HVAC Controller Retrofit

1// HVAC Ctrl 1.0, by LD design
2// revision 2.5, 2019-02-10
3
4//  Copyright 2018, Louis Desbiens, All rights reserved.
5
6
7#include <avr/pgmspace.h>
8
9
10
11
12//
13//
14//
15//
16//  beginning of global variables and constant declarations
17//
18//
19//
20//
21
22
23
24
25
26
27//  digital addresses
28
29// outputs
30
31const byte LED_ctrl = 13;      // LED  control pin address
32const byte H1_ctrl = 12;       // Heat strip #1, relay pin  address
33const byte H2_ctrl = 11;       // Heat strip #2, relay  pin address
34const  byte H3_ctrl = 10;       // Heat strip #3, relay pin address
35const byte H4_ctrl  = 9;        // Heat strip #4, relay pin address
36const byte BLO_ctrl = 8;       //  Blower low speed, relay pin address
37const byte BMED_ctrl = 7;      // Blower  medium speed, relay pin address
38const byte BHI_ctrl = 6;       // Blower high  speed, relay pin address
39const byte BSSR_ctrl = 5;      // Blower circuit, solid-state  relay pin address
40
41// inputs
42
43const byte G = 3;              // Thermostat  G line status address (blower)
44const byte W1 = 2;             // Thermostat W1  line status address (heat stage 1)
45const byte W2 = 1;             // Thermostat  W2 line status address (heat stage 2)
46const byte W3 = 0;             // Thermostat  W3 line status address (heat stage 3), connected to heat pump Y in the current implementation  to override the fan speed algorithm
47
48
49// analog input signal, addresses
50
51const  byte TH1 = 0;           // Thermistor 1 address
52const byte TH2 = 6;           //  Thermistor 2 address
53const byte CSFAN = 1;         // Fan current sense address
54const  byte CSH1 = 5;          // Heat strip #1 current sense address
55const byte CSH2  = 4;          // Heat strip #2 current sense address
56const byte CSH3 = 3;          //  Heat strip #3 current sense address
57const byte CSH4 = 2;          // Heat strip  #4 current sense address
58
59
60// constant values
61
62const byte nb_of_heating_elements  = 4;                           // nb of heating elements
63const byte CS_vector_size  = 144;                                 // current sense vector size
64const int  delta_H = 1000;                                        // minimal delay (ms) between  two subsequent activation / dactivation of heat strip relays
65const int delta_G0  = 5000;                                       // minimal delay (ms), after a blower  power-up at the lowest speed, before engaging the speed adjustment algorithm
66const  int delta_G = 1000;                                        // minimal delay (ms),  between two subsequent blower speed change
67const int delta_W1_level_1 = 5;                                  //  minimal delay (s) before engaging the second heat strip on a W1 heat request, (2  x 5 kW capacity)
68const int delta_W2_level_1 = 5;                                  //  minimal delay (s) before engaging the second heat strip on a W2 heat request, (2  x 5 kW capacity)
69const int delai_SSR = 10;                                        //  minimal delay (ms) before adjusting the blower speed selection relays after opening  the circuit with the SSR relay
70const int delai_relay = 15;                                      //  minimal delay (ms) after adjustment the blower speed selection relays before closing  the circuit with the SSR relay
71const int delta_T_LO_up = 1000;                                  //  minimum temp for going from LO to MED in 1/100 of C (hysteresis)
72const int delta_T_MED_up  = 1500;                                 // minimum temp for going from MED to HI  in 1/100 of C (hysteresis)
73const int delta_T_HI_up = 2000;                                  //  minimum temp for going from HI to VHI in 1/100 of C (hysteresis)
74const int delta_T_MED_down  = 900;                                // minimum temp for going from MED to LO in  1/100 of C (hysteresis)
75const int delta_T_HI_down = 1400;                                //  minimum temp for going from HI to MED in 1/100 of C (hysteresis)
76const int delta_T_VHI_down  = 1900;                               // minimum temp for going from VHIGH to HI  in 1/100 of C (hysteresis)
77const int H_current_conversion_1 = 35;                           //  current sense conversion constant (30A model, heat strip)
78const int B_current_conversion_1  = 210;                          // current sense conversion constant (5A model,  blower)
79const int HB_current_conversion_2 = 10000;                       // current  sense conversion constant
80const byte nb_pts_period = 4;                                    //  nb of points per 60Hz cylce for the current sense evaluation
81const int current_FAN_min[]  = {0, 1300, 1400, 1600, 1900};       // blower current sense minimal threshold (mA)  for OFF, LO, MED, HIGH, VHIGH states (PRELIMINARY)
82const int current_FAN_max[]  = {500, 2200, 2400, 2700, 3200};     // blower current sense maximal threshold (mA)  for OFF, LO, MED, HIGH, VHIGH states (PRELIMINARY)
83const int current_H_min[]  = {0, 15000};                          // heat strip current sense minimal threshold  (mA) for OFF, ON states (PRELIMINARY)
84const int current_H_max[] = {1000, 25000};                       // heat strip current sense maximal threshold (mA) for OFF,  ON states (PRELIMINARY)
85const int USB_comm_period = 2000;                                //  periodic delay (ms) between checks whether a USB connection is present
86
87
88//  constants stored in the flash (instead of SRAM)
89
90const PROGMEM int16_t thermistor_conversion[]  = {32767, 32767, 29765, 26554, 24485, 22984, 21820, 20876, 20087, 19411, 18822,  18301, 17836, 17415, 17032, 16681, 16358, 16058, 15779, 15518, 15273, 15042, 14824,  14618, 14422, 14235, 14058, 13888, 13726, 13570, 13421, 13277, 13139, 13006, 12877,  12753, 12633, 12517, 12404, 12295, 12189, 12086, 11987, 11889, 11795, 11703, 11613,  11525, 11440, 11357, 11275, 11196, 11118, 11042, 10967, 10895, 10823, 10753, 10685,  10618, 10552, 10487, 10424, 10362, 10300, 10240, 10181, 10123, 10066, 10010, 9955,  9901, 9847, 9795, 9743, 9692, 9642, 9592, 9543, 9495, 9448, 9401, 9355, 9309, 9265,  9220, 9177, 9133, 9091, 9049, 9007, 8966, 8926, 8885, 8846, 8807, 8768, 8730, 8692,  8655, 8618, 8581, 8545, 8509, 8474, 8439, 8404, 8370, 8336, 8302, 8269, 8236, 8203,  8171, 8139, 8107, 8076, 8044, 8014, 7983, 7953, 7923, 7893, 7863, 7834, 7805, 7776,  7748, 7720, 7691, 7664, 7636, 7609, 7582, 7555, 7528, 7501, 7475, 7449, 7423, 7397,  7372, 7346, 7321, 7296, 7272, 7247, 7223, 7198, 7174, 7150, 7126, 7103, 7079, 7056,  7033, 7010, 6987, 6965, 6942, 6920, 6897, 6875, 6853, 6832, 6810, 6788, 6767, 6746,  6724, 6703, 6682, 6662, 6641, 6620, 6600, 6580, 6560, 6539, 6519, 6500, 6480, 6460,  6441, 6421, 6402, 6383, 6364, 6345, 6326, 6307, 6288, 6269, 6251, 6232, 6214, 6196,  6178, 6160, 6142, 6124, 6106, 6088, 6071, 6053, 6036, 6018, 6001, 5984, 5966, 5949,  5932, 5915, 5899, 5882, 5865, 5849, 5832, 5815, 5799, 5783, 5766, 5750, 5734, 5718,  5702, 5686, 5670, 5655, 5639, 5623, 5608, 5592, 5577, 5561, 5546, 5530, 5515, 5500,  5485, 5470, 5455, 5440, 5425, 5410, 5395, 5381, 5366, 5351, 5337, 5322, 5308, 5293,  5279, 5265, 5250, 5236, 5222, 5208, 5194, 5180, 5166, 5152, 5138, 5124, 5111, 5097,  5083, 5069, 5056, 5042, 5029, 5015, 5002, 4989, 4975, 4962, 4949, 4935, 4922, 4909,  4896, 4883, 4870, 4857, 4844, 4831, 4818, 4805, 4793, 4780, 4767, 4754, 4742, 4729,  4717, 4704, 4692, 4679, 4667, 4654, 4642, 4630, 4617, 4605, 4593, 4581, 4568, 4556,  4544, 4532, 4520, 4508, 4496, 4484, 4472, 4460, 4448, 4437, 4425, 4413, 4401, 4389,  4378, 4366, 4354, 4343, 4331, 4320, 4308, 4297, 4285, 4274, 4262, 4251, 4240, 4228,  4217, 4206, 4194, 4183, 4172, 4161, 4150, 4138, 4127, 4116, 4105, 4094, 4083, 4072,  4061, 4050, 4039, 4028, 4017, 4006, 3996, 3985, 3974, 3963, 3952, 3942, 3931, 3920,  3910, 3899, 3888, 3878, 3867, 3857, 3846, 3835, 3825, 3814, 3804, 3793, 3783, 3773,  3762, 3752, 3741, 3731, 3721, 3710, 3700, 3690, 3680, 3669, 3659, 3649, 3639, 3628,  3618, 3608, 3598, 3588, 3578, 3568, 3558, 3548, 3538, 3527, 3517, 3507, 3498, 3488,  3478, 3468, 3458, 3448, 3438, 3428, 3418, 3408, 3399, 3389, 3379, 3369, 3359, 3350,  3340, 3330, 3320, 3311, 3301, 3291, 3282, 3272, 3262, 3253, 3243, 3233, 3224, 3214,  3205, 3195, 3186, 3176, 3166, 3157, 3147, 3138, 3128, 3119, 3109, 3100, 3091, 3081,  3072, 3062, 3053, 3044, 3034, 3025, 3015, 3006, 2997, 2987, 2978, 2969, 2959, 2950,  2941, 2932, 2922, 2913, 2904, 2895, 2885, 2876, 2867, 2858, 2849, 2839, 2830, 2821,  2812, 2803, 2793, 2784, 2775, 2766, 2757, 2748, 2739, 2730, 2721, 2712, 2702, 2693,  2684, 2675, 2666, 2657, 2648, 2639, 2630, 2621, 2612, 2603, 2594, 2585, 2576, 2567,  2558, 2549, 2540, 2531, 2522, 2513, 2504, 2496, 2487, 2478, 2469, 2460, 2451, 2442,  2433, 2424, 2415, 2407, 2398, 2389, 2380, 2371, 2362, 2353, 2344, 2336, 2327, 2318,  2309, 2300, 2291, 2283, 2274, 2265, 2256, 2247, 2239, 2230, 2221, 2212, 2203, 2195,  2186, 2177, 2168, 2159, 2151, 2142, 2133, 2124, 2116, 2107, 2098, 2089, 2081, 2072,  2063, 2054, 2046, 2037, 2028, 2019, 2011, 2002, 1993, 1984, 1976, 1967, 1958, 1949,  1941, 1932, 1923, 1914, 1906, 1897, 1888, 1880, 1871, 1862, 1853, 1845, 1836, 1827,  1818, 1810, 1801, 1792, 1784, 1775, 1766, 1757, 1749, 1740, 1731, 1722, 1714, 1705,  1696, 1687, 1679, 1670, 1661, 1653, 1644, 1635, 1626, 1618, 1609, 1600, 1591, 1583,  1574, 1565, 1556, 1548, 1539, 1530, 1521, 1512, 1504, 1495, 1486, 1477, 1469, 1460,  1451, 1442, 1433, 1425, 1416, 1407, 1398, 1389, 1381, 1372, 1363, 1354, 1345, 1336,  1328, 1319, 1310, 1301, 1292, 1283, 1274, 1266, 1257, 1248, 1239, 1230, 1221, 1212,  1203, 1194, 1185, 1176, 1168, 1159, 1150, 1141, 1132, 1123, 1114, 1105, 1096, 1087,  1078, 1069, 1060, 1051, 1042, 1033, 1024, 1015, 1006, 997, 988, 979, 969, 960, 951,  942, 933, 924, 915, 906, 897, 887, 878, 869, 860, 851, 842, 832, 823, 814, 805,  795, 786, 777, 768, 758, 749, 740, 730, 721, 712, 702, 693, 684, 674, 665, 655,  646, 637, 627, 618, 608, 599, 589, 580, 570, 561, 551, 542, 532, 523, 513, 503,  494, 484, 475, 465, 455, 445, 436, 426, 416, 407, 397, 387, 377, 367, 358, 348,  338, 328, 318, 308, 298, 288, 278, 268, 259, 249, 238, 228, 218, 208, 198, 188,  178, 168, 158, 147, 137, 127, 117, 106, 96, 86, 76, 65, 55, 44, 34, 24, 13, 3, -8,  -18, -29, -40, -50, -61, -71, -82, -93, -104, -114, -125, -136, -147, -158, -168,  -179, -190, -201, -212, -223, -234, -245, -257, -268, -279, -290, -301, -312, -324,  -335, -346, -358, -369, -381, -392, -404, -415, -427, -438, -450, -462, -473, -485,  -497, -509, -521, -532, -544, -556, -568, -580, -592, -605, -617, -629, -641, -654,  -666, -678, -691, -703, -716, -728, -741, -753, -766, -779, -792, -804, -817, -830,  -843, -856, -869, -883, -896, -909, -922, -936, -949, -963, -976, -990, -1003, -1017,  -1031, -1045, -1058, -1072, -1086, -1100, -1115, -1129, -1143, -1157, -1172, -1186,  -1201, -1216, -1230, -1245, -1260, -1275, -1290, -1305, -1320, -1335, -1351, -1366,  -1381, -1397, -1413, -1428, -1444, -1460, -1476, -1492, -1509, -1525, -1541, -1558,  -1575, -1591, -1608, -1625, -1642, -1659, -1677, -1694, -1711, -1729, -1747, -1765,  -1783, -1801, -1819, -1838, -1856, -1875, -1894, -1913, -1932, -1951, -1971, -1990,  -2010, -2030, -2050, -2070, -2091, -2111, -2132, -2153, -2174, -2196, -2217, -2239,  -2261, -2283, -2306, -2328, -2351, -2375, -2398, -2422, -2446, -2470, -2494, -2519,  -2544, -2569, -2595, -2621, -2647, -2674, -2701, -2728, -2756, -2784, -2812, -2841,  -2870, -2900, -2930, -2961, -2992, -3024, -3056, -3089, -3122, -3156, -3190, -3225,  -3261, -3297, -3334, -3372, -3411, -3451, -3491, -3533, -3575, -3618, -3663, -3708,  -3755, -3803, -3853, -3904, -3956, -4010, -4066, -4124, -4184, -4247, -4311, -4379,  -4449, -4523, -4600, -4682, -4768, -4859, -4956, -5059, -5171, -5291, -5423, -5568,  -5731, -5915, -6128, -6384, -6704, -7138, -7839, -32768}; // use this form
91const  PROGMEM uint16_t current_sensing_conversion[] = {64532, 64280, 64029, 63778, 63527,  63277, 63027, 62778, 62530, 62281, 62034, 61787, 61540, 61294, 61048, 60803, 60558,  60314, 60070, 59827, 59585, 59342, 59101, 58859, 58619, 58378, 58139, 57899, 57661,  57422, 57185, 56947, 56711, 56474, 56238, 56003, 55768, 55534, 55300, 55067, 54834,  54602, 54370, 54138, 53908, 53677, 53447, 53218, 52989, 52761, 52533, 52305, 52078,  51852, 51626, 51401, 51176, 50951, 50727, 50504, 50281, 50058, 49836, 49615, 49394,  49173, 48953, 48734, 48515, 48296, 48078, 47861, 47644, 47427, 47211, 46995, 46780,  46566, 46352, 46138, 45925, 45712, 45500, 45289, 45077, 44867, 44657, 44447, 44238,  44029, 43821, 43613, 43406, 43199, 42993, 42787, 42582, 42378, 42173, 41970, 41766,  41564, 41361, 41160, 40958, 40758, 40557, 40357, 40158, 39959, 39761, 39563, 39366,  39169, 38973, 38777, 38582, 38387, 38192, 37998, 37805, 37612, 37420, 37228, 37036,  36846, 36655, 36465, 36276, 36087, 35898, 35710, 35523, 35336, 35150, 34964, 34778,  34593, 34409, 34225, 34041, 33858, 33676, 33494, 33312, 33131, 32950, 32770, 32591,  32412, 32233, 32055, 31877, 31700, 31524, 31348, 31172, 30997, 30822, 30648, 30475,  30301, 30129, 29957, 29785, 29614, 29443, 29273, 29103, 28934, 28765, 28597, 28429,  28262, 28095, 27929, 27763, 27598, 27433, 27269, 27105, 26942, 26779, 26617, 26455,  26294, 26133, 25973, 25813, 25653, 25495, 25336, 25178, 25021, 24864, 24708, 24552,  24397, 24242, 24087, 23933, 23780, 23627, 23475, 23323, 23171, 23020, 22870, 22720,  22570, 22421, 22273, 22125, 21977, 21830, 21684, 21538, 21392, 21247, 21103, 20959,  20815, 20672, 20529, 20387, 20246, 20105, 19964, 19824, 19684, 19545, 19407, 19269,  19131, 18994, 18857, 18721, 18585, 18450, 18316, 18181, 18048, 17914, 17782, 17650,  17518, 17387, 17256, 17126, 16996, 16867, 16738, 16610, 16482, 16355, 16228, 16102,  15976, 15850, 15726, 15601, 15478, 15354, 15231, 15109, 14987, 14866, 14745, 14625,  14505, 14385, 14266, 14148, 14030, 13913, 13796, 13679, 13564, 13448, 13333, 13219,  13105, 12991, 12878, 12766, 12654, 12542, 12431, 12321, 12211, 12101, 11992, 11884,  11776, 11668, 11561, 11455, 11349, 11243, 11138, 11033, 10929, 10826, 10723, 10620,  10518, 10416, 10315, 10214, 10114, 10015, 9916, 9817, 9719, 9621, 9524, 9427, 9331,  9235, 9140, 9045, 8951, 8857, 8764, 8671, 8579, 8487, 8396, 8305, 8215, 8125, 8036,  7947, 7859, 7771, 7684, 7597, 7511, 7425, 7339, 7255, 7170, 7086, 7003, 6920, 6838,  6756, 6674, 6594, 6513, 6433, 6354, 6275, 6196, 6119, 6041, 5964, 5888, 5812, 5736,  5661, 5587, 5513, 5439, 5366, 5294, 5222, 5150, 5079, 5009, 4939, 4869, 4800, 4731,  4663, 4596, 4529, 4462, 4396, 4330, 4265, 4201, 4136, 4073, 4010, 3947, 3885, 3823,  3762, 3701, 3641, 3581, 3522, 3464, 3405, 3348, 3290, 3234, 3177, 3122, 3066, 3012,  2957, 2904, 2850, 2798, 2745, 2694, 2642, 2591, 2541, 2491, 2442, 2393, 2345, 2297,  2250, 2203, 2156, 2110, 2065, 2020, 1976, 1932, 1888, 1846, 1803, 1761, 1720, 1679,  1638, 1598, 1559, 1520, 1481, 1443, 1406, 1369, 1332, 1296, 1261, 1226, 1191, 1157,  1124, 1091, 1058, 1026, 995, 963, 933, 903, 873, 844, 815, 787, 760, 733, 706, 680,  654, 629, 604, 580, 557, 533, 511, 488, 467, 446, 425, 405, 385, 366, 347, 329,  311, 294, 277, 261, 245, 229, 215, 200, 187, 173, 160, 148, 136, 125, 114, 104,  94, 84, 76, 67, 59, 52, 45, 39, 33, 27, 22, 18, 14, 10, 7, 5, 3, 2, 1, 0, 0, 1,  2, 3, 5, 7, 10, 14, 18, 22, 27, 33, 39, 45, 52, 59, 67, 76, 84, 94, 104, 114, 125,  136, 148, 160, 173, 187, 200, 215, 229, 245, 261, 277, 294, 311, 329, 347, 366,  385, 405, 425, 446, 467, 488, 511, 533, 557, 580, 604, 629, 654, 680, 706, 733,  760, 787, 815, 844, 873, 903, 933, 963, 995, 1026, 1058, 1091, 1124, 1157, 1191,  1226, 1261, 1296, 1332, 1369, 1406, 1443, 1481, 1520, 1559, 1598, 1638, 1679, 1720,  1761, 1803, 1846, 1888, 1932, 1976, 2020, 2065, 2110, 2156, 2203, 2250, 2297, 2345,  2393, 2442, 2491, 2541, 2591, 2642, 2694, 2745, 2798, 2850, 2904, 2957, 3012, 3066,  3122, 3177, 3234, 3290, 3348, 3405, 3464, 3522, 3581, 3641, 3701, 3762, 3823, 3885,  3947, 4010, 4073, 4136, 4201, 4265, 4330, 4396, 4462, 4529, 4596, 4663, 4731, 4800,  4869, 4939, 5009, 5079, 5150, 5222, 5294, 5366, 5439, 5513, 5587, 5661, 5736, 5812,  5888, 5964, 6041, 6119, 6196, 6275, 6354, 6433, 6513, 6594, 6674, 6756, 6838, 6920,  7003, 7086, 7170, 7255, 7339, 7425, 7511, 7597, 7684, 7771, 7859, 7947, 8036, 8125,  8215, 8305, 8396, 8487, 8579, 8671, 8764, 8857, 8951, 9045, 9140, 9235, 9331, 9427,  9524, 9621, 9719, 9817, 9916, 10015, 10114, 10214, 10315, 10416, 10518, 10620, 10723,  10826, 10929, 11033, 11138, 11243, 11349, 11455, 11561, 11668, 11776, 11884, 11992,  12101, 12211, 12321, 12431, 12542, 12654, 12766, 12878, 12991, 13105, 13219, 13333,  13448, 13564, 13679, 13796, 13913, 14030, 14148, 14266, 14385, 14505, 14625, 14745,  14866, 14987, 15109, 15231, 15354, 15478, 15601, 15726, 15850, 15976, 16102, 16228,  16355, 16482, 16610, 16738, 16867, 16996, 17126, 17256, 17387, 17518, 17650, 17782,  17914, 18048, 18181, 18316, 18450, 18585, 18721, 18857, 18994, 19131, 19269, 19407,  19545, 19684, 19824, 19964, 20105, 20246, 20387, 20529, 20672, 20815, 20959, 21103,  21247, 21392, 21538, 21684, 21830, 21977, 22125, 22273, 22421, 22570, 22720, 22870,  23020, 23171, 23323, 23475, 23627, 23780, 23933, 24087, 24242, 24397, 24552, 24708,  24864, 25021, 25178, 25336, 25495, 25653, 25813, 25973, 26133, 26294, 26455, 26617,  26779, 26942, 27105, 27269, 27433, 27598, 27763, 27929, 28095, 28262, 28429, 28597,  28765, 28934, 29103, 29273, 29443, 29614, 29785, 29957, 30129, 30301, 30475, 30648,  30822, 30997, 31172, 31348, 31524, 31700, 31877, 32055, 32233, 32412, 32591, 32770,  32950, 33131, 33312, 33494, 33676, 33858, 34041, 34225, 34409, 34593, 34778, 34964,  35150, 35336, 35523, 35710, 35898, 36087, 36276, 36465, 36655, 36846, 37036, 37228,  37420, 37612, 37805, 37998, 38192, 38387, 38582, 38777, 38973, 39169, 39366, 39563,  39761, 39959, 40158, 40357, 40557, 40758, 40958, 41160, 41361, 41564, 41766, 41970,  42173, 42378, 42582, 42787, 42993, 43199, 43406, 43613, 43821, 44029, 44238, 44447,  44657, 44867, 45077, 45289, 45500, 45712, 45925, 46138, 46352, 46566, 46780, 46995,  47211, 47427, 47644, 47861, 48078, 48296, 48515, 48734, 48953, 49173, 49394, 49615,  49836, 50058, 50281, 50504, 50727, 50951, 51176, 51401, 51626, 51852, 52078, 52305,  52533, 52761, 52989, 53218, 53447, 53677, 53908, 54138, 54370, 54602, 54834, 55067,  55300, 55534, 55768, 56003, 56238, 56474, 56711, 56947, 57185, 57422, 57661, 57899,  58139, 58378, 58619, 58859, 59101, 59342, 59585, 59827, 60070, 60314, 60558, 60803,  61048, 61294, 61540, 61787, 62034, 62281, 62530, 62778, 63027, 63277, 63527, 63778,  64029, 64280, 64532};
92const PROGMEM byte LED1[] = {0, 0, 0, 0, 0, 0, 0, 0, 0,  1, 1, 1, 1, 1, 1, 1, 1, 1, 2, 2, 2, 2, 2, 2, 2, 2, 2};
93const PROGMEM byte LED2[]  = {0, 0, 0, 1, 1, 1, 2, 2, 2, 0, 0, 0, 1, 1, 1, 2, 2, 2, 0, 0, 0, 1, 1, 1, 2, 2,  2};
94const PROGMEM byte LED3[] = {0, 1, 2, 0, 1, 2, 0, 1, 2, 0, 1, 2, 0, 1, 2,  0, 1, 2, 0, 1, 2, 0, 1, 2, 0, 1, 2};
95
96// thermistor conversion :  the "analogread"  value is used as an index, what is stored in the flash are the correspoding 1024  temperatures (in 1/100 C)
97// current sense conversion, the instanteous current  (mA) is given by :   sqrt(current_sensing_conversion)/H_current_conversion_1*HB_current_conversion_2  for the heat strips and  sqrt(current_sensing_conversion)/B_current_conversion_1*HB_current_conversion_2  for the blower
98
99
100
101// working variables
102
103byte current_speed = 0;                                                    // 0 min speed, 1,2,3 max speed  (blower, current state)
104byte new_speed = 0;                                                        //  0 min speed, 1,2,3 max speed (blower, new state)
105byte G_current_status = 0;                                                 //  current status of the G line (0=OFF, 1=ON)
106byte G_new_status = 0;                                                     //  new status of the G line (0=OFF, 1=ON)
107byte W1_current_status = 0;                                                //  current status of the W1 line (0=OFF, 1=ON)
108byte W1_new_status = 0;                                                    //  new status of the W1 line (0=OFF, 1=ON)
109byte W2_current_status = 0;                                                //  current status of the W2 line (0=OFF, 1=ON)
110byte W2_new_status = 0;                                                    //  new status of the W2 line (0=OFF, 1=ON)
111byte W3_current_status = 0;                                                //  current status of the W3 line (0=OFF, 1=ON)
112byte W3_new_status = 0;                                                    //  new status of the W3 line (0=OFF, 1=ON)
113int TH1_value = 0;                                                         //  Temperature value (1/100 C), thermistor 1
114int TH2_value = 0;                                                         //  Temperature value (1/100 C), thermistor 2
115byte active_elements_W1_W2[5] = {H4_ctrl,  H1_ctrl, H2_ctrl, H3_ctrl, H4_ctrl}; // indexes 0 and 1 correspond to W1, indexes  2 and 3 to W2, the addresses of the heat strips are cycled through in the vector  each time a new activation of W1 occcurs
116byte W1_heating_state = 0;                                                 //  heating states associated with W1  (0: no heat strips activates, 1: first heat strip  is activated, 2: both heat strips are activated)
117byte W2_heating_state = 0;                                                 //  heating states associated with W2  (0: no heat strips activates, 1: first heat strip  is activated, 2: both heat strips are activated)
118byte speed_change_stage = 3;                                               // blower speed change states (0:  beginning of speed change sequence, 1: the circuit is open, 2: The speed adjustment  has been made, 3: the circuit is closed)
119byte fan_activation_state = 0;                                             //  blower fan state sequence for shutdown (=0 fan is ready for first step of startup  or shutdown sequence, =1 shutdown sequence intermediate step, after SSR has openend  the circuit before fan speed goes back to minimal value, =2 fan is off and speed  is at low)
120byte pointer_CS = 0;                                                       //  current sense consist of measuring multiplie instantaneous current value samples  (4 per 60 Hz cycle, 36 consecutives cycles, 144 samples in total representing 600  ms) and calculating the RMS value, pointer_CS is the index in the vector current
121long  correction_us = 0;                                                    // To ensure  the current measurement are performed every 4.16 ms, a delay is adjusted each cycle  to compensate for the small variations, correction_us is the correction to the fized  latenccy in us, reevaluated at each cycle
122byte system_status_LED[] = {0, 0, 0,  0, 0, 0, 0, 0};                       //  LED1 LED2 LED3 color   0 =green  1 = yellow  2 = red,   FAN status  H1 H2 H3 H4   0 = OK(green)   1 = UC(yellow)  2 = OC(red)   PRELIMINARY
123byte FAN_status = 0;                                                       //  FAN_status (0= OFF, 1= LOW, 2= MED, 3= HIGH, 4= VHIGH) to be used as an indicator  in the reporting system (USB) and eventually in the LED control PRELIMINARY
124byte  HEATER_status = 0;                                                    // HEATER_status  (0= OFF, 1= W1 1st heat strip, 2= W2 both heat strip, 3= W2 1st heat strip, 4= W2  both heat strip) to be used as an indicator in the reporting system (USB) and eventually  in the LED control PRELIMINARY
125byte system_status_index = 0;                                              //  global value indicating the status in which the system is in, 27 possible states  PRELIMINARY
126byte USB_connection_status = 0;                                            //  indication whether a USB connection is present or not
127unsigned int H1_current_vector[CS_vector_size];                            // current sense vector of 144 samples for heat strip  #1
128unsigned int H2_current_vector[CS_vector_size];                            //  current sense vector of 144 samples for heat strip #2
129unsigned int H3_current_vector[CS_vector_size];                            // current sense vector of 144 samples for heat strip  #3
130unsigned int H4_current_vector[CS_vector_size];                            //  current sense vector of 144 samples for heat strip #4
131unsigned int FAN_current_vector[CS_vector_size];                           // current sense vector of 144 samples for the blower
132unsigned  long H1_CS_sum = 0;                                               // current sense  sum for heat strip #1
133unsigned long H2_CS_sum = 0;                                               //  current sense sum for heat strip #2
134unsigned long H3_CS_sum = 0;                                               //  current sense sum for heat strip #3
135unsigned long H4_CS_sum = 0;                                               //  current sense sum for heat strip #4
136unsigned long FAN_CS_sum = 0;                                              //  current sense sum for the blower
137unsigned int current_sense_H_vector[nb_of_heating_elements];               // actual current value in mA for the heat strips
138unsigned int  current_sense_FAN = 0;                                        // actual current  value in mA for the blower
139
140
141
142
143// time measurements
144
145unsigned  long time_H0 = 0;                  // absolute time of the last relay activation
146unsigned  long time_W1 = 0;                  // absolute time of the last W1 activation
147unsigned  long time_W2 = 0;                  // absolute time of the last W2 activation
148unsigned  long time_G0 = 0;                  // absolute time of the last blower activation
149unsigned  long time_G = 0;                   // absolute time of the last speed change
150unsigned  long time_SC = 0;                  // absolute time used for counting during the  intermediate steps associated with a speed change
151unsigned long time_AF = 0;                  // absolute time used for couting during the intermediate steps  associated with the activation of the fan
152unsigned long time_USB = 0;                 //  absolute time used for the delays in the USB connection presence check
153unsigned  long current_time = 0;             // absolute time to verify, at each cycle whether  the time overflow has occured (~ every ~ 50 days)
154unsigned long old_current_time  = 0;         // previous value of the absolute time to verify whether the time overflow  has occured
155unsigned long time_old_CS = 0;              // absolute time used  in current sense algorithm to synchronize the measurements on a 60 Hz cycle (previous  value)
156unsigned long time_new_CS = 0;              // absolute time used in current  sense algorithm to synchronize the measurements on a 60 Hz cycle (new value)
157unsigned  int fixed_latency_old = 0;         // latency to be waited at each cycle to stay  synchronized with the 60 Hz electrical supply (previous value)
158unsigned int fixed_latency_new  = 0;         // latency to be waited at each cycle to stay synchronized with the  60 Hz electrical supply (new value)
159
160
161//
162//
163//
164//
165// end of  global variables and constant declarations
166//
167//
168//
169//
170
171
172/////////////////////////////////////////////////////////////////////////////
173//  routine for evaluating whether a speed change of the blower is required
174/////////////////////////////////////////////////////////////////////////////
175
176void  new_speed_evaluation() {
177
178
179  // The verification is performed only if we're  are not currently in the process of changing the speed
180  if (speed_change_stage  == 3) {
181
182
183    // If the heat pump is active (W3) we force the blower to  high speed for maximum efficiency
184    if (W3_current_status == 1) {
185      new_speed  = 3;
186    }
187    else {
188
189
190
191      // validation of the current speed  and check whether the temperature difference is over or under the thresholds we  have defined
192      switch (current_speed) {
193        case 0:   // LO speed
194          if (abs(TH1_value - TH2_value) >= delta_T_LO_up) {
195            new_speed  = 1;
196          }
197          break;
198
199        case 1:   // MED speed
200          if (abs(TH1_value - TH2_value) >= delta_T_MED_up) {
201            new_speed  = 2;
202          }
203          if (abs(TH1_value - TH2_value) < delta_T_MED_down)  {
204            new_speed = 0;
205          }
206          break;
207
208        case  2:   // HI speed
209          if (abs(TH1_value - TH2_value) >= delta_T_HI_up) {
210            new_speed = 3;
211          }
212          if (abs(TH1_value - TH2_value)  < delta_T_HI_down) {
213            new_speed = 1;
214          }
215          break;
216
217        case 3:   // VHI speed
218          if (abs(TH1_value - TH2_value) < delta_T_VHI_down)  {
219            new_speed = 2;
220          }
221          break;
222      }
223
224    }
225  }
226}
227
228/////////////////////////////////////////////////////////////////////////////
229
230
231
232
233
234
235/////////////////////////////////////////////////////////////////////////////
236//  routine for changing the fan speed
237/////////////////////////////////////////////////////////////////////////////
238
239void  speed_change() {
240
241  if (new_speed != current_speed) {
242
243    // if the  speed_change_stage is equal to 3, its a new speed change sequence (and not an ongoing  sequence), therefore we start at the beginning (speed_stage_stage=0)
244    if (speed_change_stage  == 3) {
245      speed_change_stage = 0;
246    }
247
248  }
249
250
251
252  switch  (speed_change_stage) {
253
254    // The electrical circuit is openend with the  SSR relay
255    case 0:
256
257      digitalWrite(BSSR_ctrl, LOW);
258      speed_change_stage  = 1;
259      time_SC = millis();
260
261      break;
262
263
264    // if the delay  after opening the circuit is over the 10 ms minimum, we select the new speed
265    case 1:
266
267      if ((long)(current_time - time_SC) >= delai_SSR) {
268
269        switch (new_speed) {
270          case 0:   // LOWEST SPEED
271
272            digitalWrite(BHI_ctrl,  LOW);
273            digitalWrite(BMED_ctrl, LOW);
274            digitalWrite(BLO_ctrl,  LOW);
275
276            break;
277          case 1:  // SECOND LOWEST
278            digitalWrite(BHI_ctrl,  LOW);
279            digitalWrite(BMED_ctrl, LOW);
280            digitalWrite(BLO_ctrl,  HIGH);
281            break;
282          case 2:  // SECOND HIGHEST
283            digitalWrite(BHI_ctrl,  LOW);
284            digitalWrite(BMED_ctrl, HIGH);
285            digitalWrite(BLO_ctrl,  HIGH);
286            break;
287          case 3:  // HIGHEST
288            digitalWrite(BHI_ctrl,  HIGH);
289            digitalWrite(BMED_ctrl, HIGH);
290            digitalWrite(BLO_ctrl,  HIGH);
291            break;
292        }
293        speed_change_stage = 2;
294        time_SC = millis();
295
296
297      }
298      break;
299
300
301
302    //  if the delay after selecting the new speed is over the 15 ms minimum (mechanical  relay boucing), we close the circuit again with the SSR
303    case 2:
304
305      if  ((long)(current_time - time_SC) >= delai_relay) {
306        digitalWrite(BSSR_ctrl,  HIGH);
307        current_speed = new_speed;
308        time_G = millis();
309        speed_change_stage  = 3;
310        break;
311
312
313      }
314  }
315}
316
317/////////////////////////////////////////////////////////////////////////////
318
319
320
321
322
323
324/////////////////////////////////////////////////////////////////////////////
325//  temperature reading routine
326/////////////////////////////////////////////////////////////////////////////
327
328int  read_temp(int pin_adress) {
329
330
331  int TH_raw_cnt;
332  int read_temp_value;
333
334  TH_raw_cnt = analogRead(pin_adress);
335
336  read_temp_value = pgm_read_word(&thermistor_conversion[TH_raw_cnt]);
337
338  return read_temp_value;
339}
340
341
342
343
344
345
346
347
348
349
350
351
352/////////////////////////////////////////////////////////////////////////////
353
354
355
356
357
358
359/////////////////////////////////////////////////////////////////////////////
360//  routine for the activation of the relays associated withe the W1 heat command
361/////////////////////////////////////////////////////////////////////////////
362
363void  activate_W1() {
364
365  switch (W1_new_status) {
366
367    // W1 heat strips deactivation
368    case 0:
369
370      // Validation of which heating state we're in (state 0  should not be an option)
371      switch (W1_heating_state) {
372
373        //  deactivation of heat strip #1 associated with W1
374        case 1:
375          digitalWrite(active_elements_W1_W2[0],  W1_new_status);
376          W1_current_status = W1_new_status;
377          W1_heating_state  = 0;
378          break;
379
380        // deactivation of heat strip #2 associated  with W1
381        case 2:
382          digitalWrite(active_elements_W1_W2[1], W1_new_status);
383          W1_heating_state = 1;
384          break;
385      }
386      break;
387
388
389    // W1 heat strips activation
390    case 1:
391
392      // Validation of which  heating state we're in (state 2 should not be an option)
393      switch (W1_heating_state)  {
394
395        // activation of heat strip #1 associated with W1
396        case  0:
397
398
399          // rotation of the heat strips associated with W1 and W2  (for even wear)
400          // before performing the rotation, we validate that  W2 is not active, it should not as thermostat usually don't activate W2 without  activating W1
401          if (W2_current_status == 0) {
402
403
404            int  i;
405            for (i = 0; i < nb_of_heating_elements; i++) {
406
407              active_elements_W1_W2[i]  = active_elements_W1_W2[i + 1];
408            }
409
410            active_elements_W1_W2[nb_of_heating_elements]  = active_elements_W1_W2[0];
411
412          }
413
414
415          // activation  of heat strip #1
416          digitalWrite(active_elements_W1_W2[0], W1_new_status);
417          time_W1 = millis();
418          W1_current_status = W1_new_status;
419          W1_heating_state = 1;
420          break;
421
422        // activation  of heat strip #2 assocviated with W1
423        case 1:
424          digitalWrite(active_elements_W1_W2[1],  W1_new_status);
425          W1_heating_state = 2;
426          break;
427
428      }
429      break;
430
431  }
432
433  time_H0 = millis();
434
435}
436
437
438/////////////////////////////////////////////////////////////////////////////
439
440
441
442
443
444
445/////////////////////////////////////////////////////////////////////////////
446//  routine for the activation of the relays associated withe the W2 heat command
447/////////////////////////////////////////////////////////////////////////////
448
449void  activate_W2() {
450
451  switch (W2_new_status) {
452
453    // W2 heat strips deactivation
454    case 0:
455
456      // Validation of which heating state we're in (state 0  should not be an option)
457      switch (W2_heating_state) {
458
459        //  deactivation of heat strip #1 associated with W2
460        case 1:
461          digitalWrite(active_elements_W1_W2[2],  W2_new_status);
462          W2_current_status = W2_new_status;
463          W2_heating_state  = 0;
464          break;
465
466        // deactivation of heat strip #2 associated  with W2
467        case 2:
468          digitalWrite(active_elements_W1_W2[3], W2_new_status);
469          W2_heating_state = 1;
470          break;
471      }
472      break;
473
474
475    // W2 heat strips activation
476    case 1:
477
478      // Validation of which  heating state we're in (state 2 should not be an option)
479      switch (W2_heating_state)  {
480
481        // activation of heat strip #1 associated with W2
482        case  0:
483          digitalWrite(active_elements_W1_W2[2], W2_new_status);
484          time_W2  = millis();
485          W2_current_status = W2_new_status; // on met  jour le status  W2
486          W2_heating_state = 1;
487          break;
488
489        // activation  of heat strip #2 associated with W2
490        case 1:
491          digitalWrite(active_elements_W1_W2[3],  W2_new_status);
492          W2_heating_state = 2;
493          break;
494
495      }
496      break;
497
498  }
499  time_H0 = millis();
500
501}
502
503
504
505/////////////////////////////////////////////////////////////////////////////
506
507
508
509
510
511
512/////////////////////////////////////////////////////////////////////////////
513//  routine for the activation of the blower
514/////////////////////////////////////////////////////////////////////////////
515
516
517void  activate_G() {
518
519
520  // check whether the fan was in a steady state (OFF  or ON)
521  // if the answer is positive, put the fan state at value for a new sequence  (ON or OFF)
522
523  if (fan_activation_state == 2) {
524    fan_activation_state  = 0;
525
526  }
527
528
529
530  switch (G_new_status) {
531
532
533    // blower  deactivation, by default we set the speed to the lowest setting for the next power-up
534    case 0:
535
536      switch (fan_activation_state) {
537
538        // The electrical  circuit is openend with the SSR relay
539        case 0:
540          digitalWrite(BSSR_ctrl,  LOW);
541          fan_activation_state = 1;
542          time_AF = millis();
543          break;
544
545        // if the delay after opening the circuit is over  the 10 ms minimum, we select the new speed (lowest value for next power-up)
546        case 1:
547
548          if ((long)(current_time - time_AF) >= delai_SSR)  {
549
550            digitalWrite(BHI_ctrl, LOW);
551            digitalWrite(BMED_ctrl,  LOW);
552            digitalWrite(BLO_ctrl, LOW);
553            current_speed =  0;
554            new_speed = 0;
555            fan_activation_state = 2;
556            G_current_status  = G_new_status;
557
558          }
559          break;
560      }
561      break;
562
563
564    // We close the circuit with the SSR for the blower power-up
565    case 1:
566
567      digitalWrite(BSSR_ctrl, HIGH);
568
569      time_G0 = millis();
570      time_G  = time_G0;
571      G_current_status = G_new_status;
572      break;
573  }
574
575}
576
577
578/////////////////////////////////////////////////////////////////////////////
579
580
581
582
583
584
585/////////////////////////////////////////////////////////////////////////////
586//  routine for the evaluation of the current sense values
587/////////////////////////////////////////////////////////////////////////////
588
589
590void  current_update() {
591
592  int CS_raw_cnt;
593  float temp_FLOAT_var;
594
595
596  // we substract the raw instantaneous current value at the current pointer position
597
598  H1_CS_sum = H1_CS_sum - H1_current_vector[pointer_CS];
599  H2_CS_sum = H2_CS_sum  - H2_current_vector[pointer_CS];
600  H3_CS_sum = H3_CS_sum - H3_current_vector[pointer_CS];
601  H4_CS_sum = H4_CS_sum - H4_current_vector[pointer_CS];
602  FAN_CS_sum = FAN_CS_sum  - FAN_current_vector[pointer_CS];
603
604
605  // we update in the raw instanteous  current vectors the value at the current pointer position
606
607  CS_raw_cnt =  analogRead(CSH1);
608  H1_current_vector[pointer_CS] = pgm_read_word(&current_sensing_conversion[CS_raw_cnt]);
609
610  CS_raw_cnt = analogRead(CSH2);
611  H2_current_vector[pointer_CS] = pgm_read_word(&current_sensing_conversion[CS_raw_cnt]);
612
613  CS_raw_cnt = analogRead(CSH3);
614  H3_current_vector[pointer_CS] = pgm_read_word(&current_sensing_conversion[CS_raw_cnt]);
615
616  CS_raw_cnt = analogRead(CSH4);
617  H4_current_vector[pointer_CS] = pgm_read_word(&current_sensing_conversion[CS_raw_cnt]);
618
619  CS_raw_cnt = analogRead(CSFAN);
620  FAN_current_vector[pointer_CS] = pgm_read_word(&current_sensing_conversion[CS_raw_cnt]);
621
622  // we update the raw sum
623
624  H1_CS_sum = H1_CS_sum + H1_current_vector[pointer_CS];
625  H2_CS_sum = H2_CS_sum + H2_current_vector[pointer_CS];
626  H3_CS_sum = H3_CS_sum  + H3_current_vector[pointer_CS];
627  H4_CS_sum = H4_CS_sum + H4_current_vector[pointer_CS];
628  FAN_CS_sum = FAN_CS_sum + FAN_current_vector[pointer_CS];
629
630  // check whether  the pointer has reached the end of the vector and update of the latency value for  synchronizing the current evaluation with the 60 Hz electrical cycle
631
632  if  (pointer_CS == CS_vector_size - 1) {
633    pointer_CS = 0;
634    time_new_CS =  millis();
635    correction_us = (long) 100000 / 6 / nb_pts_period - (time_new_CS  - time_old_CS) * 1000 / CS_vector_size;
636    time_old_CS = time_new_CS;
637
638
639    fixed_latency_new = fixed_latency_old + correction_us;
640
641    fixed_latency_old  = fixed_latency_new;
642
643
644  }
645  else {
646    pointer_CS++;
647  }
648
649  // conversion of the current value from raw to physical value in mA
650
651  temp_FLOAT_var  = (float) sqrt(H1_CS_sum / CS_vector_size) / H_current_conversion_1 * HB_current_conversion_2;
652  current_sense_H_vector[0] = temp_FLOAT_var;
653
654  temp_FLOAT_var = (float)  sqrt(H2_CS_sum / CS_vector_size) / H_current_conversion_1 * HB_current_conversion_2;
655  current_sense_H_vector[1] = temp_FLOAT_var;
656
657  temp_FLOAT_var = (float)  sqrt(H3_CS_sum / CS_vector_size) / H_current_conversion_1 * HB_current_conversion_2;
658  current_sense_H_vector[2] = temp_FLOAT_var;
659
660  temp_FLOAT_var = (float)  sqrt(H4_CS_sum / CS_vector_size) / H_current_conversion_1 * HB_current_conversion_2;
661  current_sense_H_vector[3] = temp_FLOAT_var;
662
663  temp_FLOAT_var = (float)  sqrt(FAN_CS_sum / CS_vector_size) / B_current_conversion_1 * HB_current_conversion_2;
664  current_sense_FAN = temp_FLOAT_var;
665}
666
667
668/////////////////////////////////////////////////////////////////////////////
669
670
671
672
673
674
675/////////////////////////////////////////////////////////////////////////////
676//  routine for comparing the current sense values to the thresholds for error management     PRELIMINARY
677/////////////////////////////////////////////////////////////////////////////
678
679void  validation_current_vs_status() {
680
681  // blower current management
682  switch  (G_current_status) {
683
684    case 0:
685      if (current_sense_FAN < current_FAN_min[0])  {
686        system_status_LED[3] = 1;
687      }
688      if (current_sense_FAN  > current_FAN_max[0]) {
689        system_status_LED[3] = 1;
690      }
691
692      break;
693    case 1:
694
695      if (current_sense_FAN < current_FAN_min[current_speed  + 1]) {
696        system_status_LED[3] = 1;
697      }
698      if (current_sense_FAN  > current_FAN_max[current_speed + 1]) {
699        system_status_LED[3] = 1;
700      }
701      break;
702  }
703
704
705
706
707
708}
709
710
711/////////////////////////////////////////////////////////////////////////////
712
713
714
715
716
717
718/////////////////////////////////////////////////////////////////////////////
719//  routine for sending the monitored values on the virtual COM port if a USB connection  is detected
720/////////////////////////////////////////////////////////////////////////////
721
722
723void  USB_status_verbose() {
724
725  //Serial.print("Current time = ");
726  Serial.println(current_time);
727  //Serial.print("system status index = ");
728  Serial.println(system_status_index);
729  //Serial.print("FAN status  = ");
730  Serial.println(FAN_status);
731  //Serial.print("HEATER  status  = ");
732  Serial.println(HEATER_status);
733  //Serial.print("FAN UC  / OC status = ");
734  Serial.println(system_status_LED[3]);
735  //Serial.print("H1  UC / OC status = ");
736  Serial.println(system_status_LED[4]);
737  //Serial.print("H2  UC / OC status = ");
738  Serial.println(system_status_LED[5]);
739  //Serial.print("H3  UC / OC status = ");
740  Serial.println(system_status_LED[6]);
741  //Serial.print("H4  UC / OC status = ");
742  Serial.println(system_status_LED[7]);
743  //Serial.print("G  status  = ");
744  Serial.println(G_current_status);
745  //Serial.print("W1 status  = ");
746  Serial.println(W1_current_status);
747  //Serial.print("W2 status  = ");
748  Serial.println(W2_current_status);
749  //Serial.print("W3 status  = ");
750  Serial.println(W3_current_status);
751  //Serial.print("Thermistor  1 value (C) = ");
752  Serial.println(TH1_value);
753  //Serial.print("Thermistor  2 value (C) = ");
754  Serial.println(TH2_value);
755  //Serial.print("FAN RMS  current (mA) = ");
756  Serial.println(current_sense_FAN);
757  //Serial.print("H1  RMS current (mA) = ");
758  Serial.println(current_sense_H_vector[0]);
759  //Serial.print("H2  RMS current (mA) = ");
760  Serial.println(current_sense_H_vector[1]);
761  //Serial.print("H3  RMS current (mA) = ");
762  Serial.println(current_sense_H_vector[2]);
763  //Serial.print("H4  RMS current (mA) = ");
764  Serial.println(current_sense_H_vector[3]);
765  //Serial.print("loop  delay = ");
766  Serial.println(fixed_latency_new);
767
768  time_USB = millis();
769}
770
771
772/////////////////////////////////////////////////////////////////////////////
773
774
775
776
777
778
779/////////////////////////////////////////////////////////////////////////////
780//  error management and system status update    PRELIMINARY
781/////////////////////////////////////////////////////////////////////////////
782
783void  system_status_update() {
784
785  FAN_status = 0;
786
787  if (G_current_status  == 1) {
788    FAN_status = current_speed + 1;
789  }
790
791  HEATER_status = 0;
792
793  if (W1_current_status == 1) {
794    HEATER_status = HEATER_status + W1_heating_state;
795
796    if (W2_current_status == 1) {
797      HEATER_status = HEATER_status + W2_heating_state;
798    }
799  }
800
801  system_status_index = FAN_status * 5 + HEATER_status;
802
803  // Check whether we are in error mode
804
805  if (system_status_LED[3] > 0) {
806
807
808    // blower issue, major error, heat strips cannot be operated (not implemented  yet)
809
810    system_status_index = 26;
811
812  }
813  else
814  {
815
816
817    // Limp mode management, blower is working but at least 1 heat strip is not  functionnal
818
819    if (system_status_LED[4] + system_status_LED[5] + system_status_LED[6]  + system_status_LED[7] > 0) {
820
821      if ((system_status_LED[4] == 0) || (system_status_LED[5]  == 0) || (system_status_LED[6] == 0) || (system_status_LED[7] == 0)) {
822
823
824        // At least one heat strip is not functionnal, we are in limp mode
825
826        system_status_index = 25;
827      }
828      else
829      {
830
831        //  Every heat strips are not functionnal, major error
832        system_status_index  = 26;
833      }
834    }
835  }
836
837  system_status_LED[0] = pgm_read_word(&LED1[system_status_index]);
838  system_status_LED[1] = pgm_read_word(&LED2[system_status_index]);
839  system_status_LED[2]  = pgm_read_word(&LED3[system_status_index]);
840
841}
842
843/////////////////////////////////////////////////////////////////////////////
844
845
846
847
848
849
850/////////////////////////////////////////////////////////////////////////////
851//  main loop initialization
852/////////////////////////////////////////////////////////////////////////////
853
854
855void  setup() {
856
857  Serial.begin(9600);
858
859  // initialisation
860
861  pinMode(LED_ctrl,  OUTPUT);
862  pinMode(H1_ctrl, OUTPUT);
863  pinMode(H2_ctrl, OUTPUT);
864  pinMode(H3_ctrl,  OUTPUT);
865  pinMode(H4_ctrl, OUTPUT);
866  pinMode(BLO_ctrl, OUTPUT);
867  pinMode(BMED_ctrl,  OUTPUT);
868  pinMode(BHI_ctrl, OUTPUT);
869  pinMode(BSSR_ctrl, OUTPUT);
870  pinMode(G,  INPUT);
871  pinMode(W1, INPUT);
872  pinMode(W2, INPUT);
873  pinMode(W3, INPUT);
874
875  // analog inputs initialization
876
877  analogRead(TH1);
878  analogRead(TH2);
879  analogRead(CSH1);
880  analogRead(CSH2);
881  analogRead(CSH3);
882  analogRead(CSH4);
883  analogRead(CSFAN);
884
885  // LED light initialization
886
887  digitalWrite(LED_ctrl,  LOW);   // HIGH = RED,   LOW = GREEN
888
889  // initialization of the heat strips  relays
890  digitalWrite(H1_ctrl, LOW);
891  digitalWrite(H2_ctrl, LOW);
892  digitalWrite(H3_ctrl,  LOW);
893  digitalWrite(H4_ctrl, LOW);
894
895  // initialization of blower relays
896  digitalWrite(BSSR_ctrl, LOW);
897  digitalWrite(BHI_ctrl, LOW);
898  digitalWrite(BMED_ctrl,  LOW);
899  digitalWrite(BLO_ctrl, LOW);
900
901
902  // initialization of the vectors
903  memset(H1_current_vector, 0, CS_vector_size);
904  memset(H2_current_vector, 0,  CS_vector_size);
905  memset(H3_current_vector, 0, CS_vector_size);
906  memset(H4_current_vector,  0, CS_vector_size);
907  memset(FAN_current_vector, 0, CS_vector_size);
908  memset(current_sense_H_vector,  0, nb_of_heating_elements);
909
910
911}
912
913
914/////////////////////////////////////////////////////////////////////////////
915
916
917
918
919
920
921/////////////////////////////////////////////////////////////////////////////
922//  main loop
923/////////////////////////////////////////////////////////////////////////////
924
925
926
927void  loop() {
928
929
930  // reading of the thermostat signals
931
932
933  G_new_status  = (digitalRead(G) == LOW);   //   inverse logic, G_new_status is equal to 1 (fan  activation) when the actual physical signal on the board is LOW
934  W1_new_status  = (digitalRead(W1) == LOW); //   inverse logic, W1_new_status is equal to 1 (heat  command active) when the actual physical signal on the board is LOW
935  W2_new_status  = (digitalRead(W2) == LOW); //   inverse logic, W2_new_status is equal to 1 (heat  command active) when the actual physical signal on the board is LOW
936  W3_new_status  = (digitalRead(W3) == LOW); //   inverse logic, W3_new_status is equal to 1 (heat  pump is active) when the actual physical signal on the board is LOW
937
938  //  current time is updated once per cycle in the main loop
939  current_time = millis();
940
941
942  // rollover just happenend, reseeting of all the time stamps, the usual delays  between the different steps will be longer just this one time, once every 50 days
943  if (old_current_time > current_time) {
944
945    time_H0 = current_time;
946    time_W1 = current_time;
947    time_W2 = current_time;
948    time_G0 = current_time;
949    time_G = current_time;
950    time_old_CS = current_time;
951    time_new_CS  = current_time;
952    time_SC = current_time;
953    time_AF = current_time;
954    time_USB = current_time;
955  }
956
957  old_current_time = current_time;
958
959
960  // Update of the thermistor temperature at every loop (mostly for monitoring purposes  as it could be performed only when the blower is active)
961  TH1_value = read_temp(TH1);
962  TH2_value = read_temp(TH2);
963
964  // security check, if the heat commands (W1  or W2) or the heat pump (W3) are active, we make sure to operate the blower
965  if ((W1_current_status == 1 || W2_current_status == 1 || W3_current_status ==  1) && (G_current_status == 0 || G_new_status == 0 )) {
966
967    G_new_status =  1;
968
969  }
970
971
972
973  // a change has been detected on the blower G command  status
974  if (G_new_status != G_current_status) {
975
976    activate_G();
977  }
978
979
980  // optimization of the blower speed and change of its speed are  performed only after a fixed delay (after power-up and after a previous speed change)
981  if (G_current_status == 1) {
982
983    if ((long)(current_time - time_G0) >=  delta_G0) {
984
985      if ((long)(current_time - time_G) >= delta_G) {
986
987        new_speed_evaluation();
988        speed_change();
989      }
990    }
991  }
992
993  // a change has been detected on the W1 heat command status
994  if  (W1_new_status != W1_current_status && (long)(current_time - time_H0) >= delta_H)  {
995    activate_W1();
996  }
997
998
999
1000  // a change has been detected  on the W2 heat command status
1001  if (W2_new_status != W2_current_status && (long)(current_time  - time_H0) >= delta_H) {
1002    activate_W2();
1003  }
1004
1005
1006  // delay validation  before activating the second heat strip of W1
1007  if (W1_current_status == 1 &&  W1_new_status == 1) {
1008    if ((long)(current_time - time_W1) / 1000.0 >= delta_W1_level_1  && W1_heating_state == 1 && (long)(current_time - time_H0) >= delta_H) {
1009      activate_W1();
1010    }
1011  }
1012
1013
1014  // delay validation before activating the second heat  strip of W2
1015  if (W2_current_status == 1 && W2_new_status == 1) {
1016    if ((long)(current_time  - time_W2) / 1000.0 >= delta_W2_level_1 && W2_heating_state == 1 && (long)(current_time  - time_H0) >= delta_H) {
1017      activate_W2();
1018    }
1019
1020  }
1021
1022  //  a change has been detected on the W3 heat command status (heat pump)
1023  if (W3_new_status  != W3_current_status) {
1024    W3_current_status = W3_new_status;
1025  }
1026
1027
1028
1029  // current sense value update
1030  current_update();
1031
1032
1033  // error management  PRELIMINARY
1034  validation_current_vs_status();
1035
1036  // system status update  PRELIMINARY
1037  system_status_update();
1038
1039
1040
1041  // Verification whether  a USB connection is present
1042
1043  if (Serial && USB_connection_status == 0) {
1044    USB_connection_status = 1;
1045  }
1046
1047  if (!Serial && USB_connection_status  == 1) {
1048    USB_connection_status = 0;
1049  }
1050
1051
1052  // Delay validation  and communication with the PC if the USB connection is active
1053  if ((long)(current_time  - time_USB) >= USB_comm_period && USB_connection_status == 1) {
1054
1055    USB_status_verbose();
1056  }
1057
1058
1059
1060
1061  // fixed latency for perfect synchonization with the 60  Hz electrical AC for precise current sense evaluation
1062  delayMicroseconds(fixed_latency_new);
1063
1064}
1065