Chuck E Cheese Choo Choo

Transcript

CHUCK E CHEESE CHOO CHOO A computer controlled model railroad redemption game. TABLE OF CONTENTS 1. UNPACKING INSTRUCTIONS Page 2. SETUP INSTRUCTIONS Page 3. OVERVIEW OF TRAIN Page 4. TRAIN OPERATIONS Page 5. TRAIN DIAGNOSTICS Page 6. ELECTRONICS BOARD DETAILS Page 7. TRAIN SERVICE AND TROUBLESHOOTING Page 8. OVERALL LOGIC DIAGRAMS & SCHEMATICS Page Coastal Amusements CEC Choo Choo Manual Page 2 UNPACKING INSTRUCTIONS 1. Remove the screws holding the protective carton to the shipping skid. 2. Carefully lift the carton straight up while removing it from the game. Do NOT cut the carton for removal to prevent damaging the game cabinet or the plexi cover. 3. Remove the protective wrapping from the game. 4. Remove the blocks from the skid that secure the console. 5. Remove the console from the skid then remove the protective "bubble wrap" from around the console. 6. Remove the boxed train set from under the game. 7. Remove the blocks securing the base legs of the game from movement. 8. The game can now be lifted off the skid. Lift the game by the main cabinet base and not any part of the plexi glass structure. 9. Save all packing materials until all pieces have been accounted for during the set up process. Coastal Amusements CEC Choo Choo Manual Page 3 OVERVIEW OF TRAIN Train Board CHUCK E CHEESE CHOO CHOO consists of a scale model train operating on a figure eight track with various accessories. The accessories are controlled by push buttons on the console panel with the train speed being controlled by a throttle mounted on the console panel. A display is provided to indicate the playing time left for the coins/tokens deposited. The display increases as each coin/token is deposited and then decreases as time elapses. Coins can be deposited at any time and display will increase to indicate the playing time remaining. Console Panel The speed has a maximum setting for the curves to prevent the train from derailing. These controls are internal in the program and not available to the player. Coastal Amusements CEC Choo Choo Manual Page 4 The train is programed to start and stop at the station. The speed is set by the program to get the train back to the station when the timer reaches 000. The accessories are enabled at various times and positions around the track. The lights on the console panel indicate when the accessory will respond to the button.. (The exception to this is the STATION LIGHTS). Once the station lights are turned on, they will stay on until the timer counts down to 000. The train HORN is sounded by pressing the thumb button in the throttle handle. There are nine (9) increments in the speed. Each LED covers two (2) settings so the speeds 3 & 4 will be indicated by the first two LEDs turned ON. Electronics Tray The train is covered by a plexi glass cover to prevent debris from being thrown into the game. Locks secure a removable panel in the front of the game. The balance of the panels are fixed to the frame with bolts. All of the electronics are mounted on a slide out tray at the rear of the game (see picture above). This tray also provides mounting of all fuses. The fuses are in clips on the driver PCB adjacent to the Ultra III PCB. The train is shipped with a "spare parts kit" and a spare engine. Following are some part numbers should you need to replace or replenish your stock: Part Number CA-TRA-MTH-301073 Coastal Amusements Description #262 Crossing Gate Signal CEC Choo Choo Manual Page 5 CA-TRA-MTH-301074 CA-TRA-MTH-301076 CA-TRA-MTH-30-11010 CA-TRA-MTH-30-9032 CA-TRA-MTH-CI000010 CA-TRA-MTH-CI000011 CA-TRA-MTH-CI000009 #154 Highway Flashing Signal #153 Operating Block Signal 0 Scale Operating Crossing Radar Tower Green Bulb Red Bulb Platform Bulb Train rubber tires: (specify model of train) Pick Up rollers: (specify model of train) You may order accessories other than those listed. Should this be the case, call our service department for part number and description. SETTING THE TRAIN FOR PLAY MODE 1. Find the four (4) bolts to secure the console to the cabinet base. Reach inside the console, unlatch the panel and remove it from the console. Have a second person help hold the console in position while the bolts are installed. It is recommended that all four be started (there are Tee nuts inside the cabinet base) before tightening any of them. Use a 9/16" ratchet wrench or equivalent to tighten the bolts. Position the console to align it while tightening the bolts. Do not over tighten the bolts. Coastal Amusements CEC Choo Choo Manual Page 6 Console Cables 2. Locate the wire harnesses going to the console. There are seven (7) harnesses.These include: A). Four wire harness for the speakers. (Harness # 6) B). Six wire harness for the coin mech. (Harness # 1) C). Four wire harness for ticket dispenser. (Harness # 7) D). Twelve wire harnesss (female connector) for the panel timer/throttle. (Harness # 3) E). Twelve wire harness (male connector) for the panel accessory switches.(Harness # 4) Coastal Amusements CEC Choo Choo Manual Page 7 F). Twelve wire harness (female connector) for the panel accessory lamps. (Harness # 5) The connectors are numerically marked for quick identification.The wire color on the male side always matches the color on the female side. (Refer to console cables picture) 3. Connect the cables for the speakers, coin mech on / off switch, and ticket dispenser. Lean the console panel against the cabinet base and connect the other three (3) cables. Note the colors on the two 12 pin female connectors. Place the console panel back onto the console and latch it in place from underneath. 4. Remove the front panel of the plexi cover and inspect the track and accessories for damage. Use a glue gun (hot glue) to fasten any trees or plants that came loose during shipment. Get the Radar Screen from the cash box and install on the tower. 5. Standing at the console facing the game, the train must be placed on the track such that it goes CLOCKWISE (see train board picture) around the right hand side loop. Place the train engine and cars on the track as described. 6. Slide the electronic tray about half way out of the cabinet at the rear of the game. Find DIP SWITCH 1 on the processor board and turn it ON. Plug the power cable into a receptable. Go around to the console and turn the Power Switch ON. The game should come up in DIAGNOSTIC MODE. This is indicated by three (3) chirps. There may be a short delay before hearing chirps while the game initializes. All of the lights on the console panel will come on and the displays should read 0. Press each switch, this will generate a "chirp sound" and will cause each accessory to turn on for a short period of time and the panel light to go off for that time.The program allows testing only one accessory at a time. The buttons will be enabled when ALL button lights are ON. The display will indicate a number. This number is different for each accessory and is the number assigned by the program software. These numbers cannot be changed and are stated here for clarity. BLOCK SIGNAL – 1 RADAR TOWER - 4 CROSSBUCK – 2 STATION - 5 RAILHOUSE – 3 R R CROSSING - 6 Pressing the HORN button on the throttle handle will cause the display to increment one digit at a time from 0 to 9 to verify that all displays are operational. Operating either of the coin switches will indicate a 45 on the display. Operating the RESET switch will display a 36 and cause the coin-in and tickets-out counters to increment by three (3) counts and three(3) tickets to be dispensed. 7. Read this section completely BEFORE attempting to test the train. This section describes testing the train performance and is stated separately due to the importance of this test. There are several objectives to this test: Coastal Amusements CEC Choo Choo Manual Page 8 A.) Prove that the train responds to the different throttle settings. B.) Prove that the "isolated track" sections are reading properly. C.) Prove that the train has been placed on the track correctly. Before proceeding, visually check that ALL WHEELS ARE PROPERLY SEATED ON THE TRACK. Move the throttle to speed “1”. This will be indicated on the display and the train should start to move clockwise around the track.. The train contacts "isolated track" section 51 or 61 while sitting in the station. The display will switch from "train speed" to track section until the last car has left this section of track when the display returns to "train speed". The last section of track on the right hand loop is "isolated track" 52 or 62. The first section after the X CROSSING TRACK is "isolated track" 50 or 60. The program checks the 50, 51, 52 sensors for about a minute and then checks 60, 61, 62 switching back and forth about every minute. The 50/60 track section is significant because the program automatically provides additional power to the engine for climbing the hill. This increase is not shown on the display but can be observed in the sounds of the engine and visual observation. Push throttle toward FASTER and observe that the train runs faster and the display indicates a higher number. Push the throttle toward FASTER until the display reads 9. The train should be moving rapidly around the track but not to the point of derailing. Now that this section has been read go back to the start of Step 7 and TEST THE TRAIN. 8. Replace the front panel of the plexi cover, turn DIP SW 1 OFF and turn the AC Power Off.Slide the electronic tray back into the cabinet and replace the access door. Turn the AC power ON and the game should now be playable. Coastal Amusements CEC Choo Choo Manual Page 9 TRAIN OPERATIONS The ULTRA III processor board has a four (4) position DIP Switch located in the corner of the PCB where the I/O connectors meet. The switches have the following meaning: Diagnostic mode ON or OFF. Reserved Ticket Dispenser ON or OFF. Reserved DIP Switch 1 DIP Switch 2 DIP Switch 3 DIP Switch 4 These switches are "read" only during a POWER ON cycle. The RESET Switch located inside the coin door provides the following functions: A.) B.) C.) D.) Reset a "coin error" condition. Reset a "out of tickets" message. Reset a "ticket jam" message. Reset a "train derailment" message. All of these conditions can be cleared while power is ON. The ERROR CODES that flash on the console display are as follows: Error 90 Error 91 Error 96 Ticket Jam The display flashes 90. Train derailment message. The display flashes 91. Memory on the processor board has an error. Go to the TRAIN SERVICE section for necessary corrective actions. Console Panel Coastal Amusements CEC Choo Choo Manual Page 10 OPERATOR MODE The "operator mode" can be entered when the game is in the "attract mode". This is done by pressing the RESET button once. This mode can be entered and exited without turning the power ON or OFF. The main menu consists of three (3) functions identified as: Indicated by the "Block Signal" button lit. Indicated by the "Tower " button lit. Indicated by the "R R Crossing" button lit OPTIONS ACCOUNTING RETURN TO ATTRACT Pressing the "Block Signal" button will enter the OPTIONS routine and provide the following Selection and Control functions. Press the "Block Signal" button . Press the "Tower" button . Press the "Crossbuck" button . Press the "R R Crossing" button . INCREMENT LIST DECREMENT LIST SELECT ITEM RETURN TO MAIN MENU The display indicates the option number. The first number is F1. The options numbers are described below. The "Block Signal" and "Tower" buttons are used to move up & down through the option list and the option value is selected for change/review by using the "Crossbuck" button. The "Station" and "Crossbuck" buttons are used to modify the value or toggle the yes/no setting. The "R R Crossing" button is used to exit back to the Option Menu. An example will be "stepped" through after defining all options. Display F1 F2 F3 F4 F5 F6 Function Coin per play Tickets per game Time allotted 1st coin Time allotted each additional coin Diagnostics Mode Demo Mode Ranges 1 to 4 Coins 1 to 25 Tickets 1 to 100 Seconds 1 to 100 Seconds Default Value 1 Coin 4 Tickets 40 Seconds 50 Seconds Yes or No Yes or No No No CROSSBUCK button will increment the value or "toggle Yes/No STATION button will decrement the value or "toggle" Yes/No RR CROSSING button will return to "option menu" EXAMPLE: If it is desired to set the number of tickets per game to 3 instead of 4: Coastal Amusements CEC Choo Choo Manual Page 11 Press RESET while in the "attract" mode to enter operator mode. Press BLOCK SIGNAL to enter the "option" mode. Press BLOCK SIGNAL until F2 appears on the display. Press "CROSSBUCK" to select the F2 option. 04 is displayed. Press RAIL STATION to decrease the number to 3. (Pressing "CROSSBUCK" would have increased it.) Press RR CROSSING to return to the option menu. Press RR CROSSING to return to the main menu. Press RR CROSSING to return to "attract" mode. All option values or enables are viewed or changed using this procedure . ACCOUNTING The procedure to review the ACCOUNTING items is described below: 1. 2. 3. Press RESET button while in the "attract" mode. This activates the MAIN MENU. Press TOWER button to activate the ACCOUNTING menu shown. The ACCOUNTING Control menu contains the following functions and actuators: MOVE UP THE LIST MOVE DOWN THE LIST SELECT ITEM FOR DISPLAY CLEAR ACCOUNTING RETURN TO MAIN MENU 4. Block Signal Button Tower Button Crossbuck Button Rail House Button AND Station Button RR Crossing Button The ACCOUNTING menu contains the following items that can be reviewed: Display A1 A2 A3 Item description Coins into game Tickets dispensed by game Games played Since the accounting items can be larger than 999 (three digits), the display cycles through three (3) displays of 3 seconds each. The cycle is: 1st display is the item number, 2nd display is the 3 most significant digits (hundred thousand, ten thousand and thousand, 3rd display is the 3 least significant digits (hundreds, tens, units). A value that exceeds 1 million (1,000,000) will be indicated by "Err" on the display. 5. EXAMPLE: Determine the number of games played this week. This assumes that the item was cleared last week and that it is desired to clear it for next week. Press RESET Button while in the “attract mode” to enter operator mode Press TOWER Button to activate the ACCOUNTING routine.(A1 is displayed) Press BLOCK SIGNAL Button until A3 appears. (A3 = Games played.) Coastal Amusements CEC Choo Choo Manual Page 12 Record the display cycles. (Display 1 = A3) (Display 2 = 010) (Display 3 = 258) This would mean there were 10,258 games played this week. Hold RAIL HOUSE Button down and press STATION Button. (This clears the value to 000000.) Press RR CROSSING Button to return to Accounting Menu. Press RR CROSSING Button to return to Operator Mode Menu. Press RR CROSSING Button to return to the "attract" mode. TRAIN DIAGNOSTICS The diagnostics are referenced in TRAIN OPERATIONS section and are repeated here to reiterate the importance of using diagnostics to isolate problems. The diagnostic routine is entered in either of two (2) ways. The first way is to use DIP Switch 1 on the Processor Board. The second way is through the Operator Mode. Each method has advantages. The DIP Sw is best when trouble-shooting a major problem where it is desired to eliminate as much software as possible and provide maximum hardware testing. This mode is entered during a "Power ON" cycle and remains active until a "Power ON" cycle when DIP Sw 1 is OFF. Entry through the Operators Mode is best used to verify that a particular function or accessory is working properly. Remember that this mode is cancelled each time the Power OFF/ON cycle occurs. Regardless of the entry method, the program issues three (3) "chirps" when starting Diagnostics. All accessory lights on the Console Panel are on and the Display is set to 0. Each accessory can be checked individually for proper operation. Pressing an Accessory Button causes a number of operations to occur. A) A"chirp" indicates that the program "saw" the switch. B) The accessory is turned ON for a fixed amount of time. C). The button lamp is turned OFF for the same time. D. A number is put on the Display. The actions from pushing a button tests and verifies several parts of the system. The button is "read" through an "input port" on the Processor Board. The button lamp is turned OFF through an "output port" on the Processor Board. The accessory is controlled through another "output port" on the Processor Board and the number is sent to the Display through a third "output port" on the Processor. Each accessory has a unique number which has been assigned in the program. The correct number on the display indicates the program is functioning. Refer to STSYS-01, STSYS-02, STSYS-03 and STSYS-04 in the Overall Logic Diagram section for the train. Note that some of the accessories require more than one output, e.g. the Block Signal requires both a "red" and a "green" output. Another characteristic is that some outputs operate more than one accessory, e.g. the Station Lights also operates some Street Lights close to the Station. Other street lights operate when the Bill Boards are turned ON. Coastal Amusements CEC Choo Choo Manual Page 13 The system drawings can be taped together to make a larger drawing that shows the entire train system. The following functional assignments have been made: Switch Button R R CROSSING RAILHOUSE STATION RADAR TOWER CROSSBUCK BLOCK SIGNAL COIN INPUT RESET SWITCH S/W Number 6 3 5 4 2 1 45 36 Hardware operated Crossing arm & lights Lights & animation Station & street lights Radar rotates Crossing lights Sig "red" then Sig "green Billboards and street lights Counters +3 & 3 tickets Redundant connections are applied to the isolated track sections. The program has assigned numbers to each section. These numbers a displayed during diagnostic operation. The "up grade" section is shown as 50 or 60, the "start loop" section is shown as 51 or 61 and the "end loop" section is shown as 52 or 62. When the train is running in Diagnostics the display will show the speed (1 - 9) until the train goes onto an isolated section. The isolated number will display until the train leaves the section when the display returns to the speed. The Diagnostic routine alternately checks numbers 50, 51 and 52 for about a minute and then checks 60, 61 and 62 for about a minute. A very important difference from a "home" train is the manner in which the tracks are handled. Track sections are soldered together at the joints. This prevents the track sections from vibrating apart as the train goes around the loops. DO NOT ATTEMPT TO TAKE THE TRACK APART!!!!!!!! The entire track would need to be removed from the train board to do that. The electrical connection around the loop is made underneath the rail section in the "roadbed" area by "fingers" that engage to conduct the power. The isolated track sections have these "fingers" cut off on the appropriate rail and also a small amount of the rail is trimmed on each end of the section. The gap in the rail should be visible when looking at the rails. A wire is attached to each end of the "isolated" section and connected to the wiring under the train board. Electronics Board Details Drawing STMAN-08 shows the layout of the electronics board. The area identified as the processor board is the Ultra III PCB. This contains the program, memory, input (J4-J10) & output (J11-J18) connectors.The DIP switches are located above J10. Coastal Amusements CEC Choo Choo Manual Page 14 Train 21 PCB is the accessory driver with a transistor switch & 2A slow blow fuse on the PCB for each accessory circuit except the train engine and the radar tower. The fuse in front of Train 21 PCB is for the radar tower. The fuse for the engine is on the Train –30 PCB. The solid state relay for operating the radar tower is directly behind Train 21. The 8 Bit Sound PCB is located behind the Ultra PCB. Volume controls are located on this PCB. Schematics drawing for the Sound PCB are shown on drawings STMAN-01, 02, and 03. The box labeled TRAIN22B is the circuitry that provides the track isolation. The PCB consists of eight (8) 4N38 IC’s. The inputs are controlled by the three (3) isolated track sections and the outputs go to inputs J8 and J10 of the processor board. The upper left corner of the electronics board has the train power supplies. The T1 section provides for the accessories and the T2 sections provides the power for the engine. This is shown in drawing STMAN-19. The box adjacent to the power supplies is marked “12V.” This is a filament transformer used to monitor the AC power and provide a signal to the processor that “a power failure” is happening. The output of this transformer is connected to J2 on the processor board. TRAIN MAINTAINENCE AND SERVICE The most important aspect of maintaining CHUCKIE CHEESE CHOO CHOO is keeping the track clean. The track should be cleaned at least once a week using 93% isopropryl alcohol (rubbing alcohol). CLEANING PROCEDURE 1. Clean the track as described above using the 93% alcohol. 2. Clean each car individually. Invert the car and clean the wheels by holding an alcohol pad against one wheel and turn the opposite wheel. Pay particular attention to the area by the flange. This is the area that keeps the car on the track and thusly is always in contact with the rail. 3. If the car has a "pick off" roller on it clean this also. The "pick off" roller contacts the center rail. Ocasionally they will wear in the center & may need to be replaced. 4. The engine is more difficult to clean because the wheels don't roll freely like the cars. Place the engine on the side and connect a 12V power source between either "pick off" roller and the frame of the engine. The engine will now run. Pressing the alcohol pads against the wheels will quickly clean them. Pay particular attention to the "drive bands" on the driving wheels. Excessive oil can get beneath them and cause the band to slip. The train wheel will be turning but the train will be stationary. These "drive bands" will wear out and have to be replaced. Coastal Amusements CEC Choo Choo Manual Page 15 TROUBLE SHOOTING THE TRAIN The most frequent problems; Train Derailment Announcements and accessories not working can be traced more rapidly in Diagnostics. Remember that the Derailment announcement means that the train has not passed over the isolated sections within the time frame allowed in the program. Look to see if the train is moving fast enough between isolated sections. The first cause is usually a dirty track. Other reasons are worn "pick off" rollers, defective axles on a car putting excessive drag on the engine, worn gearbox in the engine. To check for a failed isolated track sensor: A.) B.) C.) D.) Put train in Diagnostic. Remove train from track. Set speed at 1. Roll one of the cars around the track and make sure that all sensors are being properly displayed. The program identifies the sections as 50 or 60 on the "upgrade", 51 or 61 by the station and 52 or 62 as the train leaves the right hand loop. These can also be tested by shorting the outside rails together at each isolated section. The circuitry for the isolated track is contained on the TRAIN22 PCB located on the electronics tray. The inputs and outputs can be checked with a volt-meter and/or using clip-leads to "force" the circuit. All of these inputs and outputs can be "forced" to ground without damage to the circuits. The normal voltage on the inputs (train speed = 1) is about 17V DC. The normal output voltage is +5V DC. The output goes to ground (0 V) when the input is ground (0 V). The 50's sensing is done on J10 of the processor and the 60's sensing is done on J8 of the processor. The wire colors match input to output for easy recognition. Several conditions may cause the train to run slowly around the track. The most likely cause is a dirty track. Removing one car from train will cause the train to run faster but MAY cause it to actually derail at higher speed levels. If the shorter train corrects the problem, check the cars for drag. Putting the "spare engine" on the train will also provide an indication of where the problem is. Determining why an accessory is not working should be reasonably easy. The most obvious is a blown fuse. Each circuit has its own fuse. These circuits can be tested in "play" mode. The ACCESSORY DRIVER PCB on the electronics tray has the fuses for all but the RADAR Tower. The Radar fuse is located directly beside the Driver board. If the fuses are good, then troubleshoot in the Diagnostic Mode. Accessory action involves four (4) steps; A.) The program must recognize the button switch. The program provides a "chirp" when it recognizes the switch. B.) The button lamp is turned off. C.) The program number is put on the display to ensure that the proper input is being "read". Coastal Amusements CEC Choo Choo Manual Page 16 D.) The accessory is operated for a preset amount of time. The accessory circuit can be "forced" by grounding the end of the fuse to turn it ON. Removing the fuse should turn the accessory OFF. Unplugging the signal cable on the input side (closest to the Logic Supply) should cause ALL of the accessories to come ON. Drawing STMAN-17 shows all of the cabling and circuits between the Processor and the Train functions. Referring to STSYS-01 through 04 will give connection and wire colors to aid in tracing circuits. Drawing STMAN-18 shows the train board harness for tracing signals under the train board. The wiring going from the electronics tray to the train board is long enough to tip the train board up at about 45 degrees for easy work. REMOVE THE TRAIN AND RADAR DISH before making any attempt to tilt the train board. The board can be tilted while in the cabinet until the RADAR TOWER hits the top cover. It will be necessary to remove the cover if it is desired to access the train board from both top and bottom. To replace any accessory, tilt the board and disconnect the wires at the connection block. Put the board back down, remove the mounting screws on top holding the accessory and pull the accessory wires out through the hole in the board. Attach the "old" wires to the "new" accessory, feed them back through the hole, fasten the accessory down, tip the board up and connect the wires to the accessory block. Most of the accessories can be tested with the train board tilted. Coastal Amusements CEC Choo Choo Manual Page 17 OVERALL LOGIC DRAWINGS The following drawings are included in this section: STSYS-01 STSYS-02 STSYS-03 STSYS-04 Train board layout Train cabling Console Panel Console cables Electronics board layout STMAN-18 STMAN-17 STMAN-10 STMAN-14 STMAN-08 ULTRA III Logic UL3-CPU UL3-COM UL3-MEM UL3-IN1 UL3-IN2 UL3-OUT1 UL3-OUT2 UL3-SND Contains the CPU portion of the logic. Contains the Communication portion of the logic Contains the Memory portion of the logic. Contains J4 - J7 of the input connectors Contains J8 - J10 of the input connectors Contains J11 - J14 of the output connectors Contains J12 - J18 of the output connectors Contains the sound portion if the CPU logic STEREO 8 BIT SOUND BOARD STMAN-01 Contains the Processor & Memory of the board STMAN-02 Contains the Digital to Analog Converters STMAN-03 Contains the Amplifiers of the Sound System Cables STMAN-06 STMAN-07 STMAN-12 STMAN-05 STMAN-15 STMAN-13 STMAN-09 MISCELLANEOUS STMAN-19 STMAN-20 STMAN-21 Coastal Amusements Contains cables TRAN-10 & TRAN-13 for Accessories Contains the PCB for the Accessory Driver Contains TRAN-01 for Accessory Switches on Panel Contains PCB for Isolated track and TRAN-14 Cable Contains TRAN-03, TRAN-04, TRAN-05 for console Contains TRAN-02 cable for Display & Speed LEDs Contains Processor cables for the Console TRAN-06, TRAN-07, TRAN-08, TRAN-09, TRAN-03 Shows the power supplies for the engine & accessories Scematic of power amplifier for engine Schematic of power amplifier for accessories CEC Choo Choo Manual Page 18 TRAIN SPEED A prime concern on any Model Railroad Set is controlling the speed of the train. The program controls the maximum speed and changes with reference to where the train is located on the track. The basic technique uses a power amplifier to change the power delivered to the tracks. A minimum amount of power is required for the train to move (Speed 1) level is about 6 volts. The maximum safe speed that would not derail the train is the “Speed 9” level is about 12 volts. The throttle is actually two switches. One closes when the throttle is pushed toward FASTER and the other closes when the throttle is pulled toward SLOWER. The program detects the closure and incrementally increases or decreases the amplifier voltage. The program also feeds this information back to the player by changing the amber LEDs located by the “throttle.” The control philosophy requires that the program knows where the train is located around the “figure 8.” The selected technique works essentially like the “big trains.” The train operating voltage is applied to the “center rail” and the power return is connected to an “outside rail.” The “other outside rail” has multiple track sections that are islolated from the rest of the rail. The control scheme need three (3) monitor points therefore there are three (3) “isolated track sections.” The sections are: A) Section 1 located just as the train starts up the grade. B) Section 2 ;located just as the train completes the “hillside” of the track. C) Section 3 located after the train has completed the “right hand loop.” It is VERY IMPORTANT to note that the “outside rail” on one “loop” is the “inside rail” on the other “loop.” This is the reason that the above description DID NOT refer to the “inside and outside rails.” The isolated section for the “upgrade is the “outside rail” of the curved track section. This section is close to the back of the Station. The section for the “start right curve” is the “outside rail” of the STRAIGHT track just before the cross over. The section for the “clear right hand loop” is the “inside rail” of the track before the two loops cross. Redundant connections are applied to the isolated track sections. The program has assigned numbers to each section. These numbers are displayed during diagnostic operation. The “upgrade” section is shown as 50 or 60, the “start loop” section is shown as 51 or 61 and the “end loop” section is shown as 52 or 62. When the train is running in Diagnostics the display will show the speed (1 - 9) until the train goes onto an isolated section. The isolated number will display until the train leaves the section when the display returns to the seed. The Diagnostic Coastal Amusements CEC Choo Choo Manual Page 19 routine alternately checks numbers 50, 51 and 52 for about a minute and then checks 60, 61 and 62 for about a minute. A very important difference from a “home” train is the manner in which the tracks are handled. Track sections are soldered together at the joints. This prevents the track sections from vibrating apart as the train goes around the loops. DO NOT ATTEMPT TO TAKE THE TRACK APART!!!!!!! The entire track would need to be removed from the train board to do that. The electrical connection around the loop is made underneath the rail section in the “roadbed” area by “fingers” that engage to conduct power. The isolated track sections have these “fingers” cut off on the appropriate rail and also a small amount of the rail is trimmed on each end of the section. The gap in the rail should be visible when looking at the rails. A wire is attached to each end of the “isolated” section and connected to the wiring under the train board. See the next Section for construction details. TRAIN CONSTRUCTION This section describes the assembly details as an aid to fully understanding the system and trouble-shooting problems. There are three (3) major components to the system. A) The cabinet and protective cover. B) The train board with the accessories, tracks, and wiring. C) The electronics board which contains ALL of the logic and control. CABINET The cabinet does not really need much discussion. The cabinet has a cutout in the front for the console to bolt into. The bolts are easily accessible when the console panel is removed. TEE nuts are attached to the inside of the cabinet to more easily bolt the console on. The console panel is secured by a latch on each end. Ensure that the panel and wiring is fully inside the console frame before latching it down. An access door at the rear of the cabinet allows the “electronics tray” to be slid partially out of the cabinet for work. A piece of wood on each side of the tray prevents the tray from sliding totally out of the cabinet. These are secured by screws and can be removed if necessary to repair or replace the electronics. The access door is secured by a lock for security. A drop-down door is under each end of the cabinet. These make it easy for rapid verification of the wiring under the train board, however the train board can be propped up for extended checking. Remember to REMOVE THE TRAIN and the RADAR DISH before tipping the board up. TRAIN BOARD The train board is built on a frame of 1” x 2” boards with the base then attached. The wires from the accessories are fed through the underside and the accessories are fastened down. Holes are drilled for the track wires. This includes power and ground for the engine at the far end of the hill “loop” and two (2) wires from each isolated track section. Drawing STMAN-04 showd the Coastal Amusements CEC Choo Choo Manual Page 20 approximate location of the accessories, the grade crossing in the middle and train direction arrows at the upper right area. The accessories shown all need power and control signals. There are other accessories (i.e. cars, roads, trees) which do not require power so they are not shown here. Note the location of the console. The train board can be rotated 180 degrees and set down into the cabinet, but the game should be shipped as shown in the drawing. Drawing STMAN-18 shows the wiring harness attached underneath the train board. The harness wires at the accessory end are fastened into connector blocks. Each block provides two (2) screw terminals for each wire and nadles two (2) wires. As an example, the Billboard will have a gy/yel wire in one terminal of the block and a red wire in the other terminal of the block. The other side of the block is where the accessory wires connect. Power for the accessories is obtained from a #18 RED wire that runs through the center of the board for the width of the board. Devices called Tee Taps are used to “tap” the red power line and then wires terminated with “blades” are connected from the taps to the accessory blocks. The cables from the board are terminated in three (3) cables with approximately 15” of loose cable. An eleven (11) wire cable carries the accessory controls and the DC power. A six (6) wire cable carries the signals from the isolated track sections and a two (2) wire cable carries the control for the RADAR tower. These connectors are unique and connont be connected incorrectly. Coastal Amusements CEC Choo Choo Manual Page 21