Fixed sensor setup when no sensors are attached

- state machine would forever stat at ‘init’ when no sensors were
connected (sensor status ‘initialising’)
- reduced Flash and RAM usage for serial UI
- runs on Adafruit Micro for first time
- EEPROM config block was not initialised to 0’s => random parameter
values. Should have cmd to force default values.

Author: oliver-reinhard

bc_setup.h

@@ -4,7 +4,7 @@
   // Uncomment AT MOST ONE (!) of the following lines:
     // #define UNIT_TEST
     // #define BLE_UI
-    // #define SERIAL_UI
+     #define SERIAL_UI
 
   #ifdef UNIT_TEST
     // Comment the following line to prevent execution of STATE tests:

boiler_controller.ino

@@ -74,7 +74,7 @@ void setup() {
     pinMode(HEATER_PIN, OUTPUT);
     controlActions.setupSensors();
 
-    Serial.println(F("Ready."));
+    Serial.println(F("Starting."));
   #endif
 
 }

config.cpp

@@ -51,13 +51,14 @@ void ConfigParams::initParams(boolean &updated) {
 
 
 void ConfigParams::print() {
+  char buf[max(MAX_TEMPERATURE_STR_LEN, MAX_TEMP_SENSOR_ID_STR_LEN)];
   AbstractConfigParams::print();
-  Serial.println(formatTemperature(targetTemp));
-  Serial.println(formatTempSensorID(waterTempSensorId));
-  Serial.println(formatTempSensorID(ambientTempSensorId));
-  Serial.println(formatTemperature(heaterCutOutWaterTemp));
-  Serial.println(formatTemperature(heaterBackOkWaterTemp));
-  Serial.println(formatTemperature(logTempDelta));
+  Serial.println(formatTemperature(targetTemp, buf));
+  Serial.println(formatTempSensorID(waterTempSensorId, buf));
+  Serial.println(formatTempSensorID(ambientTempSensorId, buf));
+  Serial.println(formatTemperature(heaterCutOutWaterTemp, buf));
+  Serial.println(formatTemperature(heaterBackOkWaterTemp, buf));
+  Serial.println(formatTemperature(logTempDelta, buf));
   Serial.println(logTimeDelta);
   Serial.println(tankCapacity);
   Serial.println(heaterPower);

control.cpp

@@ -24,43 +24,53 @@ uint32_t heatingTotalMillis(OperationalParams *op) {
 
 
 uint8_t ControlActions::setupSensors() {
-  context->op->water.setId(context->config->waterTempSensorId);
-  context->op->water.rangeMin = WATER_MIN_TEMP;
-  context->op->water.rangeMax = WATER_MAX_TEMP;
+  DS18B20TemperatureSensor *waterSensor = &context->op->water;
+  waterSensor->setId(context->config->waterTempSensorId);
+  waterSensor->rangeMin = WATER_MIN_TEMP;
+  waterSensor->rangeMax = WATER_MAX_TEMP;
 
-  context->op->ambient.setId(context->config->ambientTempSensorId);
-  context->op->ambient.rangeMin = AMBIENT_MIN_TEMP;
-  context->op->ambient.rangeMax = AMBIENT_MAX_TEMP;
+  DS18B20TemperatureSensor *ambientSensor = &context->op->ambient;
+  ambientSensor->setId(context->config->ambientTempSensorId);
+  ambientSensor->rangeMin = AMBIENT_MIN_TEMP;
+  ambientSensor->rangeMax = AMBIENT_MAX_TEMP;
 
   uint8_t matched = context->controller->setupSensors();
 
-  if (context->op->water.sensorStatus == SENSOR_ID_UNDEFINED) {
-   context->log->logMessage(MSG_WATER_TEMP_SENSOR_ID_UNDEF, 0, 0); 
-   #ifdef DEBUG_CONTROL
-     Serial.println(F("DEBUG_CONTROL: Water temp sensor ID undefined"));
-   #endif
-  } else if (context->op->water.sensorStatus == SENSOR_ID_AUTO_ASSIGNED) {
-   context->log->logMessage(MSG_WATER_TEMP_SENSOR_ID_AUTO, 0, 0); 
-   #ifdef DEBUG_CONTROL
-     Serial.println(F("DEBUG_CONTROL: Water temp sensor ID assigned automatically."));
-   #endif
+  if (waterSensor->sensorStatus == SENSOR_INITIALISING) {
+    logSensorSetupIssue(waterSensor, MSG_WATER_TEMP_SENSOR_SILENT); 
+  } else if (waterSensor->sensorStatus == SENSOR_ID_UNDEFINED) {
+    logSensorSetupIssue(waterSensor, MSG_WATER_TEMP_SENSOR_ID_UNDEF); 
+  } else if (waterSensor->sensorStatus == SENSOR_ID_AUTO_ASSIGNED) {
+    logSensorSetupIssue(waterSensor, MSG_WATER_TEMP_SENSOR_ID_AUTO); 
   }
 
-  if (context->op->ambient.sensorStatus == SENSOR_ID_UNDEFINED) {
-   context->log->logMessage(MSG_AMBIENT_TEMP_SENSOR_ID_UNDEF, 0, 0); 
-   #ifdef DEBUG_CONTROL
-     Serial.println(F("DEBUG_CONTROL: Ambient temp sensor ID undefined"));
-   #endif
-  } else if (context->op->ambient.sensorStatus == SENSOR_ID_AUTO_ASSIGNED) {
-   context->log->logMessage(MSG_AMBIENT_TEMP_SENSOR_ID_AUTO, 0, 0); 
+  if (ambientSensor->sensorStatus == SENSOR_INITIALISING) {
+    logSensorSetupIssue(ambientSensor, MSG_AMBIENT_TEMP_SENSOR_SILENT); 
+  } else if (ambientSensor->sensorStatus == SENSOR_ID_UNDEFINED) {
+    logSensorSetupIssue(ambientSensor, MSG_AMBIENT_TEMP_SENSOR_ID_UNDEF); 
+  } else if (ambientSensor->sensorStatus == SENSOR_ID_AUTO_ASSIGNED) {
+   logSensorSetupIssue(ambientSensor, MSG_AMBIENT_TEMP_SENSOR_ID_AUTO); 
+  } 
+
    #ifdef DEBUG_CONTROL
-     Serial.println(F("DEBUG_CONTROL: Ambient temp sensor ID assigned automatically."));
+     Serial.print(F("DEBUG_CONTROL: Sensors matched or found = "));
+     Serial.println(matched);
    #endif
-  }
-
   return matched;
 }
 
+void ControlActions::logSensorSetupIssue(DS18B20TemperatureSensor *sensor, ControlMessageEnum msg) {
+  context->log->logMessage(msg, 0, 0); 
+  #ifdef DEBUG_CONTROL
+    Serial.print(F("DEBUG_CONTROL: "));
+    Serial.print(sensor->label);
+    Serial.print(F(" sensor status = "));
+    Serial.println(sensor->sensorStatus);
+  #else
+    if (sensor != NULL) { } // prevent 'unused parameter' warning
+  #endif
+}
+
 void ControlActions::swapTempSensorIDs() {
   context->op->swapTempSensorIDs();
 }

control.h

@@ -9,11 +9,13 @@
   #define ONE_WIRE_PIN 10 // Temperature sensors
 
   typedef enum {
-    MSG_WATER_TEMP_SENSOR_ID_UNDEF = 20,   // Sensor ID of water-temperature sensor could not be obtained. Check wiring and sensor, then restart.
-    MSG_WATER_TEMP_SENSOR_ID_AUTO =  21,   // Sensor ID of water-temperature sensor was assigned automatically. Confirm that it refers to the correct sensor, then restart.
-    MSG_AMBIENT_TEMP_SENSOR_ID_UNDEF = 22, // Sensor ID of ambient-temperature sensor could not be obtained. Check wiring and sensor, then restart.
-    MSG_AMBIENT_TEMP_SENSOR_ID_AUTO =  23, // Sensor ID of ambient-temperature sensor was assigned automatically. Confirm that it refers to the correct sensor, then restart.
-    MSG_TEMP_SENSOR_IDS_CLEARED =  24      // Sensor IDs of water- and ambient-temperature sensor cleared. Restart to see the effect.
+    MSG_WATER_TEMP_SENSOR_SILENT = 20,      // Water-temperature sensor not responding. Check wiring and sensor, then restart.
+    MSG_WATER_TEMP_SENSOR_ID_UNDEF = 21,    // Sensor ID of water-temperature sensor could not be obtained. Check wiring and sensor, then restart.
+    MSG_WATER_TEMP_SENSOR_ID_AUTO =  22,    // Sensor ID of water-temperature sensor was assigned automatically. Confirm that it refers to the correct sensor, then restart.
+    MSG_AMBIENT_TEMP_SENSOR_SILENT = 23,    // Ambient-temperature sensor not responding. Check wiring and sensor, then restart.
+    MSG_AMBIENT_TEMP_SENSOR_ID_UNDEF = 24,  // Sensor ID of ambient-temperature sensor could not be obtained. Check wiring and sensor, then restart.
+    MSG_AMBIENT_TEMP_SENSOR_ID_AUTO =  25,  // Sensor ID of ambient-temperature sensor was assigned automatically. Confirm that it refers to the correct sensor, then restart.
+    MSG_TEMP_SENSOR_IDS_CLEARED =  26       // Sensor IDs of water- and ambient-temperature sensor cleared. Restart to see the effect.
   } ControlMessageEnum;
 
 
@@ -160,6 +162,8 @@
     protected:
       ControlContext *context;
       ReadWriteRequests pendingRequests = READ_WRITE_NONE;
+
+      void logSensorSetupIssue(DS18B20TemperatureSensor *sensor, ControlMessageEnum msg);
   };
 
 #endif

log/LogTime.cpp

@@ -1,7 +1,7 @@
 #include <assert.h>
 #include "LogTime.h"
 
-//#define DEBUG_LOG_TIME
+// #define DEBUG_LOG_TIME
 
 #define ASCII_0 48  // char(48)
 
@@ -32,7 +32,8 @@ Timestamp LogTime::timestamp() {
   Timestamp ts = t.sec << TIMESTAMP_ID_BITS | timestampCount;
   #ifdef DEBUG_LOG_TIME
     Serial.print(F("DEBUG_LOG_TIME: Timestamp "));
-    Serial.println(format(ts));
+    char buf[MAX_TIMESTAMP_STR_LEN];
+    Serial.println(formatTimestamp(ts, buf));
   #endif
   return ts;
 }
@@ -56,8 +57,7 @@ void LogTime::reset() {
 }
 
 
-String formatTimestamp(Timestamp t) {
-  char s[13];
+char *formatTimestamp(Timestamp t, char s[MAX_TIMESTAMP_STR_LEN]) {
   uint32_t sec = t >> TIMESTAMP_ID_BITS;
   uint8_t timestampCount = t % 16;
   s[12] = '\0';

log/LogTime.h

@@ -70,10 +70,11 @@
       uint8_t timestampCount = 0;
   };
 
-  
-/**
- * Returns the timestamp in a 13-character dotted notation, terminated by '\0': sssssssss.cc  (s = seconds: 2^28 = 268435456 (9 digits), cc = count: 0..15 (2 digits))
- */
-String formatTimestamp(Timestamp t);
+
+  #define MAX_TIMESTAMP_STR_LEN 13
+  /**
+   * Returns the timestamp in a 13-character dotted notation, terminated by '\0': sssssssss.cc  (s = seconds: 2^28 = 268435456 (9 digits), cc = count: 0..15 (2 digits))
+   */
+  char *formatTimestamp(Timestamp t, char buf[MAX_TIMESTAMP_STR_LEN]);
 
 #endif

log/Logging.cpp

@@ -125,7 +125,8 @@ LogEntry AbstractLog::addLogEntry(LogDataTypeID type, LogData *data) {
     Serial.print(F("DEBUG_LOG: createLogEntry: type "));
     Serial.print(entry.type);
     Serial.print(F(" => timestamp: "));
-    Serial.println(logTime.format(entry.timestamp));
+    char buf[MAX_TIMESTAMP_STR_LEN];
+    Serial.println(formatTimestamp(entry.timestamp, buf));
   #endif
   memcpy(&(entry.data), data, sizeof(LogData));
 
@@ -180,9 +181,10 @@ boolean AbstractLog::nextLogEntry(LogEntry &entry) {
     EEPROM.get(entryOffset(reader.nextIndex), entry); 
     #ifdef DEBUG_LOG
       Serial.print(F("DEBUG_LOG: getLogEntry: timestamp: "));
-      Serial.print(logTime.format(entry->timestamp));
+      char buf[MAX_TIMESTAMP_STR_LEN];
+      Serial.print(formatTimestamp(entry.timestamp, buf));
       Serial.print(F(", type: "));
-      Serial.println(entry->type);
+      Serial.println(entry.type);
     #endif
     reader.read++;
     if (reader.kind == LOG_READER_MOST_RECENT) {
@@ -206,8 +208,9 @@ void AbstractLog::S_O_S(MessageID id, int16_t param1, int16_t param2) {
   Timestamp ts = logMessage(id, param1, param2);
   ts = ts; // prevents warning: unused variable
   #ifdef DEBUG_LOG
+    char buf[MAX_TIMESTAMP_STR_LEN];
     Serial.print(F("DEBUG_LOG: S.O.S. : See log message "));
-    Serial.println(logTime.format(ts));
+    Serial.println(formatTimestamp(ts, buf));
   #endif
   S_O_S(NULL);
 }

sensors/OneWireSensors.cpp

@@ -21,6 +21,11 @@ uint8_t DS18B20Controller::setupSensors() {
   for(uint8_t i=0; i<numSensors; i++) {
     if(sensors[i]->idUndefined()) {
       sensors[i]->sensorStatus = SENSOR_ID_UNDEFINED;
+      #ifdef DEBUG_SENSORS
+        Serial.print(F("DEBUG_SENSORS: Sensor "));
+        Serial.print(sensors[i]->label);
+        Serial.println(F(": setting to status ID undefined"));
+      #endif
     }
   }
 
@@ -90,30 +95,31 @@ void DS18B20Controller::completeSensorReadout() {
 
     DS18B20TemperatureSensor *sensor = getSensor(addr);
     if (sensor != NULL) {
+      TemperatureReadout readout = getCelcius(data);
       #ifdef DEBUG_SENSORS
         Serial.print(F("DEBUG_SENSORS: Sensor "));
         Serial.print(sensor->label);
       #endif
 
       // only set temperature and state for NOK sensors and AUTO_ASSIGNED sensors (leave others untouched):
       if (sensor->sensorStatus == SENSOR_ID_AUTO_ASSIGNED) {
-        TemperatureReadout readout = getCelcius(data);
         sensor->currentTemp  = readout.celcius;
         #ifdef DEBUG_SENSORS
+          char buf[MAX_TEMP_SENSOR_ID_STR_LEN];
           Serial.print(F(": ID AUTO ASSIGNED, "));
-          Serial.println(formatTemperature(readout.celcius));
+          Serial.println(formatTemperature(readout.celcius, buf));
         #endif
 
       } else if (sensor->sensorStatus == SENSOR_NOK) {
-        TemperatureReadout readout = getCelcius(data);
         // Ensure temperature is plausible:
         if((sensor->rangeMin == UNDEFINED_TEMPERATURE || readout.celcius >= sensor->rangeMin) 
             && (sensor->rangeMax == UNDEFINED_TEMPERATURE || readout.celcius <= sensor->rangeMax)) {
           sensor->sensorStatus = SENSOR_OK;
           sensor->currentTemp  = readout.celcius;
           #ifdef DEBUG_SENSORS
+            char buf[MAX_TEMP_SENSOR_ID_STR_LEN];
             Serial.print(F(": OK, "));
-            Serial.println(formatTemperature(readout.celcius));
+            Serial.println(formatTemperature(readout.celcius, buf));
           #endif
         } else {
           #ifdef DEBUG_SENSORS
@@ -195,8 +201,7 @@ TemperatureReadout DS18B20Controller::getCelcius(uint8_t data[]) {
 }
 
 
-String formatTemperature(Temperature t) {
-  char s[9];
+char *formatTemperature(Temperature t, char s[MAX_TEMPERATURE_STR_LEN]) {
   uint8_t deg = t / 100;
   uint8_t frac = t % 100;
   s[8] = '\0';
@@ -211,8 +216,7 @@ String formatTemperature(Temperature t) {
   return s;
 }
 
-String formatTempSensorID(TempSensorID id) {
-  char s[3*TEMP_SENSOR_ID_BYTES];
+char *formatTempSensorID(TempSensorID id, char s[MAX_TEMP_SENSOR_ID_STR_LEN]) {
   uint8_t pos = 0;
   for (uint8_t i=0; i<TEMP_SENSOR_ID_BYTES; i++) {
     sprintf(&s[pos], "%02X", id[i]);

sensors/OneWireSensors.h

@@ -20,11 +20,11 @@
    * States of a DS18B20 Temperature Sensor.
    */
   typedef enum {
-    SENSOR_INITIALISING = 1,
-    SENSOR_ID_AUTO_ASSIGNED = 2, // a physical sensor was assigned to the logical sensor but it may not correspond to the intended sensor
-    SENSOR_ID_UNDEFINED = 3,     // no physical sensor could be found for the logical sensor
-    SENSOR_OK = 4,               // temperature value is defined and within the given range
-    SENSOR_NOK = 5               // temperature value could not be obtained or is outside the given range
+    SENSOR_INITIALISING = 0x1,
+    SENSOR_ID_AUTO_ASSIGNED = 0x2, // a physical sensor was assigned to the logical sensor but it may not correspond to the intended sensor
+    SENSOR_ID_UNDEFINED = 0x4,     // no physical sensor could be found for the logical sensor
+    SENSOR_OK = 0x8,               // temperature value is defined and within the given range
+    SENSOR_NOK = 0x10              // temperature value could not be obtained or is outside the given range
   } SensorStatusEnum;
 
   typedef uint8_t SensorStatusID;
@@ -174,14 +174,19 @@
       TemperatureReadout getCelcius(uint8_t data[]);
   };
 
+  #define MAX_TEMPERATURE_STR_LEN 9
+  
   /**
    * Returns the temperature in a dotted notation, 8 chars + terminal '\0': ["-"]dd.ff"°C" (optional "-", d = degrees Celsius (2 digits), f = fraction (1 digit))
    */
-  String formatTemperature(Temperature t);
+  char *formatTemperature(Temperature t, char buf[MAX_TEMPERATURE_STR_LEN]);
+
 
+  #define MAX_TEMP_SENSOR_ID_STR_LEN (3*TEMP_SENSOR_ID_BYTES)
+  
   /*
-   * Returns the ID in a dashed hex notation, e.g."28-8C-8C-79-6-0-0-89"
+   * Returns the ID in a dashed hex notation, e.g."28-8C-8C-79-6-00-00-89"
    */
-  String formatTempSensorID(TempSensorID id);
+  char *formatTempSensorID(TempSensorID id, char buf[MAX_TEMP_SENSOR_ID_STR_LEN]);
 
 #endif

sensors/sensors.ino

@@ -15,7 +15,7 @@
  *  *******       - virtual void reset_search();
  *  *******       - virtual uint8_t search(uint8_t *newAddr, bool search_mode = true);
  */
-#define MOCK_ONE_WIRE
+// #define MOCK_ONE_WIRE
 
 //#define DEBUG_SENSORS_MAIN
 
@@ -70,7 +70,7 @@ test(a_sensor_setup) {
   #endif
   uint8_t matched = controller.setupSensors();
   #ifndef MOCK_ONE_WIRE
-    if (matched < 2) }
+    if (matched < 2) {
       Serial.println(F("Cannot access one or more physical sensors -> check wiring."));
     }
   #endif
@@ -122,8 +122,9 @@ test(b_single_sensor_readout) {
   #ifdef MOCK_ONE_WIRE
     assertEqual(s1.currentTemp, 2300);
   #else
+    char buf[MAX_TEMP_SENSOR_ID_STR_LEN];
     Serial.print(F("Temperature readout S1: "));
-    Serial.println(formatTemperature(s1.currentTemp));
+    Serial.println(formatTemperature(s1.currentTemp, buf));
     // assumed room temperature between 0 and 40°C:
     assertTrue(s1.currentTemp > 0);
     assertTrue(s1.currentTemp < 4000);
@@ -184,13 +185,14 @@ test(c_twin_sensor_readout) {
     assertEqual(s1.currentTemp, 2300);
     assertEqual(s2.currentTemp, 2400);
   #else
+    char buf[MAX_TEMP_SENSOR_ID_STR_LEN];
     Serial.print(F("Temperature readout S1: "));
-    Serial.println(formatTemperature(s1.currentTemp));
+    Serial.println(formatTemperature(s1.currentTemp, buf));
     // assumed room temperature between 0 and 40°C:
     assertTrue(s1.currentTemp > 0);
     assertTrue(s1.currentTemp < 4000);
     Serial.print(F("Temperature readout S2: "));
-    Serial.println(formatTemperature(s2.currentTemp));
+    Serial.println(formatTemperature(s2.currentTemp, buf));
     // assumed room temperature between 0 and 40°C:
     assertTrue(s2.currentTemp > 0);
     assertTrue(s2.currentTemp < 4000);