





DETAILED DESCRIPTION
Overview
Controller board for a lighting fixture with 960 RGBWW LEDs. This controller drives a chain of 30 LedBoard's, each with 32 LED packages. Each package contains four LED dies (reg, green, blue and warm white), which makes for a grand total of 3840 LED dies, across the 30 boards. Each LedBoard also has two DM633 constant-current LED drivers, which each have 16 channels. Each channel has an individual 12-bit PWM. The 30 LedBoard's contain a total of 60 drivers, for a total of 960 individually controllable channels. The LEDs are arranged in groups of four, so every driver channel controls a single color of four LED packages.
LedBoard: https://workspace.circuitmaker.com/Projects/Details/Wouter-Devinck/LedBoard
The controller board is packed with functionality:
- Espressif ESP32 dual core microcontroller with WiFi and Bluetooth, on a certified ESP-WROOM-32 module
- Lattice ice40 UltraPlus FPGA responsible for sending the serial data to the LED drivers (12 bit brightness value for all 960 channels @ 120 fps)
- With a configuration SPI flash, also writable by the ESP32 during OTA firmware upgrade
- With an EEPROM to store animation sequence to be shown during microcontroller boot
- RGB status LED (WiFi connection etc.)
- Crypto chip for secure connections to IoT frameworks
- Sensors:
- Current sensor measuring total current on 15V DC rail (limited to 8A for total fixture = 120W)
- Digital microphone
- IR receiver
- Light sensor
- Power supply:
- Passthrough 15V DC input to LedBoard chain (for current measurement)
- Generates 5V DC rail from 15V for LED drivers logic supply (output to LedBoard chain)
- Generates 3.3V DC rail for all controller logic and for the ESP32
- Generates 1.2V DC rail for FPGA core supply
Block diagram
Layer stackup
This is a four layer board.
- Top: components & signal
- Internal 1: ground plane
- Internal 2: signal
- Bottom: power & signal
Bill of materials
Reference | Description | Manufacturer | Part number | Package | Value | Quantity |
---|---|---|---|---|---|---|
C1-4, C16 | Capacitor | Murata | GRM32DR61E106KA12L | 1210 | 10uF - 25V | 5 |
C5, C9, C13 | Capacitor | Kemet | C0603C332K5RACTU | 0603 | 3.3nF - 50V | 3 |
C6-8, C10-12, C14-15, C27 | Capacitor | Taiyo Yuden | LMK212BBJ226MG-T | 0805 | 22uF - 10V | 9 |
C17, C20-C23 | Capacitor | - | - | 0603 | 1nF | 5 |
C18, C25-26, C28-33 | Capacitor | - | - | 0603 | 0.1uF | 9 |
C19 | Capacitor | - | - | 0603 | 0.01uF | 1 |
C24 | Capacitor | - | - | 0603 | 0.1nF | 1 |
D1 | TVS Diode | ON Semi | SMBJ15A | SMB | - | 1 |
D2 | RGB LED | Cree | CLY6D-FKC-CK1N1D1BB7D3D3 | PLCC6 | - | 1 |
D3 | Schottky Diode | Comchip | CDBU0520 | SOD-523F | - | 1 |
F1 | Fuse | Littelfuse | 0466001.NR | 1206 | 1A | 1 |
J1, J2 | Screw terminal | - | - | - | - | 2 |
J3 | Connector | JST | SM04B-SRSS-TB | - | - | 1 |
J4 | Connector | JST | SM14B-SRSS-TB | - | - | 1 |
Q1-5 | Transistor | - | MMBT3904 | - | - | 5 |
R1 | Resistor | Yageo | RC0603FR-07953KL | 0603 | 953K/1% | 1 |
R2, R4 | Resistor | Yageo | RC0603FR-07180KL | 0603 | 180K/1% | 2 |
R3 | Resistor | Yageo | RC0603FR-07562KL | 0603 | 562K/1% | 1 |
R5 | Resistor | Yageo | RC0603FR-0775KL | 0603 | 75K/1% | 1 |
R6 | Resistor | Yageo | RC0603FR-07150KL | 0603 | 150K/1% | 1 |
R7-9, R20-23 | Resistor | - | - | 0603 | 10K | 7 |
R10-11, R18-19 | Resistor | - | - | 0603 | 4.7K | 4 |
R12-14, R24-27 | Resistor | - | - | 0603 | 100 | 7 |
R15-17 | Resistor | - | - | 0603 | 1K | 3 |
U1 | MCU module | Espressif | ESP-WROOM-32 | - | - | 1 |
U2 | FPGA | Lattice | ICE40UP5K-SG48ITR50 | QFN-48 | - | 1 |
U3 | Current sensor | Allegro | ACS712ELCTR-20A-T | SOIC-8 | 20A | 1 |
U4 | Level shifter | Texas Instruments | TXS0104EPWR | 14-TSSOP | - | 1 |
U5-7 | DC/DC converter | Texas Instruments | LMZ21701SILT | - | - | 3 |
U8 | SPI flash | Winbond | W25Q32JVSSIQ | SOIC-8 | 32Mbit | 1 |
U9 | Crypto chip | Microchip (Atmel) | ATECC508A | SOIC-8 | - | 1 |
U10 | EEPROM | Microchip (Atmel) | AT24C512C-SSHD-B | SOIC-8 | 512kbit | 1 |
U11 | IR receiver | Vishay | TSOP75338TR | - | - | 1 |
U12 | Light sensor | AMS | TSL25911FN | - | - | 1 |
U13 | Microphone | Knowles | SPK0415HM4H-B | - | - | 1 |
X1 | Oscillator | Abracon | ASE-20.000MHZ-LR-T | - | 20MHz | 1 |
Revision history
v1 - May 2018 - Boards ordered and to be assembled and tested (order here)
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