Installing the New ESU XL 5.0 sound decoder -- Part 2

Live from the workshop -- Part 2

By now, Klaus is about to program and edit the new sound into the blank ESU decoder. Using the ESU Lok programmer and his laptop he can easily select a sound file of a locomotive which comes close to the project he is looking for. ESU provides more than 100 recorded sound files of locomotives from all over the world . These you can find on their web page, free of charge.

Within this loco sound file Klaus first defines the driving characteristics by selecting the correct motor (Buehler) and driving curve (e.g.linear or exponential). The acceleration and stop characteristics are chosen next.
The next task is defining the function mapping. According to his standard based on the LGB MTS standard the functions have to be available basically on the same function key. So we have horns and whistles on functions #1 and #2. Function #3 is regularly the bell. Function #6 switches on the sound and function #7 is the smoker. The function keys then must be linked to AUX outputs if necessary. For example, if you have coal shoveling on function #4 the firebox light must be triggered on an output linked to function #4. Thus you have the firebox light come on whenever coal shoveling sound is played.

The next step is to define the function outputs (e.g. light effect and output voltage). In case Klaus is not satisfied with a certain sound he may choose a different sound from a huge sound library. This way he changes for instance the whistle or the air pump to better match it with the type of loco he is working on. He may even add a self produced sound to the library as long as it is a .wav file.

Due to the fact that generally the sound varies with the chosen loudspeaker some sounds need to be raised in volume to fit into the sound scheme.Unfortunately one is limited in the size of the loudspeaker because of the engine body/housing at hand. So the choice of the loudspeaker is critical. Klaus preferred choice are VISATON loudspeakers. For certain locos he has to dig into his vast selection of specialty loudspeakers.

Once programming is done Klaus puts the sound file onto the blank decoder via the Lok programmer. This procedure may take up to 30 minutes depending on the file size.

Now it's time to install the programmed decoder into the locomotive and do the final wiring. Then he reassembles the locomotive. Test driving may show the necessity for slight changes which can always be done by reconnecting the locomotive to the Lok programmer and changing the file accordingly.

ESU Loksound decoders prove to be the most versatile and effective decoder on the market in regard to motor control and sound quality paired with output. Various implemented safety features guard the function outputs and motor control making it not only safer but also more fun programming and editing the ESU 5.0 XL sound decoder.

Klaus is well stocked with ESU decoders. Give him a call or email him. Klaus is always happy to help!

Installing the new ESU XL 5.0 sound decoder

                       

Live From The Workshop - Part 1

Reporting live from   "Famous Klaus Workshop" : preparing and installing the XL 5.0 ESU sound decoder into ( today) the LGB# 4067 cleaning loco.

Installing a digital ESU sound decoder into an LGB loco in 5 steps steps:

• check and prepare for loudspeaker mounting and installation
• check and prepare for decoder board mounting and installation
• programming and editing of ESU XL 5.0 sound decoder
• installation of decoder, hall sensor set (when needed), and connecting loudspeakers
• re-assembly of loco parts and test driving the new decoder w/fine tuning

Please note that these steps are in Klaus' procedure no matter what type of digital decoder he installs. Can you do it any other way? YES -- which in Klaus' view  means mangling an otherwise very fine engine of  very fine provenance... Therefore:

ventilation grille painted on loco housing

Check and prepare for loudspeaker mounting:
It's hard to say what takes the longest in prepping an LGB engine for sound decoder installation. Klaus being Klaus he stands for Old Original LGB standards where a loco is the better the more she looks like her Original.
Installing sound therefore means to provide space for the loudspeakers and create openings for the sound not by merely drilling holes somewhere ( urrrghh--- you can hear Klaus say, even from your spot!) But to provide meaningful openings where the sound would come from in reality. In the case of the 2067 Cleaning engine this is clearly the front side of the engine where the

ventilation grille cut out

grills are painted with black lines to visualize the ventilation grille for the diesel engine(s). On the pics to the right: the upper engine shows the painted ventilation grilles where the lower pic shows cutouts have been made. Note: the LGB 2060 and 2067 share these same housing parts.

Klaus starts by dismantling the 2067 engine housing to extract the housing part. Klaus uses his 3-D milling machine - programmed accordingly- to cut out the "ventilation grille" part of the housing.

3-D milling in action

Detail cleaning the new opening by hand  is the next step.






Klaus will need mounting support for the loudspeakers so he cuts supporting blocks from hard-PVC plate (1/2 " thick). They guarantee non-deforming support in hot and cold environments. The loudspeaker mounting gets glued into place  in the respective housing part.
Klaus uses a specialty glue that slightly 'melts' the surface of the engine housing so the hard PVC piece will 'combine' with the housing plastic. Then the loudspeaker is wired and mounted. In the photo left notice the little piece of rectangular plastic below Klaus' wrist; that is the first mounting piece. He will need two in this case.






 Trying to mount the loudspeaker Klaus notices a need for space currently held by the lead weight. Each LGB engine sports a lead weight to ensure optimum driving characteristics. In the case of the LGB 2067 the lead weight is elongated and needs to be adjusted to give Klaus enough room to install the loudspeaker. Klaus utilizes his 3-D mill again, programmed, to refit the lead weight.

Now the loudspeaker is connected to the deoder board and mounted into the engine housing.

And the cutouts made previously are getting a mesh for looks

Follow Klaus in his workshop with the next steps, programming, editing and installing the sound decoder.++++ to be continued