Overview

This project has come about from my desire to control my home heating from work.  As I have a VPN between work and home a straightforward relay controlled from a PC would seem the easiest solution.  However I also wanted a control unit that I could operate in the house without resorting to the computer.  For example, I get up late and the heating is off, I just want to hit a button and turn it on.  In fact the programmer shown on this page is now next to my bed so I can turn the heating on before I  get up late, and also switch it off if I turn in early, which helps save on the fuel bills J

Features

• Independent control for heating and hot water.

• 10 flexible program entries.

• Programs can be set to operate Mon-Fri / Sat-Sun / Mon-Sun.

• Manual advance for water and heating

• Water and heating can be independently set to manual or programmed control.

• Operation and setup from front panel or remote serial CLI

• Battery backup for Real Time Clock (RTC), program settings and manual control.

• Programmer can be located remotely from boiler using low voltage signals over CAT5 or 6-core alarm cable.

• RS232 serial interface with command line interface allows full control and setting from any computer.

• Front panel control can be locked-out from serial CLI

• Based on Microchip PIC 16F628A microcontroller

This programmer has been designed for use with a domestic heating boiler.  It provides outputs via two relays to control the supply of Hot Water and Heating.  There are 10 program entries available and each one can control the heating and water independently. The programmer allows manual advance of the heating and water and  disabling of program control, useful if you're going away for a few days and want to leave the heating and water off. As well as providing normal front panel switch control of the heating and water, the programmer also features a serial terminal interface that allows it to be operated remotely from a PC running a Terminal Emulator.

The program entries can be set to switch weekdays only, weekends only or everyday but not individual days.  I believe a programmer that can switch weekdays or weekends is a 5/2-day programmer so I would call mine a 5/2/7 day programmer since it can do the whole week as well.  However, a 7-day programmer is one that can do individual days so I've settled on calling mine an Enhanced 5/2-day programmer.

The programmer and boiler control relays are contained in separate units so that the relays can be located close to the boiler while the programmer itself can be located anywhere in the house using low voltage connections back to the relay unit.  The connection between the programmer and relay unit requires six wires for power, serial data and relay controls making it possible to use 6-core alarm cable or, as I have done, operate it over the CAT5 UTP cabling installed throughout my house.  Of course it's quite simple to build it as a single unit if that suits the application.  There is also no reason why you can't make the serial interface connection local to the programmer in which case you only need 4 wires for power and relay controls.

If you don't require the remote computer CLI the programmer is fully functional using just the front panel and likewise, if the front panel isn't required, it can be fully controlled from the serial interface and the LCD and switches omitted from the hardware.

Software

The latest version of the programmer ready .HEX file is provided here.

Firmware Version 2.0.2 28 May 2005  Please read conditions of use and disclaimer before downloading Programmer ready HEX file: chctrl_mainV202.hex (right-click Save As) V2.0.2 code supports the CLI diagnostic commands Programmer ready HEX file: chctrl_mainV203.hex (right-click Save As) V2.0.3 does not have the diagnostic CLI commands in the code.   Source code: chp.zip

Developed using MPLAB V7.10 and Oshonsoft PIC Simulator IDE. Assembled with MPASM v04.00

The software is fully functional and the system as described on this web page is currently working with my domestic heating system.  I've been using prototypes since March 2005.  The latest code, Version 2.0.2, has been running since 28 May 2005.  As of 25 March 2014 it's still working and has proved to be 100% reliable.

This is the final version of the code. I'm not going to develop it any further since the programmer now implements all the features I want and works as I intended.  I will do maintenance code releases to fix any software related bugs / issues reported to me.

Known issues

• no known critical issues.

• Some CLI commands allow superfluous text on the line after the command. The command executes correctly and any superfluous text is ignored.

• Please send any bug reports to

  Contact us:
  

Functionality as designed

• The current relay output and manual mode settings are stored in NVRAM. In the event of a power failure these are restored when the power resumes. If a programmed setting should have applied at a time during the power outage, it will not get applied when the power is restored. The saved settings that were active at the time of the power failure will be reapplied. 

• When in front panel setup mode, no programmed outputs will be activated. If a programmed setting should have applied while the programmer was in setup mode, it will not get applied on exit. 

• On power up the programmer sends a VT100 [ESC] c command to the terminal to reset it. This may cause extraneous characters to be displayed or other issues on a non VT100 emulator.  

• Time is displayed / entered in 24 hour format only. 

• Serial interface operates at 9600bps, 8 bits, 1 stop, No parity.  Baud rate is not configurable

• When in front panel setup mode the serial CLI is disabled.

Code Revisions

V2.0.3

• As version 2.0.2 code but without the CLI diagnostic commands. These commands where implemented from an include file which has simply been omitted during assembly for V2.0.3. 

V2.0.2

• Enabled the PIC Watch Dog Time (WDT) and added supporting code.

• New command 'dw' shows number of Watch Dog timeouts that have occurred since power-up. These should not occur if the programmer is functioning correctly, if they do this alerts you to a potential problem.

• Implemented front panel setup functions. Allows time to be set. Program entries to be viewed, cleared, entered and edited.

• Changed handling of serial CLI input buffer overflow. The behavior is now consistent with handling of unknown commands. 

• The CLI 'p' command now shows output control for Hot Water followed by Central Heating. This is the opposite way round to firmware before V2.0.0 

V1.9.1

• Added CLI command to enable / disable front panel control. This has been added to allow the front panel to be locked out when using automated control of the unit from the CLI.  It also provides a way to stop my girlfriend from turning the heating on all the time:-)

• CLI relay control command letter has been changed from 't' to 'u'. 

• The relay control and manual mode CLI commands worked by inverting the current setting.  This has now changed so that the setting for on/off or manual/programmed is explicitly specified on the command line. 

• Moved the on/off text for heating and water on the LCD to the extreme ends of the display. This is to allow the display of the text 'Locked' when the front panel is disabled.

V1.9

• Prior to FW V1.9 the LCD display had the text CH- and -HW on the second line but as the programmer is now cased and the front panel artwork has legends on it, this text has been removed from the V1.9 code.

• The manual mode status was indicated with the characters 'm' and 'p'. This has now been replaced by the text 'Man' and 'Prg'

• Added CLI function to send a VT100 [ESC] c command to the terminal to reset it. 

• Send VT100 [ESC] c command to the terminal at power-up.

• Added command to return an ASCII hex byte with the current status of the relay outputs and manual mode settings. For use with automated control of the CLI.

• Improved the CLI 'p' command entry format and parsing.

• Made program control for CH and HW outputs fully independent by adding a no-change flag and enabling this feature within all related functions.

Hardware

The hardware for the programmer comprises two units.  The first contains the two relays that switch the mains power to control the boiler.  This also has an RJ45 socket to allow connection into a CAT5 cabling system that takes power, serial data and relay control input signals to the second unit, an intelligent programmer.  There is also a 2.1mm DC power socket that is used to connect an external 9~12V DC power adapter. This supplies power to the relay board and the programmer controller. A 9-pin 'D' socket provides connectivity to a PC serial interface.

The programmer  unit is based on a PIC16F628A micro controller.  The programmer front panel has a 2x16 line LCD display that shows the time and programmer status, with switches for manually overriding the programmer. A  serial interface for connection to a computer running a terminal emulator allows complete control and programming of the unit remotely.  A Dallas DS1307 Real Time Clock (RTC) is used for time keeping and storing the program time settings in its NVRAM.  When power to the programmer is removed, the RTC uses a 3V lithium coin cell to maintain the time, date and NVRAM data.

The programmer control unit itself only draws about 10~15mA from the power supply. The current for the relays is additional to this and the LCD used in the programmer is not back-lit.  The relays I used operate from 12V and draw ~30mA when on.  The 12V power supply for the whole setup as described only needs to provide about 100mA.  In practice something capable of supplying 500mA would be better. The exact specification of the relays and LCD panel used should also to taken into consideration when specifying the PSU. The 78L05 regulator IC shown on the schematic is not capable of supplying power to an LCD panel with LED backlight.

The schematic diagram of the programmer is shown below, click on the image for large copy.  Construction details can be found in the next section.

Programmer schematic (click to enlarge) Schematic in PDF format

Final assembled version and a development prototype.

During development I used the serial interface driver shown here rather than the MAX202CPE device.  This circuit is very cheap to construct and works quite reliably from a PC. However, it does derive its negative 12 volt supply in a parasitic fashion from the serial transmit line of the host device. Therefore the host must drive its TxData line with RS232 signal levels.  If you don't want the expense of the specialized driver chip and know what you want to connect to, this makes a cheap alternative. To make the final circuit more compliant and function reliably with any serial device I made a decision to use the MAX202CPE line driver. A number of manufacturers produce similar pin-compatible devices to the Maxim part that could be used here.

I'm using the programmer with the relays located at the end of about 10M of CAT5 UTP cable. Although the PIC is driving the line, internal protection diodes on the port pin will pass any spikes onto the power rail.  The 120 ohm resistor / 1nF capacitor on each relay control output are there to slow rise and fall times on the output and also filter any transient noise on the line from reaching the output pins of the PIC. 

The display is a standard 2 x 16 LCD and the code is written for the HD44780 controller command set.

The relay outputs from the programmer were designed to connect to a logic level relay interface and will not drive relays directly.  I used a 2-channel relay board kit from Quasar Electronics. Kit No 3156.  (This is made by DIY Electronics, their kit K156 which is resold by various other companies)

As I'm using the programmer with the relay kit above I can say that the two work reliably together.  In principal there is no reason why you can't construct your own relay driver.  The one shown in this schematic should also work with 12volt relay coils.  The BC548 transistor shown can be replaced with any general purpose NPN transistor.  You will need to take into account the current drawn by the relays and ensure that;

• The transistor is capable of sinking the current drawn by the relay coil.   Small PCB mount relays with a 12V coil will typically draw about 35mA and the BC548 can sink 100mA continuous max.  
  

• If you use 5volt relays remember that the 78L05 voltage regulator can only supply 100mA maximum and that both relays may be energized at the same time. You will therefore almost certainly need to use a 7805 1Amp regulator in place of the 78L05. 
  

• The relays used will need to be specified according to the specific boiler being controlled, but typically, for use in the UK a relay rated for 240V mains operation and 3A contacts would be suitable. 
  

• If you locate the relays remotely from the programmer as described here, you must locate the relay driver circuit with the relays. Don't put the relay driver on the programmer circuit board and then switch the current to the relay coils through several metres of cable. 

** This project involves the control of mains voltages.  If you are not confident about working with high voltages or don't understand about wiring this into your existing heating system you should employ the services of a qualified electrician.  You should also ensure you comply with any local regulations with respect to the installation of the programmer **

Datasheets

• PIC16F628A, Microchip
• MAX202, Maxim Dallas Semiconductor
• DS1307, Maxim Dallas Semiconductor
• DS1307 available from Rapid Online - Rapid Electronics Ltd.
  Farnell in-one order code 787139
   

Construction

  The following description of the construction is based on the unit I've built myself which includes the front panel display and controls. The programmer doesn't actually need the front panel interface. The software will function correctly with or without the front panel interface components installed, so if you want to control it from the serial interface only, you can omit the LCD display and 10K contrast preset, switches Sw1 thru Sw5 and diodes D1 thru D5. You must keep the 10K pull-up resistor to pin 4 (RA4) of the PIC.   You could also use it with the LCD display but without the switches.

The main programmer unit is housed in a 130 x 95 x 30mm ABS case. (See Rapid Electronics part # 30-3892 by Evatron) The LCD display panel and five push button switches are mounted in the top half of the case.  When mounting the switches the top of the buttons should be just proud of the top of the case, this makes them easier to operate once the front panel overlay is fitted.  The switches have then been fixed using hot-melt glue.  The ribbon cable to the LCD panel was fitted and then LCD glued into the case, again using hot-melt glue.  Once all the cables to the top of the case were fitted some hot-melt glue was used to secure them and provide strain relief .  The use of hot-glue does make it difficult to replace or repair parts in the future but not impossible. Since it's a one off project I was happy with the ease of construction and felt this outweighed maintainability.   An RJ45 socket was removed from a Network Interface Card and used for the external connections.  A cut out was carefully made in one of the end panels.  This was then attached using hot-melt glue and the cabling attached afterwards.  Keeping the cut-out an interference fit with the RJ45 socket helps keep it nice and solid when assembled.

The main control board was fitted in the bottom half of the case and secured with a couple of small dabs of hot melt glue.  The moulded mounting  pillars in the bottom of the case where shaped to hold the board mechanically so only the smallest amounts of glue where needed to secure it. This was done intentionally so that it will be easy to remove the board.

The central heating boiler in my home is located in the garage next to the data comms' cabinet. There's a standard commercial heating programmer that was installed with the heating system and I have wired my control box in parallel with this.  When my programmer is operating, the commercial programmer is set to manual off.  This means I can easily revert back to using the commercial programmer if needed. A 40mm deep double gang surface mount box has been used to mount the relay control board and connectors.  Slots have been cut into one side of the box to take a 2.1mm DC power socket, RJ45 socket and 9-pin 'D' connector.  The three wires from the boiler are brought in through a hole in one end of the box and secured with cable ties.  The relay control box is located in the bottom of the comms' cabinet which allows it to hook up to the PC (also located in the cabinet), the CAT5 cabling patch panel and power from a small 12volt / 500mA plug-top adapter.  I have a small PC in the bottom of the cabinet that functions as a file server and systems controller for the house, so this was the logical system to connect the serial interface to.  A terminal emulator runs on the PC and this is accessed via a  remote desktop application.

Relay control box with the cover removed.

The main programmer has been constructed on double sided matrix board and a detailed construction layout is provided below.  Construction is fairly straightforward and should be done in conjunction with the schematic diagram provided in the hardware section above.  

Circuit construction notes:

• The 10Kohm resistors are 1/8 watt devices and somewhat smaller than standard 1/4 watt carbon film types. You can use 1/4 watt resistor but you will need to mount them vertically if you follow this layout.
   
• The 47nF capacitor shown on the schematic diagram decoupling the power rail to the 16F628A has been soldered on the reverse side of the board directly across the Vss-Vdd pins of the PIC. See Photo
   
• The oscillator pins of the DS1307 RTC device have been bent out horizontally from the package, the narrow ends of the pins cut off and the crystal soldered directly to the stubs on the IC. I've done it this way because it's difficult to meet the layout requirements for the crystal circuit as detailed in the datasheet for the device without using a PCB.  Done the way I've shown the RTC clock should run very accurately.
   
• The battery holder used was a surface mount type, tacked to the copper pads on the top side of the board. After construction visually inspect the connection between the +VE terminal of the battery holder and pin 3 of the DS1307 socket to ensure there are no shorts to ground or anything else.
   
• Once the board has been assembled, apply power to the board before inserting the three IC's or connecting the LCD. Ensure that 5volts appears at the IC sockets power pin positions and the LCD header. Correct any problems.
   
• Adjust the LCD contrast preset so pin 3 of the LCD header plug is at 0v.
   
• After the power supply has been tested install the three IC's and connect the serial interface to a PC running a terminal emulator application.  The programmer will function for testing purposes without the LCD or switches connected so you can check the basic functions through the serial CLI interface and then connect the LCD and switches once you've established the basic operation of the circuit is okay.
   
• With the LCD connected, adjust the contrast preset resistor until the display can be read.
   
• Switch functions
  Sw1 - HW on/off
  Sw2 - CH on/off
  Sw3 - HW manual
  Sw4 - CH manual
  Sw5 - 'Setup' button   

pad board construction layout	Assembled board	Reverse side of board
Detail of battery holder  and 32Khz crystal	Assembled programmer	RJ45 socket detail

Although I installed connector pins for attaching the LCD display, keypad and RJ45 socket, I ended up soldering the connecting cables directly to the board, mainly because I didn't have the necessary sockets and also because once assembled it isn't likely to be opened up again.

Front panel artwork

Artwork for the front panel was produced using Microsoft Visio.  This was then printed onto photo quality glossy paper. Once the ink was dry (make sure it is or you'll be doing it again)  the area where the LCD panel locates was carefully removed and the whole artwork cut out from the A4 sheet.   This was then laminated using a normal office document laminator.  The only thing I did before laminating was to work out where the switches would be and then cut out rectangles in the second layer of the laminating sheet.  This reduces the stiffness of the completed panel and makes the operation of the switches underneath more tactile.

Operation 

When the programmer powers-up it displays the firmware version on the LCD display for 2 seconds.  It then checks two validation bytes in the RTC NVRAM. If these do not contain the correct validation data the LCD will display RTC Initialized for 7 seconds, other wise it displays RTC ok for 2 seconds.  In normal operation, the LCD display shows the status of the CH and HW outputs, manual mode status and the day and time. A separator ':' between the hours and minutes on the display blinks every second.   Photo right: Programmer with FW Rev 1.8 Photo far right: Programmer with FW Rev 1.9