fyi: The 3A converter works fine as expected.  BTW: I also figured out that for my project current draw at startup is highest. I could therefore use the 1.5A converter without issue if I just restart the ESP32 when it is powering up cold.  Like so:

int reason = esp_reset_reason();

sp2("Reset reason = ", reason);

if ( reason != RESET_REASON_CORE_SW ) {
   vTaskDelay(1000 / portTICK_PERIOD_MS);
   ESP.restart();
}

That insures the stepper motor driver isn't getting initialized during the “brownout” period during startup.

The datasheet says it can be powered with 3.3 or 5v but I found it was unstable when powered with 3.3v.  Powering it with 5v is much better but one thing related to the speaker is still odd. When I give the pre-programmed command, “volume up” it turns up the volume on its speaker.  The documentation doesn't suggest that this command is any different than the others.  So you might need a custom command for controlling project-connected speakers such as my Internet Radio.

It's 2025 and the problem seems to remain with an additional wrinkle.  Problem #2: I'm using the SEN0539 as part of an Internet Radio project.  The darn thing falsely wakes up when I'm listening to talk radio.  My custom wake word is Zenith because I've put the whole thing into a 1940's Zenith radio box.  It's a bummer because when the VR module wakes up, the radio speaker is muted so the the following commands don't get lost or confused with the radio.

To solve the second problem, I'll try changing the custom wake word to “Hey, Zenith” – in any case I am also finding the my custom wake word stops working after a while and until Hey Robot is used.

OTOH, it's pretty awesome to say NPR, watch the tuner needle sweep across the dial and hear the voice of Noel King come booming out. If I have to wake it up with hello robot, it will still be awesome.