feat: fault state gpio setting replaced with cascade control

2025-12-11 02:34:29 +05:00 · 2024-10-18 06:14:09 +03:00
parent 57cf98ca19
commit 7f701a74e7
9 changed files with 506 additions and 117 deletions
--- a/src/MainTask.h
+++ b/src/MainTask.h
@@ -119,6 +119,7 @@ protected:

    this->emergency();
    this->ledStatus();
+    this->cascadeControl();
    this->externalPump();
    this->yield();

@@ -336,6 +337,170 @@ protected:
    this->blinker->tick();
  }

+  void cascadeControl() {
+    static uint8_t configuredInputGpio = GPIO_IS_NOT_CONFIGURED;
+    static uint8_t configuredOutputGpio = GPIO_IS_NOT_CONFIGURED;
+    static bool inputTempValue = false;
+    static unsigned long inputChangedTs = 0;
+    static bool outputTempValue = false;
+    static unsigned long outputChangedTs = 0;
+
+    // input
+    if (settings.cascadeControl.input.enable) {
+      if (settings.cascadeControl.input.gpio != configuredInputGpio) {
+        if (configuredInputGpio != GPIO_IS_NOT_CONFIGURED) {
+          pinMode(configuredInputGpio, OUTPUT);
+          digitalWrite(configuredInputGpio, LOW);
+
+          Log.sinfoln(FPSTR(L_CASCADE_INPUT), F("Deinitialized on GPIO %hhu"), configuredInputGpio);
+        }
+        
+        if (GPIO_IS_VALID(settings.cascadeControl.input.gpio)) {
+          configuredInputGpio = settings.cascadeControl.input.gpio;
+          pinMode(configuredInputGpio, INPUT);
+
+          Log.sinfoln(FPSTR(L_CASCADE_INPUT), F("Initialized on GPIO %hhu"), configuredInputGpio);
+
+        } else if (configuredInputGpio != GPIO_IS_NOT_CONFIGURED) {
+          configuredInputGpio = GPIO_IS_NOT_CONFIGURED;
+
+          Log.swarningln(FPSTR(L_CASCADE_INPUT), F("Failed initialize: GPIO %hhu is not valid!"), configuredInputGpio);
+        }
+      }
+
+      if (configuredInputGpio != GPIO_IS_NOT_CONFIGURED) {
+        bool value;
+        if (digitalRead(configuredInputGpio) == HIGH) {
+          value = true ^ settings.cascadeControl.input.invertState;
+        } else {
+          value = false ^ settings.cascadeControl.input.invertState;
+        }
+
+        if (value != vars.cascadeControl.input) {
+          if (value != inputTempValue) {
+            inputTempValue = value;
+            inputChangedTs = millis();
+
+          } else if (millis() - inputChangedTs >= settings.cascadeControl.input.thresholdTime * 1000u) {
+            vars.cascadeControl.input = value;
+
+            Log.sinfoln(
+              FPSTR(L_CASCADE_INPUT),
+              F("State changed to %s"),
+              value ? F("TRUE") : F("FALSE")
+            );
+          }
+
+        } else if (value != inputTempValue) {
+          inputTempValue = value;
+        }
+      }
+    }
+    
+    if (!settings.cascadeControl.input.enable || configuredInputGpio == GPIO_IS_NOT_CONFIGURED) {
+      if (!vars.cascadeControl.input) {
+        vars.cascadeControl.input = true;
+
+        Log.sinfoln(
+          FPSTR(L_CASCADE_INPUT),
+          F("Disabled, state changed to %s"),
+          vars.cascadeControl.input ? F("TRUE") : F("FALSE")
+        );
+      }
+    }
+
+
+    // output
+    if (settings.cascadeControl.output.enable) {
+      if (settings.cascadeControl.output.gpio != configuredOutputGpio) {
+        if (configuredOutputGpio != GPIO_IS_NOT_CONFIGURED) {
+          pinMode(configuredOutputGpio, OUTPUT);
+          digitalWrite(configuredOutputGpio, LOW);
+
+          Log.sinfoln(FPSTR(L_CASCADE_OUTPUT), F("Deinitialized on GPIO %hhu"), configuredOutputGpio);
+        }
+        
+        if (GPIO_IS_VALID(settings.cascadeControl.output.gpio)) {
+          configuredOutputGpio = settings.cascadeControl.output.gpio;
+          pinMode(configuredOutputGpio, OUTPUT);
+          digitalWrite(
+            configuredOutputGpio,
+            settings.cascadeControl.output.invertState
+              ? HIGH 
+              : LOW
+          );
+
+          Log.sinfoln(FPSTR(L_CASCADE_OUTPUT), F("Initialized on GPIO %hhu"), configuredOutputGpio);
+
+        } else if (configuredOutputGpio != GPIO_IS_NOT_CONFIGURED) {
+          configuredOutputGpio = GPIO_IS_NOT_CONFIGURED;
+
+          Log.swarningln(FPSTR(L_CASCADE_OUTPUT), F("Failed initialize: GPIO %hhu is not valid!"), configuredOutputGpio);
+        }
+      }
+
+      if (configuredOutputGpio != GPIO_IS_NOT_CONFIGURED) {
+        bool value = false;
+        if (settings.cascadeControl.output.onFault && vars.states.fault) {
+          value = true;
+
+        } else if (settings.cascadeControl.output.onLossConnection && !vars.states.otStatus) {
+          value = true;
+
+        } else if (settings.cascadeControl.output.onEnabledHeating && settings.heating.enable && vars.cascadeControl.input) {
+          value = true;
+        }
+
+        if (value != vars.cascadeControl.output) {
+          if (value != outputTempValue) {
+            outputTempValue = value;
+            outputChangedTs = millis();
+            
+          } else if (millis() - outputChangedTs >= settings.cascadeControl.output.thresholdTime * 1000u) {
+            vars.cascadeControl.output = value;
+
+            digitalWrite(
+              configuredOutputGpio,
+              vars.cascadeControl.output ^ settings.cascadeControl.output.invertState
+                ? HIGH
+                : LOW
+            );
+
+            Log.sinfoln(
+              FPSTR(L_CASCADE_OUTPUT),
+              F("State changed to %s"),
+              value ? F("TRUE") : F("FALSE")
+            );
+          }
+
+        } else if (value != outputTempValue) {
+          outputTempValue = value;
+        }
+      }
+    }
+
+    if (!settings.cascadeControl.output.enable || configuredOutputGpio == GPIO_IS_NOT_CONFIGURED) {
+      if (vars.cascadeControl.output) {
+        vars.cascadeControl.output = false;
+
+        if (configuredOutputGpio != GPIO_IS_NOT_CONFIGURED) {
+          digitalWrite(
+            configuredOutputGpio,
+            vars.cascadeControl.output ^ settings.cascadeControl.output.invertState
+              ? HIGH
+              : LOW
+          );
+        }
+
+        Log.sinfoln(
+          FPSTR(L_CASCADE_OUTPUT),
+          F("Disabled, state changed to %s"),
+          vars.cascadeControl.output ? F("TRUE") : F("FALSE")
+        );
+      }
+    }
+  }
+
  void externalPump() {
    static uint8_t configuredGpio = GPIO_IS_NOT_CONFIGURED;

--- a/src/OpenThermTask.h
+++ b/src/OpenThermTask.h
@@ -28,8 +28,6 @@ protected:
  unsigned long dhwSetTempTime = 0;
  unsigned long heatingSetTempTime = 0;
  byte configuredRxLedGpio = GPIO_IS_NOT_CONFIGURED;
-  byte configuredFaultStateGpio = GPIO_IS_NOT_CONFIGURED;
-  bool faultState = false;

  #if defined(ARDUINO_ARCH_ESP32)
  const char* getTaskName() override {
@@ -133,28 +131,7 @@ protected:
      }
    }

-    // Fault state setup
-    if (settings.opentherm.faultStateGpio != this->configuredFaultStateGpio) {
-      if (this->configuredFaultStateGpio != GPIO_IS_NOT_CONFIGURED) {
-        digitalWrite(this->configuredFaultStateGpio, LOW);
-      }
-      
-      if (GPIO_IS_VALID(settings.opentherm.faultStateGpio)) {
-        this->configuredFaultStateGpio = settings.opentherm.faultStateGpio;
-        this->faultState = false ^ settings.opentherm.invertFaultState ? HIGH : LOW;
-
-        pinMode(this->configuredFaultStateGpio, OUTPUT);
-        digitalWrite(
-          this->configuredFaultStateGpio,
-          this->faultState
-        );
-
-      } else if (this->configuredFaultStateGpio != GPIO_IS_NOT_CONFIGURED) {
-        this->configuredFaultStateGpio = GPIO_IS_NOT_CONFIGURED;
-      }
-    }
-
-    bool heatingEnabled = (vars.states.emergency || settings.heating.enable) && this->pump && this->isReady();
+    bool heatingEnabled = (vars.states.emergency || settings.heating.enable) && this->pump && vars.cascadeControl.input && this->isReady();
    bool heatingCh2Enabled = settings.opentherm.heatingCh2Enabled;
    if (settings.opentherm.heatingCh1ToCh2) {
      heatingCh2Enabled = heatingEnabled;
@@ -212,16 +189,6 @@ protected:
      vars.states.fault = false;
      vars.states.diagnostic = false;

-      // Force fault state = on
-      if (this->configuredFaultStateGpio != GPIO_IS_NOT_CONFIGURED) {
-        bool fState = true ^ settings.opentherm.invertFaultState ? HIGH : LOW;
-
-        if (fState != this->faultState) {
-          this->faultState = fState;
-          digitalWrite(this->configuredFaultStateGpio, this->faultState);
-        }
-      }
-
      return;
    }

@@ -251,16 +218,6 @@ protected:
      vars.states.heating, vars.states.dhw, vars.states.flame, vars.states.fault, vars.states.diagnostic
    );

-    // Fault state
-    if (this->configuredFaultStateGpio != GPIO_IS_NOT_CONFIGURED) {
-      bool fState = vars.states.fault ^ settings.opentherm.invertFaultState ? HIGH : LOW;
-      
-      if (fState != this->faultState) {
-        this->faultState = fState;
-        digitalWrite(this->configuredFaultStateGpio, this->faultState);
-      }
-    }
-
    // These parameters will be updated every minute
    if (millis() - this->prevUpdateNonEssentialVars > 60000) {
      if (this->updateMinModulationLevel()) {
--- a/src/Settings.h
+++ b/src/Settings.h
@@ -51,8 +51,6 @@ struct Settings {
    byte inGpio = DEFAULT_OT_IN_GPIO;
    byte outGpio = DEFAULT_OT_OUT_GPIO;
    byte rxLedGpio = DEFAULT_OT_RX_LED_GPIO;
-    byte faultStateGpio = DEFAULT_OT_FAULT_STATE_GPIO;
-    byte invertFaultState = false;
    unsigned int memberIdCode = 0;
    uint8_t maxModulation = 100;
    float pressureFactor = 1.0f;
@@ -156,6 +154,25 @@ struct Settings {
    unsigned short antiStuckTime = 300;
  } externalPump;

+  struct {
+    struct {
+      bool enable = false;
+      byte gpio = GPIO_IS_NOT_CONFIGURED;
+      byte invertState = false;
+      unsigned short thresholdTime = 60;
+    } input;
+
+    struct {
+      bool enable = false;
+      byte gpio = GPIO_IS_NOT_CONFIGURED;
+      byte invertState = false;
+      unsigned short thresholdTime = 60;
+      bool onFault = true;
+      bool onLossConnection = true;
+      bool onEnabledHeating = false;
+    } output;
+  } cascadeControl;
+
  char validationValue[8] = SETTINGS_VALID_VALUE;
 } settings;

@@ -205,6 +222,11 @@ struct Variables {
    float exhaust = 0.0f;
  } temperatures;

+  struct {
+    bool input = false;
+    bool output = false;
+  } cascadeControl;
+
  struct {
    bool heatingEnabled = false;
    byte heatingMinTemp = DEFAULT_HEATING_MIN_TEMP;
--- a/src/strings.h
+++ b/src/strings.h
@@ -24,4 +24,6 @@ const char L_SENSORS_INDOOR[]       PROGMEM = "SENSORS.INDOOR";
 const char L_SENSORS_BLE[]          PROGMEM = "SENSORS.BLE";
 const char L_REGULATOR[]            PROGMEM = "REGULATOR";
 const char L_REGULATOR_PID[]        PROGMEM = "REGULATOR.PID";
-const char L_REGULATOR_EQUITHERM[]  PROGMEM = "REGULATOR.EQUITHERM";
+const char L_REGULATOR_EQUITHERM[]  PROGMEM = "REGULATOR.EQUITHERM";
+const char L_CASCADE_INPUT[]        PROGMEM = "CASCADE.INPUT";
+const char L_CASCADE_OUTPUT[]       PROGMEM = "CASCADE.OUTPUT";
--- a/src/utils.h
+++ b/src/utils.h
@@ -342,8 +342,6 @@ void settingsToJson(const Settings& src, JsonVariant dst, bool safe = false) {
    dst["opentherm"]["inGpio"] = src.opentherm.inGpio;
    dst["opentherm"]["outGpio"] = src.opentherm.outGpio;
    dst["opentherm"]["rxLedGpio"] = src.opentherm.rxLedGpio;
-    dst["opentherm"]["faultStateGpio"] = src.opentherm.faultStateGpio;
-    dst["opentherm"]["invertFaultState"] = src.opentherm.invertFaultState;
    dst["opentherm"]["memberIdCode"] = src.opentherm.memberIdCode;
    dst["opentherm"]["maxModulation"] = src.opentherm.maxModulation;
    dst["opentherm"]["pressureFactor"] = roundd(src.opentherm.pressureFactor, 2);
@@ -447,6 +445,19 @@ void settingsToJson(const Settings& src, JsonVariant dst, bool safe = false) {
    dst["externalPump"]["postCirculationTime"] = roundd(src.externalPump.postCirculationTime / 60, 0);
    dst["externalPump"]["antiStuckInterval"] = roundd(src.externalPump.antiStuckInterval / 86400, 0);
    dst["externalPump"]["antiStuckTime"] = roundd(src.externalPump.antiStuckTime / 60, 0);
+
+    dst["cascadeControl"]["input"]["enable"] = src.cascadeControl.input.enable;
+    dst["cascadeControl"]["input"]["gpio"] = src.cascadeControl.input.gpio;
+    dst["cascadeControl"]["input"]["invertState"] = src.cascadeControl.input.invertState;
+    dst["cascadeControl"]["input"]["thresholdTime"] = src.cascadeControl.input.thresholdTime;
+
+    dst["cascadeControl"]["output"]["enable"] = src.cascadeControl.output.enable;
+    dst["cascadeControl"]["output"]["gpio"] = src.cascadeControl.output.gpio;
+    dst["cascadeControl"]["output"]["invertState"] = src.cascadeControl.output.invertState;
+    dst["cascadeControl"]["output"]["thresholdTime"] = src.cascadeControl.output.thresholdTime;
+    dst["cascadeControl"]["output"]["onFault"] = src.cascadeControl.output.onFault;
+    dst["cascadeControl"]["output"]["onLossConnection"] = src.cascadeControl.output.onLossConnection;
+    dst["cascadeControl"]["output"]["onEnabledHeating"] = src.cascadeControl.output.onEnabledHeating;
  }
 }

@@ -665,32 +676,6 @@ bool jsonToSettings(const JsonVariantConst src, Settings& dst, bool safe = false
      }
    }

-    if (!src["opentherm"]["faultStateGpio"].isNull()) {
-      if (src["opentherm"]["faultStateGpio"].is<JsonString>() && src["opentherm"]["faultStateGpio"].as<JsonString>().size() == 0) {
-        if (dst.opentherm.faultStateGpio != GPIO_IS_NOT_CONFIGURED) {
-          dst.opentherm.faultStateGpio = GPIO_IS_NOT_CONFIGURED;
-          changed = true;
-        }
-        
-      } else {
-        unsigned char value = src["opentherm"]["faultStateGpio"].as<unsigned char>();
-
-        if (GPIO_IS_VALID(value) && value != dst.opentherm.faultStateGpio) {
-          dst.opentherm.faultStateGpio = value;
-          changed = true;
-        }
-      }
-    }
-
-    if (src["opentherm"]["invertFaultState"].is<bool>()) {
-      bool value = src["opentherm"]["invertFaultState"].as<bool>();
-
-      if (value != dst.opentherm.invertFaultState) {
-        dst.opentherm.invertFaultState = value;
-        changed = true;
-      }
-    }
-
    if (!src["opentherm"]["memberIdCode"].isNull()) {
      unsigned int value = src["opentherm"]["memberIdCode"].as<unsigned int>();

@@ -1470,6 +1455,127 @@ bool jsonToSettings(const JsonVariantConst src, Settings& dst, bool safe = false
        }
      }
    }
+
+
+    // cascade control
+    if (src["cascadeControl"]["input"]["enable"].is<bool>()) {
+      bool value = src["cascadeControl"]["input"]["enable"].as<bool>();
+
+      if (value != dst.cascadeControl.input.enable) {
+        dst.cascadeControl.input.enable = value;
+        changed = true;
+      }
+    }
+
+    if (!src["cascadeControl"]["input"]["gpio"].isNull()) {
+      if (src["cascadeControl"]["input"]["gpio"].is<JsonString>() && src["cascadeControl"]["input"]["gpio"].as<JsonString>().size() == 0) {
+        if (dst.cascadeControl.input.gpio != GPIO_IS_NOT_CONFIGURED) {
+          dst.cascadeControl.input.gpio = GPIO_IS_NOT_CONFIGURED;
+          changed = true;
+        }
+        
+      } else {
+        unsigned char value = src["cascadeControl"]["input"]["gpio"].as<unsigned char>();
+
+        if (GPIO_IS_VALID(value) && value != dst.cascadeControl.input.gpio) {
+          dst.cascadeControl.input.gpio = value;
+          changed = true;
+        }
+      }
+    }
+
+    if (src["cascadeControl"]["input"]["invertState"].is<bool>()) {
+      bool value = src["cascadeControl"]["input"]["invertState"].as<bool>();
+
+      if (value != dst.cascadeControl.input.invertState) {
+        dst.cascadeControl.input.invertState = value;
+        changed = true;
+      }
+    }
+
+    if (!src["cascadeControl"]["input"]["thresholdTime"].isNull()) {
+      unsigned short value = src["cascadeControl"]["input"]["thresholdTime"].as<unsigned short>();
+
+      if (value >= 5 && value <= 600) {
+        if (value != dst.cascadeControl.input.thresholdTime) {
+          dst.cascadeControl.input.thresholdTime = value;
+          changed = true;
+        }
+      }
+    }
+
+    if (src["cascadeControl"]["output"]["enable"].is<bool>()) {
+      bool value = src["cascadeControl"]["output"]["enable"].as<bool>();
+
+      if (value != dst.cascadeControl.output.enable) {
+        dst.cascadeControl.output.enable = value;
+        changed = true;
+      }
+    }
+
+    if (!src["cascadeControl"]["output"]["gpio"].isNull()) {
+      if (src["cascadeControl"]["output"]["gpio"].is<JsonString>() && src["cascadeControl"]["output"]["gpio"].as<JsonString>().size() == 0) {
+        if (dst.cascadeControl.output.gpio != GPIO_IS_NOT_CONFIGURED) {
+          dst.cascadeControl.output.gpio = GPIO_IS_NOT_CONFIGURED;
+          changed = true;
+        }
+        
+      } else {
+        unsigned char value = src["cascadeControl"]["output"]["gpio"].as<unsigned char>();
+
+        if (GPIO_IS_VALID(value) && value != dst.cascadeControl.output.gpio) {
+          dst.cascadeControl.output.gpio = value;
+          changed = true;
+        }
+      }
+    }
+
+    if (src["cascadeControl"]["output"]["invertState"].is<bool>()) {
+      bool value = src["cascadeControl"]["output"]["invertState"].as<bool>();
+
+      if (value != dst.cascadeControl.output.invertState) {
+        dst.cascadeControl.output.invertState = value;
+        changed = true;
+      }
+    }
+
+    if (!src["cascadeControl"]["output"]["thresholdTime"].isNull()) {
+      unsigned short value = src["cascadeControl"]["output"]["thresholdTime"].as<unsigned short>();
+
+      if (value >= 5 && value <= 600) {
+        if (value != dst.cascadeControl.output.thresholdTime) {
+          dst.cascadeControl.output.thresholdTime = value;
+          changed = true;
+        }
+      }
+    }
+
+    if (src["cascadeControl"]["output"]["onFault"].is<bool>()) {
+      bool value = src["cascadeControl"]["output"]["onFault"].as<bool>();
+
+      if (value != dst.cascadeControl.output.onFault) {
+        dst.cascadeControl.output.onFault = value;
+        changed = true;
+      }
+    }
+
+    if (src["cascadeControl"]["output"]["onLossConnection"].is<bool>()) {
+      bool value = src["cascadeControl"]["output"]["onLossConnection"].as<bool>();
+
+      if (value != dst.cascadeControl.output.onLossConnection) {
+        dst.cascadeControl.output.onLossConnection = value;
+        changed = true;
+      }
+    }
+
+    if (src["cascadeControl"]["output"]["onEnabledHeating"].is<bool>()) {
+      bool value = src["cascadeControl"]["output"]["onEnabledHeating"].as<bool>();
+
+      if (value != dst.cascadeControl.output.onEnabledHeating) {
+        dst.cascadeControl.output.onEnabledHeating = value;
+        changed = true;
+      }
+    }
  }

  // force check emergency target
@@ -1587,6 +1693,9 @@ void varsToJson(const Variables& src, JsonVariant dst) {
  dst["temperatures"]["dhw"] = roundd(src.temperatures.dhw, 2);
  dst["temperatures"]["exhaust"] = roundd(src.temperatures.exhaust, 2);

+  dst["cascadeControl"]["input"] = src.cascadeControl.input;
+  dst["cascadeControl"]["output"] = src.cascadeControl.output;
+
  dst["parameters"]["heatingEnabled"] = src.parameters.heatingEnabled;
  dst["parameters"]["heatingMinTemp"] = src.parameters.heatingMinTemp;
  dst["parameters"]["heatingMaxTemp"] = src.parameters.heatingMaxTemp;