Tip: Märklin 3748 Electric Locomotive adding LP4.0 Decoder ...members.ozemail.com.au/~rossstew/public_html/rms/pdf/3748_tele… · Tip: Märklin 3748 Electric Locomotive adding LP4.0

Tip: Märklin 3748 Electric Locomotive adding LP4.0 Decoder, Telex

Couplers, LED Lights and Telex Warning Light Date: 28-12-2016

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Hi All,

The 3748 E70 21 is a good candidate for Telex couplers as the coupling pockets are well supported to

avoid coupler droop. I replaced the original 6090 decoder with a LokPilot 4.0 decoder to get the un-

coupling shuffle/waltz in either forward or reverse using the F1 function key as designed by ESU.

The front and rear lights were upgraded to LED lights using “Rule 17” to dim the lights when the

locomotive is stationary. I also decided to add rear red lights that will change over when there is a

direction change.

If The Telex function is left on when controlling the locomotive manually from a command station the

lights will flash as a warning to remind you to switch off the F1 function.

I decided not to have cabin lights as there aren’t any interior details to light.

This conversion required a lot of planning and experimentation to get the final results shown below.

The photo on the left shows the red tail

lights without any light bleeding to the

centre top light.

The photo on the right shows the head

lights

Warning: - You undertake the following modifications at your own risk. Drilling holes and cutting slots

in the metal casting is required. A high level of soldering skill is required for the wiring of the LEDs.




Main Chassis Modifications

The locomotive must be stripped down to its component parts making sure hand rails and steps are

removed to avoid damage. Care must be taken not to damage the parts as they are removed.

I spent a lot of time planning how the wires from the Telex couplers and four extra LEDs would be routed

to the decoder area (yellow rectangle) before drilling and cutting any metal.

For the rear there would be a total of 8 wires, main LED x2, extra LEDs x3, Telex x2 and the collector

shoe x1.

For the front there would be a total of 5 wires, main LED x2, extra LEDs x3. The front Telex coupler

wires would be routed under the locomotive to the hole shown by the red arrow.

Holes and Slots

Before drilling and filing I removed the motor.

A 2.5mm hole was drilled at the location of the red arrow and

deburred with a larger drill. At the blue arrow locations I cut a

2.5mm wide slot shown here.

The chassis metal was very hard so some effort to drill and file

was required.

Exit position of the hole from the decoder area.

Rear Front




Non Drive Bogie Modifications

The orange line indicates where the gears have been ommitted and provides an access point to route the

Telex wires by drilling a 2.5mm hole in the direction of the yellow arrow. I pre shrunk some 3mm heat

shrink tube to fit into the hole to get past the axle position shown by the blue arrow to provide protection

for the Telex wires throught the hole and under the axle.

With the Telex mounted into the coupler pocket I made sure that there was enough flex in the wires to

allow full movement of the Telex coupler and that it would self centre.




Non Drive Bogie Modifications continued

Note how the Telex wires fit close to the top of the chassis which is above the coupler pocket.

The Telex coupler wires and collector shoe wire exits as shown above. Care should be taken not to

damage the wires while routing them through the slots.




Drive Bogie Modification

I pre shrunk some 3mm heat shrink tube flat to keep the profile low and glued it in place with hot melt

glue. The wires close to the Telex have a small loop to allow freedom of movement then are threaded

through the tube.

Wiring Diagram Telex and LEDs

The wiring diagram above shows the wiring for the LEDs and Telex couplers. Refer to page 8 for the

connection diagram.

All resistors are 1k 1206 size.

The top LEDs are 3mm warm white.

Marker LEDs are 0603 size

Yellow White

F1 Telex

Rear Front

+Pole

Telex

1k

1k

F2

1k

1k

1k

1k

Top

Marker




Sub Assemblies

Main Top Lights

For the main top lights I used 3mm warm white LEDs and filed

the shoulder of each LED off to allow insertion into the original

bulb holder.

I soldered a blue wire (90mm) to the anode of the LED and a

black wire (90mm) to the cathode.

Marker Lights Red and White

These LED light assemblies were difficult as there is very little room to mount these in the main chassis.

Using 90mm length wire I soldered the blue wire

across the red and white 0603 LEDs on the anode side

by splitting the strands of the wire to form a tee

section. I wanted the wire to remain centred between

the red and white LED.

For the cathode of the white LED I used a black wire

and the cathode of the red LED I used a grey wire.

It is very important that the wires are centred between the LEDs and no wire

protrudes past the LED extents which would cause shorts with the metal chassis

hole shown by the red rectangle.

The LEDs were tested by using 1k resistors for current limiting before

proceeding to the next step.

To provide a self-centering mount for the LEDs I bent some thin clear plastic as

shown above that were a neat fit in the hole. Before gluing these to the LEDs I

had to tint them.

LED Tinting

The 0603 bright white LED’s I have show a blue tinge to the light

output. To cure this problem I used Tamiya Clear Yellow X-24

acrylic paint.

After the paint had dried I used Gel super glue to glue the clear

plastic mounts to the tops of the LEDs. I also cut some thin black

card, drilled a 1mm hole for the wires as this would be a light baffle

to prevent light bleeding into the top main light.

Once again the LEDs were tested by using 1k resistors for

current limiting.




Decoder Insulator and Wires

Using thin clear plastic I foldered the shape shown with a slot for the

wires from the rear of the locomotive see brown arrow.

The red arrow shows another

slot and small square cutout to

allow the heat shrink tube to

enter the decoder area.

The decoder is a neat fit seated

in the insulator.

Decoder Wiring Details

I soldered the wires (80mm) required to the correct solder pads as shown in the ESU manual for the

“54614 LokPilot V4.0” decoder. Please note the direction of the wires soldered to the decoder solder

pads.

Description Colour

Motor R Grey

Motor L Orange

Left Track Black

Right Track Red

+ Pole Blue

Head Light White

Rear Light Yellow

Aux 1 Green

Aux 2 Violet Decoder Top View




Front Telex Wire Connection

The wires for the front Telex needs to be

extended, for this I soldered 90mm lengths of

grey and black wire to a very small piece of Vero

board.

LED Light Limiting Resistor PCB

All resistors are 1k, 1206 size. Under each resistor the copper foil has been cut using a 3mm drill. Please

note the two wire links for the Head Light and the Rear light shown with red dotted lines.

Direct connections from the decoder are F1 Green, F2 Violet, +Pole Blue, Head Light and Rear Light.

Locomotive PCB Original

Direct connections from the decoder are Left Track, Motor R, Motor L and Right Track. The collector

shoe wire is also soldered on this PCB.

F1 Green F2 Violet +Pole Blue Head Light Red Led Rear Light

Top Led Marker Led

Rear

Top Led

Red Led

Marker Led

+Pole Blue

Front

Left Track

Motor R

Motor L Right Track Collector Shoe




Marker Light Assembly

From the top I inserted the marker light assembly and on the bottom you can see the assembly just below

the surface of the rectangle. I tested all wires to make sure there were no short circuits with the chassis.

In the top view the wires were routed through the cut slot and held in place with a 3mm heat shrink tube

and squeezed into the existing wire channel. I made sure the thin black card was fully seated in the

bottom of the existing light well.

Top Light Assembly

The original light holder is now placed as shown

with the wires routed in the wire channel




Final Assembly

For the non drive bogie I refitted the wheels making sure that they rotated freely.

With the marker lights fitted and tested I reassembled the bogies to the chassis.

In the decoder recess I inserted a small length of 3mm heat shrink tube through the hole then placed the

decoder insulator over the tube into the recess. Finally I inserted the LokPilot 4.0 decoder into the

insulator.

The front Telex wire extension is shown in position with the wires inserted into the hole and held in

position with a small section of heat shrink tube super glued to the chassis.




Wiring the Locomotive

The locomotive original PCB is fitted and held in place by two screws. The decoder wires for

Left Track, Motor R, Motor L and Right Track are soldered at this time, see connection diagram on page

8 and colour chart on page 7. The collector shoe wire is also soldered.

Wiring the Lights and Telex Couplers

The LED Light Limiting Resistor PCB should be a snug fit above the original PCB.

Solder the remaining wires shown above and refer to the connection diagram on page 8.

Please note I also placed some tin foil under the top 3mm LEDs to help reflect the light up.

Finally I place thick black card over the PCB to prevent any wires or components being

visible.

Front Telex Wires Front Light Wires

Rear Light Wires,

Rear Telex Wires,

Front White, and Rear Yellow Light Wires,

Collector Shoe Wire

F1, F2 and +Pole Wires




CV Values for the LokPilot V4

Warning: Make sure you read the ESU decoder instructions before programming any CV’s

Please note any Value = *xx means the default value wasn’t changed.

The Index settings CV31 and CV32 must be changed when doing direct CV programming.

Motor Settings [Index:0 (CV31=0, CV32=0)]

CV# Name Range Value Default

1 Primary Address 1-255 34 3

2 Start Voltage 1-255 *3 3

3 Acceleration 0-255 20 32

4 Deceleration 0-255 10 24

5 Maximum Speed 0-64 160 255

6 Medium Speed 0-64 55 22

13 Analogue Mode F1-F8 (F0 Lights) 0-255 0 1

51 Load Control Parameter “I slow speed” 0-255 *0 0

52 Load Control Parameter “K slow speed” 0-255 18 32

53 Control Reference Voltage 0-255 100 140

54 Load Control Parameter “K” 0-255 46 48

55 Load Control Parameter “I” 0-255 30 32

66 Forward Trim (1 x Voltage) 0-255 126 128

95 Reverse Trim (1 x Voltage) 0-255 124 128

246 Automatic Uncoupling Speed 0-255 80 0

247 Automatic Uncoupling Move Time (2 sec.) 0-255 60 0

248 Automatic Uncoupling Push Time (1 sec.) 0-255 60 0

Timing Functions [Index:4096 (CV31=16, CV32=0)]

277 Aux1 [1] Turn Off After Timeout (3.28 sec.) 1-255 8 0

285 Aux2 [1] Turn Off After Timeout (3.28 sec.) 1-255 8 0

292 Aux3 Time Delay Turn On/Off (1.64 sec.) 68 0

Mapping Functions to Outputs [Index:4098 (CV31=16, CV32=2)]

362 F1f (forward) mapped to Aux1[1] *4 4

363 F1f (forward) Rear Light[2], Aux1[1] mapped together 32 0

378 F1r (reverse) mapped to Aux2[1] 8 4

379 F1r (reverse) Front Light[2], Aux2[1] mapped together 16 0

394 F2f (forward) mapped to Aux2[1] (deleted) 0 8

410 F2r (reverse) mapped to Aux2[1] (deleted) 0 8

481 F5 Stop, Forward Condition on Aux3 6 4

490 F5f (forward) mapped to Aux3 16 0

497 F5 Stop, Reverse Condition on Aux3 10 8

506 F5r (reverse) mapped to Aux3 16 0

Function Control Settings [Index:4096 (CV31=16, CV32=0)]

Function

Output

Mode Select Brightness 0-31 Special Function

CV# Value CV# Value CV# Value

Head Light[1] 259 2 262 *31 263 132

Rear Light[1] 267 2 270 *31 271 136

Aux1 Telex 275 28 278 15 279 0

Aux2 Telex 283 28 286 15 287 0

Aux3 Cabin Light 291 2 294 6 295 144

Head Light[2] Flash 355 12 358 31 359 128

Rear Light[2] Flash 363 12 366 31 367 128




CV Values for the LokPilot V4 continued

CV13 has been changed so F1 Telex function won’t turn on but F0 lights will operate when running in

Analogue Mode.

For people that don’t have the LokProgrammer or the ECoS and have to rely on direct CV programming

you may find my article “Using LokProgrammer to Find Undocumented CV’s” really useful.

Please note some CV values may change in time once I have tried running the locomotive in a schedule

with TrainController to test the Uncoupling function. Any changes will be updated once testing is

complete.

Speed profile for TrainController with the maximum speed set at 80km/h

Left is the speed profile

showing all decoder speed

settings.

Bonus Time The bonus file 3748_zip (84Kb) contains the following listed files

3748.yra Icon for ECoS 50200 Icon for ECoS 50000

The file 3748_451.esux can be used as a starting point for a locomotive conversion similar to this loco.

This file overrides any CV values in the table on page 12. It can only be used with LokProgrammer 4.5.1

and above.

http://members.ozemail.com.au/~rossstew/rms/pdf/lokprogrammer_compare_cv_list.pdf

http://members.ozemail.com.au/~rossstew/rms/files/3748.zip




Locomotive Control

Above is the ECoS command station window showing F0 lights on, F1 telex function off, F3 slow mode

off, F4 Inertia on. To the right is the TrainController Train window which has Telex Jog and Telex

Automatic macros.




Small Problem with F1 Automatic Uncoupling

Using the F1 automatic uncoupling function on the ECoS controller works well for the first time but if

you forget to turn it off once the locomotive has done its uncoupling shuffle, then reverse the locomotive

the uncoupling function will start in the opposite direction which you may not have intended. There isn’t

an option to have a time delay before turning off the function button.

Small Problem with F1 Automatic Uncoupling Solved

Using a Train window in TrainController I have solved this problem by having a list associated with the

locomotive functions that ensures the train has stopped, performs the uncoupling function then turns the

F1 function off.

In the Engine functions window you

will notice the first Coupler “Uncouple

Auto Timer” associated with F1 is

Hidden and the second Coupler

“Uncouple Telex Jog” I have defined

the actions in a List... – On/Off Switch.

It is important that the graphics for the

coupler symbols are different when

triggering the actions from a schedule.

The List of Operations for the loco

is a message followed by a macro

Uncouple Telex(N) Jog

The Uncouple Telex(N) Jog macro

contains a List of Operations Stop

the locomotive, delay 2 seconds,

Play Sound file “train uncoupling”

then the hidden F1 “Uncouple Auto

Timer” is turned “On”, then after a

delay of 4 seconds the “Uncouple

Auto Timer” is turned “Off”.

This works well and is much safer

than operating the locomotive with

the ECoS.




Parts required:-

As always enjoy your model trains.

Part Number Supplier Description Quantity

54614 ESU ESU LokPilot V4.0 Decoder 1

51940 ESU White cable, 0.5mm diameter, AWG36, 10m 1

51942 ESU Black cable, 0.5mm diameter, AWG36, 10m 1

51943 ESU Red cable, 0.5mm diameter, AWG36, 10m 1

51944 ESU Orange cable, 0.5mm diameter, AWG36, 10m 1

51945 ESU Green cable, 0.5mm diameter, AWG36, 10m 1

51946 ESU Grey cable, 0.5mm diameter, AWG36, 10m 1

51947 ESU Yellow cable, 0.5mm diameter, AWG36, 10m 1

51948 ESU Brown cable, 0.5mm diameter, AWG36, 10m 1

51949 ESU Blue cable, 0.5mm diameter, AWG36, 10m 1

E117 993 Märklin Telex Coupler (pkt of 2) 1

207 3877 Element14 1K Ceramic Resistor 0.25W, 1% 6

330PW04C Ledz.com Warm white LED 3mm 2

0603KRCT Ledz.com Red 0603 LED 2

0603LWCT Ledz.com White 0603 LED 2

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Tip: Märklin 3748 Electric Locomotive adding LP4.0 Decoder ...members.ozemail.com.au/~rossstew/public_html/rms/pdf/3748_tele… · Tip: Märklin 3748 Electric Locomotive adding LP4.0