Intermediate to advanced electronic skills are required in order to manufacture your own circuit boards and controllers, if you are able to lay your hands on a couple of transformers.
 |
| A consignment of Smilodon™ Model Train Controllers en route to the Southern Cape. |
Monday, January 22, 2018
A GREAT ALTERNATIVE:
A powerful 3,5 Ampere (50 watt) custom built DC Model Train Controller:
Connected to the AC mains power via an HP laptop power adapter instead of an internal transformer.
Transformers are hard to find nowadays, due to the popularity of switch mode power supplies...
 |
| Left side view... Controlled DC output for bi-directional model train control. Terminal Block Female angle PCB mount 4 way, Terminal Block male angled 4 way, #1 & #2. |
 |
| Right side view... |
 |
| Front view... A bi-colour LED is mounted in the front of the black lid to indicate direction of travel. A toggle switch On-Off-On, for bi-directional model train control. A Pot, Wire Wound, 1K ohm, 3 Watt, a 300 degree heavy duty speed control, gives throttle extended range for three times the control arc of ordinary power packs. |
 |
| Rear view... Fuse holder with a 4 Amp glass fuse, Angled PCB mount DC power socket for 18.5 Volt, 3,5 Amp DC input from an HP laptop power adapter. |
 |
| The original Dual Model Train Controller circuit diagram. |
 |
| The modified circuit diagram. |
 |
| The specifications of my HP laptop power adapter. |
 |
| Added the Trademark Logo and Labels |
Tuesday, November 18, 2014
My proven MODULAR FILTERED DC Single or Dual Model Train Controller.
 |
| The Trademark Logo |
I have initially decided to name my range of DC Model Train Controllers after this extinct saber-toothed cat for two reasons:
1. DC Model Train Controllers are not freely available in the market, discontinued due to the popularity of DCC. Thus extinct, I had to address this shortfall in the DC market...
2. My DC Model Train Controllers are powerful, with higher power ratings than its predecessors to address the demand of the modern larger DC Model Train Layouts... A combination of Old School technology and a little bit of New School technology.
The circuit diagram was designed, initially tested in NI Multisim 11.0, then built on a breadboard, further tested and tweaked on my Layout.The circuits for Controller 1 and Controller 2 are identical and assembled separately on it's own Printed Circuit Boards (PCB) hence the Modular Concept...
IMPORTANT: The PolySwitch® for overcurrent circuit protection is mounted on a separate PCB, the cross over jumpered toggle switches and potentiometers are mounted on the enclosure and hard wired on the PCBs. Both the voltage regulator ICs and power transistors are mounted on large enough heat sinks. [Some useless information: If only two terminals of a potentiometer are used, one end and the wiper, it acts as a variable resistor or rheostat]
I make use of two centre tap Transformers in the construction of a Dual Model Train Controller (the spare tap of each transformer is being used for power feeding other miscellaneous circuits or as a spare). The reason for this is to have two electrically isolated controllers especially when power feeding Reverse Loops.
The detailed connections making use of
discrete components.
FOR A SINGLE CONTROLLER !!
Components are assembled on a
neatly etched PCB.
neatly etched PCB.
Two of these boards are needed for
a Dual Controller plus the extras.
NOTE: Also add two LED's, a green and a red LED with appropriate resistors
at the output of each controller after the
toggle switch and the Polyswitch to monitor
the output and to indicate the direction of travel.
The green LED for forward polarity and travel,
the red LED for reversed polarity and travel
in the opposite direction.
 |
| 20 mm 250 mA F/B fuse - meaning a 250 mA Fast Blow glass fuse, 20mm long. HINT: Rather use a 500 mA fuse - the 250 mA fuse will not blow under normal working conditions, but I blew the fuse during an overload test when I applied a deliberate short on the tracks (takes a few milliseconds for the polyswitch to react). |
|
| Dual Model Train Controller circuit diagram. |
“Smilodon 3000 DTC” Description: (Standard version) Build 2.
For ages 14 and over. (This is NOT a toy)
State-of-the-art design, electronics and construction, offer the very best in performance and capability. Components are supplied by Janca Electronics, Bloemfontein. All Printed Circuit Boards are also professionally etched by the same Company.
Features:
* Simple screw connections.
* Twin isolated, controlled DC outputs for bi-directional Model train control.
* Realistic operation, suitable for HO and N scale 12 volt DC train sets/layouts.
* Two 300 degree heavy duty speed controls give throttle extended range for three times the control arc of ordinary power packs.
* Delivers superior slow speed operation, smooth acceleration/deceleration, for increased railroad realism.
* Each controlled output boasts with an integrated circuit protector (overload protector) – Latest Polyswitch ® technology. (Automatic re-set fuse restores power to tracks as soon as the over-current fault is removed from tracks) This is the beauty of this Controller!!
* Heavy duty robust construction for long lasting power.
* Double insulated construction for extra safety.
* Master Mains rocker switch is illuminated.
Requirements:
* 220/240 Volts AC socket outlet (RSA Standard AC - three pin plug fitted).
* Model Train locomotive - Motor Type 12 volt DC.
* Small standard 3 mm flat tip screwdriver.
* Adult supervision.
* Optional: A decent quality Multi meter test instrument: for testing of DC track voltage/potentials and fault finding purposes. (Definitely a recommendation for future investment).
Technical specifications:
* Dimensions: Length: 330 mm x Width: 110 mm x Height: 170 mm.
* Output connections are Screw Type PCB 4 Pole Male/Female Socket Connectors.
* Twin isolated Polyswitch ® protected controlled outputs – 42 watt/3 ampere - 13.96 volt DC outputs for bi-directional train control, inductive load, ON- CENTRE OFF-ON toggle switch.
* Each 220/240 volts AC mains-powered controller, is designed with twin 90 VA centre tap transformers, to supply correct voltage to each track with one spare secondary winding on each Transformer – keep this in mind, if one winding goes faulty, simply change the wire configuration inside – this can be done by me or a reputable qualified repair centre or technician (Ts and Cs apply here).
* A 1 Ampere mains input Fuse is located inside the “Fused IEC Chassis Mains Kettle Socket” drawer mounted on the side of this Controller.
* Fully tested and guaranteed for 1 year.
End of document.
My very first "Smilodon 3000 DTC™" BUILD 1:
(Designed, built and in operation since May 2013)
(Designed, built and in operation since May 2013)
A Dual Model Train Controller
for my own Layout.
for my own Layout.
 |
Front
Rear
|
Delivers superior slow speed operation,
smooth acceleration, for increased
railroad realism. A short video to
demonstrate the slow start and
followed by a full speed session
through the automatic reverse
loop.
Smooth deceleration at the station,
for increased railroad realism.
"Smilodon 3000 DTC™" BUILD 2:
all the optional extras for my first
Customer in Beaufort West,
Western Cape, South Africa.
It delivers superb slow speed operation, smooth acceleration and deceleration, for increased railroad realism.
Another finished custom built "Smilodon 3000 DTC™" - DC Dual Model Train Controller with built in PME (Point Motor Energiser) and Adjustable / Preset DC Accessory Supply, FOUR in one.. This one is weighing in at 3,4 kg. (Approximately 7,48 lbs). It was shipped to the Customer on Monday Nov 18, 2013. He received his controller on Nov 24, 2013 and informed me that he is VERY pleased and happy with the outcome and performance.
"Smilodon 3000 STC™" 3 Ampere
A Single Model Train Controller
for my own Layout.
A Single Model Train Controller
for my own Layout.
Finished this one for my personal Layout's future Mainline Extension and for performance demonstration purposes. I have replaced the 30VA Transformer with a 45VA Transformer (42 watt). Recycled a PC Power Supply housing for this purpose. The fan was a bonus.
"Smilodon 3000 STC™" With built in SMD Polyswitch®. A polymeric positive temperature coefficient device (PPTC, commonly known as a re-settable fuse or a polyfuse or a polyswitch), is a passive electronic component used to protect against overcurrent faults in electronic circuits. Had new embossed labels made locally; Smilodon 2000 STC™ and Smilodon 3000 STC™ for the 28watt and 42watt single controllers, respectively.
 |
| Single Controller (inside) |
 |
| "Smilodon 3000 STC™" 3Ampere, 42 Watt - with a built in CDU (AND-01), supplied to a customer in Joubertina, Eastern Cape, South Africa. |
"Smilodon 2000 STC™" 2 Ampere
A Single Model Train Controller
for my own Layout.
A Single Model Train Controller
for my own Layout.
 |
| Single Controller (front) |
 |
| Single Controller (rear) |
"Smilodon 3000 DTC™" BUILD 2:
A Standard Dual Model Train Controller
without the optional extras for a
Customer in Durban, Kwazulu Natal,
South Africa.
without the optional extras for a
Customer in Durban, Kwazulu Natal,
South Africa.
Two emails from a happy customer...
 |
| An extract of an email received from the new owner of this brand new "Smilodon 3000 DTC™" - DC Dual Model Train Controller. I am posting this extract without Toms consent - I know for a fact he won't mind me posting this extract, he is sometimes unreachable via email due to his busy schedule as Managing Editor of his world renowned publications Company. Thank you very much Tom for your kind words, and no need to worry about cooling fans, the heat sink will do a proper job. |
 |
| An extract of another email received from the new owner of this brand new "Smilodon 3000 DTC™" - DC Dual Model Train Controller. I am posting this extract without Toms consent - I know for a fact he won't mind me posting this extract, he is sometimes unreachable via email due to his busy schedule as Managing Editor of his world renowned publications Company. Thank you very much Tom for your kind words, ENJOY!! |
The final test results and specifications of the above Controller:
First of all, as an Electronics and DC Power Technician, I can say that the rule for power supplies, "weight equals quality," is absolutely almost always true and this Power Supply Controller is one more example.
A custom built, robust “SMILODON 3000 DTC™” DC Dual Model Train Controller.
A common problem with cheaper quality power supplies or controllers, is that when you approach the load limit, voltage starts to drop because they have no reserve amperage overhead.
I have tested this power supply controller and got a stable 9 volts under SAFE NORMAL OPERATING CONDITIONS - operating at approximately 70 % of its rated capacity.
(Scale speed of about 100 km/hour)
IMPORTANT: It is normal practice to NEVER over load any Power Supply into a current limit situation!
With a maximum approximately 3 ampere rated load over a short period, the supply voltage was measured at a stable 12.5 volts.
Measured the voltage regulator heat dissipation temperature on the larger heat sink after the 12th and the 16th minutes mark at 46,3°C at an ambient room temperature of 27°C.
The beauty of this whole package is that it boasts with integrated overload protection. The PolySwitch® - A Polymeric Positive Temperature Coefficient device (PPTC, commonly known as a resettable fuse, polyfuse or polyswitch) is a passive electronic component used to protect against over-current faults in electronic circuits.
HINTS: Switch the Controller off at the Mains whenever you realise that a train has all of a sudden stopped, although the LED on the Controller is still illuminated and with the throttle (potensiometer) turned clockwise, also check the mode of the direction toggle switch. Turn the throttle anti-clockwise to the off position and switch the Direction Toggle Switch to the center / OFF position. A possible short circuit or over-current condition is likely the cause, test and remedy the situation. A Multimeter tester, set to measure DC volts on the 20 volt scale, is a very handy test instrument to have readily available at ALL times – please acquire such a test instrument.
Remove the particular Locomotive, switch the Controller on, set the direction toggle switch to the desired mode of operation, turn the throttle clockwise and measure the track voltage with your Multimeter - the track voltage should range from approximately 1,25 volt to approximately 13,96 volt through the 300 degree turn cycle of this particular potensiometer used.
(Always turn the throttle anti-clockwise towards the off position and switch the Direction Toggle Switch to the centre / OFF position when not running trains).
The Controlled Output Voltage Final Test Results:
Controlled DC 1 = 1,24V to 13,94V (14V ± 1%) [It is dependant on the accurate value of 100R resistor at the adjust terminal of the voltage regulator LM317T]
Controlled DC 2 = 1,24V to 13,98V (14V ± 1%) [It is dependant on the accurate value of 100R resistor at the adjust terminal of the voltage regulator LM317T]
End of document
Description of the Controller features and the different models:
The Dual DC Model Train Controller - called "Smilodon 3000 DTC™"
Standard features of this Controller:
2 x controlled 42 watt (3 ampere rated - inductive load) approximately 1,25 Volt to 13,96 Volt DC Bi-directional outputs for train control.
A "beefed up" model train controller with overload protection - made use of the latest PolySwitch® technology (Automatic re-settable fuse technology)
Optional extra features of this Controller:
1 x uncontrolled 3 amp 15 Volt AC output for switching Point Motors via AND-02 Point Motor Energiser Board and 1 x controlled DC output for layout accessory circuits that can be preset between approximately 1,25 Volt to 13,96 Volt.
Standard features of this Controller:
2 x controlled 42 watt (3 ampere rated - inductive load) approximately 1,25 Volt to 13,96 Volt DC Bi-directional outputs for train control.
A "beefed up" model train controller with overload protection - made use of the latest PolySwitch® technology (Automatic re-settable fuse technology)
Optional extra features of this Controller:
1 x uncontrolled 3 amp 15 Volt AC output for switching Point Motors via AND-02 Point Motor Energiser Board and 1 x controlled DC output for layout accessory circuits that can be preset between approximately 1,25 Volt to 13,96 Volt.
Break down of the different "Smilodon" models:
"Smilodon 3000 DTC" ™
["Smilodon" - named after the extinct saber toothed cat, Smilodon.]
["3000" - a 42 watt, 3 amp rated output per Controller]
["DTC" - Dual Train (Model Train) Controller]
"Smilodon 3000 STC" ™
["Smilodon" - named after the extinct saber toothed cat, Smilodon.]
["3000" - a 42 watt, 3 amp rated output]
["STC" - Single Train (Model Train) Controller]
"Smilodon 2000 DTC" ™
["Smilodon" - named after the extinct saber toothed cat, Smilodon.]
["2000" - a 28 watt, 2 amp rated output per Controller]
["DTC" - Dual Train (Model Train) Controller]
"Smilodon 2000 STC" ™
["Smilodon" - named after the extinct saber toothed cat, Smilodon.]
["2000" - a 28 watt, 2 amp rated output]
["STC" - Single Train (Model Train) Controller]
MONTHS OF PLANNING WENT INTO THE DESIGN OF THESE CONCEPTS, BUILDING IT AND EVENTUALLY PUTTING IT INTO SERVICE - PLEASE FEEL FREE TO POST A QUESTION IF NEEDED - ENJOY !
LINK to Model Railway Controllers Review
No comments:
Post a Comment