JunkersControl

NOTE: Documentation is mostly accurate right now.

Feel free to open an issue if something is unclear.

Community

You can reach out to us on Discord where we can discuss and help eachother.

Purpose and Aim

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.

Cerasmart-er

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.

Contribution

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

Intended Audience

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.

Disclaimer:

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

A word of warning

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.

But why? We are talking about a data line!

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.

Prerequisites

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

Installation (Quick Start)

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.bin

The 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/

Features

MQTT

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).

Where?

The topics are described inside /data/configuration.json or Configuration > MQTT on the web UI.

How?

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"
        }
    },

Example Parameter JSON for setting Heating Parameters:

{
  //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
}

Examples & Detailed Explanation

Heating Parameters

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

Night/Economy Mode

There are two ways to switch the economy mode.

Option #1 (MQTT):

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,

Option #2 (Amend Code):

Set commandedValues.Heating.Active to false or true depending on if you want to switch economy on or off.

Switch Off/On

See Night/Economy Mode

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

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

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

Fallback and Failsafe

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

Automatic Controller Detection

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.

External Temperature Sensors

The oneWire and DallasTemperature libraries are included and used to fetch additional temperatures like the return temperature which isn't available on the bus.

Where?

Configured using /data/configuration.json or Configuration > Temperature Sensors on the web UI

See Auxiliary Sensors

Dynamic Adaption

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": 0

Calculate yourself

You 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": true

Valve-based control

This 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,
[...]
}

Updating

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.

Telnet Console

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.

Home Assistant Integration

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

Hints

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 OverrideControl in main.cpp to false. This way nothing will be sent on the bus udner any circumstances but you can read everything.
For debug purposes the configuration.General.Debug variable 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 within sprintf calls.
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.ini to your preference.

Getting Started

Copy Configuration.json to the data folder.
Use this configuration.json to configure the project to your requirements.
Upload the project
Now it will format the SPIFFS filesystem.
Build Filesystem Image and Upload Filesystem Image so 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.

Configuration

See the Configuration guide for details.

Dedicated PCB

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.

Todo

Special Thanks

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

Name		Name	Last commit message	Last commit date
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.github		.github
Home Assistant		Home Assistant
assets		assets
data		data
include		include
lib		lib
src		src
test		test
.gitignore		.gitignore
CODE_OF_CONDUCT.md		CODE_OF_CONDUCT.md
CONTRIBUTING.md		CONTRIBUTING.md
Changelog.md		Changelog.md
LICENSE		LICENSE
README.md		README.md
gzip-data.py		gzip-data.py
partitions_custom.csv		partitions_custom.csv
platformio.ini		platformio.ini

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Neuroquila-n8fall/JunkersControl

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JunkersControl

NOTE: Documentation is mostly accurate right now.

Table of contents

Community

Purpose and Aim

Cerasmart-er

Contribution

Intended Audience

Disclaimer:

A word of warning

But why? We are talking about a data line!

Prerequisites

Installation (Quick Start)

Features

MQTT

Where?

How?

Example Parameter JSON for setting Heating Parameters:

Examples & Detailed Explanation

Heating Parameters

Night/Economy Mode

Option #1 (MQTT):

Option #2 (Amend Code):

Switch Off/On

Boost

Fast Heatup

Fallback and Failsafe

Automatic Controller Detection

External Temperature Sensors

Where?

Dynamic Adaption

Calculate yourself

Valve-based control

Updating

Telnet Console

Home Assistant Integration

Hints

Getting Started

Configuration

Dedicated PCB

Todo

Special Thanks

About

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Code of conduct

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Forks

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