makes a complete range of these miniature remote control circuits of different shapes,
sizes and power ratings. This will allow maximum flexibility in their application to different
types of loco, scale and gauge

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How the System Works
To use the ZTC System you do not need to know any of the technicalities, but the basics
are: -
The actual voltage on the track is in the range of 12 to 24 VAC according to the gauge or
scale requirements. Superimposed on the track voltage is a digital signal containing the
commands to the various locos or accessory decoders on the layout.
Locos have a decoder between the power pickup from the wheels and the electric motor.
The function of the decoder is to rectify the AC voltage on the track and convert it to DC for
use by the electric motor. A power controller stage smoothly varies the applied voltage
according to the received commands decoded from the track signal by a small, dedicated,
microprocessor. Direction is also controlled by the same stage and has nothing to do with
the polarity of the track.
Motor Drive
Moving the unmodified (no decoder installed) loco is achieved by the controller varying the
symmetry of the AC voltage on the track so that a DC bias appears in one direction. The
controller uses a special address to control this mode, but for the user, it is as if the loco
actually had a decoder!
In a decoder, the voltage control to the DC motor in a loco is achieved by pulse width
modulation (PWM). This means that the on/off ratio of an electronic switch is varied, so that
the average voltage can be controlled. This method is very power efficient, a factor that
must be considered due to the tiny dimensions of the typical loco decoder. The frequency at
which this is done is about 70 Hz, which is generally suitable for most commercial model
motors. However, not all motors have the same characteristics and so the ZTC decoders
have the ability to have the PWM frequency changed. Lower frequencies suit some larger
motors better such as G and Gauge 1 models. The coreless precision motors such as
Portescap and Faulhaber type vibrate too much at 70 Hz, but the decoder can be set to a
much higher frequency to suit them.
Power Boosting
The ZTC 505 Master Controller has a maximum current output of 3.0 amps to the track.
This is of course fed to all the track in parallel. The maximum power is drawn when locos
are simultaneously starting, which might be double their nominal running currents.
Accessory modules may also be connected to the track or the controller and taking power
as well. So eventually the system could ‘run out of steam’!
The power booster operates like an amplifier, taking the signal from the master controller
and providing a separate power output feed. This is connected to additional (remote) parts
of the railway system and can provide up to another 5 amps of power. A separate mains
transformer has to be connected to the booster to provide its source of power. More
boosters can be connected if even more power is needed.

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9-17 VOLTS
AC ONLY
TRACK
O/P 1
TRACK
O/P 2
PROGRAM
TRACK O/P
ACCESSORY
OPTION
SLAVE
CTLS
BOOSTER
CTLS
D
CONNECTION
K
AC
TN
TS
+P
G
–
LOW VOLTAGE PO
W
–
TRACK NORTH OU
T
–
TRACK SOUTH OU
T
–
AUX +DC OUTPUT
–
AUX 0V. DC OUTPU
WARNING! DO NOT CONNECT
TO LIVE MAINS SUPPLY
WITHOUT ISOLATING
MAXIMUM INPUT VOLTAGE 17 VAC
AC+P G AC TSTN TSTNTS TN
AC MAINS SUPPLY
Rear of ZTC 505
Controller
ZTC 560 Transformer
Unit or Equivalent
9 to 17 V AC Max.
9 to 17 V
AC Max
Plug-in, 4-way
terminal block
Reverse Loops
The main problem with a reverse loop is the fact that the left rail sweeps round to join up
with the right and visa-versa. To prevent short circuits an insulated joint must be placed at
the entry and exit of the loop. However, if the loop section is fed by a ZTC power booster
(ZTC 550), continuous running will be possible through the loop. The booster senses the
polarity of the track signal needed and automatically switches itself at either the entry or exit
as the train passes the insulated joint.
Additional material on the subject is available on the ZTC one hour DVD (ZTC 110) or the
Video (ZTC 111) DCC Expert Programme or In the Digital Command Control Book sub
titled “DCC for beginners” written by Stan Ames, Rutger Friberg & Ed Loizeaux, which is
also available from ZTC Controls ltd. As product number ZTC 112
1.0 Connecting Power to the ZTC 505
1.1 Transformer Required
DO NOT CONNECT THE ZTC 505 DIRECTLY TO THE MAINS POWER SUPPLY.
Power for the ZTC 505 is provided by a suitable, low voltage, transformer. The ZTC 560
transformer unit is recommended for most applications. A plug-in, 4-way, terminal block
connector, with screw terminals for connecting wires, is provided with all ZTC transformers.
Additional 4 pin connectors can be supplied for use with your own transformers if required.
This must be used for connecting the transformer to the unit. It plugs into the power socket
on the rear of the ZTC 505. Ensure that the transformer wires are connected to the two
outer screw terminals. The diagram below shows how power is connected to the unit. See
section 11.1 for transformer specification details and more instructions on how connections
are made to the ZTC 505.

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1.2 Powering Up
There is no power switch on the unit. Power is applied when the ZTC 560 transformer unit
is connected to mains power. When power is applied to the unit, all the indicator lamps will
illuminate for a brief period. Power on is indicated when one of the TRACK power indicators
are lit continuously. The unit will also give a short "beep" to indicate that power is now
present on the output. The liquid crystal display (LCD) will also show a series of start-up
messages.
1.3 Fast Track start-up
On powering-up the ZTC 505, the system will immediately operate,
with loco number 3 (default address of a new loco decoder) selected.
1. Check that the ZTC 505 Display unit is plugged into its socket at the rear of the unit.
2. Plug the ZTC 56X Transformer power unit into the POWER INPUT socket
3. Plug the transformer into the mains supply and switch on.
4. Attach two wires to some track using a 2 way plug-in terminal block and plug it into
the TRACK O/P 1 socket at the rear of the unit.
5. Turn the BRAKE handle fully anti-clockwise to the OFF position.
6. Push the reverser gear lever to the FWD position.
7. Operate the regulator lever to adjust the speed of the loco.
To gain the most benefit from operating the controller, read the rest of this manual
before proceeding.

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ZTC 505 Controls and Panel Features
51
1
DOUBLE
HEADING
OVERLOAD
CLEAR ZTC 505 Digital Master Controller
REMOTE
CONTROL
INERTIA PRESET
SIGNAL
POINT
A
UTO
PROGRAM
LOCO OFF ON
BRAKE
FUNCTION
1
2 3
4 5 6
7 8
9
0
SIMULATION
SYSTEM
DIGITAL
D.C
CURRENT
TRACK
FWD
MID
REV
+
LR
ALL STOP
Loco: 4472 mph.+70
ZTC 505 Display Unit
CONTROLS
CONTROLS
32 4
19 15
18 1617 13 12
10 119 1765 8
ENTER
14
1
OFF OPEN