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I recently replaced 2 pot mounting brackets on postwar ZW-C. When putting the unit back together. I put all handles to the off position. Then turned the pot gears to max off and assembled.

I then turned on the transformer holding in the button for recalibration. I then started checking the output voltages on each post. Three seemed within range 18 to 19.5 volts. But. one of the post was about 16 volts. I then set the problem handle to full throttle and moved the gear raising the voltage.

 

What is the true procedure for reinstallation of the gears. If I was correct in the procedure why would the voltage be low on one post. I wonder if they are better being set at full throttle. What should be the voltage on the outputs no load......I do know about the meter with chopped waveforms..Please help.

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I suspect it may need a calibration.

 

All four channels can be calibrated by moving each handle to zero, and holding the program button in while the power is turned on. The red light will flash five times to indicate calibration is complete. This must be done with the Command Base disconnected.

 

Also, have you tried a different channel to see if you get the same low voltage?

I actually did try a calibration last night. I just did again to make sure. I re-watched the ZW-C instructional video from Mike Regan last evening to see if I was performing the calibration correctly. The readings are odd in that I can get a 17v reading at the Lionel meter and 17.8v at the DVOM, so with what you originally said about the 1 volt lost that is normal. That will only happen in conventional. When I operate the ZW-C with the Cab-2 there is 16.7v at the DVOM. Seems strange that I still have that added loss in command.  I did make sure the handles were fully off with base disconnected during the calibration (the red light flashed 5 times) and fully on while commanding the track power again with the base reconnected. Your help is very much appreciated!

The answer to the question about the channels, it is on all of them. I decided to switch to an older ZW-C. The gears had jumped on this one. I now have the new plates inside among a couple other things to keep the gears in place. Switched over the bricks and wires, performed a recalibration. I even  removed the top and verified the pot was moving to it's full on position. I think it may be the nature of the beast. Again, in conventional I get 17.5v and in command it will only give a max 16.7v. Thanks again for all your help and suggestions.

Thats how our ZW-C works. We lose about a volt through electronics. Check that on the volt meter and the analog volt meters that are wired to the layout. I inquired about it when we originally wired the layout and everyone told me it was normal. It doesn't seem to effect the way any of the engines operate.

Perhaps the voltages were set in command mode to lower than maximum. Try setting the voltages with the cab2 and base connected using the cab2 to set the voltage.

 

I get 18.25VAC consistently at the rails with mine using two 180 bricks for 4 channels with a load on the track (ie., lighted car, LionChief Engine, Legacy engine) 

The calibration measures for any resistance in the off position and sets the output to aka

zero volts/off. I tried another method of physical gear alignment to even the outputs.

I physically set all handles to max. I then loosened the pot brackets. Moved each gear to the point of max output. Reseated the pot brackets and turned handles to the off position and perform a calibration. Checked with handles at max-all even.

 

Verified with a engine locally and not on layout. Maybe, someone else can try this out and verify my results. Do it at your own risk....

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