ErnieHorning: Restored from the archived ChristmasWiki backup. Image references updated where required.

2026-08-06T22:48:44Z

Restored from the archived ChristmasWiki backup. Image references updated where required.

New page

This area will list some general Design Guidelines for PCBs that will be fabricated on a coop basis and hand-assembled in users workshops. There are also suggestions for selecting components that will be used to populate these boards.

==Benefits of following the guidelines==

1) Using common component PCB footprints and outlines eases documentation burdens and helps reduce assembly errors. 
2) Using the same components on several boards increases the volume of coop components purchases, thereby decreasing costs through better price breaks. 
3) Using common components helps prevent unnecessary duplication of tooling (e.g. expensive connector crimping tools). 
4) Helps reduce incompatabilities that interfere with boards working together. 

==Using these guidelines==
These are only guidelines and should not be treated as gospel. We ask you to adhere to these guidelines when designing new PCB's if you can. If you need to deviate from these guidelines we ask that you specify the deviation in your assembly notes and list them when releasing your design. This way, others will know if there are any compatibility issues. If you are populating a circuit board please double check to make sure these guidelines were followed before you start populating your board based on what you read on this page.

==PCB Design==

PCBs intended for coop distribution will often be assembled by people without previous electronic assembly experience. Therefore, it is strongly preferred that they should be designed using only through-hole components. They should also include a silk-screen for the component side, with reference designators and orientation indicators for all components. These reference designators should be visible when the components are installed on the board.

The PCBs traces should be no less than .010". The minimum copper-to-copper spacing should be .010". The minimum via size should be .020". All component connections to (ground) planes should include thermal reliefs (wagon-wheels) so that the components can be successfully soldered in place.

*'''Leds''' should be placed with a square pad as the cathode.
*'''Diodes''' should be placed with a square pad as the cathode.
*'''Power Connectors''' should be placed with a square pad as the ground.
*'''Polarized Capacitors''' should be placed with a square pad as the positive pin.
*'''Resistor''' lead spacing should be .400" unless required otherwise.
*'''Pads''' on the PCB should be .056" diameter with .029" hole, unless otherwise required.
*'''Mounting holes''' should be .300" diameter via with .167" hole. There should be a minimum of 3 mounting holes per board. This size hole will fit a 6/32 screw nicely.
 
==Pinouts==
===Controller Output (SSR Input)===
'''RJ45 controller outputs should be pinned out as follows:''' 
Pin 1 - +5v supply 
Pin 2 - Channel 1 output 
Pin 3 - reserved 
Pin 4 - Channel 2 output 
Pin 5 - reserved 
Pin 6 - Channel 3 output 
Pin 7 - Ground 
Pin 8 - Channel 4 output 
 

===595 Style Controllers: Inputs===
'''595/Grinch Controller RJ45 inputs (and daisy-chain outputs) should be pinned as follows:''' 
Pin 1 - Power (optional) 
Pin 2 - no connection 
Pin 3 - Ground 
Pin 4 - no connection 
Pin 5 - Clock 
Pin 6 - no connection 
Pin 7 - Data Latch 
Pin 8 - Serial Data In/Out 
 

===Renard Controllers: Inputs===
'''Renard Controller RJ45 inputs (and daisy-chain outputs):''' 
Pin 1 - Ground 
Pin 2 - Ground 
Pin 3 - alternate zero-cross input 
Pin 4 - Data- 
Pin 5 - Data+ 
Pin 6 - no connection 
Pin 7 - Power input (preferably pulsing DC to allow use as both power and zero-crossing source) 
Pin 8 - Power input (preferably pulsing DC to allow use as both power and zero-crossing source) 
 

===DMX Controllers: Inputs===
'''DMX Controller RJ45 Inputs (per ESTA):''' 
Pin 1 - Data1+ 
Pin 2 - Data1- 
Pin 3 - Data2+ 
Pin 4 - no connection 
Pin 5 - no connection 
Pin 6 - Data2- 
Pin 7 - Link Common for Data1 
Pin 8 - Link Common for Data2 
 
===DMX Controllers: Inputs===
'''DMX Controller Cannon Inputs (per ESTA):''' 
Pin 1 - Link Common 
Pin 2 - Data- 
Pin 3 - Data+ 

 

===Power Input Connectors===
'''Power Connectors''' 
Pin 1 - Ground 
 

==Component Selection==
===Through-hole parts===
Through-hole parts are preferred for coop boards, due to the difficulties in handling and soldering surface-mount components.

===Power Connectors===
'''Power Connectors''' 
Molex SL Series headers for low voltage/amperage applications. .100 pad spacing. Example Mouser part number : 538-70543-0037 
Molex SL Series plugs for low voltage/amperage applications. .100 spacing. Example Mouser part number : 538-50-57-9403 
Molex connector terminals for low voltage/amperage applications. Example Mouser part number : 538-16-02-0102 
 

===Jumpers/Headers===
'''Headers''' 
Headers for jumpers due to design/configuration options. any .100 pad spacing header so a standard jumper can be utilized. 
 

===Integrated Circuits===
'''IC's''' 
Sockets should be utilized on all IC's. This will prevent overheating of the IC's and ease of replacement if required. 
 

===Fuses===
'''Fuses''' 
Fuses should be 5x20mm unless otherwise required. 
 

===Screw Terminals===
'''Terminals''' 
Screw Terminals should have a 5.08mm lead spacing. Example Mouser part number : 571-2828374 

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Archived ChristmasWiki:Hardware Design Guidelines - Revision history

ErnieHorning: Restored from the archived ChristmasWiki backup. Image references updated where required.