Scaling With PODs

Table of contents

Scaling With PODs

Purpose

This guide explains how LCC Fusion systems scale over time using PODs as the primary physical build-out unit.

Rather than focusing on individual cards, this document describes:

when to add more hardware,
how expansion is structured,
and how power and communication scale together.

This is a planning guide, not an assembly or configuration reference.

Scaling Philosophy

LCC Fusion is designed for incremental growth.

Systems typically start small:

one Node Card,
one Node Bus Hub,
one power source.

As layouts evolve, capacity is increased by:

adding Node Cards,
adding Node Bus Hubs,
adding additional power entry points,
and organizing hardware into PODs.

Scaling does not require redesigning existing installations.

What a POD Represents

A POD is a physical grouping of one or more Node Bus Hubs installed near the devices they serve.

A POD may include:

multiple Node Bus Hubs,
multiple Node Cards and I/O cards,
one or more power sources,
wired and/or wireless CAN connectivity.

A POD is used to describe physical build-out, not logical control.

When to Add Another Hub

Adding a Node Bus Hub is appropriate when:

available card slots are exhausted,
I/O devices are spread across a larger area,
it is convenient to place hardware closer to field devices,
or additional local power capacity is needed.

Multiple hubs may exist within a single POD or across multiple PODs.

Power Scaling With PODs

Power scaling is achieved by adding power where it is needed, not by increasing a single centralized supply.

Common patterns include:

one power source per Node Bus Hub,
multiple power entry points within a POD,
mixed power sources (e.g., network cable power and local supplies).

Built-in protection allows multiple power sources to coexist safely without manual configuration.

Power Zones (Planning Concept)

For planning purposes, each Node Bus Hub can be considered a power zone.

A power zone:

defines a local current envelope,
simplifies reasoning about load placement,
does not require strict electrical isolation.

Power zones are a planning aid, not a rigid rule.

Scaling Across a Layout

As layouts grow, PODs are commonly:

placed near groups of turnouts, signals, or detectors,
connected via wired CAN or wireless links,
powered locally to reduce long power runs.

This approach improves:

fault isolation,
wiring simplicity,
and long-term maintainability.

Wired and Wireless Expansion

PODs may be connected using:

wired CAN connections, or
wireless CAN connectivity (such as ESP-NOW).

Wireless links are used when:

wiring is impractical,
distance is significant,
or modules must be movable.

Wireless communication extends CAN participation but does not change POD structure.

What Scaling Does Not Require

Scaling with PODs does not require:

designating primary or secondary nodes,
centralized power supplies,
reconfiguring existing nodes,
or restructuring the CAN network.

Nodes always operate as peers.

Typical Scaling Examples

One POD with multiple hubs serving a dense yard
Multiple PODs distributed around a layout
A POD powered locally with an additional POD powered remotely
Mixed wired and wireless POD connections
Incremental expansion as new layout sections are added

All are supported configurations.

Summary

Scaling with PODs provides a clear, repeatable way to grow LCC Fusion systems:

PODs organize physical hardware
Hubs expand I/O capacity
Power is introduced locally and incrementally
Nodes remain peers on the CAN network
Expansion is additive, not disruptive

This model supports layouts ranging from small test setups to large, distributed installations.