ESP32 LED Board Design

Created 4 project docs

Block Diagram

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Block Diagram System Architecture Assemblies
  1. Main controller/power PCB — USB-C PD input, 2S charger/protection/balancing, 5 V LED buck, 3.3 V MCU buck, ESP32-C3, level shifting, LED output, pack connector, debug/programming, and button-cable connector.
  2. Separate six-button PCB — six momentary switches and matching polarized locking ribbon connector. Allocation: six signals, two grounds, and two reserved/ground positions for return-path robustness.
Functional-Block Sourcing Plan
  • USB-C PD sink: reference search required; import exact/close standalone reference if available.
  • Balanced 2S charger: reference search required; import exact/close standalone reference if available.
  • 2S protection/balancing: reference search required; import exact/close standalone...

Project Specification

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Project Specification Project Overview
Status: Draft — schematic phase. A two-PCB BLE LED controller for installation in a non-conductive tube.
Intended Use
Portable battery-powered controller for 100 Adafruit ADA2328 5 V addressable LEDs, operated by six wired buttons and BLE.
What the Device Should Do
  • Drive 100 addressable LEDs while enforcing a 20 W electrical LED-output cap.
  • Provide BLE control with Wi-Fi disabled in firmware.
  • Charge a protected/balanced 2S 18650 pack from a USB-C PD supply.
  • Positively disable LED power and normal operation whenever USB-C is inserted/charging.
  • Read six independent momentary buttons on a separate PCB.
Main Features
ESP32-C3 module; 2S pack protection/balancing; 9 V PD sink; balanced 2S charger; 5 V/4 A LED rail; efficient ...

Firmware Getting Started

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Firmware Getting Started Toolchain
PlatformIO + Arduino-ESP32. platformio.ini:
Final MCU Pin Mapping Compilable Starter (src/main.cpp)
Depending on Arduino-ESP32 release, include `` and omit btStop() if it conflicts with NimBLE startup. The hardware shutdown/charge inhibit must not depend on this firmware.
Startup Sequence
  1. Confirm hardware charge inhibit is inactive.
  2. Initialize serial diagnostics.
  3. Keep Wi-Fi disabled.
  4. Configure buttons and ADC.
  5. Initialize FastLED power limiter before enabling patterns.
  6. Start BLE GATT service and advertising.

Board Bring-Up Plan

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Board Bring-Up Plan Preconditions
Do not install cells until charger, protection, and regulator support circuits have been checked against final datasheets and ERC is clean. Use a current-limited bench supply and thermal camera.
Main Board
  1. Visual inspection: polarity, exposed pads, solder bridges, antenna keepout, connector pin-1 orientation.
  2. Resistance checks: GND-to-pack, GND-to-5 V, and GND-to-3.3 V must not be shorted.
  3. Power protected pack input from 6.0 V at 100 mA limit with LED load disconnected. Pass: no unexpected heating/current-limit entry.
  4. Verify 3.3 V rail within ±3%; verify EN reset behavior and programming access.
  5. Verify ESP32 boot log; flash starter firmware; confirm BLE advertising with Wi-Fi disabled.

flux

The specification and six-button subsystem are complete. I found the first pass left the high-power charging and protection circuitry unfinished, so I’m completing that block now rather than treating an unsafe partial schematic as done.

flux

The requirements, power budget, firmware starter, bring-up plan, six-button board, and most main-controller circuitry are complete. The design now includes full 2S protection, USB-C PD charging, charge-time shutdown, 5 V/4 A LED power, and ESP32-C3 BLE control.
Blocked: a manufacturable 3-wire battery connector must be selected for PACK− / cell midpoint / PACK+, followed by a final capacitor/package audit and ERC cleanup. Please specify a preferred connector family—JST-XH, JST-PH, or direct solder pads—before I finalize the schematic.
Use JST-XH connector
Use JST-PH connector
Use solder pads
U5
J1
U3
U6
  • Generic Inductor
    Generic Inductor
    A generic fixed inductor suitable for rapid circuit topology development. The footprint automatically adapts based on the selected package, supporting standard SMD sizes (e.g., 0402, 0603, 0805) as well as well-known inductor packages such as SDR1806, PA4320, SRN6028, and SRR1260. Standard inductor values: 1.0 nH, 10 nH, 100 nH, 1.0 µH, 10 µH, 100 µH, 1.0 mH 1.2 nH, 12 nH, 120 nH, 1.2 µH, 12 µH, 120 µH, 1.2 mH 1.5 nH, 15 nH, 150 nH, 1.5 µH, 15 µH, 150 µH, 1.5 mH 1.8 nH, 18 nH, 180 nH, 1.8 µH, 18 µH, 180 µH, 1.8 mH 2.2 nH, 22 nH, 220 nH, 2.2 µH, 22 µH, 220 µH, 2.2 mH 2.7 nH, 27 nH, 270 nH, 2.7 µH, 27 µH, 270 µH, 2.7 mH 3.3 nH, 33 nH, 330 nH, 3.3 µH, 33 µH, 330 µH, 3.3 mH 3.9 nH, 39 nH, 390 nH, 3.9 µH, 39 µH, 390 µH, 3.9 mH 4.7 nH, 47 nH, 470 nH, 4.7 µH, 47 µH, 470 µH, 4.7 mH 5.6 nH, 56 nH, 560 nH, 5.6 µH, 56 µH, 560 µH, 5.6 mH 6.8 nH, 68 nH, 680 nH, 6.8 µH, 68 µH, 680 µH, 6.8 mH 8.2 nH, 82 nH, 820 nH, 8.2 µH, 82 µH, 820 µH, 8.2 mH #generics #CommonPartsLibrary
    jharwinbarrozo
    16.7k
  • Generic Capacitor
    Generic Capacitor
    A generic fixed capacitor ideal for rapid circuit topology development. You can choose between polarized and non-polarized types, its symbol and the footprint will automatically adapt based on your selection. Supported options include standard SMD sizes for ceramic capacitors (e.g., 0402, 0603, 0805), SMD sizes for aluminum electrolytic capacitors, and through-hole footprints for polarized capacitors. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard capacitor values: 1.0pF, 10pF, 100pF, 1000pF, 0.01uF, 0.1uF, 1.0uF, 10uF, 100uF, 1000uF, 10000uF 1.1pF, 11pF, 110pF, 1100pF 1.2pF, 12pF, 120pF, 1200pF 1.3pF, 13pF, 130pF, 1300pF 1.5pF, 15pF, 150pF, 1500pF, 0.015uF, 0.15uF, 1.5uF, 15uF, 150uF, 1500uF 1.6pF, 16pF, 160pF, 1600pF 1.8pF, 18pF, 180pF, 1800pF 2.0pF, 20pF, 200pF, 2000pF 2.2pF, 22pF, 220pF, 2200pF, 0.022uF, 0.22uF, 2.2uF, 22uF, 220uF, 2200uF 2.4pF, 24pF, 240pF, 2400pF 2.7pF, 27pF, 270pF, 2700pF 3.0pF, 30pF, 300pF, 3000pF 3.3pF, 33pF, 330pF, 3300pF, 0.033uF, 0.33uF, 3.3uF, 33uF, 330uF, 3300uF 3.6pF, 36pF, 360pF, 3600pF 3.9pF, 39pF, 390pF, 3900pF 4.3pF, 43pF, 430pF, 4300pF 4.7pF, 47pF, 470pF, 4700pF, 0.047uF, 0.47uF, 4.7uF, 47uF, 470uF, 4700uF 5.1pF, 51pF, 510pF, 5100pF 5.6pF, 56pF, 560pF, 5600pF 6.2pF, 62pF, 620pF, 6200pF 6.8pF, 68pF, 680pF, 6800pF, 0.068uF, 0.68uF, 6.8uF, 68uF, 680uF, 6800uF 7.5pF, 75pF, 750pF, 7500pF 8.2pF, 82pF, 820pF, 8200pF 9.1pF, 91pF, 910pF, 9100pF #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Generic Resistor
    Generic Resistor
    A generic fixed resistor ideal for rapid circuit topology development. Its footprint automatically adapts based on the selected package case code—supporting 0402, 0603, 0805, 1203, and many other standard SMD packages, as well as axial horizontal and vertical configurations. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0 ohm, 10 ohm, 100 ohm, 1.0k ohm, 10k ohm, 100k ohm, 1.0M ohm 1.1 ohm, 11 ohm, 110 ohm, 1.1k ohm, 11k ohm, 110k ohm, 1.1M ohm 1.2 ohm, 12 ohm, 120 ohm, 1.2k ohm, 12k ohm, 120k ohm, 1.2M ohm 1.3 ohm, 13 ohm, 130 ohm, 1.3k ohm, 13k ohm, 130k ohm, 1.3M ohm 1.5 ohm, 15 ohm, 150 ohm, 1.5k ohm, 15k ohm, 150k ohm, 1.5M ohm 1.6 ohm, 16 ohm, 160 ohm, 1.6k ohm, 16k ohm, 160k ohm, 1.6M ohm 1.8 ohm, 18 ohm, 180 ohm, 1.8K ohm, 18k ohm, 180k ohm, 1.8M ohm 2.0 ohm, 20 ohm, 200 ohm, 2.0k ohm, 20k ohm, 200k ohm, 2.0M ohm 2.2 ohm, 22 ohm, 220 ohm, 2.2k ohm, 22k ohm, 220k ohm, 2.2M ohm 2.4 ohm, 24 ohm, 240 ohm, 2.4k ohm, 24k ohm, 240k ohm, 2.4M ohm 2.7 ohm, 27 ohm, 270 ohm, 2.7k ohm, 27k ohm, 270k ohm, 2.7M ohm 3.0 ohm, 30 ohm, 300 ohm, 3.0K ohm, 30K ohm, 300K ohm, 3.0M ohm 3.3 ohm, 33 ohm, 330 ohm, 3.3k ohm, 33k ohm, 330k ohm, 3.3M ohm 3.6 ohm, 36 ohm, 360 ohm, 3.6k ohm, 36k ohm, 360k ohm, 3.6M ohm 3.9 ohm, 39 ohm, 390 ohm, 3.9k ohm, 39k ohm, 390k ohm, 3.9M ohm 4.3 ohm, 43 ohm, 430 ohm, 4.3k ohm, 43K ohm, 430K ohm, 4.3M ohm 4.7 ohm, 47 ohm, 470 ohm, 4.7k ohm, 47k ohm, 470k ohm, 4.7M ohm 5.1 ohm, 51 ohm, 510 ohm, 5.1k ohm, 51k ohm, 510k ohm, 5.1M ohm 5.6 ohm, 56 ohm, 560 ohm, 5.6k ohm, 56k ohm, 560k ohm, 5.6M ohm 6.2 ohm, 62 ohm, 620 ohm, 6.2k ohm, 62K ohm, 620K ohm, 6.2M ohm 6.8 ohm, 68 ohm, 680 ohm, 6.8k ohm, 68k ohm, 680k ohm, 6.8M ohm 7.5 ohm, 75 ohm, 750 ohm, 7.5k ohm, 75k ohm, 750k ohm, 7.5M ohm 8.2 ohm, 82 ohm, 820 ohm, 8.2k ohm, 82k ohm, 820k ohm, 8.2M ohm 9.1 ohm, 91 ohm, 910 ohm, 9.1k ohm, 91k ohm, 910k ohm, 9.1M ohm #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Terminal
    Terminal
    An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
    natarius
  • RMCF0805JT47K0
    RMCF0805JT47K0
    General Purpose Thick Film Standard Power and High-Power Chip Resistor 47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film Features: - RMCF – standard power ratings - RMCP – high power ratings - Nickel barrier terminations standard - Power derating from 100% at 70ºC to zero at +155ºC - RoHS compliant, REACH compliant, and halogen free - AEC-Q200 compliant
    jharwinbarrozo
    1.2M
  • 875105359001
    875105359001
    10 µF 16 V Aluminum - Polymer Capacitors Radial, Can - SMD 30mOhm 2000 Hrs @ 105°C #commonpartslibrary #capacitor #aluminumpolymer #radialcan
    jharwinbarrozo
    1.2M
  • CTL1206FYW1T
    CTL1206FYW1T
    Yellow 595nm LED Indication - Discrete 1.7V 1206 (3216 Metric)
    jharwinbarrozo
    1.1M
  • 1070TR
    1070TR
    Battery Holder (Open) Coin, 20.0mm 1 Cell SMD (SMT) Tab bate or batt #forLedBlink
    jharwinbarrozo
    700.5k
  • Push Button
    Push Button
    A momentary or non-latching switch which causes a temporary change in the state of an electrical circuit only while the switch is physically actuated. SWITCH TACTILE SPST-NO 0.05A 24V
    jharwinbarrozo
    490.7k
  • XY301V-A-5.0-3P
    XY301V-A-5.0-3P
    Straight 3 pin 5mm 3-pin Pitch 5mm 15A 1.5 300V Screw terminal block 01x03 #screwblock #connector #commonPartsLibrary
    jharwinbarrozo
    537.9k

ESP32-C3 LED Tube Controller

ESP32-C3 LED Tube Controller thumbnail
Two-board ESP32-C3 BLE controller for a 2S-powered, USB-C PD-charged 100-pixel 5 V LED tube with a six-button remote board.

Properties

Properties describe core aspects of the project.

Pricing & Availability

Distributor

Qty 1

Arrow

$12.90–$16.43

Digi-Key

$0.98

HQonline

$5.05

LCSC

$14.11

Mouser

$36.42

TME

$4.77

Verical

$13.94–$20.41

Controls