Hardware problem

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

Moderator: hvxl

Re: Hardware problem

Postby mvroosmalen » Sat Oct 01, 2016 11:03 am

Hi

Tested the OTGW X1 and measure 24.1V connected to the thermostat it decreases to 7V-->7.5V-->7V.
next test #2 shows:
00140000 Read-Data Day of week and time of day: Unk 00:00
500,1018,500,509,501,507,503,507,500,519,495,508,502,508,502,508,502,507,500,518,494,507,1007,1013,1006,1021,494,507,502,507,502,507,502,508,502,506,513,501,502,509,502,509,502,509,503,506,513,499,502,508,502,508,502,508,502,506,513,500,503,509,1007.
00140000 Read-Data Day of week and time of day: Unk 00:00
500,1014,501,511,502,508,502,506,513,500,502,507,502,507,502,508,502,506,513,499,502,508,1006,1015,1003,1017,503,508,502,509,502,508,502,509,499,519,494,508,502,508,503,508,501,508,500,519,494,508,503,508,502,508,503,508,499,519,495,508,502,508,1008.
00140000 Read-Data Day of week and time of day: Unk 00:00

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

nothing.......... Basically confirms test #4

You state:
If not, check for bad contacts in the slave interface part of the OTGW.

can you be a bit more precise?

Thanks Mark
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Re: Hardware problem

Postby hvxl » Sat Oct 01, 2016 1:20 pm

In your previous post you reported that nothing happens when you run test #2. Without changing anything you now do get output from test #2. So at this point I'm totally lost on what works and what doesn't. This way of debugging apparently doesn't work. When you report unexpected results I don't know if the circuitry is broken, or you are not performing the test correctly.

You are going to have to use your own intellect. Study the web site and any other resources you need to understand what the circuitry is supposed to do. Then start over with the troubleshooting instructions and make sure you are clear on what each step is checking. Then when you get unexpected results you will be able to determine if you performed the test correctly, which components could be causing the problems, and what to do next to narrow things down to the actual root cause.
Schelte
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Re: Hardware problem

Postby mvroosmalen » Sat Oct 01, 2016 1:39 pm

Hi

you are correct that things seems strange though last time I must have connected some things wrong (I guess I connected boiler to thermo etc) resulting in the failure last time. Now going through the different steps I getting repeatably the impression X2 is not OK. I checked all steps on the website and end up in the failure of test #3 & #4
OK1B high-to-low: ### Error
OK1B low-to-high: ### Error

This would indicate the optical is not OK??

Sorry getting you confused but I'm not getting to the solution. I might be to stupid for it I don't know... Sorry

I would really appreciate help to solve this issue .
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Re: Hardware problem

Postby hvxl » Sat Oct 01, 2016 3:41 pm

Test #3 needs to be done with the thermostat and boiler connected. Test #4 must have X1 looped to X2. Can you confirm that is what you did? If so, the problem seems to be near OK1B. Since you verified that OK1A is OK. A quick check would be to remove OK1 from its socket (you did use a socket for OK1, I hope) and move it over 2 pins, so only 4 pins of the chip are in the socket and the other 4 are hanging in space. If you shift it towards X2, the known working OK1A will be doing the job of OK1B. If the OK1B part of test #4 now passes (the OK1A part will fail), the opto-coupler is broken. Get a new one.

If the OK1B test still fails, there's at least another problem than the opto-coupler. In that case, try plugging in the chip with the 4 pins in the air on the side of X2. If the OK1A test gives good results this way, the opto-coupler is fine. The problem is somewhere else.
Schelte
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Re: Hardware problem

Postby mvroosmalen » Sun Oct 02, 2016 10:07 am

Hi

Thanks for the suggestion. Indeed with the 4 pins in the air. the problem shifts to A and B seems OK though I wonder why I see high values and if they are OK?

Enter test number: 4
OK1A high-to-low: ### Error
OK1A low-to-high: ### Error
OK1B high-to-low: 9053us
OK1B low-to-high: 2652us

after repeat testing I get:
OK1B high-to-low: ### Error
OK1B low-to-high: 2us
or
OK1B high-to-low: 2us
OK1B low-to-high: ### Error

Is that OK?


retested and confirmed the position of the OK now it reads
Enter test number: 4
OK1A high-to-low: 9us
OK1A low-to-high: 25us
OK1B high-to-low: ### Error
OK1B low-to-high: ### Error

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: 4
OK1A high-to-low: 9us
OK1A low-to-high: 25us
OK1B high-to-low: ### Error
OK1B low-to-high: ### Error

when I place the OK over A and it reads
Enter test number: 4
OK1A high-to-low: ### Error
OK1A low-to-high: ### Error
OK1B high-to-low: ### Error
OK1B low-to-high: ### Error

over B

so must be around B thing go wrong...
Last edited by mvroosmalen on Sun Oct 02, 2016 10:40 am, edited 1 time in total.
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Re: Hardware problem

Postby hvxl » Sun Oct 02, 2016 10:37 am

Those values are way too high. You should see numbers of a few microseconds, not several milliseconds. Check that you have the correct values for R1, R2, R3, and R4.
Schelte
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Re: Hardware problem

Postby mvroosmalen » Sun Oct 02, 2016 10:45 am

I read
R1 to R4: 325, 99, 217 & 325
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Re: Hardware problem

Postby hvxl » Thu Oct 13, 2016 2:47 pm

That all sounds reasonable. Still there must be something wrong around those components (R1-R3, D5-D11, Q1). Check that all components are the correct ones and all joints are soldered properly.

Whereabouts are you located? Maybe someone near you is able to help with debugging.
Schelte
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Re: Hardware problem

Postby mvroosmalen » Thu Oct 13, 2016 7:44 pm

Hi

Decided to send it back, since I've not the correct equipment to do the intensive debugging. I trust the shop is able to help me out. Thanks for the help so far!

Update: 1-dec-2016
kiwi-electronics.nl, confirmed the OTGW has hardware failures and was waiting for replacement parts. They promised to ship the repaired OTGW this week, can not wait to finally test it :-). No idea what they found as the root cause.....

Mark
Last edited by mvroosmalen on Thu Dec 01, 2016 8:46 pm, edited 1 time in total.
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Re: Hardware problem

Postby Mario from Spain » Tue Oct 25, 2016 8:36 am

mvroosmalen wrote:Hi,

Just constructed the OTGW and started with the diagnostics part (http://otgw.tclcode.com/debugging.html#power) to be sure everything is correct. The first check:
Check for 5V +/- 1% between pins 5 and 14 of IC1 and pin 15 and 16 of IC2

measures around 6.5V which is well above the set specs. Can someone help me out how to proceed?

Thanks,

Mark


I just built my OTGW and also measured output of 7805 without ICs mounted. In my case it was 6.1V. I replaced the 7805 and the voltage with the new one was 5.6V

I checked the 7508 with my adjustable power supply and I can see the output voltage at the 7805 is steady until the input voltage is around 20V, then it increases until 5.6V output with a 24V input.

At this point I don't know if I should go ahead and connect the ICs (and the 5.6V will drop with the load) or substitute the 7805 with one of these small 1€ step down adjusted at 5.0V. Probably I'll do the second one to be in the safe side.
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Re: Hardware problem

Postby mvroosmalen » Sat Dec 03, 2016 6:03 pm

mvroosmalen wrote:Hi

Decided to send it back, since I've not the correct equipment to do the intensive debugging. I trust the shop is able to help me out. Thanks for the help so far!

Update: 1-dec-2016
kiwi-electronics.nl, confirmed the OTGW has hardware failures and was waiting for replacement parts. They promised to ship the repaired OTGW this week, can not wait to finally test it :-). No idea what they found as the root cause.....

Mark


Today I received the OTGW back from repair (not sure what they replaced, but talked about the voltage regulator). Now it seems OK:
Enter test number: 4
OK1A high-to-low: 10us
OK1A low-to-high: 23us
OK1B high-to-low: 6us
OK1B low-to-high: 5us

Will test the OTGW tomorrow :-)

Mark
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