OTGW with USB doesn't work.

[hvxl]

OK that greatly reduces the problem area. The boiler measurement is measuring the voltage on pin 18 of IC1. If you check the schematic you'll see that with OK1 removed there is only R4 attached to that pin. R4 should be pulling the pin to GND. So the expected reading for Boiler would be 0V, but for some reason you are getting 3.88V. So either R4 isn't pulling the pin low, or something else is pulling it up.

Next steps:

1. Remove the power from the gateway
2. Carefully remove IC1 from its socket (assuming it's in a socket).
3. Measure the resistance between pin 18 and pin 5 of the IC1 socket.
4. If you don't get a value around 330 Ohm, check what's wrong with R4 (bad soldering, broken print traces, etc).
5. If the resistance is OK, look for shorts around R4, IC1 pin 18, and OK1 pin 5 (e.g. soldering that touches an adjacent pin).

After fixing any problem you find, you can run diagnostics test #5 again until you get a reading of 0V. Then put OK1 back and run test #5 again. You should still get a very low reading for the boiler.

[roblom]

After resoldering also the top side (where the components are) of the print, I got these values WITHOUT OK1 in place.

Thermostat: 3.03
Boiler: 0.00
Reference: 1.21

Thermostat: 3.05
Boiler: 0.00
Reference: 1.21

Thermostat: 3.07
Boiler: 0.00
Reference: 1.21

Thermostat: 3.05
Boiler: 0.00
Reference: 1.21

WITH the OK1 in it's socket again I get the following:

Thermostat: 3.05
Boiler: 0.00
Reference: 1.21

Thermostat: 3.06
Boiler: 0.00
Reference: 1.21

Thermostat: 3.06
Boiler: 0.00
Reference: 1.21

Thermostat: 3.05
Boiler: 0.00
Reference: 1.21

Thermostat: 3.06
Boiler: 0.00
Reference: 1.21

Now what's the next step ?

[hvxl]

That's another step closer. Now connect the thermostat and boiler and run test #5 again to see if your latest resoldering action changed anything on the thermostat side. If the thermostat measurements are still above the reference value, temporarily put a resistor of around 47k (anything between 22k-82k that you have lying around) in parallel with R6. Then run test #5 again. Some of the thermostat measurements should now be below the reference value. In that case you should also see more than one value for the boiler.

If that all goes as expected, you can load the gateway firmware. If you had to add a resistor in parallel with R6, you can remove it and raise the reference value, if you want.

[roblom]

It seems to go better. Without adding an extra resistor some of the thermostat measurements were below the reference value and I got more values for the boiler. So I loaded the gateway firmware but all i got was R00000000 results. In monitor mode nothing happened. And in the display of my iSense was a connection error (F203) shown. So I loaded the diagnostics firmware again and with test 5 I get the folowing results...

Thermostat: 2.80, 2.81
Boiler: 4.09
Reference: 1.21

Thermostat: 2.80, 2.86
Boiler: 4.10
Reference: 1.21

Thermostat: 2.80, 2.86
Boiler: 4.11
Reference: 1.21

Thermostat: 2.80, 2.85
Boiler: 4.11
Reference: 1.21

Thermostat: 2.79, 2.81
Boiler: 4.11
Reference: 1.21

Thermostat: 2.80, 2.81
Boiler: 4.09
Reference: 1.21

Thermostat: 2.80, 2.83
Boiler: 4.11
Reference: 1.21

So it seems the problem is back again....

[roblom]

Although I think I'm not a bad solderer (made several other projects) I finally got some results (now hope it's still there tomorrow). I managed to get the test 5 results ok. Then I loaded the gateway firmware again. After a while I get the following logs.

Code: Select all

23:06:16.409890	T10145703	Write-Data	Day of week and time of day: Tue 23:03
23:06:16.420633	R807A0000	Read-Data 	DHW pump/valve operation hours: 0
23:06:16.579859	BC07A6724	Read-Ack  	DHW pump/valve operation hours: 26404
23:06:16.592775	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:17.407375	T10145703	Write-Data	Day of week and time of day: Tue 23:03
23:06:17.445357	R007B0000	Read-Data 	DHW burner operation hours: 0
23:06:17.687397	B407B038C	Read-Ack  	DHW burner operation hours: 908
23:06:17.698340	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:18.417284	T10145703	Write-Data	Day of week and time of day: Tue 23:03
23:06:18.428688	R00740000	Read-Data 	Burner starts: 0
23:06:18.577437	BC074F048	Read-Ack  	Burner starts: 61512
23:06:18.588031	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:19.417308	T10145703	Write-Data	Day of week and time of day: Tue 23:03
23:06:19.428177	R80750000	Read-Data 	CH pump starts: 0
23:06:19.792460	B4075FFFF	Read-Ack  	CH pump starts: 65535
23:06:19.803804	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:20.422331	T10145703	Write-Data	Day of week and time of day: Tue 23:03
23:06:20.433616	R80760000	Read-Data 	DHW pump/valve starts: 0
23:06:20.682463	BC0768E10	Read-Ack  	DHW pump/valve starts: 36368
23:06:20.693201	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:21.422331	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:21.435223	R00770000	Read-Data 	DHW burner starts: 0
23:06:21.796899	B4077AB00	Read-Ack  	DHW burner starts: 43776
23:06:21.807739	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:22.419938	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:22.430823	R00780000	Read-Data 	Burner operation hours: 0
23:06:22.680022	BC0782744	Read-Ack  	Burner operation hours: 10052
23:06:22.691748	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:23.422369	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:23.433346	R80790000	Read-Data 	CH pump operation hours: 0
23:06:23.794965	B40792C2A	Read-Ack  	CH pump operation hours: 11306
23:06:23.806341	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:24.428984	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:24.437118	R807A0000	Read-Data 	DHW pump/valve operation hours: 0
23:06:24.686118	BC07A6724	Read-Ack  	DHW pump/valve operation hours: 26404
23:06:24.692399	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:25.427449	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:25.444726	R007B0000	Read-Data 	DHW burner operation hours: 0
23:06:25.787538	B407B038C	Read-Ack  	DHW burner operation hours: 908
23:06:25.806511	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:26.427462	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:26.443656	R00740000	Read-Data 	Burner starts: 0
23:06:26.783036	BC074F048	Read-Ack  	Burner starts: 61512
23:06:26.799405	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:27.427460	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:27.444214	R80750000	Read-Data 	CH pump starts: 0
23:06:27.782465	B4075FFFF	Read-Ack  	CH pump starts: 65535
23:06:27.797109	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:28.422691	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:28.438577	R80760000	Read-Data 	DHW pump/valve starts: 0
23:06:28.779872	BC0768E10	Read-Ack  	DHW pump/valve starts: 36368
23:06:28.810728	AD0145706	Write-Ack 	Day of week and time of day: Tue 23:06
23:06:29.440056	T90145704	Write-Data	Day of week and time of day: Tue 23:04
23:06:29.453542	R00770000	Read-Data 	DHW burner starts: 0

Is this correct? Because I don't see any temperature values or something. Also the right upper corner value in the otmonitor stays empty.

[roblom]

With the thermostat disconnected I do receive temperature values and all other. But when I reconnect the thermostat (log says "Thermostat connected") I get only statistic information (see above) and the thermostat displays a connection error F203. The log shows then repeatedly:

23:28:11.851140 T1002010B Write-Data Master configuration: 00000001 11
23:28:11.951226 BD002010B Write-Ack Master configuration: 00000001 11

[hvxl]

So 3 of the 4 communication paths are OK now. Thermostat -> Gateway, Gateway -> Boiler, Boiler -> Gateway. Only Gateway -> Thermostat is apparently not working. The thermostat keeps repeating the same message because it either doesn't receive or doesn't understand the response. Hence also the communication error (F203).

Power down the gateway, disconnect the thermostat and boiler, remove IC1, and power up the gateway again. Then perform the checks described in the first two paragraphs of the Opentherm interfaces section of the troubleshooting instructions.

[roblom]

Now use two pieces of wire to connect X1 to X2 and plug the mains power back in. You should now find a voltage between 15V and 18V on X2 (and X1).

I measure around 6,9V #

If you connect pin 2 of the IC1 socket to VDD (e.g. pin 14), the voltage on X2 should drop to between 5V and 7V.

I measure 5,5V.

Measure the voltage on pin 18 of the IC1 socket with pin 3 left open and again when it is connected to ground. In the former case the voltage should be below 1.25V (it is actually expected to be 0V). In the latter case the voltage must be above 1.25V (and will probably be close to 5V).

(feedback: don't try to tell a story because it isn't, so make a step by step plan like below).
* On the IC1 socket, measure the voltage on pin 18, and ground (pin 5)??. The voltage should be below 1.25V (it is actually expected to be 0V)
I measure 4,07V ##
* Connect pin 3 of IC1 to pin 5 (ground) and measure again the voltage between pin 18 and pin 5 of IC1. The voltage must be above 1.25V (and will probably be close to 5V).
I measure 4,46V

So measure # and ## are incorrect, but the trouble shouting doesn't tell what to do.

[hvxl]

Having trouble counting? The first two paragraphs are the ones starting with "Next measure the voltage ..." and "If you connect pin 3 ..." Your quotes are from the 3rd and 4th paragraph.

[roblom]

These test are all passed...

Next measure the voltage on X1. This should produce a value somewhere between 18V and 34.5V.

I measure 23,4V.

If the voltage is correct you can measure the current between the two terminals of X1. It should be between 5mA and 9mA.

I measure 6,6mA.

If you connect pin 3 of the IC1 socket to ground (e.g. pin 5), the current between the two terminals of X1 should be between 17mA and 23mA

I measure 20,7mA.

[hvxl]

With those measurements, the Gateway -> Thermostat connection should work perfectly. But the numbers from your previous post indicate problems for Thermostat -> Gateway or on the boiler side. However, your earlier logs show the exact opposite situation. So your gateway is behaving inconsistently. That normally points to a bad connection. But after you resoldered everything 3 times already, that's also very unlikely.

I'm unsure how to proceed from here. Where are you located? Maybe we can meet up to get to the bottom of this. Or maybe another nearby gateway user can assist you in person to figure this thing out.

[roblom]

I will try the gateway firmware again this evening.
I'm located in the Netherlands (nearby alkmaar).

[roblom]

It drives me nuts....
I desoldered the socket of IC1 and replaced it with a new one. I resoldered all the resistors, but I without the OK1 I keep getting a voltage on the boiler.

Thermostat: 2.80, 2.81
Boiler: 3.25
Reference: 1.21

Thermostat: 2.79, 2.81
Boiler: 3.25
Reference: 1.21

Thermostat: 2.80, 2.81
Boiler: 3.29
Reference: 1.21

Thermostat: 2.80, 2.81
Boiler: 3.30
Reference: 1.21

I can't find any bad solderings or shortcuts...

[roblom]

OK that greatly reduces the problem area. The boiler measurement is measuring the voltage on pin 18 of IC1. If you check the schematic you'll see that with OK1 removed there is only R4 attached to that pin. R4 should be pulling the pin to GND. So the expected reading for Boiler would be 0V, but for some reason you are getting 3.88V. So either R4 isn't pulling the pin low, or something else is pulling it up.

Next steps:

1. Remove the power from the gateway
2. Carefully remove IC1 from its socket (assuming it's in a socket).
3. Measure the resistance between pin 18 and pin 5 of the IC1 socket.
4. If you don't get a value around 330 Ohm, check what's wrong with R4 (bad soldering, broken print traces, etc).
5. If the resistance is OK, look for shorts around R4, IC1 pin 18, and OK1 pin 5 (e.g. soldering that touches an adjacent pin).

After fixing any problem you find, you can run diagnostics test #5 again until you get a reading of 0V. Then put OK1 back and run test #5 again. You should still get a very low reading for the boiler.

The measurements are ok, I measure 330 Ohm between pin 18 and pin 5 of IC1. I can't find any shortcuts.
I assume this is correct, measure resistance between pin 18 and pin 5 of IC1, and check for shortcuts around pin 5 of OK1

[hvxl]

Unfortunately I don't usually visit that part of the country. So, until another friendly West-Frisian gateway user offers to cast a fresh pair of eyes on your device, we'll have to continue our current mode of debugging.

To make sure we're not chasing ghosts, can you measure the voltage on IC1 pin 18 with a voltmeter in the same situation where you run diagnostics test #5? So, IC1 installed, OK1 removed and power applied. The results should be similar to what test #5 reports for the boiler, so around 3.3V.

If that is the case, let's narrow down where it's coming from: Disconnect the gateway power, remove IC1, and reapply power. Now measure the voltage on IC1 pin 18 again. If you still find 3.3V, it's coming from somewhere outside IC1. If you now measure 0V, the short-circuit must be to some IC1 pin. In that case, remove the power from the gateway and measure the resistance from every IC1 pin to pin 18. You should see infinite on most pins, although a few may give a reading. Any reading below 330 ohm needs further scrutiny.