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doc: add v4 changes

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King Kévin 2023-12-04 17:53:30 +01:00
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10
CHANGELOG.md
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@ -1,3 +1,13 @@
v4
--
changes:
- add WLED status LED visible when inside enclosure
- change ESP32-WROOM to ESP32-MINI on front for automated assembly
- change buck voltage regulator to LMR16030, limiting to 3A output, since the board can't dissipate the heat generted by 5A buck (even in highest efficiency)
- now able to measure input voltage
v3
--

64
README.md
View File

@ -7,7 +7,7 @@ The [WLED](https://kno.wled.ge/) firmware is ideal to control addressable LEDs s
WLED chain is a hardware board for it, matching my usage: robust remotely controlled LED strip based light installations for festivals.
It allows to:
- use of the shelf 12-48V power supplies to power 5V LED strips
- use of the shelf 6-60V power supplies to power 5V LED strips
- inter-connect the boards to form long chains (only connecting the first to externally provided power and data)
- use cheap Ethernet CAT5E cables to inter-connect them (also over long distances)
- provide power and data (DMX512) over the Ethernet cables
@ -51,10 +51,10 @@ status
On the RJ45 ports there are 4 LEDs.
These indicate the status:
- the center-right LED indicates the >8V status: it is on when 8-60V power is provided to the board
- the rightmost LED indicates the 5V status: it is on when the on-board DC-DC voltage regulator converts the 8-60V to 5V right after 8-60V is plugged in, or when 5V power is provided externally
- the center-left LED indicates the WLED status: it is on when WLED started successfully
- the leftmost LED indicates the DMX status: it blinks on DMX input traffic
- the center-right LED indicates the >6V status: it is on when 6-60V power is provided to the board
- the rightmost LED indicates the 5V status: it is on when the on-board DC-DC voltage regulator converts the 6-60V to 5V right after 6-60V is plugged in, or when 5V power is provided externally
- the center-left LED indicates the DMX RX traffic: it blink on DMX input traffic (when the board is configure as slave)
- the leftmost LED indicates the DMX TX traffic: it blinks on DMX output traffic (when the board is configure as master)
installation
============
@ -62,7 +62,7 @@ installation
The board can be used in various configurations:
- LED strip (for small, medium, or large LED installations): using 5V or 12V
- power supply: 5V or 8-60V
- power supply: 5V or 6-60V
- enclosure: with or without a waterproof enclosure
- chain: a single standalone device, or with additional WLED chain devices
- DMX: controlled using WiFi, or DMX
@ -86,7 +86,7 @@ For tiny installations, with 5 meters of 30 LEDs/meter strips:
- connect the 5V LED strip to the 5V screw terminal and one of the IO spring loaded ports next to it
- use the screw terminal to also have separate wires for power injection on the LED strip in the middle and or other end of it
- connect a 12V to 48V 2A (or more) power supply to the barrel jack
- the on-board 5V regulator will provide power to the LEDs (up to 5A)
- the on-board 5V regulator will provide power to the LEDs (up to 3A)
For medium installations:
@ -100,7 +100,7 @@ For large installations:
- connect the 12V LED strip ground and data wires to the board (see above)
- use an external 12V power supply powerful enough for the number of LEDs you want
- connect the external power supply to the 8-60V screw terminal
- connect the external power supply to the 6-60V screw terminal
- connect the LED strip power pins directly to the power supply
- thanks to the 12V supply, you need far less injection points (every 5-10 meters should be enough)
@ -108,13 +108,13 @@ For small wide-spread installations:
- this uses multiple boards, and chains tiny installations
- on each board, connect the 5V LED strip to the 5V screw terminal and one of the IO spring loaded ports next to it
- on only the first board, connect a 12V to 60V (the higher to better) 2A power supply to the barrel jack or 8-60V screw terminal
- on only the first board, connect a 12V to 60V (the higher to better) 2A power supply to the barrel jack or 6-60V screw terminal
- connect all boards using Ethernet cables on the RJ45 ports, allowing the first board to power all others
For outdoor wide-spread installations:
- this is similar to small wide-spread installations, but the boards are mounted in waterproof enclosures
- since the barrel jack port is not accessible anymore, use the 8-60V screw terminal
- since the barrel jack port is not accessible anymore, use the 6-60V screw terminal
- since the RJ45 ports are not accessible anymore, and the RJ45 connector do not fit through the enclosure cable cables anymore, cut Ethernet cables and insert the individual wires in the RJ45 1-8 spring loaded terminals (the color of the wires is described on the back of the board, or just look at the cut RJ45 connector)
- you can insert the two wires of both Ethernet cables in each terminal
@ -122,7 +122,7 @@ For large wide-spread installations:
- connect the 12V LED strip ground and data wires to the board
- use multiple external 12V power supplies powerful enough for each site
- only connect one board to the external power supply to the 8-60V screw terminal
- only connect one board to the external power supply to the 6-60V screw terminal
- connect all boards using Ethernet cables, allowing the first board to power all others
LED strip
@ -193,27 +193,31 @@ And I find the logo nice.
power
-----
The built-in 5V DC-DC converter is only rated up to 5A, limiting the total maximum output to 25W.
This means you can power up to 5 meters of WS2812b 30 LEDs/m strip at full brightness.
The built-in 5V DC-DC converter is only rated up to 3A, limiting the total maximum output to 15W.
This means you can power up to 3 meters of WS2812b 30 LEDs/m strip at full brightness.
For more LEDs, limit the brightness in WLED, or use multiple boards and chain them.
Voltage regulators capable of more current are rare and expensive.
They are also less compact, would exceed the space available in the enclosure.
The initial design used a 5A capable voltage converter, but this current could not be sustained.
Even with 90% high efficiency, the board could not handle passive dissipation of the generated heat.
You could add a heat sink and fan when used outside the enclosure, but this is not the intended use.
If you need more than 5A, you are exceeding the use case of this board.
You can us multiple board if you have separate LED strips.
Else switch back to using an external power supply and connect the LED strips directly to it.
You can even power the board with the same 5V or 8-60V power supply using the DC jack (for 8-60V) or screw terminals (for 5V and 8-60V).
If you need more than 3A continuously, you are exceeding the use case of this board.
You can use multiple boards if you have separate LED strips, sharing the same 6-60V power supply.
Else switch back to using an external 5V or 12V power supply and connect the LED strips directly to it.
You can even power the board with the same 5V or 12V power supply using the DC jack (for 6-60V) or screw terminals (for 5V and 6-60V).
The 8-60V power input allows using any kind of power supply, like common 12V, 24V, or 48V.
The 6-60V power input allows using any kind of power supply, like common 12V, 24V, or 48V.
It also allows using 48V LiPo batteries (going up to 55V), to operate the devices without grid power.
There is an over current input protection of 2A using a PPTC.
There is an over current input protection of 1.8A using a PPTC.
This is to protect the board from very bad accidents, and because Ethernet cables are no meant to carry power (PoE limit is 960 mA per pair, we are using two).
To be able to power multiple WLED chain boards, each drawing 25W, use higher voltages (48V up to 60V).
To be able to power multiple WLED chain boards, each drawing up to 15W, use higher voltages (48V up to 60V).
The 8-60V input is also reverse polarity protected using an inline Schottky diode after the fuse.
The 5V rail input/outputs are not fuse or reverse polarity protected.
The 6-60V input is also reverse polarity protected using an inline Schottky diode after the fuse.
The 5V rail input/outputs is not reverse polarity protected.
The onboard voltage regulator has an 3A over-current protection.
wiring
------
@ -228,8 +232,8 @@ The resulting wires can be inserted in the spring loaded terminal marked RJ45, f
The wire colors are also listed on the back of the board, in case it is already not mounted.
In case boards need to be chained, two Ethernet cable can be inserted using the two glands, and the same number wires should be inserted together in the terminal.
8-60V power supply can be inserted using additional glands on the opposite side of the Ethernet cables.
The wires should be connected using the screw terminal marked 8-60V.
6-60V power supply can be inserted using additional glands on the opposite side of the Ethernet cables.
The wires should be connected using the screw terminal marked 6-60V.
Follow the +/- indications on the board.
The LEDs strips cables can be inserted using additional glands on the opposite side of the Ethernet cables.
@ -241,7 +245,7 @@ The corresponding I/O configured in WLED is indicated on the side.
In case the board is not mounted in the enclosure, other ports can be used.
5V power can be provided through the USB port.
8-60V power input can be connected using the 2.1/5.5 mm ID/OD DC barrel jack.
6-60V power input can be connected using the 2.1/5.5 mm ID/OD DC barrel jack.
The Ethernet cables can be directly connected using the two RJ45 ports (either is fine as they are interconnected).
The USB, DC barrel, and RJ45 ports are not accessible when the board is in the enclosure simply because there isn't enough space.
@ -254,18 +258,18 @@ features
Features already implemented:
- daisy chain capability (providing data and power)
- built-in power 5V DC-DC converter (input up to 60V, output up to 5A)
- built-in power 5V DC-DC converter (input up to 60V, output up to 3A)
- RS-485/DMX512 interface (not galvanicailly isolated)
- RJ45 port, providing power (PoE, passive, alternative B) and data (as used in DMX512), 2x for chaining capability
- RJ45 individual wires connector, using easy to insert spring loaded terminal, for allowing using Ethernet cable in waterproof enclosure, where the 8P8C connector does not fit through the PG7 cable gland
- DC barrel jack power input for 8-60V, for convenient use with off-the-shelves power bricks, allowing injecting power
- DC barrel jack power input for 6-60V, for convenient use with off-the-shelves power bricks, allowing injecting power
- screw terminals for thicker wires, for larger power supplies and usage in waterproof enclosure
- proper 5V DOUT for WS2812B IC input, 3 channels (can be combined for LEDs requiring an additional clock signal)
- in-line LED data resistors for [signal conditioning](https://quinled.info/data-signal-cable-conditioning/). Ideally it should use a smaller value since it's intended for running the signal along ground over short distances, but there were already 100 Ohm on the board for DMX512 termination, and it allows better compatibility for longer single ended cables.
- external WiFi antenna port, by using the U variant of the ESP32-S2-MINI, with appropriate connector
- PCB fitting in waterproof enclosure (sonoff or generic 100x68x50)
- high voltage input (up to 60V, using TPS54560DDAR)
- input protection (reverse polarity, PPTC), only for 8-60V power input
- input protection (reverse polarity, PPTC), only for 6-60V power input
- microphone for sound reactive
Features that might get implemented:
@ -277,9 +281,9 @@ Features will not be implemented:
- XLR DMX512 connectors: they take too much space and I never know if I should use the 3 or 5-pin variant. Instead I designed a separate DMX + power injector adapter board
- full galvanic isolation: not really needed as the devices should be chained with a single power supply, preventing any ground potential difference. Another splitter board could provide isolation, at the beginning of the chain.
- USB Power Delivery: this is just a convenience feature, but using expensive lower power USB chargers with expensive ISB-C cables is not ideal for the intended usage (festival installation). And you can still use power-delivery by adding a cheap PD trigger board next to it.
- Lithium battery input and charger: it does not fit the intended usage, with large external power supplies providing enough power for power hungry LED strips. Small batteries would not be able to handle that over longer time. You can still use the power bank on the 5V power input though, and charge the battery separately. The 8-60V allows connecting 3-13S LiPo batteries.
- Lithium battery input and charger: it does not fit the intended usage, with large external power supplies providing enough power for power hungry LED strips. Small batteries would not be able to handle that over longer time. You can still use the power bank on the 5V power input though, and charge the battery separately. The 6-60V allows connecting 3-13S LiPo batteries.
- Power over Ethernet (active): I do use passive Power over Ethernet, by providing power on 2 pairs of the Ethernet cable that are not used for 10/100 Mbps communication. This allows using very simple and inexpensive injectors to power power, using and power supply. Active PoE require specials and more expensive injectors or power supplies, and complex extractors in each device. Feel free to use PoE though. There are plenty of relatively cheap injectors and extractors that you can use as external devices next to the boards.
- fuse protection for input and output protection, round or automotive: there is not enough space to place such large fuses. We already have one input protection (fuse + reverse polarity on 8-60V), so you just have pay attention to the 5V outputs (limited to 5A by the DC-DC converter) or input (supported, but not the intended use).
- fuse protection for input and output protection, round or automotive: there is not enough space to place such large fuses. We already have one input protection (fuse + reverse polarity on 6-60V), so you just have pay attention to the 5V outputs (limited to 3A by the DC-DC converter) or input (supported, but not the intended use).
- line-in audio input (using [ESP32-LyraT-Mini](https://docs.espressif.com/projects/esp-adf/en/latest/design-guide/dev-boards/board-esp32-lyrat-mini-v1.2.html) design as reference): running additional audio wires is too cumbersome, particularly for simple effects based on loudness or FFT. Clubs or festivals are loud enough for the microphone to pick up the audio at a decent level.
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