PRR Panhandle 2.0

Nice. That's going to be perfect!

Updated 7/25/2024:

Around the middle of June, I completed the wiring of the WSX Yard control panel.  Tonight I finished the 1st turnout on the Weirton Junction (WC for its call sign) tower control panel.  Here's a pictorial stroll through the effort.

The laminated track plan was glued to the front of the 1/8" Masonite board using 3M #77 Spray Adhesive.  When sufficiently dry I drilled holes for the toggle switches (7/16 Forstner bit).  Basically, they can be screwed into the board.  For the LEDs, I used a #10 drill bit.   The terminal blocks were fastened with double-stick Gorilla Tape.

Here's the start of wiring.

Next, come the 1"x2" supports.  These are cut at 10 degree slant so that they will tilt the control panel, making it easier to see.  Note the slant on the right.  Another support will be installed on the far side of the board.  The top of the board is to the right.  When upright, the tops of the supports will be screwed to the bench work top.

Here's the installed control panel from the rear.

Finally, after connecting one of the toggle switches, LED, and Tortoise machine for #3, here's the finished result.

I'll tackle the others tomorrow when I'm fresh.

More when I know it. 

George

George that panel looms great. I am to assume that you will have multiple small control panels like that around the layout instead of one large one? This will allow you to be moving around the layout as it functions? Wonderful! I think this is the idea I will use on my expansion as the first portion of my layout has one large panel.

Mike

George, the panel looks great!  What will be on the extended Masonite at the top?

@LT1Poncho posted:

George that panel looms great. I am to assume that you will have multiple small control panels like that around the layout instead of one large one? This will allow you to be moving around the layout as it functions? Wonderful! I think this is the idea I will use on my expansion as the first portion of my layout has one large panel.

Mike

Mike,

Thank you!  The plan is for 4 control panels (towers) around the layout that will be occupied during operating sessions.

• Staging:  This controls 12 turnouts behind the divider (it has the Weirton Steel blast furnaces on it).  The operator there will be in charge of storing, starting, and ending through trains on the Panhandle.  Also, all engines not in use are stored back there.  And he/she will be in charge of operating the Loads / Empties track (exchanging loaded cars for empties & vice-versa).  The control panel back there runs DZ-2500 switches using the DZ-2502 push buttons.
• Weirton Steel Yard (WSX):  This controls the 13 turnouts in the vicinity of Weirton Steel and the Staging Area entry and exit tracks.  The operator will control the actions of the 2-3 switch engines as well as trains entering and exiting Weirton Steel.
• Weirton Junction (WC):  This tower operator controls the 6 turnouts for Weirton Junction Yard and Standard Slag.
• QN:  This tower in the yet to be built Steubenville section of the layout will control the 5 turnouts around the Steubenville PRR station as well as Armour Packing and Federal Paperboard.

If I am just running trains by myself or for an open house display, the turnouts can be set to the mainline.  I do plan to follow the trains around.  I could have just placed a toggle switch near each turnout in the fascia, but it's less work to group them.  And it creates the illusion of towers for operating purposes.

George

@Mark Boyce posted:

George, the panel looks great!  What will be on the extended Masonite at the top?

Thank you, Mark.

The extended portion of Masonite is part of the fascia and forms a 1" high lip or guard at the edge of the layout.  May it never been needed (if you know what I mean)!  It will mate up with the rest of the fascia when I install that.  The regular fascia is 4" in height.  Working from the top, 1 5/8" gets you to the bottom of the table top.  The rest of the height provides an anchor point on the backside of the fascia for a strip of velcro which will hold the skirting in place.

George

George, that sounds like a great plan!  You are right, may it never be needed.  If you have it, all will go well!

Updated 7/26/2024:

After pushing all day to get the 4 remaining toggle switches working on the WC Control panel, I realized that I am 1 Z-Zips edge connector short!

I will be making a trip to Hobby Express tomorrow.

George

George, Harry and crew will be glad to see you!  😊

@Mark Boyce posted:

George, Harry and crew will be glad to see you!  😊

They always are, even if I just drop in to say "Hi!".

Updated 7/27/2024:

I finished the Weirton Junction (WC) control panel today.  Let's look at some photos.

First up, this is a pair of indicator LEDs that a friend soldered for me.  @Bob provided the circuit design (thanks again!).  They are long leg (+) to short leg (-) so that when power is applied, one is lit and the other is off.  Flip the toggle and the reverse happens (as well as throwing the turnout).

These are all glued into the back of the control panel using CA glue.  A medium viscosity formula gives me enough time to press them into the holes.  I used color coding, spiral wire wrap, and zip-ties to keep the mess somewhat under control.  Green for ground and white for hot.  Tortoises are powered by 12VDC.

More wire wrap here to keep me from snagging wires when I move around under the layout on my rolling stool.

Even more wire wrap with the river and the bridge in the background.

Finally, here's a look at the fully populated, operational control panel for Weirton Junction tower.

And even though it might be hard to see, I made a video of switches #4 and #43 throwing together.  These create the runaround track that permits a switcher to escape the yard after leading in a cut of cars.

And just for fun, I moved one of the I1s Decapods in front of the Open Hearth for a "glamor" shot.  Gee, I don't think anyone ever referred this locomotive as "Beauty" - more like "The Beast"! 

The next step is wiring those DZ-1060 PRR signals to the Tortoise machines and get them to change aspect appropriately.  I've got that problem posted over on the Electrical Sub-forum.

More when I know it. 

George

The cabling looks great as does the panel!!  Just as it is with people, it takes a lot of behind the scenes workers to make what is visible work correctly!   It is great when a plan comes together!  I'll go with glamour shot!! 

Updated 7/29/2024:

While I wait for some assistance with an electrical issue, I started pulling together resources for the next animation project.

I am beginning to collect the hardware components needed.  The missing ones have been ordered.

I also fired up my Arduino IDE and downloaded / installed some libraries that I will need.  Then I got the demo program to compile, which is a nice baby step.

As I am done with the divider mock-up, I pulled down the cardboard and put it in the recycle bin.

More when I know it. 

George

Updated 7/30/2024:

I "fixed" Switch 33 by putting a small piece of electrical tape on one of the guide rails - the black rail in the center of the circle.  This was causing a short when the locomotive crossing the frog on the diverging route. 

Would a permanent solution be to cut the rail?

George

Yes, I think I had a similar problem and I think I slid the offending track away a bit.  Memory isn’t what it once was. 🙄

Updated 8/1/2024:

I resolved 2 issues tonight.  First, my double-headed signal had stopped working.  Upon close inspection of the Arduino, I saw that several wires had popped out of their screw terminals.  This is because someone (I have no idea who) must have bumped into the mounting board while moving around under the layout.    The lesson learned here is to do a better job of:

1. Mounting any such board so that it doesn't hang down and get run into.
2. Do a better (neater) and more direct job of routing the wiring so that it stays out of the way.

Here are some photos of the repaired and remounted Arduino board.  It now is screwed to the bottom of the bench work.

With the help of Dennis Zander of Z-Stuff (thank you Dennis!!!), I now have a Tortoise switch machine activating a DZ-1060 PRR signal.  Here are some photos.  Switch #17 in the center of the photo is now controlling the signal in the foreground.  Left:  The turnout is set for straight (to the Staging Area).  Center:  Switch #17 has been thrown against the Staging Entry track and the signal indicates STOP.  Right:  Switch #17 has been set back to straight and signal is returning to CLEAR.

And here's short video of the signal in operation.

The very next step is to document the wiring of these signals carefully (just in case).  After that, the very next steps are to wire signals to Switches 3 and 35.  And to connect a couple more to block-occupancy insulated rails.

More when I know it. 

George

That's awesome! Are you going to produce a cheat sheet so operators can really follow the signals?

@BillYo414 posted:

That's awesome! Are you going to produce a cheat sheet so operators can really follow the signals?

You mean like this? 

Actually, there's only 1 signal that will need interpretation.  Everything else is pretty simple and straightforward.

George

@G3750 yes! Like that! Pretty awesome stuff.

@BillYo414 posted:

@G3750 yes! Like that! Pretty awesome stuff.

Thank you!  I think I found that poster at York - many, many moons ago.

George

Updated 8/2/2024:

I'm pleased to report that except for the PRR signal bridge, all single mast signals are operational.  The signals are operated by the Tortoise switches - #3, #17, and #35.

George

Updated 8/3/2024:

• All 3 signals operated by Tortoises - Switches #3, #17, #35 are operational
• All 3 signals operated by insulated rail (block occupancy) are operational
• Dual-headed signal operated by Arduino and the position of Tortoise Switches #9 and #10 is operational

Still to be fixed:

• Signal on Staging Exit Track just before it joins the Westbound Mainline (Switch #36)
• Bridge signal that interacts with Switch #36 (it indicates CLEAR when mast signal #36 indicates STOP and vice-versa)
• PRR signal bridge at west end of the Ohio River bridge; this was operational prior to swapping DZ-2500s for Tortoises and will have to be redone.

Experimentation with Arduino using a distance sensor is in progress.  I have modified some C code for my Slag Dump animation.  It's now registering distances.  I will put it on the layout and determine a correct distance for slag cars.

More when I know it. 

George

Updated 8/6/2024:

Solely because of Bob Bartizek's help @Bob the two signals controlled by Switch 36 (where the Staging Exit track joins the westbound mainline) are working properly.  Thank you, Bob!!! 

Here's the video.

I can now button up this part of the fascia and tackle the myriad of projects waiting their turn.

More when I know it.

George

"But wait, there's more!"     With Bob's help later last night, I was able to get the circuit to successfully detect occupancy of the mainline west of Switch #36.  In that case, both signals display STOP!  Thanks again, @Bob !

This is a major accomplishment as the fascia can now be buttoned up and my focus will turn to (in no particular order):

• Slag dump work
• Yard tower painting and permanent installation
• Divider parts procurement and installation
• Crawford's Crossing overpass construction (still waiting on railings)

More when I know it! 

George

Wow!  Excellent addition!

George, the layout is progressing beautifully. I am very impressed with the backdrop. I'm going to look back at your posts for details about it. It looks great!

Mike

@G3750 posted:

"But wait, there's more!"     With Bob's help later last night, I was able to get the circuit to successfully detect occupancy of the mainline west of Switch #36.  In that case, both signals display STOP!  Thanks again, @Bob !

This is a major accomplishment as the fascia can now be buttoned up and my focus will turn to (in no particular order):

• Slag dump work
• Yard tower painting and permanent installation
• Divider parts procurement and installation
• Crawford's Crossing overpass construction (still waiting on railings)

More when I know it! 

George

Nice work there George! Digging the progress you’ve been making so far.

Updated 8/16/2024:

With another big thank you to Bob Bartizek @Bob I am able to report more signal progress.  A week or so, the westbound mainline at Switch #36 had its signaling straightened out.  Tonight, I completed wiring the MTH 30-11030 signal bridge to an insulated track section to signal block occupancy.  Here's the circuit (thanks Bob!).

And the electronics...

And the proof of the pudding.  Train 30 passes under the signal bridge, occupying the section beyond it and triggering the change.

Reversing direction, Train 30 restores the original signal aspect.

More when I know it. 

George

I hope I can replicate this level of function one day. I think this is so cool!

Also, that open hearth is enormous. I watched the video once for the signal and then again for the mill.

@BillYo414 posted:

I hope I can replicate this level of function one day. I think this is so cool!

Also, that open hearth is enormous. I watched the video once for the signal and then again for the mill.

Thanks Bill! I know you will.

George

Great progress @G3750 ! Thanks for sharing!

Updated 8/20/2024:

The Division 2 picnic has been occupying most of my time over the last week, but now that it's out of the way I am turning my attention back to layout concerns.

There are a number of projects stacked up waiting for something or another:

• Crawford's Crossing highway overpass
• 24" high divider between Weirton Junction and North Weirton
• Standard Slag

However, it is important to take advantage of those delays and deal with an issue that must come first - fixing the Open Hearth's electrical issues.  For some reason over the past year I have had various components (lights on 1 smokestack, a set of interior lights, large smoke generator) fail to operate.  I believe these are all caused by some poor connections somewhere on the charging side of the building.  I am also unhappy with the waviness of the roof - I think it detracts from a detailed model I worked very hard to build.

The first step in correcting these problems is enlarge the access hole behind the Open Hearth.  Here's the area in question.  Beyond the square hand hole is a roughly triangular area.  That's going to be cut away.  Another table leg will be added directly the mill.  Access to the back of the Open Hearth will allow me to easily fill some of the smoke units in the building and reach any derailments that might occur.  The area will be blocked from view by the Blooming Mill building and the support pillars (behind it) of the Crawford's Crossing highway overpass.

Once the access hole has been cut and the bench top supported, I will begin by removing (and reusing) some of the roof panels, disassembling the main roof sections, and fitting and painting the underlying support styrene (shown below).

More when I know it. 

George

That's a lot of work, but it should be better in the long run.

@Mark Boyce posted:

That's a lot of work, but it should be better in the long run.

Yes, it will be.  But I really need to fix it now or put up with the issue (Yeah, we all know that's never going to happen ).

George

Updated 8/21/2024:

Today I worked on relocating electrical buses and other wires in the area of the new proposed access hatch.  I also took the opportunity to neaten up some of the existing wiring (wire wrap and extra zip ties and attachments).  I cut a cross-beam for under the bench top and found a 2x2 that will become a leg.  I don't have any photos (nothing too exciting anyway).

More when I know it.

George

Updated 8/22/2024:

Here's a slightly more useful look at what's going on.  First is a view of the general area.  I use that Werner stepladder to get up onto the layout.  By wearing knee pads, I am able to carefully move towards the divider.

Below is a close up of the access hole (cut before the final location of the mill was determined ) that I will expand.  The expansion will involve making a triangular shaped cut in the bench top between the access hole and the divider.

I have added a corner brace to help support the area between the current access hole and the wall.  A red line on that rib indicates where I will make the cut.

I will also install a leg to help support the remainder of the rib.  The leg is not in the correct spot.  It will be located much farther off to the right (off camera in fact).

From below, you can see where a diagonal table support will be installed.  The "tailwheel" of the mill is visible protruding through the bench top.  

Finally, here is part of the area that will be cut away.  The black line is the cut line.  I've got to be very careful of the Tortoise switch machine (which I will cover with plastic).

More when I know it. 

George

Updated 8/23/2024:

After some careful thinking and re-thinking of the new access hole, I actually made the cut.  This took place in very close quarters.  I wish I had done this before placing the mill, but I didn't realize I would need access to the rear or have electrical problems after I put it in place.

I used a hand saw, a Dremel Sawmax, and a saber saw.  It was quite the struggle.  Here are the casualties - all stiff as a board. 

From below, here's the new access hole.  It's big enough to comfortably stand up in.  We will give some thought to making the section of Crawford's Crossing highway (that will cross over it) easily removable.  I will need to get in here to put smoke fluid in parts of the Open Hearth.

Here's the view from the top.  Keep in mind that parts of the overpass and the Blooming Mill will block the holes from view.

I also picked up some additional CA and Un-cure in preparation for taking apart sections of the Open Hearth to find and fix the electrical problems.

More when I know it. 

George

That’s an acceptable old-guy hatch!!  Not that you are old, but planning for the distant future is wise! 😃

@Mark Boyce posted:

That’s an acceptable old-guy hatch!!  Not that you are old, but planning for the distant future is wise! 😃

"Hey!  You talkin' to me?"

George

Who, me?? 😄