ESP32-EVB becomes unresponsive, when switching loads

Biblbub · May 03, 2025, 11:14:14 AM

Hello everyone,

I am running ESPHome on an Olimex ESP32-EVB-IND K1 Revision board.
The Olimex is connected to my network via wired Ethernet. No WiFi.
When I toggle the relay without any load, everything is fine.
But once I attach a lightbulb to switch #1 and connect it to mains, the device becomes unresponsive as soon as I flip the switch. It reboots after some time.

This is what my ESPHome yaml looks like:

Code Select

esphome:
  name: solarsteuerung

esp32:
  board: esp32-evb
  flash_size: 4MB
  framework:
    type: esp-idf

# Enable logging
logger:

# Enable Home Assistant API
api:
  password: ""

ethernet:
  type: LAN8720
  mdc_pin: GPIO23
  mdio_pin: GPIO18
  clk_mode: GPIO0_IN
  phy_addr: 0

one_wire:
  - platform: gpio
    pin: 16

sensor:
  - platform: dallas_temp
    address: 0x450623b23acfbb28
    name: "Solarsteuerung Puffertemperatur"
    update_interval: 20s
    icon: "mdi:thermometer"
    on_value:
      then:
        - lambda: !lambda |-
            if ((x >= id(solarsteuerung_temperaturschwelle_ein).state) &&
                      id(solarsteuerung_automatikbetrieb).state == 1.0 &&
                      !id(solarsteuerung_schalter_1).state) {
              id(solarsteuerung_schalter_1).turn_on();
              ESP_LOGI("main", "Puffertemperatur groesser als Einschaltwert, schalte Ein");
            } else if ((x <= id(solarsteuerung_temperaturschwelle_aus).state) &&
                             id(solarsteuerung_automatikbetrieb).state == 1.0 &&
                             id(solarsteuerung_schalter_1).state) {
              id(solarsteuerung_schalter_1).turn_off();
              ESP_LOGI("main", "Puffertemperatur kleiner als Ausschaltwert, schalte Aus");
            }

number:
  - platform: template
    name: "Solarsteuerung Temperaturschwelle EIN"
    id: solarsteuerung_temperaturschwelle_ein
    optimistic: true
    icon: "mdi:thermometer"
    initial_value: 100
    min_value: 0
    max_value: 200
    step: 5
    restore_value: true
    on_value:
      then:
        - lambda: !lambda |-
            if ( x <  (id(solarsteuerung_temperaturschwelle_aus).state)) {
              auto call = id(solarsteuerung_temperaturschwelle_aus).make_call();
              call.set_value(id(solarsteuerung_temperaturschwelle_ein).state - 20);
              call.perform();
              ESP_LOGI("main", "Einschaltwert kleiner als Ausschaltwert, verringere Ausschaltwert auf: %f", id(solarsteuerung_temperaturschwelle_aus).state);
            }
  - platform: template
    name: "Solarsteuerung Temperaturschwelle AUS"
    id: solarsteuerung_temperaturschwelle_aus
    optimistic: true
    icon: "mdi:thermometer"
    initial_value: 60
    min_value: 0
    max_value: 200
    step: 5
    restore_value: true
    on_value:
      then:
        - lambda: !lambda |-
            if ( x >  (id(solarsteuerung_temperaturschwelle_ein).state)) {
              auto call = id(solarsteuerung_temperaturschwelle_ein).make_call();
              call.set_value(id(solarsteuerung_temperaturschwelle_aus).state + 20);
              call.perform();
              ESP_LOGI("main", "Ausschaltwert groesser als Einschaltwert, erhoehe Einschaltwert auf: %f", id(solarsteuerung_temperaturschwelle_ein).state);
            }

switch:
  - platform: restart
    name: "Neustart"
    id: solarsteuerung_neustart
  - platform: gpio
    name: "Solarsteuerung Schalter 1"
    id: solarsteuerung_schalter_1
    pin: 32
  - platform: gpio
    name: "Solarsteuerung Schalter 2"
    id: solarsteuerung_schalter_2
    pin: 33
  - platform: template
    name: "Automatikbetrieb AN/AUS"
    id: solarsteuerung_automatikbetrieb
    optimistic: true
    icon: "mdi:cog-play-outline"
    restore_mode: RESTORE_DEFAULT_ON

select:
  - platform: logger
    name: "Logger select"

and these are the log messages I see in ESPHome from UART, when it was unresponsive for a while:

Code Select

[E][api:129]: No client connected to API. Rebooting...
[I][app:125]: Forcing a reboot...
[I][ethernet:604]: Powering down ethernet PHYets Jul 29 2019 12:21:46

rst:0xc (SW_CPU_RESET),boot:0x1b (SPI_FAST_FLASH_BOOT)
configsip: 0, SPIWP:0xee
clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
mode:DIO, clock div:2
load:0x3fff0030,len:7112
load:0x40078000,len:15624
load:0x40080400,len:4
load:0x40080404,len:3876
entry 0x4008064c
I (29) boot: ESP-IDF 5.1.5 2nd stage bootloader
I (29) boot: compile time Apr 28 2025 11:07:45
I (29) boot: Multicore bootloader
I (33) boot: chip revision: v3.1
I (37) boot.esp32: SPI Speed      : 40MHz
I (42) boot.esp32: SPI Mode       : DIO
I (46) boot.esp32: SPI Flash Size : 4MB
I (51) boot: Enabling RNG early entropy source...
I (56) boot: Partition Table:
I (60) boot: ## Label            Usage          Type ST Offset   Length
I (67) boot:  0 otadata          OTA data         01 00 00009000 00002000
I (75) boot:  1 phy_init         RF data          01 01 0000b000 00001000
I (82) boot:  2 app0             OTA app          00 10 00010000 001c0000
I (90) boot:  3 app1             OTA app          00 11 001d0000 001c0000
I (97) boot:  4 nvs              WiFi data        01 02 00390000 0006d000
I (105) boot: End of partition table
I (109) esp_image: segment 0: paddr=00010020 vaddr=3f400020 size=17cd0h ( 97488) map
I (153) esp_image: segment 1: paddr=00027cf8 vaddr=3ffb0000 size=0217ch (  8572) load
I (156) esp_image: segment 2: paddr=00029e7c vaddr=40080000 size=0619ch ( 24988) load
I (169) esp_image: segment 3: paddr=00030020 vaddr=400d0020 size=47b34h (293684) map
I (275) esp_image: segment 4: paddr=00077b5c vaddr=4008619c size=06a88h ( 27272) load
I (293) boot: Loaded app from partition at offset 0x10000
I (293) boot: Disabling RNG early entropy source...
I (305) cpu_start: Multicore app
I (306) cpu_start: Pro cpu up.
I (306) cpu_start: Starting app cpu, entry point is 0x40081cc0
I (293) cpu_start: App cpu up.
I (323) cpu_start: Pro cpu start user code
I (323) cpu_start: cpu freq: 160000000 Hz
I (323) cpu_start: Application information:
I (328) cpu_start: Project name:     solarsteuerung
I (334) cpu_start: App version:      2025.4.0
I (339) cpu_start: Compile time:     Apr 28 2025 11:07:29
I (345) cpu_start: ELF file SHA256:  0323c6c158d58eca...
I (351) cpu_start: ESP-IDF:          5.1.5
I (355) cpu_start: Min chip rev:     v0.0
I (360) cpu_start: Max chip rev:     v3.99
I (365) cpu_start: Chip rev:         v3.1
I (370) heap_init: Initializing. RAM available for dynamic allocation:
I (377) heap_init: At 3FFAE6E0 len 00001920 (6 KiB): DRAM
I (383) heap_init: At 3FFB38D0 len 0002C730 (177 KiB): DRAM
I (389) heap_init: At 3FFE0440 len 00003AE0 (14 KiB): D/IRAM
I (396) heap_init: At 3FFE4350 len 0001BCB0 (111 KiB): D/IRAM
I (402) heap_init: At 4008CC24 len 000133DC (76 KiB): IRAM
I (410) spi_flash: detected chip: generic
I (413) spi_flash: flash io: dio
I (418) app_start: Starting scheduler on CPU0
I (422) app_start: Starting scheduler on CPU1
I (422) main_task: Started on CPU0
I (432) main_task: Calling app_main()
[I][logger:171]: Log initialized
[I][app:029]: Running through setup()...

[C][ethernet:041]: Setting up Ethernet...
[D][esp-idf:000]: E (1141) eth_phy_802_3: esp_eth_phy_802_3_pwrctl(250): power up timeout
[D][esp-idf:000]: E (1141) eth_phy_802_3: esp_eth_phy_802_3_basic_phy_init(433): power control failed
[D][esp-idf:000]: E (1142) lan87xx: lan87xx_init(341): failed to init PHY
[D][esp-idf:000]: E (1142) esp_eth: esp_eth_driver_install(229): init phy failed
[E][ethernet:204]: ETH driver install error: (-1) ESP_FAIL
[E][component:119]: Component ethernet was marked as failed.
[E][component:164]: Component ethernet set Error flag: unspecified

Any idea what might be causing this?

Biblbub · May 03, 2025, 11:32:35 AM

I am using this power supply with 5V: https://cdn-reichelt.de/documents/datenblatt/D400/APV-8-SPEC.pdf may this cause the issue? Do I really need the 10W version to run the Olimex ESP32-EVB-IND soothly?

LubOlimex · May 05, 2025, 09:11:05 AM

I don't think this is related to the power supply. These are two problems:

1) Something hanging and causing reset of the Ethernet or the board. Likely the load is somehow hanging the board. Could be bigger than possible to toggle, could be lose connections, could be too close to the board, etc. Try with another, lower load and see how it behaves.

2) It is another problem that the Ethernet initialization fails. This hang happens if Ethernet is initialized too quickly after reset. Add some delay at the start of the code before the Ethernet initialization. For example, in Arduino try with:

void setup()
{
Serial.begin(115200);
delay (500);
WiFi.onEvent(WiFiEvent);
ETH.begin();
}

Experiment with delay value. Usually 500 is enough. But if it doesn't fix the issue use 1000 or 1500 or 2000.

There was such a problem in the past with some loads and we improved the reliability of the Ethernet during relay switching in revision I1 by adding capacitor C2 and since then we haven't had complaints. Your board is revision K which has the fix with capacitor C2 applied. Here is the change log:

https://github.com/OLIMEX/ESP32-EVB/blob/master/HARDWARE/README.md

We've done a lot of tests with loads in the past:

https://www.youtube.com/watch?v=1GCLtMmOKN8

https://www.youtube.com/watch?v=iTl9EQknGjA

https://www.youtube.com/watch?v=x3e_u8LgnTs

Biblbub · May 05, 2025, 06:13:03 PM

Hi,

thank you for the reply, if we focus on issue 1:
I tested pretty straightforward with two lamps.
The setup:

The lamp on PIN32 Relay is ON:

The lamp on PIN33 is ON:

Both lamps are ON:

I followed your links and the relays on your board are orange, while mine are black, could this cause the problems?

I should be nowhere near the power usage I saw in you video with the drill.

Biblbub · May 05, 2025, 06:48:58 PM

Switching the relays, without load is not a problem at all:
https://streamable.com/5vh9u0

But when I try to switch the relays with a load, I get only a few tries:
https://streamable.com/w4ba0t

I have attached a USB connector to see the logs in putty and when I try to switch with a load, this is what I get:

Code Select

[D][switch:012]: 'Solarsteuerung Schalter 2' Turning ON.
[D][switch:055]: 'Solarsteuerung Schalter 2': Sending state ON

[D][switch:016]: 'Solarsteuerung Schalter 2' Turning OFF.
[D][switch:055]: 'Solarsteuerung Schalter 2': Sending state OFF

[D][switch:012]: 'Solarsteuerung Schalter 1' Turning ON.
[D][switch:055]: 'Solarsteuerung Schalter 1': Sending state ON

[D][switch:016]: 'Solarsteuerung Schalter 1' Turning OFF.
[D][switch:055]: 'Solarsteuerung Schalter 1': Sending state OFF

[D][switch:012]: 'Solarsteuerung Schalter 2' Turning ON.
[D][switch:055]: 'Solarsteuerung Schalter 2': Sending state ON

[D][switch:012]: 'Solarsteuerung Schalter 1' Turning ON.
[D][switch:055]: 'Solarsteuerung Schalter 1': Sending state ON

[V][ethernet:411][sys_evt]: [Ethernet event] ETH disconnected (num=3)
[W][ethernet:274]: Connection via Ethernet lost! Re-connecting...
[W][component:157]: Component ethernet set Warning flag: waiting for IP configuration
[V][ethernet:472]: DHCP Client Status: 0
[W][api.connection:109]: Home Assistant 2025.4.4 (192.168.64.17): Network unavailable, disconnecting
[V][api:116]: Removing connection to Home Assistant 2025.4.4
[W][component:157]: Component api set Warning flag: unspecified
[W][ethernet:265]: Connecting via ethernet failed! Re-connecting...
[V][ethernet:472]: DHCP Client Status: 0
[W][ethernet:265]: Connecting via ethernet failed! Re-connecting...
[V][ethernet:472]: DHCP Client Status: 0

It lines up very well with what we see in the video

LubOlimex · May 06, 2025, 08:44:28 AM

The setup looks alright. Looks like only the Ethernet hangs not the whole board. Orange and black relays are similar, but we will test in similar terms as you.

Can you tell me about the bulbs that you used? Type, brand, wattage?

Can you test with other type or wattage of of bulbs?

Biblbub · May 06, 2025, 09:01:45 AM

I initially tested with these LED light bulbs: https://manuals.plus/m/e8c22ed756cd0095734a658d5bff9f7aeb5089dcd9e156197a70f3c7d48e967c.pdf

"OSRAM LED BASE CLASSIC A" - 6,5 W - model number AC03079

As requested, I also switched bulbs and replaced the OSRAM with IKEA LED1934G3 bulbs: https://www.ikea.com/de/en/p/tradfri-led-bulb-e27-250-lumen-smart-wireless-dimmable-warm-white-globe-40439254/ they have 2,7W.

I have the same problem with the IKEA bulbs as with the OSRAM bulbs

LubOlimex · May 06, 2025, 10:24:47 AM

So far I can't replicate it but I am waiting to get LED bulb, only have regular incandescent bulb. Attached it to both relays. In this video it is attached to relay 1:

https://www.youtube.com/watch?v=kJwsUbcyFOY

My wires are longer.

I am using variable power supply for the ESP32-EVB, it draws around 1W.

This is my Arduino IDE code, I use Arduino 1.8.19 and latest ESP32 package for Arduino (3.2.0):

Code Select

/*
    This sketch shows the Ethernet event usage

*/

// Important to be defined BEFORE including ETH.h for ETH.begin() to work.
// Example RMII LAN8720 (Olimex, etc.)
#ifndef ETH_PHY_MDC
#define ETH_PHY_TYPE ETH_PHY_LAN8720
#if CONFIG_IDF_TARGET_ESP32
#define ETH_PHY_ADDR  0
#define ETH_PHY_MDC   23
#define ETH_PHY_MDIO  18
#define ETH_PHY_POWER -1
#define ETH_CLK_MODE  ETH_CLOCK_GPIO0_IN
#elif CONFIG_IDF_TARGET_ESP32P4
#define ETH_PHY_ADDR  0
#define ETH_PHY_MDC   31
#define ETH_PHY_MDIO  52
#define ETH_PHY_POWER 51
#define ETH_CLK_MODE  EMAC_CLK_EXT_IN
#endif
#endif

#define RELAY1 32
#define RELAY2 33
#define BUTTON 34

#include <ETH.h>

static bool eth_connected = false;

// WARNING: onEvent is called from a separate FreeRTOS task (thread)!
void onEvent(arduino_event_id_t event) {
  switch (event) {
    case ARDUINO_EVENT_ETH_START:
      Serial.println("ETH Started");
      // The hostname must be set after the interface is started, but needs
      // to be set before DHCP, so set it from the event handler thread.
      ETH.setHostname("esp32-ethernet");
      break;
    case ARDUINO_EVENT_ETH_CONNECTED: Serial.println("ETH Connected"); break;
    case ARDUINO_EVENT_ETH_GOT_IP:
      Serial.println("ETH Got IP");
      Serial.println(ETH);
      eth_connected = true;
      break;
    case ARDUINO_EVENT_ETH_LOST_IP:
      Serial.println("ETH Lost IP");
      eth_connected = false;
      break;
    case ARDUINO_EVENT_ETH_DISCONNECTED:
      Serial.println("ETH Disconnected");
      eth_connected = false;
      break;
    case ARDUINO_EVENT_ETH_STOP:
      Serial.println("ETH Stopped");
      eth_connected = false;
      break;
    default: break;
  }
}

void testClient(const char *host, uint16_t port) {
  Serial.print("\nconnecting to ");
  Serial.println(host);

  NetworkClient client;
  if (!client.connect(host, port)) {
    Serial.println("connection failed");
    return;
  }
  client.printf("GET / HTTP/1.1\r\nHost: %s\r\n\r\n", host);
  while (client.connected() && !client.available());
  while (client.available()) {
    Serial.write(client.read());
  }

  Serial.println("closing connection\n");
  client.stop();
}

void setup() {
  Serial.begin(115200);
  Network.onEvent(onEvent);
  ETH.begin();
  pinMode (BUTTON, INPUT);
  pinMode (RELAY1, OUTPUT);
  pinMode (RELAY2, OUTPUT);
}

void loop() {
  if (eth_connected) {
    testClient("google.com", 80);
    while (!digitalRead (BUTTON));
    digitalWrite (RELAY1, HIGH);
    digitalWrite (RELAY2, LOW);
    delay (1000);
    digitalWrite (RELAY1, LOW);
    digitalWrite (RELAY2, HIGH);
    delay (1000);
}
  delay(1000);
}

LubOlimex · May 06, 2025, 10:46:16 AM

Now I got 10W LED bulb, I will also test with USB instead of the 5V DC from the variable supply.

Biblbub · May 06, 2025, 12:38:41 PM

I uploaded your code and the switching continues, but the Ethernet card seems to crash as well and it looks like it doesn't recover. It works for a few times and then the connection fails:

Code Select

ETH Started
ETH Connected
ETH Got IP
*eth0: <UP,100M,FULL_DUPLEX,AUTO,ADDR:0x0> (DHCPC,GARP,IP_MOD)
      ether A0:A3:B3:31:15:7F
      inet 192.168.178.75 netmask 255.255.255.0 broadcast 192.168.178.255
      gateway 192.168.178.1 dns 192.168.178.1


connecting to google.com
HTTP/1.1 301 Moved Permanently
Location: http://www.google.com/
Content-Type: text/html; charset=UTF-8
Content-Security-Policy-Report-Only: object-src 'none';base-uri 'self';script-src 'nonce-0Qa7DJ453lNiWRKtnacemw' 'strict-dynamic' 'report-sample' 'unsafe-eval' 'unsafe-inline' https: http:;report-uri https://csp.withgoogle.com/csp/gws/other-hp
Date: Tue, 06 May 2025 09:36:09 GMT
Expires: Thu, 05 Jun 2025 09:36:09 GMT
Cache-Control: public, max-age=2592000
Server: gws
Content-Length: 219
X-XSS-Protection: 0
X-Frame-Options: SAMEORIGIN

<HTML><HEAD><meta http-equiv="content-type" content="text/html;charset=utf-8">
                                                                              <TITLE>301 Moved</TITLE></HEAD><BODY>
                                                                                                                   <H1>301 Moved</H1>
           The document has moved
                                 <A HREF="http://www.google.com/">here</A>.
</BODY></HTML>
closing connection


connecting to google.com
HTTP/1.1 301 Moved Permanently
Location: http://www.google.com/
Content-Type: text/html; charset=UTF-8
Content-Security-Policy-Report-Only: object-src 'none';base-uri 'self';script-src 'nonce-tXHn53rHNohrS_Vq_dP7Dw' 'strict-dynamic' 'report-sample' 'unsafe-eval' 'unsafe-inline' https: http:;report-uri https://csp.withgoogle.com/csp/gws/other-hp
Date: Tue, 06 May 2025 09:36:12 GMT
Expires: Thu, 05 Jun 2025 09:36:12 GMT
Cache-Control: public, max-age=2592000
Server: gws
Content-Length: 219
X-XSS-Protection: 0
X-Frame-Options: SAMEORIGIN

<HTML><HEAD><meta http-equiv="content-type" content="text/html;charset=utf-8">
                                                                              <TITLE>301 Moved</TITLE></HEAD><BODY>
                                                                                                                   <H1>301 Moved</H1>
           The document has moved
                                 <A HREF="http://www.google.com/">here</A>.
</BODY></HTML>
closing connection


connecting to google.com
HTTP/1.1 301 Moved Permanently
Location: http://www.google.com/
Content-Type: text/html; charset=UTF-8
Content-Security-Policy-Report-Only: object-src 'none';base-uri 'self';script-src 'nonce-bwrpRWT5_nXVjpE7Eyww8w' 'strict-dynamic' 'report-sample' 'unsafe-eval' 'unsafe-inline' https: http:;report-uri https://csp.withgoogle.com/csp/gws/other-hp
Date: Tue, 06 May 2025 09:36:16 GMT
Expires: Thu, 05 Jun 2025 09:36:16 GMT
Cache-Control: public, max-age=2592000
Server: gws
Content-Length: 219
X-XSS-Protection: 0
X-Frame-Options: SAMEORIGIN

<HTML><HEAD><meta http-equiv="content-type" content="text/html;charset=utf-8">
                                                                              <TITLE>301 Moved</TITLE></HEAD><BODY>
                                                                                                                   <H1>301 Moved</H1>
           The document has moved
                                 <A HREF="http://www.google.com/">here</A>.
</BODY></HTML>
closing connection


connecting to google.com
HTTP/1.1 301 Moved Permanently
Location: http://www.google.com/
Content-Type: text/html; charset=UTF-8
Content-Security-Policy-Report-Only: object-src 'none';base-uri 'self';script-src 'nonce-sdF25WkmzZ0boF2zmevuYw' 'strict-dynamic' 'report-sample' 'unsafe-eval' 'unsafe-inline' https: http:;report-uri https://csp.withgoogle.com/csp/gws/other-hp
Date: Tue, 06 May 2025 09:36:19 GMT
Expires: Thu, 05 Jun 2025 09:36:19 GMT
Cache-Control: public, max-age=2592000
Server: gws
Content-Length: 219
X-XSS-Protection: 0
X-Frame-Options: SAMEORIGIN

<HTML><HEAD><meta http-equiv="content-type" content="text/html;charset=utf-8">
                                                                              <TITLE>301 Moved</TITLE></HEAD><BODY>
                                                                                                                   <H1>301 Moved</H1>
           The document has moved
                                 <A HREF="http://www.google.com/">here</A>.
</BODY></HTML>
closing connection


connecting to google.com
connection failed

connecting to google.com
connection failed

connecting to google.com
connection failed

LubOlimex · May 06, 2025, 01:01:40 PM

I also got it to hang but only when powering from USB. If there is power jack attached it doesn't hang here will do a lot more tests now and will report back.

Edit: I can't get it to hang in the same setup and code when I use incandescent regular bulb instead of LED. So type of bulb/load seem to matter.

Biblbub · May 06, 2025, 01:12:26 PM

Just a little additional information: I saw the same behaviour without USB attached and only the jack being used, couldn't get any logs though, as there was no UART output.

LubOlimex · May 06, 2025, 03:23:21 PM

I managed to hang both relays with different power supplies. I had to move the bulb around but all methods of powering and both relays hang, some cases faster than other. The closer the bulb to the board is the faster it hangs.

I think it is RF or/and EMI interference from the LED bulb, yet to discover what it influences, the LAN chip at the board directly or the power supply or the Ethernet cable or the relays.

I will now test with a battery to see if power supply is the influenced point.

I know it is popular problem with LEDs, a lot of people complain that LEDs interfere with their networks and garage doors:

https://www.reddit.com/r/led/comments/172hj6n/is_there_an_led_light_bulb_that_doesnt_interfere/

Try to place LED bulbs further away from the board or from the Ethernet cable and see if hangs remains. Try shielded Ethernet cable.

LubOlimex · May 06, 2025, 03:51:55 PM

Yeah upon some further testing and measurements - treat LED bulbs like EMI/RF emitters. Consider capacitors and ferrite beads (even clap-on will probably work), place LED bulbs away from sensitive equipment. Use shielded cables.

Biblbub · May 06, 2025, 04:34:22 PM

I tested with a single halogen light bulb and get the same result, so I think it is not necessarily a LED issue:

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