lost OT communication after restart

This Forum is about the Opentherm gateway (OTG) from Schelte

Moderator: hvxl

lost OT communication after restart

Postby Philip_Inc » Fri Oct 12, 2018 8:41 am

I use OTG in stand-alone working mode. Without thermostat with boiler of Thermona.
Everything worked well for a few months but few days ago after some hours of work or after power outage OTG stops communication with boiler. The same with GW=R command.
Code: Select all
10:17:35.314614   OpenTherm Gateway 4.2.5
10:17:35.400497   Command: SC=10:17/5
10:17:35.470303   Command: SR=21:10,12
10:17:35.495786   Command: SR=22:7,226
10:17:35.520152   Thermostat disconnected
10:17:35.556328   SC: 10:17/5
10:17:35.569668   SR: 21:10/12
10:17:35.592700   SR: 22:7/226
10:17:36.253090   R00000000   Read-Data    Status: 00000000 00000000
10:17:37.269427   R00000000   Read-Data    Status: 00000000 00000000
10:17:38.284816   R00000000   Read-Data    Status: 00000000 00000000
10:17:43.661204   R00000000   Read-Data    Status: 00000000 00000000
10:18:00.000881   Command: SC=10:18/5
10:18:00.161051   SC: 10:18/5
10:19:00.001411   Command: SC=10:19/5
10:19:00.214855   SC: 10:19/5
10:20:00.000968   Command: SC=10:20/5
10:20:00.150603   SC: 10:20/5


The only thing which helps is placing a wire on X1 interface and it starts works well for a few hours.

I already tried to reflash PIC, but nothing changed. I have very strange test results with diagnosis firmware:
Code: Select all
Opentherm gateway diagnostics - Version 1.1

1. LED test
2. Bit timing thermostat
3. Bit timing boiler
4. Delay symmetry
5. Voltage levels
6. Idle times

Enter test number: 3
4403.
3910.
4583.

Opentherm gateway diagnostics - Version 1.1

1. LED test
2. Bit timing thermostat
3. Bit timing boiler
4. Delay symmetry
5. Voltage levels
6. Idle times

Enter test number: 5
Thermostat: 2.43, 2.50
Boiler: 2.56
Reference: 1.22

Opentherm gateway diagnostics - Version 1.1

1. LED test
2. Bit timing thermostat
3. Bit timing boiler
4. Delay symmetry
5. Voltage levels
6. Idle times

Enter test number: 6

Opentherm gateway diagnostics - Version 1.1

1. LED test
2. Bit timing thermostat
3. Bit timing boiler
4. Delay symmetry
5. Voltage levels
6. Idle times

Enter test number: 6
B: 9223.107
T: 14326.677
B: 19429.080


Please be noted that there is nothing connected to X1.
Philip_Inc
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Re: lost OT communication after restart

Postby hvxl » Wed Oct 17, 2018 8:26 pm

You are running diagnostic tests that are intended to be executed with a thermostat and boiler connected, without a thermostat. Then you shouldn't be surprised that you get meaningless results.

I'm not sure why the OTGW stops sending messages to the boiler, but in the log you provided it never received (or recognized) any response from the boiler for the ones it did send. So there's some problem there.

If you put a wire across X1, the OTGW will instruct the boiler to start heating. That's not a situation you would normally want for a few hours.
Schelte
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Re: lost OT communication after restart

Postby Philip_Inc » Thu Oct 18, 2018 2:30 am

The boiler stops answer without any reason, the OTGW stops sending without any reason. But closing of X1 they start normal communication.
I need to understand what to replace: OTWG or boiler PCB.
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Re: lost OT communication after restart

Postby hvxl » Thu Oct 18, 2018 8:22 pm

If you suspect hardware issues with the OTGW, I suggest you go through the troubleshooting procedure.
Schelte
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Re: lost OT communication after restart

Postby Philip_Inc » Fri Nov 16, 2018 9:41 pm

I've checked everything from the troubleshooting section you mentioned and didn't a problem there. I talked with other user of OTGW and he confirmed that it not works without shorted X1.
My symptoms: after a few days of normal functioning it lost any communication with boiler. When I short X1 for a second it start working normally.

Could you please specify what functions are available when X1 is shorted? I see that I can switch heating off by CH=0. Is it possible to change the temperature by CS or SH? I see one of them is works but still not figured which one. I don't have a way to use your software because OTGW is connected to PLC by serial port.
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Re: lost OT communication after restart

Postby hvxl » Mon Dec 03, 2018 5:46 pm

As indicated before, the OTGW is not intended to be used that way. So I don't know what functions are available. And I'm not interested to find out.

What I don't understand is why you keep going in this direction. So, you have a problem with the OTGW when used in the normal configuration? Then you try to use it in some unusual configuration and you have a different problem. Why do you then focus on the problem with the unusual configuration rather than the problem in the configuration that is supposed to work?

If you want to investigate the original problem, I can try to help. If you want to get things working with a shorted X1, you're on your own.
Schelte
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Re: lost OT communication after restart

Postby Philip_Inc » Wed Dec 05, 2018 10:15 pm

As I reported previously it losts a communication over OT after some hours of working or restart. If the X1 is shorted there is no such behavior.
I will be very glad if you can help me to resolve this issue and make it works without X1 shorting. I already reimaged it for a few times with the latest firmware.
Philip_Inc
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Re: lost OT communication after restart

Postby hvxl » Sat Dec 08, 2018 6:09 pm

In your last post you indicate that the OTGW keeps working when X1 is shorted. Earlier you said that it "works well for a few hours" in that situation. Which is it? Because if it also stops working after a while with X1 shorted, the problem is likely in a completely different area than when the problem only happens with nothing connected to X1.

In any case, the first thing to check is the A/D value when the OTGW stops communicating. You do this by running the command DP=57. Repeat the command a couple of times to get a good picture of the measured values. Also run the commands DP=7e and DP=61. These last two only need to be run once. Finally use DP=00 to disable the debugging again.
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Re: lost OT communication after restart

Postby Philip_Inc » Mon Dec 10, 2018 10:47 am

Thanks a lot for your assistance!
OTGW works fine for a long period of time if X1 is shorted. And it works for a few hours or until the first power reset when X1 is opened.

I had removed a jumper over X1 and made a test. Before reboot (power disconnect) registers had following data:
7E = 20
57 = 70-78 (values in range)
61 = 07

After reset of power:
Code: Select all
Th▒OpenTherm Gateway 4.2.5
Thermostat disconnected
R00000000
R00000000
R00000000
DP: 57
57=81
DP: 7E
7E=40
DP: 61
61=04
DP: 57
57=81
DP: 57
57=81
DP: 57
57=81
DP: 57
57=81
DP: 7E
7E=40
DP: 61
61=04
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