A2ThreeD operations guide

ProtonPal

User Guide for ProtonPal, a sound/light upgrade for the HalloweenCostumes/Fun.com pack

This guide covers everyday pack operation after installation, configuration, troubleshooting and options.

Use the pack Open configurator Installation guide

Normal operation

Using the ProtonPal

ProtonPal works alongside the original pack electronics. The pack works just the way it did before, but with new sounds and an optional music mode.

The switches that ProtonPal cares about are the Intensify, Activate and Fire buttons. The other two switches on the wand don't change at all and are just used for wand lights.

In this guide, we'll refer to Intensify, Activate, and Fire like the original wand is labeled (We know in the movies, Activate is for booting up the pack/wand, and Intensify is firing).

Turn on power

Using the left-bottom switch labelled Activate on the wand, flip the switch up to turn on power to the pack. If you're using the factory LEDs, you should immediately see them start to light up.

Start the pack

Switch the pack on by flipping the switch labelled Intensify on the wand up. ProtonPal will play the boot up sound, and then enter idling with the idle hum sound.

Fire

Hold Fire / Intensify to play the firing loop. The idle hum is reduced while firing, then returns to normal volume when the fire-tail sound starts.

Release Fire

Release Fire to play the fire tail and return to idle. Pressing Fire again during the tail resumes firing immediately.

Shut down

Switch the Intensify switch down to shut down the pack. You'll hear the pack shutdown sound play, and the pack will return to the on but not running state. The factory LEDs will still remain cycling.

Enter Music Mode

With the pack power on, but not running (Activate switch is up, Intensify switch is down); hold Fire and flip the Intensify switch up. Release the Fire button. You can perform a short press of the Fire button to skip to the next track. Holding the Fire button down for almost a second will cause the music to pause/resume. To exit music mode, simply turn the Intensify switch off.

Status Indicator LED

Reading the Status Indicator LED

ProtonPal has an RGB status LED, which displays colors and flashes to show status and problems.

WhiteSteadyProtonPal booting

BlueSlow flash (2s)Pack off / standby

CyanRapid flashPack booting

GreenSteadyIdle and ready to fire

RedRapid flashFiring / Venting

OrangeRapid flashFire released

Red / yellowRapid alternatingOverheating alarm

PurpleRapid flashPack shutting down

MagentaLong FlashMusic is playing / music is paused

YellowDouble flash (2s)Informational: MicroSD card is unavailable

Red120 ms on / 120 ms offError: Audio failure

Configurator Mode feedback: a valid USB command flashes white for 250 ms; LED preview/test flashes cyan; and a sound test flashes magenta.

MicroSD WAV audio

Using a MicroSD card for Sounds and Music

A MicroSD card is optional for normal pack sounds because ProtonPal has them already stored in flash memory (in 8-bit 22khz format). If you want to play music, or use higher quality/longer WAV files you will need to use a MicroSD card. Currently, ProtonPal has only been tested to work with up to 32GB U1 rated MicroSD cards.

Format and copy

Format the card as FAT32. Place optional pack-effect WAV files in the card root. A valid card file takes priority over the matching embedded fallback.

bootup.wavBoot sound

idlehum.wavIdle loop

firing.wavFiring loop

firetail.wavFire tail

shutdown.wavShutdown sound

overheat.wav / vent.wavOptional overheating and venting sounds

Use compatible WAV files

Use PCM WAV files: 8- or 16-bit, mono or stereo, with sample rates from 8 kHz through 96 kHz. ProtonPal outputs at 44.1 kHz; 44.1 kHz / 16-bit PCM is the simplest choice.

Add music

Create /music at the card root. Name each track with a two-digit prefix from 01 through 99, for example /music/01 Theme.wav. Tracks play in numeric order.

Enter Music Mode

With the pack off, hold Fire while switching the pack on. Release Fire after the first track starts. A short press skips to the next track; hold Fire for at least 750 ms and release to pause or resume. Switch the pack off to exit Music Mode.

LED expansion

Attach Powercell and Cyclotron LEDs

ProtonPal has separate 3-pin JST LED connectors labeled PCELL and CYC. They are for addressable WS2812B or WS2811 LED chains, not plain two-wire LEDs.

Choose the correct connector

Connect the Powercell chain to the PCELL connector, and the the Cyclotron LEDs to the CYC connector. Start each chain at the LED end marked DIN, never DOUT.

Wiring information

When looking down at the ProtonPal board, each LED JST connection carries (from left to right)5V, DATA, and GND. You can use a 3-pin JST-XH connector to connect up to your LEDs (or contact use for adapter cables). Each vendor's LEDs may have different connectors or wiring orders, so pay close attention to them.

Power and signal safety

Turn the pack/ProtonPal off before connecting or removing the JST plugs. Confirm polarity before power-up; reversed 5V and GND can damage the LEDs or ProtonPal board.

Use the configurator tool to configure your LEDs

In the configurator, select WS2812B (800 kHz) or WS2811 (400 kHz) for each chain. Set Powercell count to 5, 8, 12, or 15 LEDs. Set Cyclotron count to 4, 12, 20, 36, or 40 LEDs. For 12-, 20-, and 36-LED puck configurations, ProtonPal animates each puck’s center LED for the classic four-light appearance; a 40-LED ring supports the full ring modes.

Web Configurator

Change settings, update firmware and test LEDs

Connect ProtonPal to a computer by USB-C and use a current desktop Chrome or Edge browser.

Connect

Open the ProtonPal Configurator, connect the board over USB-C, and select ProtonPal when the browser asks for serial permission.

Configure operation

Set default volume when no physical volume pot is detected, choose whether external LEDs run at startup or wait for Activate, and enable optional overheating protection with its firing delay.

Tune LEDs

Set each output’s color, brightness, effect, speed, direction, LED type, and count. Add the optional fade modifier and choose the 40-ring Cyclotron mode when applicable. Use Preview and individual LED tests to verify the physical chain before closing the pack.

Test sounds

Use the sound-test controls to confirm the boot, idle, shutdown, firing, and fire-tail effects. Overheat and vent tests appear on compatible firmware. Music Mode must be off before sound tests can run.

Update firmware

Use the firmware update panel in the ProtonPal Configurator. Keep the USB cable connected and select the RP2 Boot device when prompted. If automatic installation is unavailable in your browser, use the configurator’s manual UF2 download and follow its on-screen instructions.

Troubleshooting

Something not working right?

If you're having trouble with your ProtonPal or pack, here is a chart that can help you out. If you're having issues that aren't listed here or need additional help, please reach out to us. Before any troubleshooting, make sure that you have fresh batteries installed and that all the wiring has been done in the correct order and is firmly connected and secure. Ensure that nothing is potentially shorting out the wiring or ProtonPal circuit board.

It will be helpful to have basic tools such as a multi-meter capable of measuring voltage and continuity for advanced troubleshooting.

No status LED or sound after turning on powerThe pack batteries are depleted, the 5V IN connection is loose, or power/ground wiring is incorrect.Install fresh batteries. With power removed, inspect the red-to-green positive and black-to-black ground connections, then make sure the 5V IN JST plug is fully seated. You can also test with a meter to ensure there is approximately 5V coming out of the JST connector.

Behaviour is erratic, especially when trying to fireThe pack batteries are lowInstall fresh batteries.

Pack powers on but will not start or fireThe Activate or Intensify / Fire control connection is loose or connected to the wrong factory wire.With batteries removed, verify the blue ProtonPal wire goes to the factory blue Activate wire and the yellow ProtonPal wire goes to the factory brown Intensify / Fire wire. Confirm each tap and connector is secure.

Rapid red status LED continues flashingAudio initialization failed.Restart the pack. If the pattern returns, contact A2ThreeD for advanced support.

Yellow status LED double-flashesThe MicroSD card did not mount.Reseat the card and confirm it is FAT32 formatted and no larger than 32GB. Check the card and MicroSD socket for debris or damage. Pack sounds can still use built-in audio, but Music Mode requires a mounted card.

Music Mode starts normal pack operation insteadThe card is unavailable, the /music folder is missing, or there are no valid numbered PCM WAV files.Confirm the yellow SD warning is absent, create /music at the card root, and use files named 01 through 99 with a .wav extension.

Add-on Powercell or Cyclotron LEDs do not lightThe LEDs areconnected to the wrong output, connected at DOUT, or configured for the wrong type/count.Turn pack power off. Confirm correct LED wiring and connections. Set the correct WS2812B or WS2811 type and LED count in the Configurator.

LED colors or animation are incorrectThe saved color, effect, direction, LED type, count, or ring mode does not match the attached hardware.Use the ProtonPal Configurator Preview and individual LED tests. Save the matching configuration only after the physical LED responds correctly.

Sound is weak, distorted, or missing from a speakerA speaker lead is loose, the speaker wiring is incorrect, or volume is set too low.Power off before checking speaker wiring. Confirm the speaker leads are firmly clamped and unused leads cannot touch another conductor. Check the physical wand volume control, or adjust Default Volume in the Configurator when no pot is detected.