Multiple Outputs with ESP32

Hi,

I have multiple stairs in the backyard setup with ESP32 and WS2815 LED strips (and 3 String Lights with TM1814). Each stair has 3 steps and each step has a WS2815 strip under it.
4 stairs are working fine by now (all the issues were user related) but I can’t figure out the last stairs and hope someone can give me more pointers.

ESP32-CAM is driving 3 outputs via pins 13, 14, 15. Total number of LEDs is 810, steps have 316, 271 and 223 LEDs each. Cable from ESP to LEDs is about 1m (less for the top steps) and I have tried both, with and without level shifter (no difference).

The issue is that the top stair string “flickers”, but only if all 3 outputs are active. If I only define 2 outputs (it doesn’t matter in what combination) everything works fine. Only if I define all 3 outputs I see the flickering. The flickering shows with all kind of brightness level and is noticeable during effects.

Everything is driven by a 300W 12V power supply, the outputs of the power supply are connected to distribution blocks and all LED strips are powered on both sides with 18 AWG wire that are connected to the distribution blocks. The Backup Data In of the WS2815 is connected to the GND distribution block. I have also exchanged the ESP32 CAM module I’m using with a known working one.

I know that flickering usually means that something with the power or data connection is off, but given that everything works fine (if not all are active) I wonder if it could be something else. Given some other experience (see thread about TM1814) I’m wondering if it could be some strange effect where the RMT memories of the ESP32 are messed up because of the number of LEDs?

Is someone driving 800+ LEDs from an ESP32, using multiple (3 or more) outputs?

Does it flicker if all are solid? All speculation but if flickering when solid could be power, while doing effect could be data.

When solid if you can remove the data line only and the flicker continues it is definitely power.

I had noise in my data line once cause by the wire used. It was the 3 conductor wire. I had to separate the data out.

Thank you for the suggestion @Thedannymullen!

I’m very confident it is the data line, haven’t pulled the data line in solid mode yet, but if there is “flicker” in solid mode it matches the solid mode refresh rate.

This is very surprising to me because the wires are 18GA and very short. I need to see how to fix this, because the ends are already sealed with hot glue… I also tested each strip after soldering and glue and didn’t see any issues.

I have two more things I can try and will update here.

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If the flickering only happens during solid or when all LEDs are on with a high intensity, you are seeing voltage drop and need to inject power to the strip in more places.
If the flickering happens lots of the time, but not all the time, it could be you need a level shifter (or use a single LED pixel close to the ESP32 data pin) to boost the voltage for the dataline.
It might be you need capacitors to avoid power supply noise or voltage droop during fast changing effects.

Thank you @huggy-d1 and @Thedannymullen for the advise.

I thought I had it narrowed down to the data line, but after the last test I’m completely at a lost again.

Clarification for the setup: I’m using a 18ga, 5 wire cable (it’s a direct burial, because I’m working outside and for some stairs it is actually buried). I’m using it for all stairs (5, 15 steps in total). All steps are powered from both sides. This setup works fine for the other 4 stairs (less LEDs) after I did modifications (1) and (2) from below.

Modifications I did:
(1) Connect wire for BI (Backup In on the WS2815) to GND
(2) Connect 5th, unused wire to GND

This lead to 4 out of 5 stairs to just work fine.

Situation for the stairs that are not working:
Top Step (316 LEDs) works fine
Middle Step (271 LEDs) works fine
Bottom Step (223 LEDs) flickers when LEDs are being reprogrammed

Additional debugging steps I did:
(1) Add 1000uF capacitor between 12V and GND
→ No difference
(2) Add 2200uF capacitor between 12V and GND
→ No difference
(3) Change the level shifter to a SN74AHCT125 (I used some bidirectional level shifter module I had lying around)
→ No difference
(4) Directly connect the data wire for bottom step to an ESP32 output instead of the level shifter
→ No difference
(5) Swap the data wire from the “flickering” bottom step with the middle step (adjust number of LEDs, not pi in the settings)
→ No difference, bottom step still “flickering”, middle step working fine
→ Conclusion: No issue with ESP32 or output pin
(6) Cut open cable and separate all wires, so that data wire doesn’t run parallel to power wires
→ No difference
(7) Disassemble stairs and remove LED Strip, use different LED Strip
→ No difference
(8) Change wire used for data connection
→ No difference

By now (it got too late and too dark) the only thing I haven’t changed is the wire for 12V and GND which I’ll do in the next days. They only explanation I would have right now is, that the GND wire is somehow bad (because I reused the GND and 12V wire).

If anyone has anything else I can try, please let me know.

Have you any other mains cables or local RF signals running near or close by the data line that could be introducing any noise?
Have you tried defining a different pinout on the problem channel?
Have you tried another ESP32 just to be sure?

Your above checklist is pretty comprehensive so it could end up being down to the old Sherlock Holmes theory ‘…when you have eliminated all which is impossible, then whatever remains, however improbable, must be the truth.’