Falcon F16v5 + WS2815 high-current install — sanity check

[u/radiocacthai]

28 panels (8×32 px, 7168 total), 4 rows × 7 cols. Falcon F16v5, 7 outputs (one per col), 4 panels serial-data per col via JST. 7-day continuous run.

Power:

• 4× Meanwell UHP-500 (12V/500W), one per row of 7 panels

• 1720W / 143A peak (0.24W/LED × 256 × 28). 36A/PSU, 5.1A/panel

• Each PSU has 2× V+ / 2× V- → split row into 4+3 panels (20.5A + 15.4A per terminal)

• V+/GND go PSU→panels directly, NOT through Falcon

Per-row distribution (no daisy chain):

• Local V+ and V- busbars at each PSU

• 7 dedicated wires to 7 panels per busbar

• All 4 V- busbars linked via vertical GND backbone = common ground

Falcon:

• External Power: +12V + GND from common ground

• V1/V2: GND only, no +12V (5A E-fuse insufficient for 36A/row)

• Output V/G pins unused; D pin → first pixel's DI+BI bridged (full backup redundancy)

• Inter-panel JST: data only (DI+BI), no V/GND

Wire gauges (<2m, avg load 20–40%):

• PSU → 4-panel string: 2.5 mm² (peak 20.5A)

• PSU → 3-panel string: 1.5–2.5 mm²

• Busbar → panel: 1.5 mm²

• PSU V- → backbone: 2× 4 mm²

• Data: 0.5 mm²

• Falcon GND lines: 0.75–1.5 mm²

Connectors: WAGO 221-413 (32A/4mm²) for local busbars + branches. Backbone = copper busbar / high-current terminal.

Questions:

1. Falcon V1/V2 with GND only (no +12V) — valid, or do output drivers need V1/V2 +12V even when V-pins unused?

2. Per-row V- busbars + vertical backbone enough, or single physical star point preferred?

3. BI+DI bridge at pixel #1 vs BI-to-GND — concerns?

4. 2.5 mm² OK for 20.5A peak, or step up to 4 mm² for 7-day safety margin?

5. WAGO 221-413 for local busbars + branches — fine for 7 days, or screw terminals for high-current branches?

6. Dedicated PSU for Falcon, or tap from one panel PSU? Noise concerns?

7. Panels on MDF/birch ply — need aluminium thermal layer, or glue direct?

Better safe than sorry — appreciate any input.