Zombie Rail

At the last club meeting I (Doug Stoll) brought three samples of Dead Rail locos that recharge while running on the rails. The system uses original Gilbert motors (can motors work also) and three Lithium Ion batteries for 12.6 volt power typically in the tender of a steam engine or the main body of the Baldwin (355) and GP (371). The Steam setup has batteries no different than your laptop or cordless drill. The smaller locos batteries are the same size as AA. To prevent issues with shorts or over charging, the track power AC or DC and 6-15 volt travels through the AF pick-up wheels, an 8 amp rectifier, and a three cell (3S) BMS (Battery Maintenance System) balance board that evenly charges the cells with a 5 volt limit for each cell.

On board batteries for all types of units, from the charging circuit the batteries are series wired for the motor. The power (15 volts total due the 10 amp/5 volt for each battery) travels to electric race car components. First the power provides life to the brushed ESC (electronic speed control) which powers the motor through two DC wires. The ESC also provides a BEC (battery eliminator circuit) that provides power to the 2.4 Ghz receiver for radio control. When connected this way, the receiver controls motor speed from the ESC. Direction is controlled through a 15A DPDT non-latching relay wired like some AF steam units which had a directional slide switch just inside the roof of the cab. The relay is activated by the head light wires provided by the Model car ESC. From the relay, power is then provided to the motor which has been converted to DC (if Gilbert original open wound). There is a slide switch currently under the tender that connects or disconnects power to the ESC from the battery circuit allowing the track, rectifier, BMS balance board to charge the batteries while track power is on should it be required.

Radio control is currently provided through airplane transmitter allowing left control stick to activate throttle (up/down) as well as bell and whistle/horn (left/right). Accessories can also be activated through right stick. Currently have cattle loader (771) and baggage loader (770) on left/right movement and the cars designed for them on the up/down movement. The channels of the radio control how many accessories to activate per model. The model of radio control transmitter control how many models you can select. I use Spectrum Radios. I use a DX7 (gen1) and a DX4e. The 7 has the ability to select up to 20 different models and display model name on LCD screen. The operators can activate all of the locos and the one you select is the one you control with a different frequency. Not all manufactures do this. The gen2 DX7E has 250 model selections so the sky is the limit. The DX4e controls only one model of choice which is OK for main line use. Deactivate and activate the loco of choice at the yard.

All components can be purchased at electronic supply houses like Digikey and/or eBay. I have used batteries from drills and laptop replacements. The replacement laptop battery provides enough cells for two steam engines (6 cells). AA size can be purchased through eBay.

Bright side is reliability even through switches and dirty or surface rusted rails and no more tender-thumping. Down side is the Baldwin still has gear noise. Can motor would correct that issue.

The used DX7 Generation 1 transmitter runs about 120 dollars, DX4e runs about 50 dollars and the loco upgrade runs about 50 dollars. Train hardware can be returned to original state, and transmitters can be used for helicopters, planes, cars, boats or for whatever you can imagine.

I have incorporated a volt-meter on the track fascia to measure available current. When the engines are charging, you will notice a pulse or change in voltage. When it stabilizes they are fully charged. I also put led cab lights in locos powered from receiver to recognize when they are activated to prevent excessive drain. Lithium cells run from 4.2 max to 3.2 min with 3.7 as storage level. Charge with no more than 5v per cell. Overcharging will cause overheating. Undercharging will cause degrading of cell and permanent inability to reach full charge. Never charge them in series. Example would be a battery pack of three connected to a trickle charger power supply without a BMS protector in a balance board. One cell can reach 7 volts and burst into flames while next cell may never get a charge causing it to die. They are safe as long as rules are followed.

The conversion will be posted in our web in BSG/Hints&Tips. DC conversion is already there.  I also have created a Facebook group called American Flyer Zombie Rail. Reasoning is the upgrade is not entirely Dead Rail. Facebook location online is American Flyer Zombie Rail | Facebook.

Doug Stoll