Hi everyone, TinMan here with another “how can we make this more better” item.  

This sale is  for the Lionel ZW transformer, which  is still the most popular model train transformer ever built, even knowing it’s  design is approaching  100 years old.  So what makes these original transformers so great even when compared to what is available with solid state parts available today? The answer is simple. The method that Lionel came up with to control the speed of the trains.  Here briefly is what they did.

The  internal transformer was engineered and built with exposed heavy duty copper windings. These windings were coated with varnish, on their sides, so they would not short each other out. The tops of the windings did not have the varnish. So what they did was design a very simple lever that had a carbon roller that would provide contact with the exposed coils. The effect was a very stable method of controlling the output voltage to the center rails of the track. Then they added an interrupter circuit to control reversing the engines, and a dc pulse circuit using a single rectifier to activate the whistles in the engines. Absolutely incredible considering the time this was engineered.

Since then, every manufacturer including Lionel has attempted to come up with a new design using modern solid-state parts to replace the original roller over the copper windings technique. Why? The original design is way to expensive to try to build today.  So far, many of their designs were prone to early failures. Why? Because they use (often unprotected) solid state parts to control the output power.  These components do not like AC. Our engines even today for O gauge still run on AC.

We at TinMan recognize that the original design is still the best way to control engine speeds. Our objective is simple. Keep the original design and make improvements in other areas and upgrade the original design. Specifically, here is what we do when we recondition these units.

·         Change the rollers (unless they are like new) with an improved copper improved design

•      Eliminate the original rectifier and replace with a modern bridge unit that will enable the transformer to operate the bell circuits found in newer engines.
•    Replace the original slow acting circuit breaker with a modern fast acting model.
•    Change the power cord with a 3-prong plug, to make phasing easier, and ground the exposed metal plate on the base. Why? Because the internal transformer is resting on 2 metal plates that are bolted to the outside metal base. While we have never had an issue with a problem with the internal transformer, it is possible and as a result send high voltage to the exposed metal plate. Grounding this plate will stop this very remote possibility, and also makes phasing with other transformers a breeze.
•  Clean the exposed copper windings.
• Add switches to the front of the transformer to select the whistle control to operate both whistles and bells.
•  Add an additional output power terminal on the back of the transformer which gives a constant 20v. Why? The transformer has two variable controls for accessories or to control speeds on trollies, bumper cars etc. Plus, other toys like the milk cars do not like wide open voltages. Switches, lights, RCS tracks etc work best with a higher voltage which is now available. In the pictures you can see the additional power output terminal to the left of the U terminals and the A to D terminals.
• Preform a final check for proper outputs with not just voltages,. but also under 3 and 6 amp loads. This is done on a "transformer report card" that is included with your transformer

Now to our latest innovation.  The circuit breakers originally installed in these transformers were designed to do one thing, and that was to protect the transformer from burning up in case of a short from derailments or other things.  The internal transformer is very heavy duty so a short circuit will not hurt anything for quite some time. In some cases, we have seen times of up to 15 seconds before the circuit breaker opens. Therefore what do is change the original breaker to a modern design that works much faster than the original Lionel designs. This is what other modern transformers have done also. 

There is some talk in the O gauge community that this is still not fast enough. With many of the new engines, that have significant electronics installed for some of their new great toys, can be damaged due to slow acting circuit breakers. Since we began changing the old breakers with the newer designed ones, we have not had one complaint about engines etc being damaged due to short circuits. That is not to say that it never happened, just that we have heard of any.

In the community there are suggestions that an additional fuse should be used in line with the train power that will blow almost instantly when it senses a short.

So, what we are now doing is installing, as an option, is we have recently purchased some very special circuit breakers, that we have installed in an add on kit for  your transformer at a very reasonable cost. This new kit has replaced our original kit with circuit breakers that have a manual reset vs auto. In case of a derailment they can just find grandpa, and let him know the train stopped, and not have to worry about the transformer constantly sending juice down the rails. This kit is listed separately on ebay for $29.95. We have tested these units very thoroughly, and find they will run trains just fine, but in case of a short circuit they will open instantly. They are equipped with LED's which will light when the breaker Opens.  They kit has 2 separate breakers which operate completely independent of each other.The two red terminals are one complete circuit, and the black terminals operate the other. Check out the pictures for how to hook up. Want to know more, Check our site for even more info and a very special price. Just google tinman3rail and there we are.

So, the question: Should you purchase this additional cost item for your transformer?  If you have some modern engines that have those new toys, absolutely. This enables us to find the issue and correct and manually reset the breaker by pushing the side buttons. This is a great addition for folks who have grandchildren etc when using the trains.  Also having a really fast power shut down can be a nuisance. It requires very little short circuit to blow the fuse, way less than ½ the time of the breaker, which could be a pain.

As with all our transformers, included are full instructions and a no BS 2 year warranty. We refurbish and sell lots of transformers and do not take pictures of each and every transformer, so the actual appearance of the unit delivered may vary  somewhat cosmetically, but every one is fully refurbished and will preform as new or better. These are all used transformers we sell and do our best to make them as attractive as possible, but naturally some are better than others

Sorry for the lengthy discussion, but we take our work very seriously and felt it was necessary. So thanks for your patience and remember:

YOU DON’T GROW OLD FROM PLAYING WITH TRAINS, YOU GROW OLD WHEN YOU STOP PLAYING WITH TRAINS!