tip: lokpilot conversion of märklin 3615 locomotive with...

Tip: LokPilot Conversion of Märklin 3615 Locomotive with Rear Telex

Coupler, Cabin Light, Firebox Light, Telex Warning Light and Sound Date: 16-04-2012, Corrections 22-07-2012, Changes 21-08-2014 Sound Version 14-05-2017, 27-03-2021

http://members.ozemail.com.au/~rossstew/rms/marklin.html 1

14-05-2017 I have just converted another 3615 locomotive with a LokSound decoder for my friend

Adrian, for details see appendix pages 14-19.

Hi All,

I started out just wanting to put LED lighting in to this 3615 locomotive but I soon found I got a little

carried away with the upgrade. The locomotive had been converted with a 6090 decoder by the previous

owner and as there are no extra functions to switch the smoke on/off I decided to use a LokPilot 4 as a

replacement.

F1 will control the smoke unit. With extra functions available I decided to put a Telex coupler on the rear

of the locomotive. The locomotive does an un-coupling shuffle only for the rear Telex using the F2

function key. The challenge was to put warm white LED lighting in the tender to replace the lower two

dummy lights. I have chosen to use fibre optic light pipes and one warm white LED for the rear lights and

change the front bulb to a warm white LED, using “Rule 17” to dim both lights when the locomotive is

stationary. The other features are an added cabin light that only comes on when the locomotive is

stationary controlled by F5. I also decided to add a Firebox flickering light controlled by F6. The last

feature is flashing head or tail lights only at the end of the locomotive where the Telex coupler is

operating and the duration is controlled by the uncoupling shuffle feature.

F3 is the shunting mode and F4 controls the inertia function on/off.

In the photo above the cabin light is on. The glass inserts for the windows are tinted which reduces the

cabin light output, but in a darkened room the light level looks great. A reflection of the firebox light can

just be seen on the front of the tender also.

Warning: - You undertake the following modifications at your own risk as drilling and filing are required

to complete the project.

Internal View Right Hand Side




Internal View Left Hand Side

Internal View of the Tender

The above view shows the decoder held in place with hot melt glue on a small wood support using the

existing features of the tender to hold it in place. The wood on the left side required two pieces and is just

a firm fit in the tender to support the decoder. I mounted four resistors on a small Vero board held in

place on the MTC 21 adaptor board with hot melt glue. The foils were drilled away under each resistor

and wired in the following order, rear light (yellow arrow), firebox light (grey arrow), cabin light (brown

arrow) and front light (white arrow).

At the rear of the tender you can see the fibre optic light pipes held in place by hot melt glue.

Fibre Optic Rear Lamps

Making the fibre optic rear lamps proved to be very easy. I used 1mm

diameter optic fibre and cut two lengths 55mm.

Using a flat tip on my soldering iron I melted the end of each optic

fibre. I then sanded the ends flat using 1200 grit sandpaper. The effect

created a lens for the rear lamps on the tender.




Fibre Optic Rear Lamps continued

Drilling the holes for the fibre optic light pipes must be done

with care to get the holes centred in the lower lamps on the

tender. I found by using a 2.5mm drill in a manual pin vice it

centred in the existing indent that the lamps already had. I just

drilled down enough to get a centre mark then using a 1mm

drill I drilled all the way through.

I then tried the fibre optic and noted that I needed to use the

2.5mm drill to counter sink/chamfer until the fibre optic light

pipe sat flush with the lamp moulding.

With the fitting now correct I used silver paint to touch up the

drill holes and once the paint was dry I inserted the light pipes

and glued inside with hot melt glue. The photo at the right

shows the lamps without being switched on.

To join the fibre optic light pipes I used a 6.5mm diameter acrylic rod and cut it to 10mm in length. At

one end I drilled a 3mm hole just deep enough to fit the 3mm warm white LED and at the other end I drill

two 1mm holes close together to a depth of 2-3mm to take the fibre optic light pipes.

I then positioned the light pipe transition piece as shown and glued it down with hot melt glue. The next

step is to insert each light pipe into the transition piece, trimming to length to get the arrangement as

shown above.

The LED is inserted in the transition piece and held with some ‘Blue Tac’ to allow for easy servicing.

Telex Coupler Wiring

The Telex wires are long enough to be soldered directly to the 21 MTC Adapter and are inserted into an

existing slot at the rear of the tender (red arrow above).

The black wire is soldered to the U+ solder pad (black arrow above) and the grey wire is soldered to the

Aux2 solder pad (grey arrow above)




Telex Coupler Mounting

In my box of bits I found a 288390 coupler pocket which I

modified by enlarging the mounting hole to have a neat fit over the

mounting spigot. I used a crinkled/wavy washer just to exert the

correct pressure to allow movement and self centre the coupling, all

held using the original screw.

The wires for the Telex coupler fit through the existing spring slot

as shown.

Once I refitted the bogie I noticed that the Telex coupler sat too

high above the track to allow wagons to couple correctly.

The cure was to file one end of the bogie

support arm to a thickness of 0.8mm (see blue

arrows)

21 MTC PCB Adaptor Board

The three blue arrows point to solder

pads “U+” that can be used for all

+pole connections

Wiring Colours

Note

The violet wire was removed from the Aux2 connection and the grey wire from

the Telex was soldered directly to the Aux2 connection.

ESU doesn’t specify wire colours for AUX3 and AUX4 so I chose the

following. You will have to solder wires direct to the “21 MTC adapter” on the

pads provided.

Description Colour

Motor R Grey

Motor L Orange

Ground Black

Centre Rail Red

+ Pole Blue

Head Light White

Rear Light Yellow

Aux 1 Green

Aux 2 Violet

Aux 3 Brown

Aux 4 Grey

Rear Light

Rear Telex

Front, Cabin and Firebox lights




Cabin and Firebox Lights

The cabin light is a PLCC2 warm white LED. A

blue wire is soldered to the anode connection and a

brown wire is soldered to the cathode connection. It

is glued with hot melt glue to the cabin roof.

The firebox LEDs are yellow and red 0603 LEDs that are

connected in series. First I glued the LEDs to a small clear

plastic sheet with super glue, the left LED anode points up

and is the connection point for the blue wire (+pole) and the

right LED cathode points up and is the connection point for

the grey wire. The cathode of the left LED was bridged

across to the anode of the right LED (yellow arrow)

I drilled a 1.5mm hole for the firebox LEDs at the bottom

side of the firebox. This hole was then painted black.

The other 1.5mm hole was drilled at the location shown

(red arrow) to allow the cabin light wires to be threaded

through. Be careful to drill at an angle as shown by the

arrow and stop when you are through the metal before

drilling into the roof.

The wires are all trimmed to a suitable length and soldered

to 3 rolled pins with the blue wires connected to the

middle pin. The wires were held place by hot melt glue to

act as a stress relief. I plugged in the wire harness,

switched on the firebox light and with a little super glue

on the LED assembly positioned the firebox LEDs by

sighting through the firebox hole for the best location.

I have since done another firebox on another locomotive and the best location is to have the LEDs

mounted horizontally with the yellow LED on the bottom and the red LED above it. The view of the

firebox from either side is more consistent in colour mix and looking from above you will see a more

yellow/orange light with a touch of red reflected on the tender. See page 17.




Cabin and Firebox Lights Socket Connections

3 rolled pin sockets are glued with hot melt glue as shown.

The brown wire is connected via a resistor

on the Vero board in the tender then from

the other end of the resistor to the Aux3

connection.

The blue socket has two blue wires

soldered to it, one wire is connected to the

+U solder pad on the 21 MTC adaptor in

the tender (see page 4) The other blue wire

runs up to the front of the locomotive for

the front LED anode connection.

The grey wire is connected via a resistor on the Vero board in the tender then from the other end of the

resistor to the Aux4 connection.

All wires are protected by heat shrink.

To assemble the body shell lay it on its side, plug in the wire harness and carefully position the body shell

ensuring no wires are pinched.

I made a small spacer 2.25mm in length from 1/8’’copper tube to ensure the motor shield remained flat so

the mounting screw cannot be over tightened (red arrow).




Motor and Chassis Connections

The orange motor wire is connected to the left

brush connection.

The grey motor wire is connected to the right

brush connection.

The black wire from the 21 MTC adapter is

soldered to a solder lug held by the left bottom

motor shield screw. Another black wire runs to

the front pony truck to improve the ground

connection of the locomotive.

Front LED and Smoke Unit Connections

The front PLCC2 warm white

LED has some resistor lead

cut offs soldered to it and

plugs into the existing light

bulb socket.

Careful attention should be

made to connect the blue

wire to the anode side of the

LED and the white wire

connects to the cathode side.

The green wire is soldered to

the smoke unit connection

tab.

In this locomotive the light pipe for the front lights has gone a milky opaque colour and the light

transmission is poor. I tried to improve the light transmission by wrapping tin foil around the light pipe. It

has improved it to an acceptable level but I will replace it on my next spare parts order.

Please see page 18 for improvements for the top front light intensity




Light Results

Front lights Rear Lights

Cabin Lights with Firebox lights

I really liked the orange and red combination for the firebox

light and will be doing it for some of my other conversions.

The use of fibre optic light pipes will be used in other locomotives which don’t have any rear working

lights provided there is room to fit them.

CV Values for the LokPilot V4 next page

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




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

CV# Name Range Value Default

1 Primary Address 1-255 98 3

2 Start Voltage 1-255 *3 3

3 Acceleration 0-255 16 32

4 Deceleration 0-255 8 24

5 Maximum Speed 0-255 80 255

6 Medium Speed 0-255 25 88

13 Analogue Mode F1-F8 (F5 Cabin light) 0-255 16 1

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

52 Load Control Parameter “K slow speed” 0-255 32 48

53 Control Reference Voltage 0-255 120 140

54 Load Control Parameter “K” 0-255 55 48

55 Load Control Parameter “I” 0-255 40 32

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

95 Reverse Trim (1 x Voltage) 0-255 127 128

246 Automatic Uncoupling Speed 0-255 20 0

247 Automatic Uncoupling Move Time (2 sec.) 0-255 122 0

248 Automatic Uncoupling Push Time (1 sec.) 0-255 61 0

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

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

292 Aux3 Time Delay Turn On (1.64 sec.) 0-16 4 0

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

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

378 F1r (reverse) mapped to Aux1[1] *4 4

395 F2f (forward) Rear Light[2], Aux2[1] mapped together 32 0

410 F2r (reverse) set to zero value so engine won’t shuffle 0 8

411 F2r (reverse) Front Light[2] only mapped 16 0

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

Mapping Functions and Conditions to Outputs [Index:4099 (CV31=16, CV32=3)]

266 F6f (forward) mapped to Aux4 32 0

268 F6f (forward) Logical Functions Firebox 32 0

282 F6r (reverse) mapped to Aux4 32 0

284 F6r (reverse) Logical Functions Firebox 32 0

299 F7 forward condition mapped to Rear Light [2] 32 0

315 F7 reverse condition mapped to Front Light [2] 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 CV# Value

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

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

Aux1 Smoke 275 24 278 24 stat 279 28 min d 280 31 max d

Aux2 Telex 283 28 286 15 287 *0

Aux3 Cabin Light 291 2 294 20 295 144

Aux4 Firebox 299 4 302 *31 303 128

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 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.

CV13 has been changed so F1 Telex function won’t turn on but F5 cabin light will operate when running

in Analogue Mode.

For the Aux1 Function Output “Seuthe smoke unit” CV278=24 Heat while locomotive stands, CV279=28

is for Minimum heat while locomotive is driving and CV280=31 is for Maximum heat while locomotive

is driving.

For the first time I had to adjust the CV55 Load Control Parameter from the default motor setting to

overcome the locomotive jerking just as it stopped.

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 have changed now that I have tried running the locomotive in a schedule

with TrainController to test the Uncoupling function in shunting operations. I had to reduce the

Acceleration (CV3) and Deceleration (CV4) and I also reduced the medium speed (CV6) which gave me

lower speed steps in the low range to provide smooth coupling and uncoupling.

Bonus Time I have supplied my latest LokProgrammer project file 3615_proj (84Kb) for people to use as a starting

point for a locomotive conversion similar to this. It can only be used with LokProgrammer 4.4.11 and

above.

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

Left is the speed

profile showing all

decoder speed

settings.

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

http://members.ozemail.com.au/~rossstew/rms/files/3615_4411.esux




Locomotive Control

Above is the ECoS command station window showing F0 lights on, F1 smoke on, F2 telex function off,

F3 slow mode off, F4 Inertia on, F5 cabin light on, F6 Firebox light on and F7 Telex warning light which

isn’t used via the control window except for debugging on initial setup. To the right is the TrainController

Train window showing the same functions.

The icon has an embedded macro (indicated by the blue background which is a convention I have

started to use for all locomotives). This icon is used to manually jog and uncouple the locomotive and is

dependent on the direction of the locomotive.

This means that if the locomotive is running in the forward direction, the train will stop first then the

locomotive pushes the train backward just enough to release the tension on the couplings, the rear telex

operates and then the locomotive moves forward separating from the train and stops a small distance in

front of the uncoupled train.

The icon is used only with schedules that require shunting operations to uncouple trains. It is used

to account for train position in the block, what direction the locomotive faces in relation to the train and

also notes if the locomotive is pulling or pushing the train. The use of this icon will be covered in another

topic.

Intermittent Smoke On and Off icons. See Intermittent_Smoke for use.

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




Small Problem with F2 Automatic Uncoupling

Using the F2 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. The rear lights will remain flashing

until the F2 Telex function is turned off.

Small Problem with F2 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

F2 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

“Uncoupler Telex(N) 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.

Under the Operations Tab for the List commands I

send a message to indentify the loco then execute

the ‘Uncouple Telex(N) Jog’ macro. See left.

Under the Macro Operations Tab, I Stop the

locomotive, delay for 2 seconds, Play a 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”.

I am now using this macro for several locomotives

as shown in the ‘Used in Operations of’ shown in

the Inspector Window.

This works well and is much safer than operating the locomotive with the ECoS.




Parts Required

Part Number Supplier Description Quantity

54614 ESU ESU LokPilot V4.0 Decoder 1

51968 ESU 21 MTC Adaptor 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

288390 Märklin Coupler Pocket 1

60941 Märklin Motor Conversion Kit for 3615 1

934-1102 Element14 1K MF25 Resistor 0.25W, 1% 4

120-1478 Element14 Protoboard 100x220 or similar 1

102-3035 Element14 Harwin SIL Socket 32Way D01-9973242 1

PLCC2LW3CT Ledz.com PLCC2 warm white LED 1

330PWO4C Ledz.com 3mm warm white LED 2

0603KYCT Ledz.com 0603 Yellow LED 1

0603RYCT Ledz.com 0603 Red LED 1




14-05-2017 Appendix for Sound

Märklin 3615 Locomotive with LokSound V4.0 decoder

Adrian supplied a Märklin 60941 Motor Conversion Kit, ESU 51968 Adaptor PCB and an ESU

LokSound V4.0 decoder with M4/mfx capability and standard 4Ω 1.5 watt round speaker. The decoder

was pre loaded with a Br50 sound project ESU 64499.

I wanted to keep the sound project file intact as ESU had just released a 4.2.0 update for the ECoS which

would allow M4/mfx functions above 15+ for a total of 31 functions. The V4.0 sounder decoder was

manufactured in March 2017 and I used the latest release of the LokProgrammer 4.5.2. Sadly when

running the locomotive in M4/mfx mode the extra functions where not available so if Adrian wants to

have all possible functions he will have to disable M4/mfx protocol in the decoder (CV47.1) which can be

found in LokProgrammer Decoder Special options and run the locomotive in DCC protocol.

The information below will only focus on what I did to install the sound decoder, define function

assignment and fitting the speaker.

Function Outputs (determined by the existing sound project file)

F0 I have used fibre optic light pipes and one warm white LED for the rear lights and change the front

bulb to a warm white LED, using “Rule 17” to dim both lights when the locomotive is stationary.

F4 (AUX1) will switch the Firebox flickering light and play the shovelling coal sound.

F8 (AUX2) will switch the added cabin light that only comes on when the locomotive is stationary

F15 (AUX3 will switch the smoke.

Fxx (AUX4) will be available to put a Telex coupler on the rear of the locomotive at a future date.

Tender Requirements

The standard ESU round

speaker is too large to fit in

the tub tender so I decided to

fit a cube speaker which is

13mm x18mm x 4.5mm

number GVM C1318

I had to cut down the rear supporting rib to fit the speaker

across the back of the tender. To avoid cutting too much of the

rib to maintain rigidity of the tender top I mounted the speaker

on wooden feet to straddle the rear rib.




For better protection of the wires not being pinched by the ribs I had to remove the plug from the speaker

wires and thread them through a 1.5mm hole in the rib and resolder the plug as shown. The speaker is

held in place with hot melt glue. Where the brass weights are located I also glued some black card over

the area to act as an insulator in case the decoder came in contact with the metal weights.

PCB Adaptor Requirements

On the adaptor I soldered

brown wires to the speaker

solder pads and soldered a

socket to the other end of

the wires.

For the front FL and rear

RL lights I used 1k 1206

resistors on the provided

solder pads which

required moving the white

and yellow wires to the

location shown.

For AUX1 and AUX2 I

used 1k 1206 resistors on

the provided solder pads

which required moving

the green and violet wires

to the location shown.

The rear warm white LED was soldered to wires as shown which would fit into the optic fibre

arrangement in the bottom of the tender.

For the motor chokes I mounted them on Vero board and wired them to the PCB adaptor MOT1 and

MOT2. The wood spacer is hot melt glued to the PCB adaptor to fit in the tender. I also used a 4mm

length of heat shrink tube glued to the wood spacer to support all wires going to the locomotive.




Bottom Arrangement of the Tender

The red arrows show the location of 3mm holes I drilled to help the sound exit the tender. I used the

natural features of the tender to mount the PCB Adaptor by gluing a wooden spacer across the tender as

shown. The optic fibre arrangement is the same method I detailed on pages 2-3.

The final Arrangement of the Tender

The original speaker wires were removed from the decoder. The provided plug and socket for the new

speaker is shown connected and will lie down beside the decoder as shown. The motor chokes on the

Vero board are held in place with hot melt glue. All wires that exit the tender are well clear of the

mounting hole and the weight (not shown above, see page 2) is put in place before the final assembly of

the tender.




Cabin and Firebox Lights Socket Connections

3 rolled pin sockets are glued with hot melt glue as shown.

The brown wire is connected via a resistor

on the PCB adaptor board in the tender

then from the other end of the resistor to

the Aux3 smoke connection.

The blue socket has two blue wires

soldered to it, one wire is connected to the

+U solder pad on the 21 MTC adaptor in

the tender (see page 4) The other blue wire

runs up to the front of the locomotive for

the front LED anode connection.

The green wire is connected via a resistor on the PCB adaptor board in the tender then from the other end

of the resistor to the Aux2 Firebox flicker light connection.

All wires are protected by heat shrink.

Firebox LED Mounting Arrangement

The Red and Yellow 0603 LEDs are mounted

horizontally as shown across the 1.5 mm drilled hole

see yellow circle.

The view of the firebox from either side is more

consistent in colour mix and looking from above you

will see a more yellow/orange light with a touch of red

reflected on the tender.




Cabin Light The cabin light is a PLCC2 warm white LED. A blue wire

is soldered to the anode connection and a brown wire is

soldered to the cathode connection. It is glued with hot

melt glue to the cabin roof.

Improve Top Front Light Intensity

By having the PLCC2 warm white LED half

above the light pipe for the lower lights more

light will reach the light pipe for the top light

which is mounted in the front of the body shell.

If a smoke unit is used it won’t diminish the light

output to the top centre light.

Speed Requirements

I used a speed curve type Exponential 1 preset to obtain the speed profile shown below.

The maximum speed is 80 km/h

Adrian wanted better slow speed

running using TrainController for

entry onto the turntable bridge.

He will now have 5 speed steps

available which will be 5 km/h to

16 km/h which should provide

smooth entry onto his turntable

bridge.




Bonus Time I have supplied my latest LokProgrammer project file 3615 Br503143 (149Kb) for people to use as a

starting point for a locomotive conversion similar to this. It can only be used with LokProgrammer 4.5.2

and above.

I have also provided file

503143.yrl for a look at

the engine information

required by

TrainController.

Adrian provided a small video (0:49) of the Br 50 operating in the turntable area on his layout.

As always enjoy your model trains.

http://members.ozemail.com.au/~rossstew/rms/files/3615_Br503143.esux

http://members.ozemail.com.au/~rossstew/rms/files/503143.yrl

https://youtu.be/PkMZMByoe18

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