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OTGW hangs with WDT reset!
Posted: Sat Jun 18, 2016 6:57 am
by mike7
Schelte,
OTGW hung after WDT reset, no message traffic logged by otmonitor.
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18:42:53.747990 T00050000 Read-Data Application-specific flags: 00000000 0
18:42:53.915467 BC0050000 Read-Ack Application-specific flags: 00000000 0
18:42:54.747950 T00110000 Read-Data Relative modulation level: 0.00
18:42:54.928987 BC0110000 Read-Ack Relative modulation level: 0.00
18:42:55.643704 AFOpenTherm Gateway 4.2.5
18:42:55.653292 WDT reset!
18:43:05.823705 Command (via websocket from 172.17.0.3:33640): SR=10:42,0
18:43:07.762148 Command (via websocket from 172.17.0.3:33644): UI=10
18:43:09.792581 Command (via websocket from 172.17.0.3:33646): SR=48:65,35
18:43:11.790784 Command (via websocket from 172.17.0.3:33648): UI=48
18:43:16.800776 Command (via websocket from 172.17.0.3:33652): SR=49:85,30
18:43:18.799805 Command (via websocket from 172.17.0.3:33656): UI=49
20:30:00.122980 Command (via websocket from 172.17.0.3:36216): SW=50
23:30:00.369659 Command (via websocket from 172.17.0.3:40532): HW=0
I've got timeout response to commands.
Unfortunately otgw is on remote location and I can't check connection between boiler and thermostat.
As I know LED "Transmit.." was off, LED "Trouble" was on.
After power recycle I've got:
Code: Select all
08:53:01.060446 00000000000000000110000
08:53:01.084953 00enTherm Gateway 4.2.5
08:53:01.097237 WDT reset!
08:53:01.139930 00000000000000000110000
08:53:01.167578 00enTherm Gateway 4.2.5
08:53:01.179653 WDT reset!
08:53:08.205454 0
0.............................................................................................................
..............................................................................................................
..................................................................OpenTherm Gateway 4.2.5
08:53:08.255320 B40001300 Read-Ack Status: 00010011 00000000
08:53:09.108236 T10010000 Write-Data Control setpoint: 0.00
08:53:09.288105 BD0010000 Write-Ack Control setpoint: 0.00
08:53:10.108401 T00050000 Read-Data Application-specific flags: 00000000 0
08:53:10.282108 BC0050000 Read-Ack Application-specific flags: 00000000 0
08:53:11.108387 T00110000 Read-Data Relative modulation level: 0.00
08:53:11.294532 BC0110000 Read-Ack Relative modulation level: 0.00
08:53:12.108181 T80001300 Read-Data Status: 00010011 00000000
08:53:12.289122 B40001300 Read-Ack Status: 00010011 00000000
What is WDT reset, is it watchdog? If yes what is timeout?
I don't understand why I've got 2 resets after power recycle.
Thank you for your work and support
Re: OTGW hangs with WDT reset!
Posted: Sat Jun 18, 2016 10:11 am
by hvxl
"WDT reset" indeed means that the watchdog timer kicked in. The timeout for the watchdog timer is 16.38 ms. Beware that after a watchdog reset, the gateway boots into monitor mode.
Normally a watchdog timer reset indicates a firmware bug. But this firmware has been running for months in hundreds of gateways without problems and you don't seem to be doing anything unusual. So the most likely cause of the reset is a flaky bit in the eeprom.
Judging by your last piece of log, the gateway is running again. But as mentioned, that's probably in monitor mode (check with PR=M). Try to switch it back to gateway mode (GW=1). If you get another WDT reset, I would suggest to reflash the firmware.
Re: OTGW hangs with WDT reset!
Posted: Sat Jun 18, 2016 10:54 am
by mike7
Strange, there were no messages after "WDT reset", I hope otmonitor should log messages when GW in monitor mode.
Before power recycling I tried GW=R command without success. Boiler problem LED also was on ...
Looks like I need to reflash firmware.
Re: OTGW hangs with WDT reset!
Posted: Fri Sep 08, 2017 9:24 am
by sincze
For some reason I now experience the following:
Code: Select all
2017-09-08 06:09:29.401 OTGW: OpenTherm Gateway 4.2.5
2017-09-08 06:09:29.401 OTGW: WDT reset!
Every day this happens at random times. I already checked the wiring.
THe OTGW has been running fine for over a year now. This started to happen exactly AFTER I had the MAINTENANCE man fix a leakage in the Heating System so I guessed he switched it off.
Normally before maintenance I power down the OTGW and then the Heating system. I think now only the heating system was switched off.
To fix it. I need to disconnect the power from OTGW and reconnect it. Than it starts running again for x hours.
I have no error messages 01/02/03/04 in the OT Monitor. Maybe I should have the monitor run for several days to see if I can catch an error.
Seems I had this issue before.... and it solved itself for some reason...
domoticaforum.eu/viewtopic.php?f=70& ... set#p77767
Suggestions are welcome.
Re: OTGW hangs with WDT reset!
Posted: Wed Sep 20, 2017 11:49 am
by sincze
So according to everything I could find a watchdog RESET could also mean a problem with the firmware.
As the incident started after technician looked at my Ferroli without removing the power from OTGW I did the following:
- Upload diagnostic.hex firmware
- Walked through the tests, all seems okay. Checked reference voltage.
- Upload 4.2.5 firmware. (in addition now all previously stored AA commands / mistakes are removed from EEPROM).
The system is now running for over 24 hours.
I'll add the missing values using AA commands later as my Ferroli Megadens supports the values and shows them in the OTGW monitor nicely.
Re: OTGW hangs with WDT reset!
Posted: Mon Sep 25, 2017 12:54 pm
by sincze
Unfortunately this did not work. Still experiening a Watchdog.
Only a powercycle brings life back to the OTGW.
Suggestions are welcome. So to recap. The gateway is working for hours almost 24 hours. It stops showing the WDT reset warning. No error 01,02,03 or 04. Reference value should be okay. Also confirmed by diagnostic firmware.
Re: OTGW hangs with WDT reset!
Posted: Thu Sep 28, 2017 9:35 am
by sincze
Well just a brief update.
Just Modified the gateway a bit with some fancy parts to see what is going on.
Add some PIN headers
- Added Pin Headers to the mainboard
- OTGW-Pins-1.jpg (43.23 KiB) Viewed 19848 times
Added RCA connectors
- RCA Connectors for better connection and easy mount/unmount
- OTGW-Connectors-1.jpg (38.16 KiB) Viewed 19848 times
Add some LIGHTS
- Added lights to the cover
- OTGW-Lights-1.jpg (24.94 KiB) Viewed 19848 times
In this case now I can actually see what is happening.
The following occurs.
The FERROLI boiler tends to reboot itself sometimes. ( I can see and hear this, display lights up and it starts it's automatic 'ontluchting' procedure).
After completion the boiler continues to work. However now with the communication leds attached to the OTGW I can see that sometimes when this happens the OTGW stops flashing communication LEDS and raises the WDT Reset in the log.
I've attached a reset button to the OTGW and once pressed the OTGW continues operation as normal
As I have no 01/02/03/04 error messages I must assume the Firmware contains some sort of error/bug.
Can this 'time-out' for rebooting boilers perhaps be implemented to that it stops raising the WDT Reset. Error message?
Many many thanks.
Re: OTGW hangs with WDT reset!
Posted: Sun Oct 08, 2017 4:10 pm
by hvxl
So sometimes the reboot of the Ferroli boiler causes the OTGW to become stuck (leading to a WDT reset), but not always? If you can provide a couple of logs of both situations, we may be able to determine what may be the trigger for the problems. Also statistics may be helpful. What's the ratio of troublesome versus trouble-free reboots?
Re: OTGW hangs with WDT reset!
Posted: Mon Oct 09, 2017 10:14 am
by sincze
Excellent I will start logging.
At the moment as I now have the pic reset completely automated I have 7 pic resets a day. (I received a notification with the actual count of that day)
It will reset the pic if no data was received for 15 minutes.
Just post the logs in here is okay as attachment?
Any specific log settings required?
Regarding the ratio it is hard to say as it also happens in the middle of the night. And when I am not home so I can't hear the boiler reset actually happening. With 7 pic resets a day that seems a lot of times for boiler resets. However I just don't know that exact answer. I can set an additional alarm.. If no data was received for 1 minute and I am home. Run to the boiler.
Re: OTGW hangs with WDT reset!
Posted: Thu Oct 12, 2017 12:13 am
by sincze
As the log file was a bit to big I added it to a google drive.
https://drive.google.com/file/d/0B1iXMF ... sp=sharing
Anything we can use in it??
I'll keep the log running.
Re: OTGW hangs with WDT reset!
Posted: Thu Oct 19, 2017 11:54 am
by sincze
I've just added another log file (12 resets in a day).
Is the log in the corret format?
Unfortunately I am unable to determine the root cause.
The auto PIC reset however brings the device back online.
but then again. Maybe it can be solved in the firmware as well.
the WDT reset! could be an auto-reset of the PIC
drive.google.com/file/d/0B1iXMFkXDcbJYU ... sp=sharing
I'll add a warning to my monitor so that in case I did not receive an update I will run to the boiler to see if I can find something suspicious before it resets the PIC.
This simple relais is my PIC reset it is operated by a Mysensors Node. Currently in "Try-Out" Position aka test-setup.
- PIC Reset
- PIC Reset.jpeg (63.75 KiB) Viewed 19509 times
Re: OTGW hangs with WDT reset!
Posted: Sat Nov 11, 2017 11:56 am
by sincze
As I noticed the OTGW PIC hangs as well without a restart of the boiler I tried a spare OTGW that I borrowed from a friend.
Just to rule out if it is my own OTGW that is causing all this
- Spare Parts
- OTGW - Spare-r.jpg (20.67 KiB) Viewed 19241 times
This borrowed 'beast' still has OTGW firmware 4.2.3.
I only had to mount 2 RCA plugs that I had somewhere to make a connection with the existing wiring.
The boiler has been running overnight without any problems. Normally the gateway would be have to reset between 7-20 times a day,,, (As it was not processing any data no led lights blinking until a reset)
Today I added a few commands using AA this morning to have the spare part providing me exactly the same data as my OTGW 4.2.5 was providing me.
Let's see what happens. As the 4.2.5. is working without any error 01/02/03/04 for a while and randomly hangs.. What would be the most obvious part to look for that could be faulty?
As the WDT does not provide the 'cause' of hanging.
Suggestions are welcome.
Re: OTGW hangs with WDT reset!
Posted: Sun Nov 12, 2017 11:01 pm
by sincze
The spare OTGW was working without any issues.
I reflashed the 'production' OTGW with the same version. Added the values I wanted to see in otmonitor with 'AA=xx".
Reconnected the cables and the OTGW is working now over 26 hours without a reset.
Well what do you know...
finally solved ?? I will let you know next week.
Re: OTGW hangs with WDT reset!
Posted: Sun Dec 03, 2017 2:24 pm
by hvxl
The changes between version 4.2.3 and 4.2.5 are very small. I don't see anything in there that seems like it could have introduced a reason for a WDT reset.
Re: OTGW hangs with WDT reset!
Posted: Sun Dec 03, 2017 9:38 pm
by sincze
hvxl wrote:The changes between version 4.2.3 and 4.2.5 are very small. I don't see anything in there that seems like it could have introduced a reason for a WDT reset.
Me neither. However it could be the PIC content got corrupted?
Even after reflashing with the 'do not keep the options' ??
The only thing I changed was:
- Get Spare OTGW...
- Attach spare to Boiler.. spare was running 4.2.3. and it did not crash,
Reflashed my own gateway with 4.2.3 using a raspberry Pi in stead of otmonitor on windows via a ser2lan connection.
And the thing has been running.
Only 1 or 2 automated resets in a week now.
I'm thinking about reflashing to 4.2.5.
Only thing i am currently looking at is:
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2017-12-03 20:36:18.546 OTGW: PR: BV
2017-12-03 20:36:18.645 (GW OpenTherm) Temp (Max. Vloerverwarming)
2017-12-03 20:36:18.736 (GW OpenTherm) General/Percentage (Maximum Relative Modulation Level)
2017-12-03 20:36:18.826 (GW OpenTherm) Thermostat (Room Setpoint)
2017-12-03 20:36:18.941 (GW OpenTherm) General/Percentage (Relative modulation level)
2017-12-03 20:36:19.056 (GW OpenTherm) General/Pressure (CH Water Pressure)
2017-12-03 20:36:19.175 (GW OpenTherm) Temp (Room Temperature)
2017-12-03 20:36:19.296 (GW OpenTherm) Temp (Boiler Water Temperature)
2017-12-03 20:36:19.403 (GW OpenTherm) Temp (DHW Temperature)
2017-12-03 20:36:19.534 (GW OpenTherm) Temp (OTGW - Outside Temperature)
2017-12-03 20:36:19.660 (GW OpenTherm) Temp (Return Water Temperature)
2017-12-03 20:36:19.766 (GW OpenTherm) Thermostat (DHW Setpoint)
2017-12-03 20:36:19.869 (GW OpenTherm) Thermostat (Max_CH Water Setpoint)
If I could just figure out what setting was causing:
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2017-12-03 20:36:18.546 OTGW: PR: BV
That would be ideal.