feat: added software overheating protection

2025-12-10 18:24:27 +05:00 · 2025-06-17 17:50:15 +03:00
parent 1eee184887
commit b985275309
9 changed files with 244 additions and 2 deletions
--- a/src/OpenThermTask.h
+++ b/src/OpenThermTask.h
@@ -171,10 +171,13 @@ protected:
    vars.master.heating.enabled = this->isReady()
      && (settings.heating.enabled || vars.emergency.state) 
      && vars.cascadeControl.input 
-      && !vars.master.heating.blocking;
+      && !vars.master.heating.blocking
+      && !vars.master.heating.overheat;

    // DHW settings
-    vars.master.dhw.enabled = settings.opentherm.options.dhwSupport && settings.dhw.enabled;
+    vars.master.dhw.enabled = settings.opentherm.options.dhwSupport 
+      && settings.dhw.enabled 
+      && !vars.master.dhw.overheat;
    vars.master.dhw.targetTemp = settings.dhw.target;

    // CH2 settings
@@ -1313,6 +1316,76 @@ protected:
        }
      }
    }
+
+
+    // Heating overheat control
+    if (settings.heating.overheatHighTemp > 0 && settings.heating.overheatLowTemp > 0) {
+      float highTemp = max({
+        vars.slave.heating.currentTemp,
+        vars.slave.heating.returnTemp,
+        vars.slave.heatExchangerTemp
+      });
+
+      if (vars.master.heating.overheat) {
+        if ((float) settings.heating.overheatLowTemp - highTemp + 0.0001f >= 0.0f) {
+          vars.master.heating.overheat = false;
+
+          Log.sinfoln(
+            FPSTR(L_OT_HEATING), F("Overheating not detected. Current high temp: %.2f, threshold (low): %hhu"),
+            highTemp, settings.heating.overheatLowTemp
+          );
+        }
+
+      } else if (vars.slave.heating.active) {
+        if (highTemp - (float) settings.heating.overheatHighTemp + 0.0001f >= 0.0f) {
+          vars.master.heating.overheat = true;
+
+          Log.swarningln(
+            FPSTR(L_OT_HEATING), F("Overheating detected! Current high temp: %.2f, threshold (high): %hhu"),
+            highTemp, settings.heating.overheatHighTemp
+          );
+        }
+      }
+
+    } else if (vars.master.heating.overheat) {
+      vars.master.heating.overheat = false;
+    }
+
+    // DHW overheat control
+    if (settings.dhw.overheatHighTemp > 0 && settings.dhw.overheatLowTemp > 0) {
+      float highTemp = max({
+        vars.slave.heating.currentTemp,
+        vars.slave.heating.returnTemp,
+        vars.slave.heatExchangerTemp,
+        vars.slave.dhw.currentTemp,
+        vars.slave.dhw.currentTemp2,
+        vars.slave.dhw.returnTemp
+      });
+
+      if (vars.master.dhw.overheat) {
+        if ((float) settings.dhw.overheatLowTemp - highTemp + 0.0001f >= 0.0f) {
+          vars.master.dhw.overheat = false;
+
+          Log.sinfoln(
+            FPSTR(L_OT_DHW), F("Overheating not detected. Current high temp: %.2f, threshold (low): %hhu"),
+            highTemp, settings.dhw.overheatLowTemp
+          );
+        }
+
+      } else if (vars.slave.dhw.active) {
+        if (highTemp - (float) settings.dhw.overheatHighTemp + 0.0001f >= 0.0f) {
+          vars.master.dhw.overheat = true;
+
+          Log.swarningln(
+            FPSTR(L_OT_DHW), F("Overheating detected! Current high temp: %.2f, threshold (high): %hhu"),
+            highTemp, settings.dhw.overheatHighTemp
+          );
+        }
+      }
+
+    } else if (vars.master.dhw.overheat) {
+      vars.master.dhw.overheat = false;
+    }
  }

  void initialize() {
--- a/src/Settings.h
+++ b/src/Settings.h
@@ -108,6 +108,8 @@ struct Settings {
    byte minTemp = DEFAULT_HEATING_MIN_TEMP;
    byte maxTemp = DEFAULT_HEATING_MAX_TEMP;
    uint8_t maxModulation = 100;
+    uint8_t overheatHighTemp = 95;
+    uint8_t overheatLowTemp = 90;
  } heating;

  struct {
@@ -116,6 +118,8 @@ struct Settings {
    byte minTemp = DEFAULT_DHW_MIN_TEMP;
    byte maxTemp = DEFAULT_DHW_MAX_TEMP;
    uint8_t maxModulation = 100;
+    uint8_t overheatHighTemp = 95;
+    uint8_t overheatLowTemp = 90;
  } dhw;

  struct {
@@ -280,6 +284,7 @@ struct Variables {
      bool blocking = false;
      bool enabled = false;
      bool indoorTempControl = false;
+      bool overheat = false;
      float setpointTemp = 0.0f;
      float targetTemp = 0.0f;
      float currentTemp = 0.0f;
@@ -292,6 +297,7 @@ struct Variables {

    struct {
      bool enabled = false;
+      bool overheat = false;
      float targetTemp = 0.0f;
      float currentTemp = 0.0f;
      float returnTemp = 0.0f;
--- a/src/strings.h
+++ b/src/strings.h
@@ -150,6 +150,9 @@ const char S_OPTIONS[]                              PROGMEM = "options";
 const char S_OUTDOOR_TEMP[]                         PROGMEM = "outdoorTemp";
 const char S_OUT_GPIO[]                             PROGMEM = "outGpio";
 const char S_OUTPUT[]                               PROGMEM = "output";
+const char S_OVERHEAT[]                             PROGMEM = "overheat";
+const char S_OVERHEAT_HIGH_TEMP[]                   PROGMEM = "overheatHighTemp";
+const char S_OVERHEAT_LOW_TEMP[]                    PROGMEM = "overheatLowTemp";
 const char S_PASSWORD[]                             PROGMEM = "password";
 const char S_PID[]                                  PROGMEM = "pid";
 const char S_PORT[]                                 PROGMEM = "port";
--- a/src/utils.h
+++ b/src/utils.h
@@ -495,6 +495,8 @@ void settingsToJson(const Settings& src, JsonVariant dst, bool safe = false) {
  heating[FPSTR(S_MIN_TEMP)] = src.heating.minTemp;
  heating[FPSTR(S_MAX_TEMP)] = src.heating.maxTemp;
  heating[FPSTR(S_MAX_MODULATION)] = src.heating.maxModulation;
+  heating[FPSTR(S_OVERHEAT_HIGH_TEMP)] = src.heating.overheatHighTemp;
+  heating[FPSTR(S_OVERHEAT_LOW_TEMP)] = src.heating.overheatLowTemp;

  auto dhw = dst[FPSTR(S_DHW)].to<JsonObject>();
  dhw[FPSTR(S_ENABLED)] = src.dhw.enabled;
@@ -502,6 +504,8 @@ void settingsToJson(const Settings& src, JsonVariant dst, bool safe = false) {
  dhw[FPSTR(S_MIN_TEMP)] = src.dhw.minTemp;
  dhw[FPSTR(S_MAX_TEMP)] = src.dhw.maxTemp;
  dhw[FPSTR(S_MAX_MODULATION)] = src.dhw.maxModulation;
+  dhw[FPSTR(S_OVERHEAT_HIGH_TEMP)] = src.dhw.overheatHighTemp;
+  dhw[FPSTR(S_OVERHEAT_LOW_TEMP)] = src.dhw.overheatLowTemp;

  auto equitherm = dst[FPSTR(S_EQUITHERM)].to<JsonObject>();
  equitherm[FPSTR(S_ENABLED)] = src.equitherm.enabled;
@@ -1342,6 +1346,29 @@ bool jsonToSettings(const JsonVariantConst src, Settings& dst, bool safe = false
    }
  }

+  if (!src[FPSTR(S_HEATING)][FPSTR(S_OVERHEAT_HIGH_TEMP)].isNull()) {
+    unsigned char value = src[FPSTR(S_HEATING)][FPSTR(S_OVERHEAT_HIGH_TEMP)].as<unsigned char>();
+
+    if (isValidTemp(value, dst.system.unitSystem, 0.0f, 100.0f) && value != dst.heating.overheatHighTemp) {
+      dst.heating.overheatHighTemp = value;
+      changed = true;
+    }
+  }
+
+  if (!src[FPSTR(S_HEATING)][FPSTR(S_OVERHEAT_LOW_TEMP)].isNull()) {
+    unsigned char value = src[FPSTR(S_HEATING)][FPSTR(S_OVERHEAT_LOW_TEMP)].as<unsigned char>();
+
+    if (isValidTemp(value, dst.system.unitSystem, 0.0f, 99.0f) && value != dst.heating.overheatLowTemp) {
+      dst.heating.overheatLowTemp = value;
+      changed = true;
+    }
+  }
+
+  if (dst.heating.overheatHighTemp < dst.heating.overheatLowTemp) {
+    dst.heating.overheatHighTemp = dst.heating.overheatLowTemp;
+    changed = true;
+  }
+

  // dhw
  if (src[FPSTR(S_DHW)][FPSTR(S_ENABLED)].is<bool>()) {
@@ -1385,6 +1412,29 @@ bool jsonToSettings(const JsonVariantConst src, Settings& dst, bool safe = false
    }
  }

+  if (!src[FPSTR(S_DHW)][FPSTR(S_OVERHEAT_HIGH_TEMP)].isNull()) {
+    unsigned char value = src[FPSTR(S_DHW)][FPSTR(S_OVERHEAT_HIGH_TEMP)].as<unsigned char>();
+
+    if (isValidTemp(value, dst.system.unitSystem, 0.0f, 100.0f) && value != dst.dhw.overheatHighTemp) {
+      dst.dhw.overheatHighTemp = value;
+      changed = true;
+    }
+  }
+
+  if (!src[FPSTR(S_DHW)][FPSTR(S_OVERHEAT_LOW_TEMP)].isNull()) {
+    unsigned char value = src[FPSTR(S_DHW)][FPSTR(S_OVERHEAT_LOW_TEMP)].as<unsigned char>();
+
+    if (isValidTemp(value, dst.system.unitSystem, 0.0f, 99.0f) && value != dst.dhw.overheatLowTemp) {
+      dst.dhw.overheatLowTemp = value;
+      changed = true;
+    }
+  }
+
+  if (dst.dhw.overheatHighTemp < dst.dhw.overheatLowTemp) {
+    dst.dhw.overheatHighTemp = dst.dhw.overheatLowTemp;
+    changed = true;
+  }
+

  if (!safe) {
    // external pump
@@ -2016,6 +2066,7 @@ void varsToJson(const Variables& src, JsonVariant dst) {
  mHeating[FPSTR(S_ENABLED)] = src.master.heating.enabled;
  mHeating[FPSTR(S_BLOCKING)] = src.master.heating.blocking;
  mHeating[FPSTR(S_INDOOR_TEMP_CONTROL)] = src.master.heating.indoorTempControl;
+  mHeating[FPSTR(S_OVERHEAT)] = src.master.heating.overheat;
  mHeating[FPSTR(S_SETPOINT_TEMP)] = roundf(src.master.heating.setpointTemp, 2);
  mHeating[FPSTR(S_TARGET_TEMP)] = roundf(src.master.heating.targetTemp, 2);
  mHeating[FPSTR(S_CURRENT_TEMP)] = roundf(src.master.heating.currentTemp, 2);
@@ -2027,6 +2078,7 @@ void varsToJson(const Variables& src, JsonVariant dst) {

  auto mDhw = master[FPSTR(S_DHW)].to<JsonObject>();
  mDhw[FPSTR(S_ENABLED)] = src.master.dhw.enabled;
+  mDhw[FPSTR(S_OVERHEAT)] = src.master.dhw.overheat;
  mDhw[FPSTR(S_TARGET_TEMP)] = roundf(src.master.dhw.targetTemp, 2);
  mDhw[FPSTR(S_CURRENT_TEMP)] = roundf(src.master.dhw.currentTemp, 2);
  mDhw[FPSTR(S_RETURN_TEMP)] = roundf(src.master.dhw.returnTemp, 2);
--- a/src_data/locales/en.json
+++ b/src_data/locales/en.json
@@ -117,6 +117,7 @@
        
        "mHeatEnabled": "Heating enabled",
        "mHeatBlocking": "Heating blocked",
+        "mHeatOverheat": "Heating overheat",
        "sHeatActive": "Heating active",
        "mHeatSetpointTemp": "Heating setpoint temp",
        "mHeatTargetTemp": "Heating target temp",
@@ -126,6 +127,7 @@
        "mHeatOutdoorTemp": "Heating, outdoor temp",

        "mDhwEnabled": "DHW enabled",
+        "mDhwOverheat": "DHW overheat",
        "sDhwActive": "DHW active",
        "mDhwTargetTemp": "DHW target temp",
        "mDhwCurrTemp": "DHW current temp",
@@ -302,6 +304,18 @@
        "max": "Maximum temperature"
      },
      "maxModulation": "Max modulation level",
+      "overheat": {
+        "title": "Overheating protection",
+        "desc": "<b>Note:</b> This feature can be useful if the built-in boiler overheating protection does not work or does not work correctly and the heat carrier boils. To disable, set 0 as <b>high</b> and <b>low</b> temperature.",
+        "highTemp": {
+          "title": "High temperature threshold",
+          "note": "Threshold at which the burner will be forcibly switched off"
+        },
+        "lowTemp": {
+          "title": "Low temperature threshold",
+          "note": "Threshold at which the burner can be turned on again"
+        }
+      },

      "portal": {
        "login": "Login",
--- a/src_data/locales/it.json
+++ b/src_data/locales/it.json
@@ -117,6 +117,7 @@
        
        "mHeatEnabled": "Riscaldamento attivato",
        "mHeatBlocking": "Riscaldamento bloccato",
+        "mHeatOverheat": "Riscaldamento surriscaldamento",
        "sHeatActive": "Riscaldamento attivo",
        "mHeatSetpointTemp": "Temp riscaldamento impostato",
        "mHeatTargetTemp": "Target Temp caldaia",
@@ -126,6 +127,7 @@
        "mHeatOutdoorTemp": "Riscaldamento, temp esterna",

        "mDhwEnabled": "ACS attivata",
+        "mDhwOverheat": "ACS surriscaldamento",
        "sDhwActive": "ACS attiva",
        "mDhwTargetTemp": "ACS temp impostata",
        "mDhwCurrTemp": "ACS temp attuale",
@@ -302,6 +304,18 @@
        "max": "Temperatura massima"
      },
      "maxModulation": "Max livello modulazione",
+      "overheat": {
+        "title": "Protezione contro il surriscaldamento",
+        "desc": "<b>Nota:</b> questa funzione può essere utile se la protezione contro il surriscaldamento integrata nella caldaia non funziona o non funziona correttamente e il fluido termovettore bolle. Per disattivarla, impostare 0 come temperatura <b>alta</b> e <b>bassa</b>.",
+        "highTemp": {
+          "title": "Soglia di temperatura alta",
+          "note": "Soglia alla quale il bruciatore verrà spento forzatamente"
+        },
+        "lowTemp": {
+          "title": "Soglia di temperatura bassa",
+          "note": "Soglia alla quale il bruciatore può essere riacceso"
+        }
+      },

      "portal": {
        "login": "Login",
--- a/src_data/locales/ru.json
+++ b/src_data/locales/ru.json
@@ -117,6 +117,7 @@
        
        "mHeatEnabled": "Отопление",
        "mHeatBlocking": "Блокировка отопления",
+        "mHeatOverheat": "Отопление, перегрев",
        "sHeatActive": "Активность отопления",
        "mHeatSetpointTemp": "Отопление, уставка",
        "mHeatTargetTemp": "Отопление, целевая температура",
@@ -126,6 +127,7 @@
        "mHeatOutdoorTemp": "Отопление, наружная темп.",

        "mDhwEnabled": "ГВС",
+        "mDhwOverheat": "ГВС, перегрев",
        "sDhwActive": "Активность ГВС",
        "mDhwTargetTemp": "ГВС, целевая температура",
        "mDhwCurrTemp": "ГВС, текущая температура",
@@ -302,6 +304,18 @@
        "max": "Макс. температура"
      },
      "maxModulation": "Макс. уровень модуляции",
+      "overheat": {
+        "title": "Защита от перегрева",
+        "desc": "<b>Примечание:</b> Эта функция может быть полезна, если встроенная защита от перегрева котла не срабатывает или срабатывает некорректно и теплоноситель закипает. Для отключения установите 0 в качестве <b>верхнего</b> и <b>нижнего</b> порога температуры.",
+        "highTemp": {
+          "title": "Верхний порог температуры",
+          "note": "Порог, при котором горелка будет принудительно отключена"
+        },
+        "lowTemp": {
+          "title": "Нижний порог температуры",
+          "note": "Порог, при котором горелка может быть включена снова"
+        }
+      },

      "portal": {
        "login": "Логин",
--- a/src_data/pages/dashboard.html
+++ b/src_data/pages/dashboard.html
@@ -184,6 +184,10 @@
                  <th scope="row" data-i18n>dashboard.states.mHeatBlocking</th>
                  <td><i class="mHeatBlocking"></i></td>
                </tr>
+                <tr>
+                  <th scope="row" data-i18n>dashboard.states.mHeatOverheat</th>
+                  <td><i class="mHeatOverheat"></i></td>
+                </tr>
                <tr>
                  <th scope="row" data-i18n>dashboard.states.sHeatActive</th>
                  <td><i class="sHeatActive"></i></td>
@@ -218,6 +222,10 @@
                  <th scope="row" data-i18n>dashboard.states.mDhwEnabled</th>
                  <td><i class="mDhwEnabled"></i></td>
                </tr>
+                <tr>
+                  <th scope="row" data-i18n>dashboard.states.mDhwOverheat</th>
+                  <td><i class="mDhwOverheat"></i></td>
+                </tr>
                <tr>
                  <th scope="row" data-i18n>dashboard.states.sDhwActive</th>
                  <td><i class="sDhwActive"></i></td>
@@ -611,6 +619,11 @@
              result.master.heating.blocking ? "red" : "green"
            );
            setState('.mHeatIndoorTempControl', result.master.heating.indoorTempControl);
+            setStatus(
+              '.mHeatOverheat',
+              result.master.heating.overheat ? "success" : "error",
+              result.master.heating.overheat ? "red" : "green"
+            );
            setValue('.mHeatSetpointTemp', result.master.heating.setpointTemp);
            setValue('.mHeatTargetTemp', result.master.heating.targetTemp);
            setValue('.mHeatCurrTemp', result.master.heating.currentTemp);
@@ -621,6 +634,11 @@
            setValue('.mHeatMaxTemp', result.master.heating.maxTemp);

            setState('.mDhwEnabled', result.master.dhw.enabled);
+            setStatus(
+              '.mDhwOverheat',
+              result.master.dhw.overheat ? "success" : "error",
+              result.master.dhw.overheat ? "red" : "green"
+            );
            setValue('.mDhwTargetTemp', result.master.dhw.targetTemp);
            setValue('.mDhwCurrTemp', result.master.dhw.currentTemp);
            setValue('.mDhwRetTemp', result.master.dhw.returnTemp);
--- a/src_data/pages/settings.html
+++ b/src_data/pages/settings.html
@@ -207,6 +207,28 @@
                <input type="number" inputmode="numeric" name="heating[maxModulation]" min="1" max="100" step="1" required>
              </label>

+              <details>
+                <summary><b data-i18n>settings.overheat.title</b></summary>
+
+                <div class="grid">
+                  <label>
+                    <span data-i18n>settings.overheat.highTemp.title</span>
+                    <input type="number" inputmode="numeric" name="heating[overheatHighTemp]" min="0" max="212" step="1" required>
+                    <small data-i18n>settings.overheat.highTemp.note</small>
+                  </label>
+
+                  <label>
+                    <span data-i18n>settings.overheat.lowTemp.title</span>
+                    <input type="number" inputmode="numeric" name="heating[overheatLowTemp]" min="0" max="211" step="1" required>
+                    <small data-i18n>settings.overheat.lowTemp.note</small>
+                  </label>
+                </div>
+
+                <small data-i18n>settings.overheat.desc</small>
+              </details>
+
+              <br>
+
              <button type="submit" data-i18n>button.save</button>
            </form>
          </div>
@@ -236,6 +258,28 @@
                <input type="number" inputmode="numeric" name="dhw[maxModulation]" min="1" max="100" step="1" required>
              </label>

+              <details>
+                <summary><b data-i18n>settings.overheat.title</b></summary>
+
+                <div class="grid">
+                  <label>
+                    <span data-i18n>settings.overheat.highTemp.title</span>
+                    <input type="number" inputmode="numeric" name="dhw[overheatHighTemp]" min="0" max="212" step="1" required>
+                    <small data-i18n>settings.overheat.highTemp.note</small>
+                  </label>
+
+                  <label>
+                    <span data-i18n>settings.overheat.lowTemp.title</span>
+                    <input type="number" inputmode="numeric" name="dhw[overheatLowTemp]" min="0" max="211" step="1" required>
+                    <small data-i18n>settings.overheat.lowTemp.note</small>
+                  </label>
+                </div>
+
+                <small data-i18n>settings.overheat.desc</small>
+              </details>
+
+              <br>
+
              <button type="submit" data-i18n>button.save</button>
            </form>
          </div>
@@ -880,6 +924,8 @@
          setInputValue("[name='heating[hysteresis]']", data.heating.hysteresis);
          setInputValue("[name='heating[turboFactor]']", data.heating.turboFactor);
          setInputValue("[name='heating[maxModulation]']", data.heating.maxModulation);
+          setInputValue("[name='heating[overheatHighTemp]']", data.heating.overheatHighTemp);
+          setInputValue("[name='heating[overheatLowTemp]']", data.heating.overheatLowTemp);
          setBusy('#heating-settings-busy', '#heating-settings', false);

          // DHW
@@ -892,6 +938,8 @@
            "max": data.system.unitSystem == 0 ? 100 : 212
          });
          setInputValue("[name='dhw[maxModulation]']", data.dhw.maxModulation);
+          setInputValue("[name='dhw[overheatHighTemp]']", data.dhw.overheatHighTemp);
+          setInputValue("[name='dhw[overheatLowTemp]']", data.dhw.overheatLowTemp);
          setBusy('#dhw-settings-busy', '#dhw-settings', false);

          // Emergency mode