Feel free to open an issue if something is unclear.
- JunkersControl
- NOTE: Documentation is mostly accurate right now.
- Table of contents
- Community
- Purpose and Aim
- Contribution
- Intended Audience
- A word of warning
- Prerequisites
- Installation (Quick Start)
- Features
- Updating
- Telnet Console
- Home Assistant Integration
- Hints
- Getting Started
- Dedicated PCB
- Todo
- Special Thanks
You can reach out to us on Discord where we can discuss and help eachother.
This project is designed around the idea of having a SCADA-like setup where your command & control server (MQTT-Broker) sends commands and receives the status of the heating. Since the rise of modern and affordable "Smart Radiator Thermostats" we are able to precisely control the room temperature whereas the usual central heating system is only able to react on outside temperatures and doesn't know what the actual demand is like. The heating is only capable of reacting to certain drops in feed and return temperatures and heat up according to setpoints defined by the consumer. This principle is proven and hasn't changed until today.
The Junkers/Bosch "Heatronic" controller of the "Cerasmart" type of boilers (yes they used that term back in pre-2000!) is by itself smart enough to keep your home warm without wasting too much energy, if properly equipped and configured, of course. You won't receive any benefits from this project if you are messing around with the parameters without knowing the concepts of a central heating system. Also if your heating isn't "tuned" to your home it will waste money nonetheless. This also means you can't tell the boiler to perform unreasonable actions because the controller inside the boiler unit is in charge of controlling the actual temperatures within a safe, predefined range that has been set either by the manufacturer or the technician that maintains your heating. We are, hoewever, able to suggest certain temperatures or switch the boiler on and off
With this project we can at least account for seasonal changes in temperature, humidity and the temperature as we feel it so we can adjust the power demand to what we actually need.
There are a lot of different possible setups around and I am happy to accept PRs no matter what they are about.
Just a few examples:
- You have found an Id and its meaning
- Something is explained wrong
- Bugs, of course
Since the upgrade to a flexible configuration format and the ability to configure things via a web UI, you will be able to tune the system to your needs without knowing much about software development. But you might find yourself in a situation where things don't work as expected. Feel free to open an issue so we can adapt things to your needs.
I have sourced the message ids from https://www.mikrocontroller.net/topic/81265 but only process those that are relevant to me. This means you should bring a little bit of patience and basic knowledge about your heating with you so you can actually make decisions about what IDs might be relevant to you or not. You should look at the CAN-Bus configuration on the web UI and the Can Analyzer to sort things out for your heating system. Also you should have Visual Studio Code ready and the extension Platformio installed. We'll talk about that in detail in Prerequisites
You should never, ever manipulate a device that's running on highly volatile substances if you don't know what you are doing. Nobody, in fact, is qualified to work on such a gas heating system but the trained technician that has the right tools and knowledge to modify your heating in a safe manner (read: without blowing up you, himself and the surrounding home). If your are missing a cable to plug in your self-made controller, don't install it yourself. Ask your qualified, local heating technician to do it.
Simply because installing the bus module or attaching the data cable requires you to open the boiler, remove the cover and also the bezel that covers up the mains voltage supply. In some countries this will also void any insurance coverage if you do it yourself.
Now that we have sorted out the serious bits, lets check if we got everything together to pull this off...
- A compatible Bosch-Junkers central gas heating system with Bosch Heatronic controller and BM1 or BM2 Bus Module equipped.
- Access to the data line that exits the bus module. Most of the time you will find a "room thermostat" like TA250 or TA270 which in fact is the control unit for you, the consumer. It won't work with 1-2-4 style room thermostats like the TR200 Again, when in doubt, ask a technician.
- Awareness to short circuits and bus failures due to wrong wiring
- Direct access to the heating itself in case of problems.
- No, really, you shouldn't mess with things that aren't yours
- Ideally an ESP32 Kit but if you are just interested in the CAN-Stuff you can of course throw away all the MQTT and WiFi and just use a bog standard arduino.
- A MCP2515 + TJA1050 Can-Bus module (i.e. branded "NiRen"). Other boards with different controllers and transceivers may work too.
- A MQTT broker (i.e. Mosquitto)
- Visual Studio Code & Platform.IO Add-On are recommended!
- Optional: DS18B20 Sensors
Either clone the repository and build/upload yourself using Platformio and your IDE of choice or download the binaries and use esptool as follows: Example for Windows environments:
esptool.exe --after no_reset --chip esp32 --baud 921600 --port <Serial port of your device> write_flash --verify 0x10000 firmware.bin
esptool.exe --after hard_reset --chip esp32 --baud 921600 --port <serial port of your device> write_flash 0x307000 littlefs.binThe important part is the addresses 0x10000 for the firmware and 0x307000for the filesystem.
If everything went well you should see the following output on the console:
Press the "BOOT" button within the next 5 seconds to enable Setup Mode!
Setup Mode not enabled. You can enable it at every time by pressing the "BOOT" button once.
[ 5047][E][vfs_api.cpp:104] open(): /littlefs/configuration.json does not exist, no permits for creation
Configuration file could not be found. Please upload it first.
Unable to read configuration.
Invalid WiFi configuration. Launching AP mode.
WiFi AP launched. Find me @ 192.168.4.1
Can't connect to MQTT broker. [No Network]
Can't connect to MQTT broker. [No Network]
Can't connect to MQTT broker. [No Network]
Can't connect to MQTT broker. [No Network]
Can't connect to MQTT broker. [No Network]
Now you can connect to the AP ("CERASMARTER" network by default) and modify/import your configuration. A sample configuration is located here
If MDNS is working properly on your end, you will be able to open the web UI using http://cerasmarter/
Have values where you need them, control on demand. You are able to actively steer the heating towards certain temperatures or modes of operation by publishing and subscribing to MQTT topics from within your favorite MQTT broker (Mosquitto is recommended).
The topics are described inside /data/configuration.json or Configuration > MQTT on the web UI.
To send parameters to the heating controller, you just have to form a JSON and send it to the topic you defined in /data/configuration.json
The MQTT section has everything and this is where you define the topics:
"MQTT": {
"Server": "1.2.3.4",
"Port": 1883,
"User": "mqtt",
"Password": "mqtt",
"Topics": {
// Topic for receiving temperatures and status
"HeatingValues": "cerasmarter/heating/values",
// Send values here to steer the heating circuit and functions
"HeatingParameters": "cerasmarter/heating/parameters",
// Topic for receiving temperatures and status
"WaterValues": "cerasmarter/water/values",
// Send values here to steer the hot water circuit and functions
"WaterParameters": "cerasmarter/water/parameters",
// Topic for receiving temperatures from auxiliary sensors
"AuxiliaryValues": "cerasmarter/auxiliary/values",
// Topic for receiving status information
"Status": "cerasmarter/status",
// Send values here to receive values on demand
"StatusRequest": "cerasmarter/status/get"
}
},{
//Enable the heating mode
"Enabled": false,
//Setpoint for Feed Temperature
"FeedSetpoint": 0,
"FeedBaseSetpoint": -10,
"FeedCutOff": 22,
"FeedMinimum": 10,
"AuxiliaryTemperature": 11.6,
"AmbientTemperature": 0,
"TargetAmbientTemperature": 21,
"OnDemandBoost": false,
"OnDemandBoostDuration": 600,
"FastHeatup": false,
"Adaption": 0,
"ValveScaling": 1,
"ValveScalingMaxOpening": 100,
"ValveScalingOpening": 75,
"DynamicAdaption": 1,
"OverrideSetpoint": false
}Originally the TAXXX and integrated Heatronic will follow a set of parameters to determine the right feed temperature according to outside temperatures. These values are commonly referred to as "base point" and "end point" and represent a linear regulation by a reference temperature - the environmental temperature on the outside.
The original controller will take the desired minimum feed temperature at -15°C as the end point and the required feed temperature at 20°C as the base point.
The meaning of base and end point is turned around in this project!
Why is that so?
Because we are now looking at the environment temperature(s) and we know what the heating can deliver it is easier to understand what we want to achieve.
The base point now represents the outside temperature at which the heating should use the maximum possible feed temperature as dialed in by the heating circuit dial on the heating itself
The end point is basically the temperature at which the heating should switch off.
In this graph the base point is -10°C and the end point is 20°C meaning at -10°C we need the full power to keep our home warm whereas 20°C is when we don't need it anymore
See FeedBaseSetpoint for base point, FeedCutOff for end point or "cut off" temperature
See Example JSON
There are two ways to switch the economy mode.
Set Enabled to false or 0 using the Parameters JSON file which you send to the Heating Parameters Topic defined in /data/configuration.json
See Example JSON and look out for:
"Enabled": true,Set commandedValues.Heating.Active to false or true depending on if you want to switch economy on or off.
Hint: The manufacturer recommends to not turn the heating off by the power switch but instead set it into economy mode with 10° feed temperature (lowest setting) to prevent getting the pump or valves stuck. If set to economy the heating will move the pump(s) and valve(s) every 24h if they haven't been moved within that range.
Boost function sets the feed temperature to the maximum reported value (ceraValues.Heating.FeedMaximum) for a selected period of time (default: 300 seconds). This is especially useful when you own electronic or "smart home" thermostats in general which in most cases offer such a boost function. the problem with this "boost" is that although the valve opens up for a few minutes, the heating won't actually deliver the required temperature. A common misunderstanding is that opening the valve to the highest setting will heat more. It will instead only allow for a much higher room temperature as the water flow through the system is almost unchanged.
Due to the natural lag of a heating system you should fire this function before you boost a specific radiator.
See Example JSON and look out for:
"OnDemandBoost": false,
"OnDemandBoostDuration": 600,Fast Heatup function compares a temperature (commandedValues.Heating.AmbientTemperature) to a given target value (commandedValues.Heating.TargetAmbientTemperature) and sets the feed temperature to maximum (ceraValues.Heating.FeedMaximum) as long as the temperature hasn't reached the target value. It will slowly decrease the feed temperature down from maximum as the target is approached.
This is how the fast heatup function works visually
See Example JSON and look out for:
"FastHeatup": false,set to true to enable this feature
The parameters defined within heating.h will become active when the connection to the MQTT broker has been lost.
//-- Fallback Values
//TODO: Should be configurable using configuration.json
struct FallBack_
{
//-- Basepoint Temperature
double BasepointTemperature = -10.0F;
//-- Endpoint Temperature
double EndpointTemperature = 31.0F;
//-- Ambient Temperature
double AmbientTemperature = 17.0F;
//-- Minimum ("Anti Freeze") Temperature.
double MinimumFeedTemperature = 10.0F;
//-- Enforces the fallback values when set to TRUE
bool isOnFallback = false;
//-- Heating Scheduler. Fallback values for when the MQTT broker isn't available
HeatingScheduleEntry fallbackStartEntry = {5, 30, 0, true};
HeatingScheduleEntry fallbackEndEntry = {23, 30, 0, false};
} Fallback;The HeatingScheduleEntry represents a very basic timeslot:
Trigger Hour, Trigger Minute, Day Of Week, Heating Enabled.
Day Of Week is currently unused.
The aforementioned values say:
- Turn on the heating every day at 5:30
- Turn off the heating every day at 23:30
Other controllers on the network will send their messages which always start at ID 0x250. As soon as such a message is detected, the Override flag will turn to false and our controller will stop sending control messages. If there is no controller message on the network for 30 seconds (defined by BusMessageTimeOut within /data/configuration.json) it will resume control and the Override flag returns to true.
Example:
"General": {
"BusMessageTimeout": 30,
"Debug": false,
"Sniffing": true
},Timeout is set to 30 seconds
You could implement this as a solution to bring in the original controller when something isn't working as expected and you don't have direct access to the ESP. You could switch back on/plug in the original TAxxx unit to run it in OEM mode. Maybe you switch on a relay that triggers the voltage supply for the original controller or you instruct someone to plug the TAxxx unit back in.
The oneWire and DallasTemperature libraries are included and used to fetch additional temperatures like the return temperature which isn't available on the bus.
Configured using /data/configuration.json or Configuration > Temperature Sensors on the web UI
Simply put: my heating system is way too powerful and the radiators are not capable of getting rid of the energy fast enough. I figured if I lower the temperature by the difference between return and desired room temperature I can get away with a more dynamic model:
Adaption = Desired target room temperature - feed temperature (+ Manual Adaption)
This means that the setpoint of the feed will be lowered by the difference. You don't have to pump in that much energy when 90% of it returns to the heat exchanger which by itself will always try to steer the feed temperature to the average setpoint.
This kind of adaption is, of course, very simple and rough. As soon as this mode is active, the Adaption value will alter the value accordingly so in my instance I put in additional 5° Adaption so if the temperature would be lowered to around 35° feed, it will be actually set to 40°.
See Example JSON and look out for:
"Adaption": 0You can do your own calculations and just tell the control to set the temperature accordingly by setting 1|0 or true|false via parameters topic to enable or disable this feature and set the desired FeedSetpoint
See Example JSON and look out for:
[...]
"FeedSetpoint": 70,
[...]
"OverrideSetpoint": trueThis feature will calculate the desired feed temperature based on the valve opening that is received, mapped using the minimum a valve can be closed (0%) and the maximum (80% for Homematic eTRV-2, set by ValveScalingMaxOpening) to the FeedMinimum plus Adaption and FeedMaximum (Reported on the topic defined at HeatingValues within Configuration)
This is the most demand focused function yet because if you always report the most open valve in the circuit, you end up with a very responsive system that will react on demand immediately.
This also means that, for example, in the morning when the heat cycle starts, the most open valve will most likely report it is running at the maximum available opening thus raising the feed setpoint to max. As the rooms get warmer and warmer it will eventually throttle and another valve may be higher. This is a self regulating system which will deactivate the influence of outside temperatures. If you want to have the temperature influenced by outside temperature, switch on DynamicAdaption which will then add a value mapped between FeedBaseSetpoint and FeedCutoff. Next set Adaption according to your needs.
Example for dynamic adaption together with valve scaling:
- Outside Temperature is 5°
- Basepoint is -15°
- Endpoint is 31°
- Feed Adaption is 20
- Valve Opening: 50%
- Max Feed: 75°
Map Function: (x - in_min) * (out_max - out_min) / (in_max - in_min) + out_min
Adaption Calculation: (Outside - Basepoint) * (Feed Adaption - 0) / (Endpoint - Basepoint) + 0
Example: (5 - -15) * (20 - 0) / (31 - -15) + 0 = 8.7
Feed Calculation: (Valve Opening - Min-Valve Opening) * (Max Feed - (Min-Feed + Adapt. Calc.)) / (Max. Valve - Min. Valve) + (Min. Feed + Adapt. Calc.)
Example: (50 - 0) * (75 - (10 + 8.7)) / (80 - 0) + (10 + 8.7) = 53.89
See Example JSON and look out for:
{
[...]
//Enable valve scaling
"ValveScaling": true,
//The maximum value of a valve
"ValveScalingMaxOpening": 100,
//The current valve opening
"ValveScalingOpening": 75,
[...]
}The standard "Arduino OTA" procedure is included which means you can upload the code to your ESP32 without having to plug in the USB cable. See platformio.ini and modify the IP address accordingly.
You can also use the web UI (See: Firmware Update on the menu bar) to upload the firmware.bin and littlefs.bin files to update the firmware and filesystem image.
Debug info can be retrieved using a very basic telnet implementation. Simply connect to the ESP32 using telnet and watch as the messages flow. You can reboot the ESP by typing reboot and press enter. Be aware you have to type very quickly because this is truly a very minimalistic and barebone implementation of a client-server console communication which is primarily designed to see debug output without having to stand near the esp.
This project was originally specifically designed to be run alongside Home Assistant and efforts have been taken to make the setup as hassle-free as possible but the so-called autodiscovery is still in the works. In the meantime you may find the necessary scripts, values and other stuff inside the Home Assistant Folder
- If you just wanna read then usually you have nothing to modify. The program will see other controllers on the bus and will go into "read-only" mode by itself. If you're not wanting to take any risks, you have to set the variable
OverrideControlin main.cpp tofalse. This way nothing will be sent on the bus udner any circumstances but you can read everything. - For debug purposes the
configuration.General.Debugvariable controls wether you want to see verbose output of the underlying routines like feed temperature calculation and step chain progress. - Keep in mind that if you are intending to migrate this to an arduino you have to watch out for the OTA feature and
float(%f) format parameters withinsprintfcalls. - When OTA is triggered, all connections will be terminated except the one used for OTA because otherwise the update will fail. The MC will keep working.
- The OTA feature is confirmed working with Arduino IDE and Platform.io but for the latter you have to adapt the settings inside
platformio.inito your preference.
- Copy Configuration.json to the
datafolder. - Use this
configuration.jsonto configure the project to your requirements. - Upload the project
- Now it will format the SPIFFS filesystem.
Build Filesystem ImageandUpload Filesystem Imageso the configuration is stored on SPIFFS- It will now read this config and will reach operational status
You should be able to perform OTA updates now for both application and configuration.
See the Configuration guide for details.
WIP
Update 09-2022: The bus is very picky about the choice of hardware. Multiple prototypes have been built and tested and further investigation is in progress. Another limitation is the amount of current the built-in power supply can deliver. This is slowing down hardware development even more.
- Find a suitable CAN module and library that is able to handle 10kbit/s using the ESP32
- Debug output over Telnet
- OTA Update Capability
- Try not to get mad while searching for the reason why the OTA update is aborting at around 2-8%
- Collecting IDs and their meaning
- Getting the calculations right for the feed setpoint
- Reading and writing MQTT topics
- Fallback Mode
- Taking Weather conditions into account when calculating the feed temperature
- Also taking indoor temperatures into account
- Getting the timings right so it doesn't throw off the controller
- Testing as a standalone solution
- Example Configuration for Home Assistant
- Dedicated PCB with all components in place and power supply through the controller
- Take more intelligent decisions for feed temperatures
- Revamp fallback mode to make use of eztime
- Make fallback mode more flexible and configurable
- Restructure code into reusable classes
- The people at the mikrocontroller.net forums
- Pierre Molinaro and contributors of the ACAN2515 library: https://github.com/pierremolinaro/acan2515
- Nick O'Leary and contributors of the PubSubClient library: https://github.com/knolleary/pubsubclient
- Rop Gonggrijp and contributors of the ezTime library: https://github.com/ropg/ezTime
- The maintainers of the ArduinoJSON library: https://arduinojson.org/
- The maintainers of the Async ESP Webserver and AsyncTCP library: https://github.com/me-no-dev/ESPAsyncWebServer
