Annotated HalloweenCostumes / Fun.com Proton Pack electronics PCB showing control, power, speaker, and volume connections

A2ThreeD installation guide

ProtonPal

Sound Effects Upgrade for HalloweenCostumes / Fun.com Proton Packs

Install ProtonPal alongside the factory pack electronics to add upgraded sound playback while keeping the original pack controls and optional wand volume control.

01

Factory controls

Keep the pack’s activation, firing, and power controls working.

02

One speaker output

Connect one speaker or wire the factory pair in series.

03

MicroSD playback

Load replacement WAV files for higher-quality custom sounds.

Before you begin

Power down and gather your tools

Turn off the pack and remove the batteries before opening the pack or changing any wiring. Work slowly: the original electronics wiring and terminals are somewhat fragile.

Tools required

  • Pliers
  • Screwdrivers of various sizes, including a Phillips screwdriver for the back and small flat-head screwdrivers for wire terminals
  • Wire cutters
  • Wire strippers
  • Optional soldering iron and solder
Annotated factory Proton Pack electronics PCB with all ProtonPal connection points identified
Use this annotated factory PCB photo to identify the control, power, speaker, and volume connections.

Installation

Install ProtonPal in the factory pack

Follow the steps in order and compare each connection with the annotated PCB photo before securing the wiring.

Numbering note: The original instructions skipped Step 4. The guide below renumbers the remaining steps consecutively.
1

Remove the ALICE frame and back

Remove the ALICE frame and the back of the pack, including the motherboard cover, so you can access the internal electronics.

2

Locate the factory PCB wiring

Locate the wiring on the original pack electronics PCB. The annotated photo identifies the control, power, speaker, and volume connections needed for ProtonPal.

Annotated factory Proton Pack electronics PCB identifying control, power, speaker, and volume wiring
Factory electronics PCB connection reference.
3

Tap the ProtonPal power wires

Take the two-pin JST-XH cable with the red and black wires from the ProtonPal kit. Slide the wire-tapping connectors over the black and green power wires identified in the photo.

  • ProtonPal red wire with the tap → factory green wire (positive)
  • ProtonPal black wire with the tap → factory black wire (ground)

Use pliers to close each tap assembly so it makes a tight connection to the factory wire.

Red and black ProtonPal wires positioned in wire tap connectors on the factory power wires
Example: Open wire tap and place wire in metal channel
Pliers closing a wire tap connector around a factory power wire
Example: Close tap using pliers to create a solid connection
4

Connect the activation and firing controls

Take the two-pin JST-XH cable with the blue and yellow wires. Locate the two control wires shown in the upper-left area of the annotated photo. The factory wires may be tightly bound, so carefully separate them without pulling on the PCB connections.

  • ProtonPal blue wire → factory blue wire (activate)
  • ProtonPal yellow wire → factory brown wire (intensify / fire)

Attach the wires with the supplied crimping connectors.

Annotated factory Proton Pack PCB showing the control wire connection area
Step 4 control wire reference.
Factory Proton Pack electronics PCB with all four wire taps installed
All four wire taps installed.
5

Connect ProtonPal wiring to the taps

Locate the two JST wiring assemblies with spade terminals. The assembly with the red and black wires plugs into the ProtonPal board’s 5V IN connector. The other assembly plugs into the yellow HC BRD connector on the board.

Attach the spade terminals to the wire taps as shown:

  • Red wire → green tapped wire (power)
  • Black wire → black tapped wire (power)
  • Blue wire → blue tapped wire (control)
  • Yellow wire → brown tapped wire (control)

Push the spade terminals firmly into the taps, but support the taps while doing so to avoid breaking the wiring.

ProtonPal JST wiring assemblies with red, black, blue, and yellow wires and spade terminals
ProtonPal wiring assemblies with spade terminals.
ProtonPal installed beside the factory PCB with the tap wiring connected
ProtonPal wiring connected to the installed taps.
6

Connect the speaker output

Clip the blue speaker wires from the bottom of the factory PCB, or desolder them. If desoldering, heat the hot glue first so the wires can be removed without stressing the board. If you clipped the wires, strip the ends.

ProtonPal has one speaker amplifier output. Choose one of these options:

  • Connect one blue speaker-wire pair directly to the ProtonPal speaker-out terminal.
  • Connect the factory speakers in series: connect one speaker’s blue wire to the other speaker’s blue/black-striped wire, then connect the two remaining blue and blue/black-striped wires to the ProtonPal speaker terminal.

Important: Insulate or secure any unused speaker wires so they cannot touch another conductor.

7

Optional: retain the factory volume control

To keep volume control from the factory wand, clip or desolder the three-wire volume-control cable identified in the photo. Strip the wire ends if you clipped them.

Open the three-position screw terminals on ProtonPal with a small flat-head screwdriver if necessary. Insert the wires from left to right in this order:

BlueBlackRed

Tighten each terminal and check that no stray wire strands are exposed.

8

Test the pack

Install the batteries and test before final installation. Verify power on/off, pack activation on/off, and both firing buttons. Confirm that the sound functions respond correctly.

9

Optional: install a MicroSD card with sounds

ProtonPal includes basic lower-quality sounds internally. You can replace them with your own sounds by installing a FAT32-formatted MicroSD card. Use WAV files up to 44 kHz, 16-bit.

FilenameFunction
bootup.wavPlays when the pack is activated
shutdown.wavPlays when the pack is shut down
idlehum.wavLoops while the pack is running / idling
firing.wavPlays while the fire button is depressed
firetail.wavPlays when the fire button is released
10

Secure ProtonPal

Secure the ProtonPal board and route the wiring so it cannot move, rub against sharp edges, or be pinched.

11

Reassemble the pack

After the test is successful, reinstall the back and ALICE frame. Confirm that the battery compartment, wiring, and shell close without issue.