OmronE5 - Temperature Controller Component

OmronE5

Path: ./src/components/OmronE5.cpp

Revision History: Initial documentation

The OmronE5 component provides an interface to Omron E5 series temperature controllers via Modbus-RTU over RS485. It enables temperature monitoring, setpoint control, and advanced heat rate analytics for industrial control applications.

REQUIREMENTS

• Hardware:
  • RS485 transceiver module connected to ESP32
  • Properly configured Omron E5 controller with Modbus RTU capabilities
• Software:
  • ENABLE_RS485 must be defined in the configuration
  • Optional ENABLE_TRUTH_COLLECTOR for advanced statistical analysis
  • Optional ENABLE_COOLING for cooling mode support

FEATURES

• Read Process Value (PV) and Setpoint (SP) from the controller
• Control the temperature setpoint
• Monitor controller running/heating/cooling status
• Start and stop the temperature controller
• Advanced statistics (with TRUTH_COLLECTOR enabled):
  • Track mean error between PV and SP
  • Calculate heat rate (oscillations per minute)
  • Monitor power consumption (Wh)
  • Calculate PV/SP response lag
  • Track longest heating duration in time windows
  • Estimate energy costs

DEPENDENCIES

• ArduinoLog - Logging functionality
• Component - Base component system
• ModbusRTU - Modbus RTU communication
• ModbusTypes - Modbus data types
• OmronE5Types - Omron E5 specific constants
• xstatistics - Statistical calculations (when TRUTH_COLLECTOR enabled)
• ValueWrapper - Value change tracking

BEHAVIOUR

The component operates through read/write operations to specific Modbus registers on the Omron controller, with additional statistical analysis when enabled.

TODOS

PERFORMANCE

• Consider optimizing the read interval based on controller activity
• Reduce read frequency during stable operations to minimize bus traffic
• Group register reads where possible to minimize transaction overhead

SECURITY

• Add range validation for all incoming Modbus values
• Implement authentication for control operations if needed in sensitive installations
• Consider adding checksums for critical value modifications

COMPLIANCE

• Ensure component behavior complies with relevant industrial control standards
• Verify compatibility with different firmware versions of Omron E5 controllers
• Document any deviations from standard Modbus implementations

RECOMMENDATIONS

• Configure the Omron E5 controller with compatible Modbus RTU settings (baud rate, parity)
• Set appropriate register access permissions on the controller
• Use the TRUTH_COLLECTOR feature for diagnostics and optimization
• When using cooling functionality, ensure the controller is properly configured for heat/cool control

EXAMPLE

The following example demonstrates how to initialize an OmronE5 component within a parent component:

#ifdef ENABLE_RS485
  // Create Omron E5 device with slave ID 1
  OmronE5* temperatureController = new OmronE5(
      this,             // owner component
      1,                // Modbus slave ID
      300               // read interval in ms
  );

  if (temperatureController)
  {
    components.push_back(temperatureController);
    Log.infoln(F("OmronE5 temperature controller initialized. SlaveID:%d, ReadInterval:%d"),
               1, 300);
  }
  else
  {
    Log.errorln(F("OmronE5 temperature controller initialization failed."));
  }
#endif

References