TheFloatingLab/HotWaterManager
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Software update, many new features. Corrected the schematics. Added a minimalistic version.

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Frans Veldman 2025-03-29 02:17:26 +00:00
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# ---> KiCad
# For PCBs designed using KiCad: https://www.kicad.org/
# Format documentation: https://kicad.org/help/file-formats/
# Temporary files
*.000
*.bak
*.bck
*.kicad_pcb-bak
*.kicad_sch-bak
*-backups
*.kicad_prl
*.sch-bak
*~
_autosave-*
*.tmp
*-save.pro
*-save.kicad_pcb
fp-info-cache
*.kicad_pro
*.lck
# Netlist files (exported from Eeschema)
*.net
# Autorouter files (exported from Pcbnew)
*.dsn
*.ses
# Exported BOM files
*.xml
*.csv
# Fabrication files
*.gb*
*.gm*
*.drl
*.zip
*.gt*
# Avrdude files
*.hex
*.elf
*.lst
*.o

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// ****** Hardware Model definitions ********
#define ARDUINO_ 0 // Use this one if you want to build this project around an Arduino
#define HWV_1_0 1 // Hardware version 1.0 of the Thermal Optimizer board (only a few were made)
#define HWV_1_1 2 // Hardware version 1.1 of the Thermal Optimizer board
#define HWV_1_2 3 // Hardware version 1.2 of the Thermal Optimizer board
// ********* Hardware Model ************
#define HWMODEL ARDUINO_ // Change this into the hardware model you want to compile for
// Debug definitions, leave commented for production!
//#define SIMTEMP 80 // Use this to test the program without actual temperature sensors connected. 50 simulates 8.0 Celcius
//#define SIMVOLT 132 // Use this to test the program for a specific voltage. 132 simulates 13.2
//#define USEDEFAULT 1 // declutter the EPROM, use the defaults
#if HWMODEL == ARDUINO_
#define HWVER "UNO"
#endif
#if HWMODEL == HWV_1_0
#define HWVER "1.0"
#endif
#if HWMODEL == HWV_1_1
#define HWVER "1.1"
#endif
#if HWMODEL == HWV_1_2
#define HWVER "1.2"
#endif
/*
* Voltage measuring
* =================
* To bring the system voltage within the range of the ADC's we have to use a resistor divider
* We want to be compatible with 24V systems, so we dimensioned the resistor dividers accordingly
* ADC1
* _______ | _______
* VCC --|_____|---|----|_____|--- GND
* R1 R2
*
* In the latest Thermal Optimizer board we use for R1 39k, for R2 7k5.
* If R1=39k, and R2=7k5...
* If we assume a maximum voltage of 15V, then this would give 2.42V on the input of ADC1, with a load of 0.25mA
* If we assume a maximum voltage of 30V, then this would give 4.84V on the input of ADC1, with a load of 0.5mA
*
* The math:
* Voltage = ADC1*AREF/(1024+1) * (R1+R2)/(R2)
*
* If you build an Arduino based circuit yourself, You can change the values of R1 and R2 in the source code.
*
*/
#define ADCREF 5000UL // Voltage of the 5V power supply in millivolts
#if HWMODEL == ARDUINO_
#define R1 10000UL // Ohms
#define R2 1800UL // Ohms
#endif
#if HWMODEL == HWV_1_0
#define R1 10000UL // Ohms
#define R2 1880UL // Ohms
#endif
#if HWMODEL > HWV_1_0
#define R1 39000UL // Ohms
#define R2 7500UL // Ohms
#endif
#if HWMODEL == ARDUINO_
#define TEMPR 4700 // Ohms of the temperature sensor pull up resistor
#endif
#if HWMODEL == HWV_1_0
#define TEMPR 4700 // Ohms of the temperature sensor pull up resistor
#endif
#if HWMODEL > HWV_1_0
#define TEMPR 10000 // Ohms of the temperature sensor pull up resistor
#endif
#define THERMISTOR 5000 // Reference value of the thermistor
#define THERMBETA 3950 // Beta value of the thermistor
#define TEMPSAMPLES 8 // Number of samples for averaging the temperature with a thermistor
// IO ports
#define BUTTON 2 // Button needs to be port PD2 or PD3 because of wake up interrupt
#define VCCREF A1 // Voltage sense
#define ENGINE 16 // Engine contact sense wire
#if HWMODEL == ARDUINO_
#define TEMP 14
#else
#define TEMP 19 // Temperature sensor (port 19 is ADC 5, conflict if I2C bus is used)
#endif
#define LED 13 // Conventionally, this port is used to control a LED
#if HWMODEL == ARDUINO_
#define HEATER 3 // Heater relay control output (Port 18 is ADC 4, conflict if I2C bus is used)
#define BACKLIGHT_B0 18 // Display backlight, bit 0
#define BACKLIGHT_B1 12 // Display backlight, bit 1
#define BACKLIGHT_B2 11 // Display backlight, bit 2
#endif
#if HWMODEL == HWV_1_0
#define HEATER 18 // Heater relay control output (Port 18 is ADC 4, conflict if I2C bus is used)
#define BACKLIGHT_B0 3 // Display backlight, bit 0, NOT IMPLEMENTED IN HWV 1_0
#define BACKLIGHT_B1 14 // Display backlight, bit 1, NOT IMPLEMENTED IN HWV 1_0
#define BACKLIGHT_B2 11 // Display backlight, bit 2
#endif
#if HWMODEL > HWV_1_0
#define HEATER 3
#define BACKLIGHT_B0 18 // Display backlight, bit 0
#define BACKLIGHT_B1 14 // Display backlight, bit 1
#define BACKLIGHT_B2 11 // Display backlight, bit 2
#endif
#if HWMODEL > HWV_1_0
#define OWPULLUP 24 // (ATMEGA328pb only, PE1) PullUp for one wire interface
#endif
#if HWMODEL > HWV_1_1
#define LUMSENS 25 // (ATMEGA328pb only, PE2) ADC port to sens LED luminance
#endif
#define AUX 17 // Auxilliary output
#define HWV 10 // Hot Water Valve
// Interfaces
//#define LCDADDR 0x3F // I2C address, uncomment for I2C display (but you have to free up ADC4 (18) and ADC5 (19))
#define LCD_RS 9 // Used only when no I2C is used
#define LCD_EN 8 // Used only when no I2C is used
#define LCD_D4 4 // Used only when no I2C is used
#define LCD_D5 5 // Used only when no I2C is used
#define LCD_D6 6 // Used only when no I2C is used
#define LCD_D7 7 // Used only when no I2C is used
// Constants
#define VERSION "1.1" // Software version to display on the screen
#define EPROMCHK 0x7875 // EPROM signature so we can detect that the EPROM content is ours.
//#define SHORTPRESS 25 // Minimum time in milliseconds to register a button press as valid instead of just a noise spike (not used with touch sensor)
#define LONGPRESS 650 // Time in milliseconds to register a key press as a long press.
#define MENUTIMEOUT 10 // Timeout in seconds to return to default operation from within the menu.
// Defaults after factory reset (can be changed in the menu afterwards)
#define BRIGHTNESS 5 // Default LCD backlight brightness, 0 to 7
#define DISPTIMEOUT 0 // LCD backlight timeout in seconds
#define NIGHTSENSOR 11 // Darkness sensor value
#define VREQ 141 // Required voltage*10 to switch on the heater automatically.
#define VFLOAT 135 // Float voltage*10 to switch off the heater automatically
#define VOFF 125 // Voltage*10 at which a pause has to be taken to recharge the batteries first
#define PAUSE 20 // Duration of the pause in minutes
#define TMIN 40 // Antifreeze protection should be initiated below this temperature (Celsius*10)
#define TTARGET 400 // Target temperature (Celsius*10) for daily usage
#define TSANITY 600 // Temperature (Celsius*10) needed to clear the "sanity alert"
#define TMAX 800 // Maximum allowed temperature (Celsius*10)
#define TNOSAN 250 // Don't display a sanity alert below this temperature (Celsius*10)
#define TSANDAYS 7 // Interval in days between reaching the "sanity temperature" to not raise the "sanity alert"
#define PUMPDELTA 25 // Difference in input and boiler temperature in Celsius*10
#define PUMPAFTERRUN 60 // Time in seconds to continue running the pump after PUMPDELTA is no longer met
#define HWVTIMER 0 // Time in minutes to enable hot water valve
#define HWVPWM 100 // Hot water valve PWM in % (100 is disable)
#define HWVBLEED 5 // Time in seconds to open the HWV when the heating element is energized, to bleed out any air.
#define HOLDON 5 // Time in seconds to hold on, after switching the boiler on, to give chargers some time to react to the load
#define RELAYPWM 100 // Percentage of hold current of the relay
// Constants that are not configurable in the menu.
#define HOLD_OFF 60 // Seconds to wait after last heater state change before switching it on again.
#define TRENDDELTA 3 // Temperature (Celsius*10) difference required to change the trend arrow
#define LUMSAMPLES 16 // Samples to average the measured luminance via the LED.
// LED mode constants
#define LEDM_TOUCH 0
#define LEDM_WARMWATER 1
#define LEDM_HEATING 2
#define LEDM_HWVALVE 3
#define LEDM_LEGIONELLA 4
// Structure definitions
struct rom_t {
uint16_t epromchk; uint8_t brightness; uint8_t disptimeout; uint16_t vreq; uint16_t vfloat; uint16_t voff; int16_t pause; boolean fahrenheit; int16_t tmin; int16_t ttarget;
int16_t tsanity; int16_t tmax; int16_t tsandays; int16_t tnosan; uint16_t calibration; int16_t pumpdelta; uint16_t pumpafterrun; uint16_t hwv_timer; bool vmul; uint8_t hwv_pwm;
uint8_t pumpMode; uint8_t ledmode; bool lcdglow; uint8_t holdon; uint8_t nightbright; uint8_t nightsensor; uint8_t relaypwm; bool altfunc;
};
struct sensors_t {
uint16_t epromchk;
uint8_t temphwa[2][8];
int16_t thermistor;
int16_t thermbeta;
bool useDS;
};
struct mma_t {
uint16_t samples;
int16_t avg;
int32_t sum;
};
struct tempdata_t {
int16_t temperature;
int16_t failures;
int16_t fallback;
mma_t mmaTemp;
};
struct button_t {
const uint8_t button;
uint32_t pressed; // Button press duration
bool longpressed;
};
void fptr_dummy(void);
void fptr_brightness(void);
void fptr_showvoltage(void);
void fptr_showTemp(void);
void fptr_showtemps(void);
void fptr_vmul(void);
void fptr_units(void);
void fptr_altfunc(void);
void fptr_ledmode(void);
void fptr_pumpsource(void);
void fptr_lumsens(void);
void fptr_versions(void);
void fptr_serialnr(void);

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This is the open source version of the BoilerOptimizer as described at https://www.thefloatinglab.world/en/boilers.html
This is the open source version of the [HotWaterManager](https://www.thefloatinglab.world/en/boilers.html).
This BoilerOptimizer is intended for controlling the Boiler on sailboats, features are:
This HotWaterManager is intended for controlling the HotWater system on sailboats, features are:
- Uses the excess energy of the solar panels, once the batteries are fully charged, to heat the electric boiler
- Can optionally be used to feed the boiler directly from the solar panels, so the heating element will be "modulated" with the available solar energy.
- It can be build with an Arduino but also a customized circuit board ([ThermalOptimizer](https://git.thefloatinglab.world/TheFloatingLab/ThermalOptimizer)) is available.
- Uses the excess energy of the solar panels, once the batteries are fully charged, to heat the Hot Water Tank.
- It will instantly switch off the heating element when a heavy consumer switches on (anchor winch etc).
- Energy saving of 66% by heating up to 40°C instead of 60°C.
- Energy saving of 66% by heating up to 40°C instead of 60°C, but when there is an ambundant of energy allowing the water to heat up to 90°C.
- Fast warmup mode to just "shower temperature" so you can take a shower for just 1/3th of the energy.
- Legionella prevention and warning, by periodically heating the water to a bacteria killing temperature or warning when it has been too long ago that this temperature could be reached.
- Thermostatic control when connected to shore power
- Can control a solenoid to switch off the hot water pressure after a configurable timer expires, to limit shower time and to reduce the chance of water leaks.
- Thermostatic control when connected to shore power.
- Can optionally control a pump based on a differential temperature, so you can build your own "solar panel" consisting of nothing more than just a hose on deck and a small electric pump.
- Guards the boiler against freezing
- Automatic energy saving when it detects that the engine is running and coolant can be used to heat up the boiler.
- Reliable voltage measurement with optional voltage reference inputs
- LCD display with boiler temperature, trend, voltage and heater status
- Fully configurable by an on screen menu
- Switchable between degrees Celsius and Fahrenheit
- Guards the hot water tank against freezing.
- Automatic energy saving when it detects that the engine is running and coolant can be used to heat up the water.
- LCD display with hot water temperature, trend, voltage and heater status.
- Fully configurable by an on screen menu.
- Low energy use when not activated.
- Switchable between degrees Celsius and Fahrenheit, 12V and 24V systems.
See for details and background https://www.thefloatinglab.world/en/boilers.html
See for details and background [https://www.thefloatinglab.world/en/boilers.html](https://www.thefloatinglab.world/en/boilers.html)
## Notes about the Boiler Optimizer Schematic
## Notes about the schematics
### Explanation of some less obvious parts
### Explanation of the Arduino version
- R1, R2 and R3 are used to bring the reference voltage into the window of the ADC's. R1 together with C1 also services as a *low pass filter* to filter out induction peaks. The function of R3 is to be able to measure GNDref voltages wich are slightly more *negative* than GND.
- R1 and R2 are used to bring the reference voltage into the window of the ADC. R1 together with C1 also services as a *low pass filter* to filter out induction peaks.
- R10, R11 and R12 are used to control the brightness of the LCD. With these 3 resistors there are 8 brightness levels possible. Brightness control could also be achieved with a single PWM output, but PWM is not available during microcontroller sleep.
- Q1 controls the output relay which is used to switch the heater. The relay is not drawn on the schematic. One pin of the coil is connected to 12V (or 24V) and the other one to the transistor output.
- Q2 controls the optional Hot Water Solenoid. The associated circuitry can be omitted if no Hot Water Solenoid is used.
- Q3 controls the optional solar pump. The associated circuitry can be omitted if no solar pump is used.
### Components
- You can use an Aduino UNO (or clone) or an Arduino Pro Mini (5V, 32Kb). Some other variants probably will work too but you might have to change the PIN definitons in the software.
- If you use an Arduino UNO, you can probably use its internal voltage regulator and ommit the 78L05. If you use an Arduino Pro Mini, you will definitely have to use the 78L05 like shown in the schematic.
- For use on 24V systems, you will have to change R1 into 27K and R4 into 18K, and you will need a 78L05 voltage regulator even for the Arduino UNO. The current version of the software doesn't support 24V yet.
- The relation between R1, R2 and R3 is important. If you change any of these values, you *MUST* change their definitions in the software too! You don't need high precision resistors; the software will be able to calibrate around small deviations.
- Q1 and Q2 can be any NPN transistor, D1 and D2 are generic diodes.
- The LCD is a generic 16x2 display (make sure it is a 5V version), you can use an I2C variant as well but then you have to adapt the schematic and uncomment the relevant definition in the software.
- If you want to connect the solar panels directly to the boiler, you *MUST* use a solid state relay and wire everything exactly like shown in "Installation". A normal mechanical relay can not break a high voltage DC current; *it will arc and melt*! The mechanical relay in the minus is ok, the solid state relay in the plus will break the arc.
- If you use an Arduino UNO, you can probably use its internal voltage regulator and ommit the 78L05. If you use an Arduino Pro Mini, you will definitely have to use the 78L05 like shown in the schematic. If you want to use 3.3V versions you will have to change some components (noticably the voltage dividers on the ADC's, and an LCD that can work at 3.3V) and change some calculations in the software.
- For use on 24V systems, you will need a 78L05 voltage regulator even for the Arduino UNO. You also have to change the input resistor (R4) of the ENGINE input to 22k.
- The relation between R1 and R2 is important. If you change any of these values, you *MUST* change their definitions in the software too! You don't need high precision resistors; the software will be able to calibrate around small deviations.
- Q1, Q2 and Q3 can be any NPN transistor or N-channel MOSFET, D1, D2 and D3 are generic diodes.
- The LCD is a generic 16x2 display (make sure it is a 5V version), you can use an I2C variant as well but then you have to free A5 (use one of the now vacant LCD ports) and adapt the software.
- You can, in addition to the onboard LED, connect an external LED (with appropriate series resistor) to pin 13.
### Commissioning
- The LCD might stay blank or black until the contrast pot has been tuned. It is best to test and adjust this before executing the software on the Arduino for the first time.
- Connect the temperature sensor(s). Perform a factory reset (will be done automatically if it is the first time the software runs) and the software will start pairing the sensor(s). If you use more than one sensor, you have to find out which one is for the boiler and which is for the solar panel. Some hot water will be handy with testing. ;-)
- Connect the voltage reference inputs to the power supply (5V!) of the Arduino and reboot. This will automatically start the calibration. Once the calibration is completed, power down and connect the voltage reference inputs to 12V.
## Changes from 1.0 to 1.1
- The name was changed from BoilerOptimizer to HotWaterManager.
- The system can still be built around an Arduino but a dedicated circuit board [ThermalOptimizer](https://git.thefloatinglab.world/thefloatinglab/thermaloptimizer) is also available.
- Some IO ports in the Arduino version are changed to match the ports used in the dedicated "ThermalOptimizer" circuit board.
- The contrast pot of the LCD is changed into a fixed resistor.
- An additional output is now used to control an optional hot water solenoid.
- To allow the microcontroller to go into sleep mode, the display brightness is no longer controlled by PWM but with 3 binary outputs to facilitate 8 brightness levels.
- We no longer use a "reference voltage" but just use the power supply voltage.
- Diodes D1, D2, and D3 are now connected in the right way.
- The software has been significantly enhanced.

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