changes to sensor config and project environments

README.md

@@ -4,31 +4,37 @@ This is the code that will control the ESP32.
 
 ## Requirements
 
-We will be using PlatformIO for this project. This will allow us to possibly use its remote test and dev features.
+We will be using PlatformIO for this project. This allows us to have greater control and allows for swapping boards if needed.
 
 ***You will need to change your upload port in `platformio.ini`.***
 
-## Env variables
+You will need to download the Silcon Labs Driver here - https://community.silabs.com/s/article/legacy-os-software-and-driver-packages?language=en_US
 
-Add the env variables to a `.env` file before building it:
-
-```sh
-XFORMER_MON_WIFI_SSID=Your-WiFi-SSID
-XFORMER_MON_WIFI_PASSWD=Your-WiFi-Password
-
-# Your MQTT server
-XFORMER_MON_MQTT_SERVER=xformer.utilitymonitor.io
-
-XFORMER_MON_MQTT_USER=test
-
-XFORMER_MON_MQTT_PASS=secure-mqtt-pass
-
-XFORMER_MON_MQTT_ID=unique-id
-
-XFORMER_MON_MQTT_PORT="8883"
+## Setup
 
-# Must be "enabled" if using SSL!
-XFORMER_MON_USE_SSL="enabled"
+*The Excel sheet has the necessary formulas to calculate the sensor config values. The important ones go in a `include/sensorConfigValues.h`.*
+
+Add the necessary variables to a `config.yml` file before building the project.
+
+*If you have the server certificate at `cert.crt` at build time, this cert will be used instead of fetching it from the server.*
+
+```yaml
+wifi:
+  # Your WiFi SSID
+  ssid: "Your-WiFi-SSID"
+  # Your WiFi Password
+  password: "Your-Secret-WiFi-Password"
+mqtt:
+  # Your MQTT server
+  server: your.mqtt-broker.tld
+  # The port the MQTT server is running on
+  port: 8883
+  # Your MQTT User
+  user: test
+  # Your MQTT Password
+  password: secure-mqtt-pass
+  # A unique ID, usually the name of the transformer
+  id: unique-id
 ```
 
 ## Development
@@ -37,7 +43,7 @@ Put .cpp files in `src`, .h files in `include`, and any libraries in `lib`.
 
 ## Tests
 
-Put tests in `src/tests`. These are not PlatformIO tests.
+Put tests in `src/tests`. **These are not PlatformIO tests.**
 
 Run and upload tests using PlatformIO's VSCode extension. Or upload them using the command `pio run -t upload -e Test[Name]`. Name is the name of the test to run.
 
@@ -59,4 +65,4 @@ build_src_filter =
 
 ## Setup
 
-Depending on which sensor is used, the board has to be set up differently.
+The PlatformIO environment `prod` is the same as `dev`, but `dev` has serial monitor code.

config.example.yml

@@ -13,20 +13,4 @@ mqtt:
   # Your MQTT Password
   password: secure-mqtt-pass
   # A unique ID, usually the name of the transformer
-  id: unique-id
-sensor:
-  config:
-    # voltage rms gain in hex. See docs/Gains.md for more information
-    ugain: 0x
-    # Voltage gain for CTs
-    lgain: 0x
-    # Voltage gain for neutral line
-    ngain: 0x
-    # power freqency
-    lfreq: 0x
-    # PGA Gain for current channels
-    pgagain: 0x
-    # Only for the ATM90E36 board
-    # determines which line to read
-    # Determines which voltage needs to be set.
-    line: "A"
+  id: unique-id

envSetup.py

@@ -24,7 +24,6 @@ mqttConfig = monitorConfigFile.get("mqtt")
 
 mqttServer = mqttConfig.get("server")
 mqttPort = mqttConfig.get("port")
-sensorConfig = monitorConfigFile.get("sensor")
 
 if wifiConfig.get("ssid") == None:
     print(f"wifi object variable SSID not defined. Define it in the config.yml file at the root of the project.")
@@ -41,6 +40,7 @@ if mqttConfig.get("server") == None:
 env.Append(CPPDEFINES=[
   ("TM_WIFI_SSID", wifiConfig.get('ssid')),
   ("TM_WIFI_PASSWD", wifiConfig.get('password') ),
+  ("TM_MQTT_ID", mqttConfig.get('id')),
   ("TM_MQTT_PORT", mqttConfig.get('port')),
   ("TM_MQTT_SVR", mqttConfig.get("server")),
   ("TM_MQTT_USER", mqttConfig.get("user")),

include/sensorConfigValues.h

@@ -0,0 +1,12 @@
+// ********* Configuration of ATM90E26 ********* //
+
+// L line calibration gain
+double lgain = 0x1D39;
+// voltage RMS gain
+double ugain = 0x6F0B;
+// L line current gain
+double igainl = 0x7FF4;
+// voltage sag threshold
+double vsag = 0x0CD5;
+
+// ********************************************* //

include/transformerMonitor.h

@@ -10,6 +10,8 @@
 #include <idf_additions.h>
 #include <energyic_UART.h>
 #include <transformerMonitorServerCert.h>
+#include <sensorConfigValues.h>
+
 
 // Turn build flags (Macros) into strings
 #define ST(A) #A
@@ -17,29 +19,33 @@
 
 // extract the WiFi SSID from its macro
 #ifdef TM_WIFI_SSID
-  char const *ssid = STR(TM_WIFI_SSID);
+char const *ssid = STR(TM_WIFI_SSID);
 #endif
 
 // extract the WiFi Password from its macro
 #ifdef TM_WIFI_PASSWD
-  char const *wifiPassword = STR(TM_WIFI_PASSWD);
+char const *wifiPassword = STR(TM_WIFI_PASSWD);
 #endif
 
 // extract the MQTT Port from its macro
 #ifdef TM_MQTT_PORT
-  uint16_t mqttPort = (uint16_t) strtoul(STR(TM_MQTT_PORT), NULL, 10);
+uint16_t mqttPort = (uint16_t)strtoul(STR(TM_MQTT_PORT), NULL, 10);
 #endif
 // extract the MQTT server hostname from its macro
 #ifdef TM_MQTT_SVR
-  char const  *mqttServer = STR(TM_MQTT_SVR);
+char const *mqttServer = STR(TM_MQTT_SVR);
 #endif
 // extract the MQTT username from its macro
 #ifdef TM_MQTT_USER
-  char const  *mqttUser = STR(TM_MQTT_USER);
+char const *mqttUser = STR(TM_MQTT_USER);
 #endif
 // extract the MQTT password from its macro
 #ifdef TM_MQTT_PASSWD
-  char const  *mqttPass = STR(TM_MQTT_PASSWD);
+char const *mqttPass = STR(TM_MQTT_PASSWD);
+#endif
+
+#ifdef TM_MQTT_ID
+char const *client_id = STR(TM_MQTT_ID);
 #endif
 
 
@@ -47,8 +53,8 @@
 //********* GPIO PINS ************* //
 
 // pins for UART
-#define PIN_SerialATM_RX       19   //RX pin for AdaFruit Huzzah32
-#define PIN_SerialATM_TX       13   //TX pin for AdaFruit Huzzah32
+#define PIN_SerialATM_RX 19 // RX pin for AdaFruit Huzzah32
+#define PIN_SerialATM_TX 13 // TX pin for AdaFruit Huzzah32
 
 // GPIO pins where the DS18B20 sensors are connected
 const int oilTempBus = 5; // one in the epoxy resin
@@ -65,14 +71,13 @@ void messageReceived(String &topic, String &payload);
 WiFiClientSecure wifiClient;
 PubSubClient mqttClient;
 
-HardwareSerial ATMSerial(1);        //1 = just hardware serial number. ESP32 supports 3 hardware serials. UART 0 usually for flashing.
+HardwareSerial ATMSerial(1); // 1 = just hardware serial number. ESP32 supports 3 hardware serials. UART 0 usually for flashing.
 ATM90E26_UART eic(&ATMSerial);
 
-
 // * we are using the transformer's name to provide a unique ID
-char* client_id = "al-xformer-592";
 
-struct tempSensors {
+struct tempSensors
+{
   DallasTemperature oil, cabinet;
 };
 
@@ -83,26 +88,28 @@ DeviceAddress cabinetTempSensorAddr;
 OneWire oilTempBusOneWire(oilTempBus);
 OneWire cabinetTempBusOneWire(cabinetTempBus);
 
-// Pass our oneWire reference to Dallas Temperature sensor 
+// Pass our oneWire reference to Dallas Temperature sensor
 DallasTemperature oilTempSensor(&oilTempBusOneWire);
 DallasTemperature cabinetTempSensor(&cabinetTempBusOneWire);
 
 // temp sensor objects
 tempSensors monitorTempSensors{oilTempSensor, cabinetTempSensor};
 
-
 // Data structs for queue
-struct tempData {
+struct tempData
+{
   float cabinet, oil;
 };
 
-struct powerData {
+struct powerData
+{
   double active, factor;
 };
 
-struct xformerMonitorData {
+struct xformerMonitorData
+{
   unsigned short sysStatus, meterStatus;
-  double lineCurrent, lineVoltage;
+  double lineCurrent, lineVoltage, freq;
   tm *timeInfo;
   tempData temps;
   powerData power;
@@ -116,7 +123,7 @@ QueueHandle_t eicDataQueue;
 // End variables for tasks
 
 // Functions for tasks
-void readEICData( void * pvParameters );
+void readEICData(void *pvParameters);
 // End functions for tasks
 
 // Timer variable and function
@@ -139,7 +146,8 @@ void setupMQTTClient();
 // function to set up and initialize the energy monitor
 void setupEnergyMonitor();
 
-struct xformerMonConfigData {
+struct xformerMonConfigData
+{
   char *wifiSsid;
   char *wifiPass;
   char *mqttName;

lib/ATM90E26/energyic_UART.cpp

@@ -140,28 +140,31 @@ unsigned short ATM90E26_UART::GetSysStatus() {
 /*
 Initialise Energy IC, assume UART has already began in the main code
 */
-void ATM90E26_UART::InitEnergyIC() {
+void ATM90E26_UART::InitEnergyIC(double ugain, double lgain, double igainl, double vSagTh) {
   unsigned short systemstatus;
 
   CommEnergyIC(0, SoftReset, 0x789A); // Perform soft reset
   CommEnergyIC(0, FuncEn, 0x0030);    // Voltage sag irq=1, report on warnout
                                    // pin=1, energy dir change irq=0
-  CommEnergyIC(0, SagTh, 0x1F2F); // Voltage sag threshhold
+  CommEnergyIC(0, SagTh, vSagTh); // Voltage sag threshhold
 
   // Set metering calibration values
   CommEnergyIC(0, CalStart, 0x5678); // Metering calibration startup command.
                                      // Register 21 to 2B need to be set
-  CommEnergyIC(0, PLconstH, 0x0014); // PL Constant MSB
-  CommEnergyIC(0, PLconstL, 0x3FB7); // PL Constant LSB
-  CommEnergyIC(0, Lgain, 0x1D39);    // Line calibration gain
+  CommEnergyIC(0, PLconstH, 0x0007); // PL Constant MSB
+  CommEnergyIC(0, PLconstL, 0x24A1); // PL Constant LSB
+  CommEnergyIC(0, Lgain, lgain);    // Line calibration gain
   CommEnergyIC(0, Lphi, 0x0000);     // Line calibration angle
   CommEnergyIC(0, PStartTh, 0x08BD); // Active Startup Power Threshold
   CommEnergyIC(0, PNolTh, 0x0000);   // Active No-Load Power Threshold
   CommEnergyIC(0, QStartTh, 0x0AEC); // Reactive Startup Power Threshold
   CommEnergyIC(0, QNolTh, 0x0000);   // Reactive No-Load Power Threshold
   CommEnergyIC(0, MMode, 0x9422); // Metering Mode Configuration. All defaults.
-                                  // See pg 31 of datasheet.
-  CommEnergyIC(0, CSOne, 0x4A34); // Write CSOne, as self calculated
+  
+  // read CS1 and write the value back
+  double cs1 =  CommEnergyIC(1, CSOne, 0x0000);
+
+  CommEnergyIC(0, CSOne, cs1); // Write CSOne, as self calculated
 
   Serial.print("Checksum 1:");
   Serial.println(
@@ -172,13 +175,17 @@ void ATM90E26_UART::InitEnergyIC() {
   CommEnergyIC(
       0, AdjStart,
       0x5678); // Measurement calibration startup command, registers 31-3A
-  CommEnergyIC(0, Ugain, 0x352F);    // Voltage rms gain
-  CommEnergyIC(0, IgainL, 0x6E49);   // L line current gain
+  CommEnergyIC(0, Ugain, ugain);    // Voltage rms gain
+  CommEnergyIC(0, IgainL, igainl);   // L line current gain
   CommEnergyIC(0, Uoffset, 0x0000);  // Voltage offset
-  CommEnergyIC(0, IoffsetL, 0x0000); // L line current offset
+  CommEnergyIC(0, IoffsetL, 0x000); // L line current offset 
   CommEnergyIC(0, PoffsetL, 0x0000); // L line active power offset
   CommEnergyIC(0, QoffsetL, 0x0000); // L line reactive power offset
-  CommEnergyIC(0, CSTwo, 0xD294);    // Write CSTwo, as self calculated
+  
+  // read CS2 and write the value back:
+  double cs2 = CommEnergyIC(1, CSTwo, 0x0000);
+  
+  CommEnergyIC(0, CSTwo, cs2);    // Write CSTwo, as self calculated
 
   Serial.print("Checksum 2:");
   Serial.println(

lib/ATM90E26/energyic_UART.h

@@ -92,7 +92,7 @@ public:
   double GetPowerFactor();
   double GetImportEnergy();
   double GetExportEnergy();
-  void InitEnergyIC();
+  void InitEnergyIC(double ugain, double lgain, double igainl, double vSagTh);
   unsigned short GetSysStatus();
   unsigned short GetMeterStatus();
 
@@ -100,6 +100,7 @@ private:
   unsigned short CommEnergyIC(unsigned char RW, unsigned char address,
                               unsigned short val);
   Stream *ATM_UART;
+  double _lgain, _ugain;
 };
 
 #endif

platformio.ini

@@ -19,12 +19,21 @@ extra_scripts = pre:envSetup.py
 monitor_speed = 9600
 upload_port = COM9
 
+[env:prod]
+build_flags = -D PROD ${env.build_flags} -D ATM90E26_EIC
+lib_deps = 
+	SPI
+	knolleary/pubsubclient
+	bblanchon/ArduinoJson @ ^6
+	paulstoffregen/OneWire@^2.3.8
+	milesburton/DallasTemperature@^3.11.0
+build_src_filter = +<transformerMonitor.cpp> -<.git/> -<.svn/> -<tests/>
+
 [env:dev]
-build_flags = -D DEV ${env.build_flags} -D ATM90E26_EIC
+build_flags = -D dev ${env.build_flags} -D ATM90E26_EIC
 lib_deps = 
 	SPI
 	knolleary/pubsubclient
-	https://github.com/whatnick/ATM90E26_Arduino
 	bblanchon/ArduinoJson @ ^6
 	paulstoffregen/OneWire@^2.3.8
 	milesburton/DallasTemperature@^3.11.0
@@ -38,8 +47,6 @@ build_src_filter = -<*> +<store-config.cpp> -<.git/> -<.svn/> -<tests/>
 build_flags = -D DEV ${env.build_flags}
 lib_deps = 
 	knolleary/pubsubclient
-	https://github.com/CircuitSetup/ATM90E36
-	https://github.com/whatnick/ATM90E26_Arduino
 	bblanchon/ArduinoJson @ ^6.21.3
 	paulstoffregen/OneWire@^2.3.8
 	milesburton/DallasTemperature@^3.11.0

src/transformerMonitor.cpp

@@ -10,10 +10,16 @@ unsigned long lastMillis = 0;
 // const char* test_client_cert = "";  //to verify the client
 void setup()
 {
+  #if defined(DEV)
+  
   Serial.begin(9600);
+  
+  #endif // DEV
   delay(1000);
+
   setupEnergyMonitor();
-  // set LED pins
+
+  // setup LED pins
   pinMode(PIN_RED, OUTPUT);
   pinMode(PIN_GREEN, OUTPUT);
   pinMode(PIN_BLUE, OUTPUT);
@@ -23,10 +29,25 @@ void setup()
   delay(1000);
 
   // create data queue
-  eicDataQueue = xQueueCreate(60, sizeof(xformerMonitorData));
+  eicDataQueue = xQueueCreate(6000, sizeof(xformerMonitorData));
+
   if (eicDataQueue == 0)
   {
+
+  #if defined(DEV)
+
     printf("Failed to create queue= %p\n", eicDataQueue);
+  
+  #endif // DEV
+
+    eicDataQueue = xQueueCreate(600, sizeof(xformerMonitorData));
+    if (eicDataQueue == 0)
+    {
+      // halt execution
+      while (1) {}
+      
+    }
+    
   }
   // configure time
   // TODO: make dst and timezone configurable
@@ -59,22 +80,32 @@ void setup()
 }
 
 // connect connects to the WiFi and restarts it
-// TODO: set LED red when not connected, green when connected
 void connect()
 {
+  #if defined(DEV)
+  
   // connect to the WiFi network
   Serial.print("Attempting to connect to SSID: ");
   Serial.println(ssid);
+  
+  #endif // DEV
+
   WiFi.begin(ssid, wifiPassword);
 
   // attempt to connect to Wifi network:
   while (WiFi.status() != WL_CONNECTED)
   {
     setLEDColor(255, 0, 0);
+  #if defined(DEV)
+
     Serial.print(".");
+  
+  #endif // DEV
     // wait 1 second for re-trying
     delay(1000);
   }
+  #if defined(DEV)
+  
   Serial.print("Connected to ");
   Serial.println(ssid);
 
@@ -85,14 +116,21 @@ void connect()
 
   // we are using the ESP32's MAC address to provide a unique ID
   Serial.printf("The client %s connects to the public mqtt broker\n", client_id);
+  
+  #endif // DEV
   if (mqttClient.connect(client_id, mqttUser, mqttPass))
   {
     setLEDColor(0, 255, 0);
+  #if defined(DEV)
     Serial.println("\nconnected!");
+  #endif // DEV
+
   }
   else
   {
+  #if defined(DEV)
     Serial.println("\nnot connected to MQTT!");
+  #endif // DEV
     // set LED color to red
     setLEDColor(255, 0, 0);
     delay(2000);
@@ -138,7 +176,7 @@ void loop()
       strftime(timeBuffer, sizeof(timeBuffer), "%FT%TZ", mqttSensorData.timeInfo);
       delay(100);
       // if sysStatus is not reporting, or if there is no current
-      if (mqttSensorData.sysStatus == 0xFFFF || mqttSensorData.lineCurrent <= 0.05)
+      if (mqttSensorData.sysStatus == 0xFFFF || mqttSensorData.lineCurrent < 0.5 || mqttSensorData.lineVoltage <= 90)
       {
         // Sensor is not working - set LED red
         setLEDColor(255, 0, 0);
@@ -161,8 +199,11 @@ void loop()
       mqttJsonData["time"] = timeBuffer;
 
       mqttJsonData["meterStatus"] = mqttSensorData.meterStatus;
+
       mqttJsonData["sysStatus"] = mqttSensorData.sysStatus;
       
+      mqttJsonData["frequency"] = mqttSensorData.freq;
+      
       // * Voltage and current
 
       mqttJsonData["voltage"] = mqttSensorData.lineVoltage;
@@ -203,9 +244,13 @@ void loop()
 
 void setupMQTTClient()
 {
-
+  #if defined(DEV)
+  
   Serial.print("Setting MQTT server: ");
   Serial.println(mqttServer);
+  
+  #endif // DEV
+  
 
   mqttClient.setClient(wifiClient);
   mqttClient.setServer(mqttServer, mqttPort);
@@ -221,7 +266,9 @@ void setupEnergyMonitor()
   // Serial RX pin
   // Serial TX pin
   ATMSerial.begin(9600, SERIAL_8N1, PIN_SerialATM_RX, PIN_SerialATM_TX);
-  eic.InitEnergyIC();
+
+  eic.InitEnergyIC(ugain, lgain, igainl, vsag);
+  
   delay(1000);
 }
 
@@ -241,10 +288,13 @@ void readEICData(void *pvParameters)
   for (;;)
   {
     static int secondsPassed = 0;
+    
     // global time variable
     time_t now;
+    
     // Get the current time and store it in a variable
     time(&now);
+
     // set {"time":"2021-05-04T13:13:04Z"}
     sensorData.timeInfo = gmtime(&now);
     
@@ -263,27 +313,31 @@ void readEICData(void *pvParameters)
 
     
     vTaskDelay(10);
-    // in hex
-    sensorData.meterStatus = eic.GetMeterStatus();
 
+    sensorData.meterStatus = eic.GetMeterStatus();
     vTaskDelay(10);
+
     sensorData.sysStatus = eic.GetSysStatus();
-    
     vTaskDelay(10);
 
     sensorData.lineVoltage = eic.GetLineVoltage();
-
     vTaskDelay(10);
-    sensorData.lineCurrent = eic.GetLineCurrent();
 
+    sensorData.lineCurrent = eic.GetLineCurrent();
     vTaskDelay(10);
+    
     sensorData.power.factor = eic.GetPowerFactor();
     vTaskDelay(10);
+
     sensorData.power.active = eic.GetActivePower();
     vTaskDelay(10);
-
+    
+    sensorData.freq = eic.GetFrequency();
+    vTaskDelay(10);
+    
     // send data to queue
     xQueueSend(eicDataQueue, &sensorData, portMAX_DELAY);
+    
     vTaskDelay(1000);
     secondsPassed++;
   }