# NaoDec Interactive wiring and schematics for a 7-channel WS2815 LED installation driven by dual ESP32-S3 controllers running WLED. Published at https://surasaknie.github.io/naodec/ (auto-indexed). --- ## Overview NaoDec is a browser-based documentation set for a large-scale addressable LED rig. All files are self-contained HTML — no build step, no dependencies. Open any file locally or browse the auto-indexed GitHub Pages site. The design uses two ESP32-S3-WROOM-1 N16R8 modules running WLED in a master/slave DDP configuration to drive 1,740 WS2815 (12 V) pixels across 7 independent channels, with a SN74AHCT245N octal transceiver for 3.3 V → 5 V logic conversion. --- ## Repository ``` naodec/ ├── index.html # GitHub Pages auto-index ├── NaoDec_Build_Work_Instructions.html # Rendered build start page (links into build/); shown on the site index ├── NaoDec_Build_Work_Instructions.md # Build sequence index (9 steps) — links to per-step docs ├── NaoDec_Build_Pending_Decisions.md # Recorded build decisions the step docs implement ├── NaoDec_Build_Step1_Base_Platform_Setup.md # Step 1: pallet, rise-up platform, chair platform ├── NaoDec_Build_Step2_Structure_Setup.md # Step 2: pentagon panels — build + hinged erection ├── NaoDec_Build_Step3_Vertex_Units_Installation.md # Step 3: vertex units (CH1) + series-coil co-route ├── NaoDec_Build_Step4_Internal_Edge_Units_Installation.md # Step 4: 6 edge LED circuits (CH2–CH7) ├── NaoDec_Build_Step5_Speaker_Installation.md # Step 5: 6 speakers on joint edges → GAB8 ├── NaoDec_Build_Step6_Move_In.md # Step 6: scent unit, subwoofer, chair + transducers ├── NaoDec_Build_Step7_Edge_Covers.md # Step 7: 25 external edge covers ├── NaoDec_Build_Step8_Controller_Unit_Hookup.md # Step 8: land node-1 cables into the controller unit ├── NaoDec_Build_Step9_Commissioning_and_Test.md # Step 9: power-up order, config, acceptance ├── build/ # Rendered HTML of each build step (reached from the start page, not the site index) ├── images/build/ # Snapshots of the 3D pages used in the build docs ├── NaoDec_WS2815_LED_Controller_Rev1.6.html # Full controller schematic (interactive) ├── NaoDec_3D_Structure_Framework_Rev1.0.html # Pure geometry: vertices/edges/faces, no LED wiring ├── NaoDec_3D_Vertex_and_Edges_LED_Mapping_Rev1.3.html # 3D LED position & channel map ├── NaoDec_Face_Edge_Marking_Rev1.0.html # 11-face dodecahedron edge-letter marking guide (fabric-frame build) ├── NaoDec_Face_Edge_Marking_Interactive_Rev1.0.html # Alternate design: same marking data, joint-highlight dropdown ├── NaoDec_Series_Coil_Build_Rev0_Pre-Release.html # Series coil / electromagnet subsystem (pre-release) ├── NaoDec_Vertex_Series_Coil_Rev1.0.html # Interactive series-coil schematic (current in-file Rev 1.0a) ├── XL4015_CC_CV_Mockup_Test_Procedure.md # Pre-coil converter qualification procedure ├── NaoDec_Media_Playback_Controller_Schematic_Rev3.0.html # ESP32-S3 operator panel + W5500 wired Ethernet (interactive, current) ├── NaoDec_Media_Playback_Controller_Schematic_Rev1.0.html # Previous revision (kept for reference) ├── NaoDec_Media_Playback_Controller_Rev3_Ethernet_Rationale.md # Why Rev 3.0 moved to wired Ethernet (6 m wire problem + new parts) ├── NaoDec_Media_Playback_Controller_Build_and_Max_Setup.md # Playback controller build, network & Max/MSP setup (Rev 3.2) ├── NaoDec_Media_Playback_Controller_Build_and_Max_Setup.docx # Word copy of the build/setup doc, for non-Markdown readers ├── NaoDec_Media_Playback_Controller_PlayPause_CrossTrigger_Fix.md # Play/Pause cross-trigger: GPIO9↔GPIO10 short — FW 3.1.2 guard + fix ├── Simple_WS2815_Controller_Rev_1.0.html # Simplified single-controller reference ├── firmware/ │ └── media_playback_controller/ # ESP32-S3 Arduino sketch — OSC operator panel └── Archived/ # Previous revisions ``` --- ## Hardware ### Controllers | Component | Part | Notes | |-----------|------|-------| | U1 — Master | ESP32-S3-WROOM-1 N16R8 | WLED master · CH1–CH4 (GPIO1, 4, 5, 6) | | U1 — Slave | ESP32-S3-WROOM-1 N16R8 | WLED DDP slave · CH5–CH7 (GPIO4, 5, 6) | | U2 | SN74AHCT245N | Octal bus transceiver · 3.3 V → 5 V · 7 ch used | | R1–R7 | 47 Ω ¼W metal film | Source-end termination, ≤20 mm from U2 | | C1 | 1000 µF 25 V electrolytic | Smoothing cap · 12 V 5 A rail | | C2–C6, C8 | 1000 µF 25 V electrolytic | Bypass caps at each strip input | | C7 | 100 nF ceramic | U2 VCC decoupling | | NTC1 | 10 Ω / 10 A NTC | Inrush limiter · 12 V 50 A rail | | F1 | 7.5 A ATC/ATO blade fuse | Strip #1 branch | | FB1 | 6-ch ATC/ATO fuse block | Strips #2–#7 · F2–F7 · 7.5 A each | ### Power Rails | Rail | Supply | Load | |------|--------|------| | 5 V logic | PSU 5 V 3 A (15 W) | Master Vin · Slave Vin · U2 VCC | | 12 V (5 A) | PSU 12 V 5 A (60 W) | Strip #1 — Vertex set (60 LEDs · ~0.9 A) | | 12 V (50 A) | PSU 12 V 50 A (600 W) | Strips #2–#7 — Edge sets (~25.2 A max) | > **⚠ Never connect the 5 V, 12 V 5 A, and 12 V 50 A positive rails together. Keep all V+ rails fully isolated.** ### LED Channels | CH | GPIO (board) | Buffer | Strip | LEDs | Cable | Wire AWG | |----|-------------|--------|-------|------|-------|----------| | 1 | GPIO1 (Master) | U2 A1→B1 | #1 Vertex | 60 | ~20 m | 18 | | 2 | GPIO4 (Master) | U2 A2→B2 | #2 Edge A | 280 | ~8 m | 12 | | 3 | GPIO5 (Master) | U2 A3→B3 | #3 Edge B | 280 | ~8 m | 12 | | 4 | GPIO6 (Master) | U2 A4→B4 | #4 Edge C | 280 | ~8 m | 12 | | 5 | GPIO4 (Slave) | U2 A5→B5 | #5 Edge D | 280 | ~8 m | 12 | | 6 | GPIO5 (Slave) | U2 A6→B6 | #6 Edge E | 280 | ~8 m | 12 | | 7 | GPIO6 (Slave) | U2 A7→B7 | #7 Edge F | 280 | ~8 m | 12 | **Total: 1,740 × WS2815 (12 V)** --- ## Physical Structure The rig is a regular dodecahedron: 20 vertices, 30 edges, 12 pentagon faces (Euler check 20−30+12=2). The pure geometry — vertex/edge/face numbering (v1–v20, f1–f12), no LED wiring — is in [`NaoDec_3D_Structure_Framework_Rev1.0.html`](NaoDec_3D_Structure_Framework_Rev1.0.html). Vertices and node numbers are hidden by default (toggle back on via Display); the default view is the 30 structural edges, each carrying its physical assembly letter (A–Z, no W) from the marking guides below — f1 is the top, f11 is the door, and the 5 base edges bordering the unbuilt bottom face `f12` are shown as OPEN (they rest on the platform). The full LED vertex/edge circuit mapping is in [`NaoDec_3D_Vertex_and_Edges_LED_Mapping_Rev1.3.html`](NaoDec_3D_Vertex_and_Edges_LED_Mapping_Rev1.3.html). Eleven of the 12 faces are built as wooden-frame + stretched-fabric panels (`f12`, the bottom, is intentionally left unbuilt as the entry opening). Every shared edge between two built faces is marked with the same letter, so on-site assembly and tear-down only require matching identical letters — no face numbering or lookup needed. Full marking guide, with a labeled diagram per face and an auto-validated edge cross-reference: [`NaoDec_Face_Edge_Marking_Rev1.0.html`](NaoDec_Face_Edge_Marking_Rev1.0.html). An alternate design covering the same 11-face marking data, with an interactive joint-highlight dropdown instead of a static-only reference table, is in [`NaoDec_Face_Edge_Marking_Interactive_Rev1.0.html`](NaoDec_Face_Edge_Marking_Interactive_Rev1.0.html). - Face numbers in the marking guides match the 3D framework's `f1`–`f12` face ids. - **Face 1** is the top (`f1`), opposite the unbuilt bottom. - **Face 11** is the door (`f11`). - Faces 7–11 carry the 5 unlettered edges that rest directly on the platform/ground instead of meeting another face (the bottom face isn't built). --- ## Build Work Instructions Step-by-step physical build sequence, indexed from one top-level file: [`NaoDec_Build_Work_Instructions.md`](NaoDec_Build_Work_Instructions.md). Nine self-contained step docs run from the base platform through structure, LED/vertex/edge install, speakers, move-in (chair · subwoofer · scent), edge covers, controller-unit hookup, and commissioning. The build decisions the docs implement are recorded in [`NaoDec_Build_Pending_Decisions.md`](NaoDec_Build_Pending_Decisions.md). A rendered, self-contained HTML version is published from the start page [`NaoDec_Build_Work_Instructions.html`](NaoDec_Build_Work_Instructions.html) (the only build page listed on the site index); it links to each step's rendered page under [`build/`](build/), with the Mermaid diagrams pre-rendered inline so the pages need no network or build step to view. > **Status:** Steps 1–9 drafted from the author's full outline; hardware specifics still marked TBD > are flagged per step, and cross-cutting gaps (occupant safety, door mechanism, controller-unit > build, teardown) are in the index's Open Items. --- ## Series Coil / Electromagnet Subsystem Sixty hand-wound copper coils are wired end-to-end in one series loop. Each coil has 7 turns of 1 mm copper around a **12.5 mm ID crystal core**, with 5 cm of straight lead before the winding and 7 cm after it. The calculated copper length is approximately 0.417 m per coil and 25.0 m for all 60 coils. Full design write-up: [`NaoDec_Series_Coil_Build_Rev0_Pre-Release.html`](NaoDec_Series_Coil_Build_Rev0_Pre-Release.html). Interactive schematic: [`NaoDec_Vertex_Series_Coil_Rev1.0.html`](NaoDec_Vertex_Series_Coil_Rev1.0.html). Standalone converter test: [`XL4015_CC_CV_Mockup_Test_Procedure.md`](XL4015_CC_CV_Mockup_Test_Procedure.md). > **⚠ An inductor does nothing on steady-state DC** (`Z = jωL → 0` at DC). The current cold-loop estimate is **~1.85 Ω**: approximately 0.55 Ω for all coils plus 1.30 Ω measured for all 20 AWG installation wiring. Direct connection to 12 V would attempt approximately 6.5 A and 78 W if the PSU allowed it. > **⚠ A crystal core is non-magnetic** (μ ≈ air) — it gives **no field boost**, so the coils behave as weak air-core coils. At the 3 A current limit, each 7-turn coil produces approximately 21 ampere-turns. ### Interactive Schematic (Rev 1.0a) [Open the live Vertex Series Coil schematic](https://surasaknie.github.io/naodec/NaoDec_Vertex_Series_Coil_Rev1.0.html). The current in-file revision is **Rev 1.0a**, presented in the Dark Blue-Mint technical theme. It documents the complete current-limited path: `12 V PSU → exact 3 A T-type fuse → local 220–470 µF + 100 nF input decoupling → dual-pot XL4015 → 70–80 °C thermal cutoff → 20 groups / 60 coils → 20 AWG return` The page includes: - Current design values: ~1.85 Ω cold-loop estimate, 3.0 A CC, ~5.55 V loaded output, and ~16.65 W total output. - Compact one-group coil detail, direct-12 V warning, and pre-release bench-qualification banner. - BOM, XL4015 harness, protection summary, engineering notes, and revision history. - Hover/focus tooltips, zoom, pan, touch support, keyboard shortcuts, fit-to-screen, print SVG export, and themed PNG export. - Explicit provisional-status messaging pending the final assembled-loop resistance and thermal commissioning measurements. ### Wiring Loop topology: ```mermaid flowchart LR PSU["12 V PSU (+)"] --> F["3 A slow-blow fuse"] F --> B["XL4015 CC/CV
CV 11 V · CC 3 A"] B --> T["70–80 °C TCO"] T --> G1["Group 1
3 coils"] G1 -->|"1 m"| G2["Group 2
3 coils"] G2 -.->|"..."| G20["Group 20
3 coils"] G20 -->|"6 m return"| PSUN["12 V PSU (-)"] ``` One coil geometry: ```mermaid flowchart LR IN["Series input"] -->|"5 cm straight lead"| C1(["7 turns · 12.5 mm ID"]) C1 -->|"7 cm straight lead"| OUT["Series output"] ``` ### Bill of Materials | Component | Spec | Notes | |-----------|------|-------| | Coils | 60 × 7-turn, 1 mm Cu, ~0.417 m each | 12.5 mm ID **crystal core**; 5 cm input lead + 7 cm output lead; ~0.55 Ω total calculated at 20 °C | | Cable | 20 AWG installation wiring, measured ~1.30 Ω total | All interconnect and return wiring; keep every run and all slack uncoiled | | Connectors | 20 × JST SM 2-pin | Both pins paralleled onto the series conductor; OK once the buck caps the loop at ~3 A (single SM pin = 3 A). VH (10 A) / XT30 / Anderson are higher-margin alternatives | | PSU | 12 V DC | Feeds the buck input; may be a shared rail, but keep this branch fused and V+ isolated | | CC/CV buck module | Dual-pot XL4015 HW-083-B, 12 V input | Set CV to 11.0 V and CC to 3.0 A; loaded output settles near 5.55 V in CC mode | | Input decoupling | 220–470 µF low-ESR electrolytic (≥25 V) ‖ 100 nF X7R (≥25 V) | Mount directly across XL4015 IN+/IN− | | Fuse | 3 A slow-blow (T-type), inline at buck input | **Exactly 3 A, not 3–5 A.** CC regulation is not fault interruption; a buck can fail shorted | | Thermal cutoff | 70–80 °C, rated ≥5 A | Required for a manned installation; bond to hottest connector/cable area | | Crystal cores | 1 per coil | Per design — non-magnetic, no field boost | | Flyback diode *(opt.)* | 1N4007 / 1N5819 | Kick is tiny (~0.4 mJ); only if switched electronically | ### Electrical Summary | Quantity | Value | Note | |----------|-------|------| | Coil resistance | ~0.55 Ω calculated | ~0.009 Ω per coil; an individual coil displays `0.0 Ω` on a 0.1 Ω-resolution meter | | Wiring resistance | ~1.30 Ω measured | Complete 20 AWG installation wiring | | Complete cold loop | ~1.85 Ω estimated | Confirm end-to-end after assembly; joints and copper temperature add variation | | Direct 12 V, no buck | ~6.5 A / ~78 W | Unsafe if the PSU can supply it; do not use this operating mode | | XL4015 operating point | 3.0 A / ~5.55 V / ~16.65 W | CV ceiling 11.0 V; converter operates in CC mode under load | | Voltage split at 3 A | ~3.90 V wiring / ~1.65 V coils | Determined by the 1.30 Ω / 0.55 Ω resistance split | | Power split at 3 A | ~11.70 W wiring / ~4.95 W coils | ~0.083 W per coil; keep wiring uncoiled for heat rejection | | Estimated input | ~1.5–1.7 A from 12 V | Depends on converter efficiency and component tolerance | | Field per coil | ~21 AT | 7 turns × 3 A; crystal core provides no magnetic gain | > **⚠ Safety:** use only the dual-pot CC/CV XL4015, set CV to 11.0 V and CC to 3.0 A. Install an exact 3 A slow-blow input fuse, local input decoupling, and a 70–80 °C thermal cutoff for manned operation. Keep the complete 20 AWG run uncoiled, keep bare copper from touching, and keep this V+ rail isolated from the LED rails. Never run the string without the buck. ### XL4015 Mockup Qualification Before connecting the real coils, reproduce the ~1.85 Ω loop with the measured 1.30 Ω mock wire and a ~0.56 Ω resistor bank. A practical metal-film bank is 10 × 5.6 Ω/1 W in parallel, giving 0.56 Ω/10 W. At the 3.0 A CC setting, expect approximately 5.58 V total, 3.90 V across the mock wire, and 1.68 V across the resistor bank. The ammeter is connected in series after XL4015 OUT+. See [`XL4015_CC_CV_Mockup_Test_Procedure.md`](XL4015_CC_CV_Mockup_Test_Procedure.md) for the complete wiring and pass/fail procedure. --- ## Signal Flow ``` Mac mini └─ USB-C → UART ──► ESP32-S3 Master (WLED) ├─ GPIO1/4/5/6 → U2 (3.3V→5V) → R1–R4 → CH1–CH4 └─ DDP (Wi-Fi) ──► ESP32-S3 Slave (WLED) └─ GPIO4/5/6 → U2 → R5–R7 → CH5–CH7 ``` The master calculates all effects and streams pixel data to the slave over DDP/Wi-Fi. The slave is a pure DDP receiver — no local effect computation. --- ## Firmware Both controllers run **WLED** . - Master: standard WLED instance, outputs CH1–CH4 - Slave: WLED configured as DDP receiver, outputs CH5–CH7 - Host: Mac mini sends WLED / Art-Net data via USB-C to UART > Avoid strapping pins **GPIO 0, 3, 45, 46** on the ESP32-S3 — these conflict with boot mode. ### Media Playback Controller Custom Arduino firmware: [`firmware/media_playback_controller/`](firmware/media_playback_controller/). An ESP32-S3-DevKitC-1 operator panel that reads a rotary volume encoder and Play/Pause/Stop buttons and sends OSC-over-UDP commands to a Max/MSP patch — no audio/video/LED data passes through this board. Firmware 3.x matches hardware Rev 3.0: the panel joins the LAN over wired Ethernet (WIZnet W5500 SPI module), DHCP-reserved at `192.168.50.114` — nothing to provision, no credentials in the sketch. See [`NaoDec_Media_Playback_Controller_Build_and_Max_Setup.md`](NaoDec_Media_Playback_Controller_Build_and_Max_Setup.md) for the full hardware build, network setup, OSC contract, and acceptance tests. --- ## Usage All documents are static HTML. No installation required. ```bash # Clone and open locally git clone https://github.com/SurasakNie/naodec.git open naodec/NaoDec_WS2815_LED_Controller_Rev1.6.html ``` Or browse online: **https://surasaknie.github.io/naodec/** Each schematic supports: - **Pan** — click and drag - **Zoom** — scroll wheel or `+` / `-` buttons - **Component info** — click any component or wire for a tooltip --- ## Revisions | File | Rev | Notes | |------|-----|-------| | NaoDec_WS2815_LED_Controller | 1.6 | Current · 7-ch dual ESP32-S3 DDP | | NaoDec_3D_Structure_Framework | 1.0 | Current · pure vertex/edge/face geometry, no LED wiring | | NaoDec_3D_Vertex_and_Edges_LED_Mapping | 1.3 | Current · 3D position map | | NaoDec_Face_Edge_Marking | 1.0 | Current · edge-letter marks for the 11 built faces (bottom face not built) | | NaoDec_Face_Edge_Marking_Interactive | 1.0 | Current · alternate design, same marking data, interactive joint-highlight dropdown | | NaoDec_Series_Coil_Build | 0 (pre-release) | Pre-release · 60-coil series electromagnet subsystem | | Simple_WS2815_Controller | 1.0 | Single-controller reference | | NaoDec_Controller_Box_Configs | 1.1 | Current · electrical enclosure vs PC case · audited power calculations | | NaoDec_Power_and_Controller_Box_Report | 1.0 | Full power budget, PSU specs, voltage-drop analysis, audit findings | | NaoDec_Build_Work_Instructions | 1.1 | Build sequence index (9 steps) + orientation/terminology + sequence-level open items | | NaoDec_Build_Pending_Decisions | — | Decision record · 10 answered build decisions the step docs implement | | NaoDec_Build_Step1_Base_Platform_Setup | 1.1 | Pallet, rise-up platform, chair platform — materials/load rating pending | | NaoDec_Build_Step2_Structure_Setup | 1.1 | Pentagon panels — build + hinged pairs + erection sequence | | NaoDec_Build_Step3_Vertex_Units_Installation | 1.0 | Vertex units (CH1) + series-coil co-route to node 1 | | NaoDec_Build_Step4_Internal_Edge_Units_Installation | 1.0 | 6 edge LED circuits (CH2–CH7) along the 30 edges | | NaoDec_Build_Step5_Speaker_Installation | 1.0 | 6 speakers on joint edges → Wondom GAB8 | | NaoDec_Build_Step6_Move_In | 1.0 | Scent unit, subwoofer, chair + 4 transducers + media controller | | NaoDec_Build_Step7_Edge_Covers | 1.0 | 25 external edge covers over the lettered joints | | NaoDec_Build_Step8_Controller_Unit_Hookup | 1.0 | Land node-1 cables into the controller unit (Node 0) | | NaoDec_Build_Step9_Commissioning_and_Test | 1.0 | Power-up order, network/WLED/audio/scent/coil tests | | NaoDec_Display_Setup_Requirements | 1.7 | Department-store setup requirements (store-facing) · full connected-load inventory · power @ 1.25× current setup, 220 V single-phase, 10 h/day | | NaoDec_Display_Setup_Notes | 1.0 | Internal team notes companion — full derivation, revision history, and sources behind the Display Setup Requirements figures | --- ## License MIT — see [LICENSE](LICENSE)