Hardware Assembly Guides

Table of contents

Hardware Assembly Guides

Introduction

The LCC Fusion Project hardware consists of PCBs that need to be built. Each PCB assembly guide provides the necessary information for obtaining the parts needed and steps for building the PCB.

Building PCBs consists of the following steps:

Ordering the PCB from a PCB fabricator using the provided PCB design files called Gerber files. A Gerber file is a zip file containing the necessary details to create the specific PCB. JLCPCB is one of several PCB fabricators available. When ordering a PCB, consider ordering a stencil for applying solder paste.
Ordering the PCB components from electronic sources such as AliExpress. The specific type and quantity of components required for each PCB are provided in the assembly guides.
Assembling the PCB is performed by soldering components to the PCB while following the steps and guidelines provided in the PCB assembly guides.
Testing the PCB is performed in a series of steps as outlined below and within each of the assembly guides.

For detailed information on design best practices and considerations, please see the PCB Design Guidelines section of our documentation.

PCB Build Sequence

The following is a recommended order in which to build the PCBs.

Node Bus Hub is required for providing power and communications between a Power-CAN Card and other cards and breakout boards. Power includes 3V3, 5V, and 12+V. Communications includes CAN, DCC, and (2) I2C serial buses.
Power-CAN Card is required for providing both power and communications for the LCC Fusion cards and breakout boards. After building this card, insert this card into the Node Bus Hub to provide power and communications with other cards and breakout boards.
Quad-Node Card is required to run LCC Node firmware which communicates with the I/O cards and devices. This card can run from 1 to 4 independent LCC Nodes by installing up to 4 SuperMini ESP32-S3 boards. The Quad-Node Card must be inserted into a Node Bus Hub and powered with a Power-CAN Card. More than one LCC Node can share power and communications provided via the Node Bus Hub.
Quad-Node Card is required to run the firmware for the LCC Node and to communicate with the I/O cards and devices. The Power-CAN Card must be used in conjunction with the Quad-Node Card to provide both power and CAN communications. Both cards should also be inserted into a Node Bus Hub.

Creating Layout Automation Solutions

Below is a summary of the many layout automation solutions available using the LCC Fusion Project PCBs (cards and breakout boards).

The table below lists the LCC Fusion Cards and LCC Fusion Breakout Boards to be added to the basic LCC Fusion Node Cluster consisting of a Node Bus Hub with either a Node Card, or a Power-CAN Card with one or more Quad-Node Card installed in the hub. Note that each Quad-Node Card can support up to 4 individual LCC Nodes by plugging in 1 to 4 SuperMini ESP32-S3 development boards.

Signal & Turnout Automation Example

For example, to control signaling and turnouts for a siding, one possible configuration consists of:

Node Card connected to a (computer) power supply to run LCC Fusion Project firmware

Node Bus Hub provides a hardware interconnect between LCC Fusion Project hardware cards

BOD Card + Block Breakout Board provides detection of trains in track blocks

PWM Card + Signal Mast Breakout Board provide control of the signal mast heads and aspects

Turnout Card + Turnout Stall Motor Breakout Board provides control of a turnout motor with point set indicators

Notes:

Node, BOD, PWM, Turnout cards are inserted into the hub for power and communications (no wiring)

Block, Signal Mast, and Turnout breakout boards positioned near their devices under the layout, connected to their corresponding card via network cables, and wired directly to the devices using the provided connectors.

flowchart TD
power🔌Computer Power Supply
subgraph cluster["LCC Fusion Node Cluster"]
  subgraph hub [" "]
  	hubtitle("Cards<br>(plugged in <br>Node Bus Hub)📦📦📦📦")	
  	hubbb["LCC Fusion Hub"]
    nodec>"🧩Node Card"]
    bodc>"🧩BOD Card"]
    pwmc>"🧩🚦PWM Card"]
    turnoutc>"🧩Turnout Card"]
  end
  subgraph blayout [" "]
    blayouttitle("Breakout Boards<br>(⬇️under layout, near devices)")
  	blockbb[["📶Block Breakout Board"]]
  	pwmbb[["🔆Signal Mast Breakout Board"]]
    turnoutbb[["🔀Turnout Stall Motor<br>Breakout Board"]]
  end
  end
  subgraph tlayout [" "]
  	tlayoutTitle("Devices<br>(⬆️top of layout)")
    turnout⚙️🔀Turnout Switch Machine
    lamps(("🚦💡Signal Lamps"))
    block[/"🚆Track Blocks"/]
  end
  power --> nodec
  nodec -.- |"📦 Card Slot 1"|hubbb
  hubbb -.- |"📦 Card Slot 4"|bodc
  hubbb -.- |"📦 Card Slot 3"| pwmc
  hubbb -.- |"📦 Card Slot 2"| turnoutc
  bodc --- |"🔗Network Cable"| blockbb
  pwmc --- |"🔗Network Cable"| pwmbb
  turnoutc --- |"🔗Network Cable"| turnoutbb
  blockbb  -.- |"⚡Rail Drop Wires"| block
  pwmbb -.- |"⚡Lamp Wires"| lamps
  turnoutbb -.-> |"⚡Motor & Frog Wires"| turnout
  
classDef lSalmonStyle fill:#FFA07A,stroke:#333,stroke-width:1px,font-size:20px;
class hub lSalmonStyle;
classDef lightGrayStyle fill:#d3d3d3,stroke:#333,stroke-width:1px,font-size:20px;
class tlayout lightGrayStyle; 
class blayout lightGrayStyle; 
classDef lightblueStyle fill:lightblue,stroke:#333,stroke-width:1px,font-size:16px;
class cluster lightblueStyle;

Implementing Automation Solutions

The following table outlines various automation solutions available with the LCC Fusion Project, highlighting the required Card and Breakout Board assemblies (if any), along with a brief description of each feature. These solutions extend the capabilities of an LCC Node Cluster, enabling enhanced diagnostics, configuration, and control functions such as wireless access, messaging, and more.

Solution	Card Assembly Guides	[Breakout Board Assembly Guides	Description
LCC Configuration Tool over BT	None	None	Provide wireless Bluetooth connections LCC Configuration Tools running on Windows and Linux. LCC Node provides a Bluetooth to CAN bridge. Note: only one Node per cluster requires this bridge.
Admin console messages over BT	None	None	Enables Bluetooth Serial Terminal applications to connect to the LCC Node(s) admin console for view system messages.
Audio Feedback System	Audio Card	None	Configured Event ID to message text can be converted to audio and played thru speakers. Use for audio indication of status or announcements.. For example, announce status after moving turnout points, or an announcement when a train is detected approaching a train station.
Direct Device I/O	None	None	Provides up to 32 I/O lines (digital input/output, PWM, ADC, and touch). LCC Events can control digital output devices (LEDs, etc). PWM is used to control motors and LED lighting effects. LCC Events can be produced using digital input, ADC to monitor sensors, or using touch of a finger to a wire/contact point.
Battery Backup	Battery Card	None	Provide battery backup to LCC Fusion Node Cluster
Block Low Voltage / Short Circuit Detection	BLVD Card	Block Breakout Board	Used in detecting low track voltage (<12 V) within a block. Produces LCC Event IDs based on a low voltage detection for up to 8 track blocks. Breakout boards provides a wire connection to each of the blocks and a wire to the track bus.
Block Occupancy Detection	BOD Card	Block Breakout Board	Used in detecting trains within blocks for signaling, crossings, etc. Produces LCC Event IDs based on block occupancy detection for up to 8 track blocks. Breakout boards provides a wire connection to each of the blocks and a wire to the track bus.
Button Control	Button Card	I/O Breakout Board	Enables up to 16 buttons to connected. Integrates noise reduction technology (Schmitt Trigger).
Control LEDs	Output Card	IO Breakout Board	Provides up to 16 digital output lines supporting 5V or 12 V, up to 500 mA. Optional GND return line.
Control Signals	BOD Card PWM Card	Signal Masts Breakout Board Signal Head Breakout Boards	Provides signal control based on block detection. Controls up to 16x lamps per PWM Card. Detect up to 8x blocks per BOD Card.
Control Turnouts	Turnout Card	One of the following breakout boards for turnouts 1. Turnout Stall Motor Switch Machine Breakout Board 2. Turnout Coils Switch Machine Breakout Board 3. Turnout Servo Stall Motor Switch Machine Breakout Board 4. Turnout Slow Motion Switch Machine Breakout Board	Control turnouts using LCC Events to throw and close a point sets. Produces LCC Event after movement is performed.
Play Sounds	Sound Card	None	Control sounds using LCC Events by starting/stopping the playing of MP3 files. Manage up to 5x players and speakers per card.
Monitor Track Electrical Issues	BOD Card BLVD Card	Block Breakout Board	The BOD Card is normally used for block occupancy detection, but it also handles current overloads (>1A) caused by shorts by using a polyfuse (resettable) to temporarily stop the current until the short is fixed. The BLVD Card will detect the drop voltage caused by shorts, bad connections, etc. and generated an LCC Event.
Control Stepper Motors	I/O Card	Stepper Motor Breakout Board	Control stepper motors using LCC Events to set speed, stop, and reverse the motor.
Control DC Motors	I/O Card	DC Motor Driver Breakout Board	Control DC motors using LCC Events to set speed and direction.

PCB Testing Sequence

PCB Assembly Guides: From Start to Finish

Below, you’ll find links to specific guides for each LCC Fusion Cards. included in the LCC Fusion Project. These guides are tailored to the unique aspects of assembling each type of PCB, yet they all follow the same fundamental principles outlined in our sequence diagram. This consistency ensures that, no matter which PCB you’re working on, the process remains familiar and straightforward.

Sequence of Activities:

Preparation: Gathering the necessary tools and components.
Soldering: Step-by-step instructions for soldering components onto the PCB.
Testing: Guidelines for testing the PCB to ensure functionality.
Integration: Advice on integrating the assembled PCB into your model railroad layout.
Troubleshooting: Common issues and how to resolve them.

Assembly Guides

The assembly guides are organized into the following two categories:

Card Assembly Guides provide the builder with details on how to assemble the LCC Fusion Cards for both the LCC Fusion Node Card and the LCC Fusion Cards.
Breakout Boards Assembly Guides provide the builder with details on how to assemble the LCC Fusion Project cards for both the LCC Fusion Node Card and the LCC Fusion Cards.