Output Card Assembly Guide

[TOC]

Introduction

See the How to Use Assembly Guides for detailed instructions.

The Output Card works in conjunction with the LCC Fusion Node Card and Node Bus Hub to provide control over up to 16 individual output devices. These devices can be actuated in response to LCC Events, allowing for automation and interaction within the layout. The Output Card interprets event IDs generated by sensor-based cards or other event sources, and then controls the corresponding output devices, providing a robust solution for managing lighting, motors, and more within your model train layout or other automated systems.

Through this design, the Output Card offers precise ON/OFF control for each connected device, enabling seamless interaction between the layout’s automation logic and the physical components.

Key Features:

Controls up to 16 Output Devices: The Output Card offers up to 16 output channels, allowing you to control a wide range of devices like LEDs, relays, motors, and more.
Supports Configuring up to 16 Output Cards per LCC Node: Each LCC Node can support up to 16 Output Cards, providing extensive output control for large or complex layouts. This allows up to 256 individual outputs across a single node, giving users incredible flexibility for controlling multiple devices.
Selectable 5V or 12 V Output: Each output can be configured to deliver either 5 V or 12 V, providing flexibility to control devices that require different voltage levels. This makes the Output Card compatible with a variety of low-voltage and higher-power devices.
Flexible Voltage Options: Output can be configured for either 5V or 12 V devices, providing versatility for different types of equipment.
Configurable Resistor Options: Choose to use integrated current-limiting resistors or external resistors, depending on the power requirements of your devices.
Lines 8 & 16 Flexibility: The 8th and 16th output line can be configured for standard output control or alternatively used as a ground (GND) connection, adding extra wiring flexibility to the design.

Typical Use Cases:

The Output Card can control a variety of devices for model train layouts, industrial automation, or hobbyist projects, offering flexibility and reliability.

Example Devices:

LEDs: Control layout signals, indicators, or lighting effects using simple ON/OFF control.
Relays: Switch larger loads such as lights, track power, or other high-power devices.
DC Motors: Drive small motors for moving elements, such as turntables or gates.
Buzzers: Trigger alarms or audio indicators in response to layout events.
Solenoids/Electromagnets: Control solenoid-based mechanisms like point motors for turnouts or electromagnets for uncoupling systems.
Fans: Activate ventilation systems or cooling fans for system components or scenery effects.

System Overview:

The Output Card is part of the LCC Node ecosystem and is typically controlled by the LCC Fusion Node Card, which processes LCC Events. When a sensor-based card detects an event (such as a train passing, a switch being thrown, or a button being pressed), it generates an event ID. The LCC Node consumes this ID and sends the appropriate signal to the Output Card, which then toggles the corresponding output device ON or OFF based on the event logic.

For example:

A track sensor detects a train approaching a signal, generating an LCC event.
The Node Card interprets the event and sends a command to the Output Card.

The Output Card then turns on an LED to signal “stop” or activates a relay to power a motor or solenoid.

  flowchart LR
  can["CAN Network"];
  subgraph layout ["Train Layout"];
direction LR;
can --> |"LCC Event<br/>(on/off)"| n["Node Card"];
n -->|"GPIO Signal <br/> (high/low)"| c["Output Card (16x)"];
c --> |"Power <br/> (5 V/12 on/off)"| bb["I/O Breakout Board"];
bb -->|"Power <br/> (5 V/12 on/off)"| device(("Devices (16x)"));
c --> |"Power <br/> (5 V on/off)"| relay["Relay <br/> Breakout Board"];
relay --> |"Power <br/> (5 V on/off)"| devices(("Devices (8x)"));
  end
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  class c lSalmonStyle;
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  class layout lightGrayStyle;

Hardware Configuration Options:

The Output Card includes several configurable options, allowing for flexibility in different scenarios:

Communication Address: The card supports two I2C buses (bus 0 or 1) and offers address offsets from 0 to 7, enabling multiple cards to be used within the same node.
Voltage Selection: The output voltage can be configured for either 5V or 12 V devices, making it compatible with a wide range of components.
Resistor Configuration: Choose whether to use built-in current-limiting resistors for each output or to use external resistors, depending on the device’s power needs.
Line 16 Configuration: Line 16 can either be used as a standard output line or as a ground connection (GND), providing additional flexibility for powering devices.

## Terminology

For other terms, please refer to the full Terminology Guide.

Assembly and Component Placement

This section combines both the component specifications and the assembly instructions to ensure a smooth assembly process. Below is a comprehensive list of components, their placement on the PCB, and orientation details to assist you during assembly.

High-Level Steps for Assembly:

PCB for the card can be ordered from any PCB fabricator using these Gerber Files.
Clean PCB with alcohol to remove residue. See Cleaning_PCB for details.
See also: Soldering Tips
PCB Components - listing of components used for PCB assembly
PCB Parts - listing of parts used for PCB assembly

Below is a list of the PCB components used for this card (see diagram before reference):

Component Identifier	Count	Type	Value	Package	Purpose	Orientation
Capacitors
C1	1	Capacitor-Ceramic	0.1uF, 50 V	1206 X7R	Decoupling Capacitor for IC Protection	None
Diodes
D1, D2	2	Diode-Schottky	SS310	SMD	Circuit protection from reverse current from the lines	Cathode end has a white line and positioned towards PCB left edge
D3	1	ESD Diode	PESD1CAN	SOT-23 SMD	I2C data bus electrostatic discharge (ESD) protection	Fits only one way
Filters & Noise Suppression
FB1, FB2	2	Ferrite Bead	BLM31PG121SN1L	1206 SMD	I2C Network Bus Data Line Noise Suppression	None
Connectors
J1, J2	2	RJ45 Socket	8P8C	PTH	Network cable (CAT5/6) connection to a breakout board or the Output’s I/O connector.	Fits only one way
Resistors
R1-R16	16	Resistor	1kΩ	1206 SMD	Limits current to the output device. May be bypassed by setting the corresponding DIP switch (SW2, SW3) to ON.	None
R17-R19	3	Resistor	10kΩ	1206 SMD	Limits current to SW1 and MCP23017 for I2C address configuration.	None
Selectors & Indicators
JP1, JP2	2	Male Header	3P, 0.1” spacing	PTH	COMM BUS selection (I2C hardware bus) for BUS A or BUS B. Must match configuration in the LCC Node CDI setup.	None
JP3, JP4	1	Male Header	3P, 0.1” spacing	<div style="text-align: center;"> </div><div style="text-align: left;"> </div><div class="jekyll-only print-container" id="components"></div>	LINE 8 and LINE 16 selection to GND or Output. Set to GND when Output devices require this card to provide the GND connection.	None
JP5	1	Male Header	3P, 0.1” spacing	PTH	VOLTAGE selection for setting Vcc for output lines. Affects all output lines (e.g., 5V for LEDs, 12 V for relays).	None
SH1-SH5	5	Jumper Caps	2.54mm	N/A	Used with I2C Bus and Vcc selections. Tall caps are recommended for easy handling.	None
SW1	1	DIP / Slide Switch	3P, 2.54mm spacing	PTH	COMM ADDR selection (I2C address offset 0-7). Added to base address of MCP23017 (0x20). Configure for CDI setup.	Position so switch so ON is towards PCB top edge
SW2, SW3	2	DIP / Slide Switch	8P, 2.54mm spacing	PTH	Enable/disable current limiting resistors (R1-R16). Used to bypass the resistors for higher current outputs.	Position so switch so ON is towards PCB top edge
ICs
U1, U3	2	Darlington Transistor	M54562FP	SOP20	Amplifies low-current signals from MCP23017, driving high-current loads on output lines.	- IC U1 indent (pin 1) is positioned towards PCB left edge - IC U3 indent (pin 1) is positioned towards PCB right edge
U2	1	I/O Expander	MCP23017	SSOP28	Expands I2C serial interface to control 16 GPIO pins, each connected to an output line.	IC indent (pin 1) is positioned towards PCB left edge

Tools Required

List of recommended tools.

Safety Precautions

See Safety Precautions.

Testing and Verification

Configure the card:

Select the I2C bus (COMM BUS) by positioning (2) Jumper Caps on either BUS A or BUS B male header pins (JP1, JP2)
Select the I2C address (COMM ADDR) switch (SW1) by slide each of the 3 switches to either the ON or OFF position. Setting a switch to ON increments the address by 1, 2, or 4 for an address range of 0 to 7. Up to 8 devices can then be configured for BUS A and 8 for BUS B.
Select the output voltage by positioning a Jump Cap on (1) pair of VOLTAGE male header pins (JP5)
Select the function of Line 16 as an output line or as a ground (GND) connection by positioning a Jumper Cap on (1) pair of LINE 8 and LINE 16 male header pins (JP3, JP4).

The following test and verifications of the card should be performed after a through inspection of the card’s soldering. Check all of the PTH component pins and SMD pads. Make sure there are no solder bridges between pins and pads.

Visual Inspection

Initial Check: Examine the board for any obvious issues like missing components, solder bridges, or components that are misaligned or not fully seated.
Solder Joint Inspection: Use a magnifying glass or a microscope to inspect solder joints. Look for cold solder joints, insufficient or excessive solder, or any shorts between pads.
Component Orientation: the IC’s are correctly oriented according to the PCB silkscreen or schematic.

Connectivity Testing

Continuity Check: Use a multimeter in continuity mode to check for shorts between power rails and ground, and to ensure there are no open circuits in critical connections.

Power-Up Tests

Assembly a tested Power Module to the LCC Fusion Node Card.
Apply Power to the Power Module and verify the following:
- Check for Hot Components: Feel for components that are overheating, which could indicate a problem like a short circuit or incorrect component.

Functional Testing

I2C Verification

Verify that the I2C connection between the LCC Fusion Node Card and the Output Card work. See Testing I2C Cards for details on how to test the I2C for a I2C enabled card.

Output Line Verification

After validating the LCC Fusion Node Card can connect with the Output Card, test each of the output lines as follows:

Connect an network cable (CAT5/6) to RJ45 connector. Use the other end of the cable with a breakout board, or exposed wires to connect to devices for testing.
Configure each line of the card for output using an LCC CDI Configuration Tool
Attach an LED anode to each line. Attach the LED cathode to common (GND) used by the LCC Fusion Node Card.
Set the card’s Vcc (5 V or 12 V)
Set the current limiting DIP switches to ON
Test using LCC events:
1. Send the configured on/off LCC Event ID’s for each output line
2. Validate that LED(s) turn on/off
  - If some of the lines work and some don’t, it probably a soldering connection for the bad line
  - If none of the lines work correctly, check the connections for the voltage settings

Troubleshooting

See I2C Trouble Shooting.

Appendences

Specifications

Specifications for the card include:

Characteristic	Value
Output	5 V, 12 V (selectable)
Max Output Line (based on M54562FP IC)	500 mA
Max Output Lines	16
Max Number of Output Lines	16
Maximum Number of Cards (per LCC Fusion Node Cluster)	16¹

The LCC Fusion Node Cluster can support up to 16 cards, distributed across two I2C hardware buses, with a maximum of 8 cards per bus.
- Note: total includes all cards using the I2C address range of 0x20 (MCP23017 IC).
GND, 5V, 12 V (optional), SLA0/SDA0, and SDA1/SCL1 (optional)

How It Works

The following outlines the flow of activity for the Output Card:

flowchart LR;
  network["LCC Network"];
  cdi[("CDI Data")];
  fPortExpander(["GPIO Port Expander<br/>(MCP23017)"]);
  cs("Communications<br>Bus/Address");
  subgraph layout ["Train Layout"];
  	direction LR;
    subgraph fIoCard ["Output Card (16x)"];
      direction LR;
      fPortExpander;
      transistor("Transistor<br/>(M54562FP)");
      vs("9 V/12 V Selection") --> transistor;
      cs --> fPortExpander;
    end
    subgraph fIoBb ["I/O<br>Breakout Board"];
    	direction LR;
    end
    subgraph fHubBb ["Node Bus Hub<br>Breakout Board"];
    	direction LR;
    end
    subgraph fNodeCard ["Node Card"];
      direction LR;
      cdi --> |"Config"| fNodeFw;
    end
    network --> |"LCC Events<br/>(cable/WiFi/Now)"| fNodeFw;
    fNodeFw("Firmware<br/>(ESP32)") --> |"on/off"| fHubBb --> fPortExpander;
    fPortExpander --> transistor -->|"on/off<br/>(9 V/12 V, 500 mA)"| fIoBb;
    fIoBb -->|"on/off"| d(("Devices<br/>(16x)"));
  end

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  class fIoCard cyanStyle;
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The firmware of the LCC Fusion Node Card interfaces with the Output Card’s port expander (MCP23017), leveraging the bus and address details specified in the card’s CDI I2C section.

Output is performed on a line as follows:

Upon receiving an LCC Event-related signal, the LCC Fusion Node Card’s firmware dispatches an I2C command to the Output Card, instructing it to set the port state to either HIGH or LOW.
The port expander sets the base of the corresponding Darlington Transistor Array’s input pin HIGH/LOW, which then switches the current for the corresponding output line HIGH or LOW.
The output voltage to the line, either 5V or 12 V, is determined by the card’s VOLTAGE selector switch.
The output current to the line is determined by the card’s RESISTOR BYPASS selection and corresponding line’s resistor value.

The output line must be attached to an output device (LED, etc.) that is grounded to the same common as the LCC Fusion Node Card using either Line 16 or the Accessory Bus.

Connections

Component Designator	Connector Label	Connector Type	Connection Number	Description
J1, J2	OUTPUT DEVICES	RJ45 Socket	1 - 8	Connection to output devices and/or I/O Breakout Board
JP1, JP2	COMM BUS	Male Header	A, B	COMM BUS selection (I2C hardware bus) for BUS A or BUS B. Must match configuration in the LCC Node CDI setup.
JP3, JP4	LINE 8, LINE 16	Male Header	GND, OUTPUT	LINE 8 and LINE 16 selection to GND or Output. Set to GND when Output devices require this card to provide the GND connection.
JP5	VOLTAGE	Male Header	5V, 12 V	VOLTAGE selection for setting Vcc for output lines. Affects all output lines (e.g., 5V for LEDs, 12 V for relays).
SW1	COMM ADDR	Slide Switch	1, 2, 3	COMM ADDR selection (I2C address offset 0-7). Added to base address of MCP23017 (0x20). Configure for CDI setup.
SW2, SW3	REGISTER BYPASS	Slide Switch	1 - 8	Enable/disable current limiting resistors (R1-R16). Used to bypass the resistors for higher current outputs.

Protection

The Output Card is equipped with several protective components to ensure reliable operation and safeguard the board and connected devices from potential electrical issues. Below is an overview of the protection mechanisms implemented:

Protected Component	Protection Component	Function	Specifications	Location
I2C Communication Lines	PESD1CAN Diode	Protects the I2C lines from ESD (Electrostatic Discharge) and other electrical surges.	Clamping voltage: 24 V max	Located on I2C data (SDA, SCL) lines.
I2C Communication Lines	BLM31 Diodes	Provides additional protection to the I2C lines by filtering out high-frequency noise and protecting against voltage spikes.	Bidirectional TVS diode	Positioned along I2C communication lines.
I/O Control Lines	1kΩ Current Limiting Resistors	Limits the current on the output lines.	1kΩ resistors to limit current	On the output lines.
I2C Address Selector	10kΩ Current Limiting Resistors	Limits the current on the I2C address configuration pins, preventing excessive current from damaging the MCP23017.	10kΩ resistors	On the I2C address offset selector switches.
MCP23017 Port Expander	0.1µF Decoupling Capacitor	Reduces noise and stabilizes the power supply to the MCP23017, ensuring smooth operation.	Capacitance: 0.1µF	Positioned near the MCP23017 power supply pins.

References

Choosing the Right Resistor for LEDs.