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Nico teWinkel's Blog Smart Wi-Fi IR Remote for my Heat Pump
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  • Author Author: ntewinkel
  • Date Created: 19 Mar 2022 7:19 PM Date Created
  • Views 5012 views
  • Likes 9 likes
  • Comments 6 comments
  • wemos d1 mini
  • ir
  • Wi-Fi Remote
  • arduino
  • smart home
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Smart Wi-Fi IR Remote for my Heat Pump

ntewinkel
ntewinkel
19 Mar 2022

My house has a lot of automations - I've automated pretty much all of my main lights to go on and off on schedules, using smart switches and plugs. I can ask Alexa to turn things on or off just by blurting things out. I can even control some lights at the house we are renovating. Pretty cool stuff, but also super handy. It saves me the walk-around to turn things on and off, it saves me re-programming timers as the seasons change, but mostly I guess it saves me from forgetting things 

It kind of started before smart switches were a thing - I had a timer switch for my outside garage lights for quite some time, to provide a bit of security lighting. I had timers for the deck lights too. Very limited, but saved me dealing with them on a daily basis.

But then BC Hydro, our electricity supplier, invited us to join in a home automation trial to gather data on how it might save energy, as well as how it might help them offset peak demand loads (very interesting trials for that actually). They installed several light switches around the house, gave us some smart plugs, and installed smart thermostats for our baseboard heaters.

We really enjoyed the automations that came with that initial installation, so we've expanded on it since then.

My wife was very hesitant about it when I first brought it up, but it didn't take long for her to notice the benefits too - she was the first to point out when a switch later failed!

So over the last several years pretty much everything is automated now.

But then we decided to install a heat pump.
For our area on the West Coast, heat pumps can be very energy efficient, especially compared to baseboard heaters, and as a bonus they give the option of air conditioning in the summer.

To my surprise, the Daikin heat pump we had installed did not include any proper thermostat or proper automation ability!
It has a very complicated way of programming different temperatures for different times of day, but it doesn't allow programming of fan speeds, and that's a huge one for us - the Daikin fan is very noisy, especially compared to our silent baseboard heaters, for our quiet corner of town. They have a "night mode" which is much quieter, but you have to manually use the remote control to change to that fan speed. There isn't a way to easily switch between night mode and automatic - it takes repeated presses through all 5 or 6 fan speeds.

Over the last few years I've tried automating it using some off-the-shelf smart Wi-Fi IR remotes, but none of the 3 that I tried include support for night mode fan speed, and they didn't include support for the swing feature, which directs air to the different corners of the space better. For a while I used one just to turn on the heat before waking up, but we would always forget to turn it down at night. And being the spoiled automated-house nerds we are, that was just not acceptable Laughing

And thus, this project!

I found some Arduino IR libraries online that fully support my Daikin heat pump, and I have a few spare Wemos D1 Mini boards that support WiFi, and are small enough to tuck away in a corner somewhere.

It didn't take long to get a prototype up and running actually - my main issue was that the IR LED didn't seem to give enough power to reach the heat pump.

After some researching and asking here on element14, I learned why: I wasn't getting enough power to the LED because I was using resistor values from the average "blink a red LED" tutorials which don't allow enough current to really get a good IR signal. Some people also suggested using multiple LEDs to get more light out.

The circuit I ended up using is derived from this Adafruit example, except that I only want the transmit part of it: https://learn.adafruit.com/building-an-infrared-transmitter-and-receiver-board 
More details in this discussion: /technologies/internet-of-things/f/forum/50669/resistor-rating-for-ir-led-for-wifi-iot-remote

Here is my simplified version of that circuitry. I'm using 2 same LEDs because that's what I have, but the Adafruit example recommends using one narrow-beam and one wide-beam IR LED for better coverage.
The added notes for the transistors were for my benefit of remembering their pinouts and current ratings while soldering up the pieces later, but it might be helpful for others as well so I left it in Slight smile

IR LED Transmitter circuit

The schematic shows 33 ohm resistors, but I used 22 ohms to get a little more power. Adafruit says you can leave them out altogether, but I worried that might burn out the IR LEDs or overheat the transistors if something went wrong - it should be ok as long as it doesn't run too often, which remote controls generally don't do. Smaller value resistors will allow more current for brighter IR signals but that might overheat the resistors if something goes wrong. My worry was that a software glitch might cause continues sending, so I went with the safer route. According to my math this can send continuously without it overheating, but do your own math and testing and all that to ensure your own safety of course.

This is what it looks like on a breadboard:

IR transmitter on breadboard

That worked well, so I went ahead and 3D-printed a little enclosure for it. The next trick being how to fit the parts inside that little box!

I also wanted a bit more control, and to see what was going on - partly for debugging, but also when using it, so I needed a few extra bits to make that happen.
To keep it simple I added only one button to manually switch between day mode and night mode, which is also good for testing that the heat pump was receiving the signal from where I placed this project on the shelf.
I added 2 LEDs to indicate when it was sending day mode (orange) and night mode (blue), as my heat pump itself doesn't display anything. For these LEDs, I drilled little indentations from the inside of the lid, but not all the way through - so from the outside you can't see them except when they light up.

I hard-coded the automations (for now) - at 8am it turns on the heat, and at 11pm it turns down the heat. The Arduino sketch includes some magic for the Wemos to connect to a time server, which also means it has to connect to the Internet.
This can take a bit of time, so I have it flash both indicator LEDs while connecting and setting up, and then alternately flashing them for a few seconds when setup has completed successfully.

Here is my workbench with the tiny things coming together:

workbench IR remote bits

I tried using SMD components on a small bit of perf-board, but that went terribly wrong. I think it was partly because my SMD transistors were too different - they were mosfets instead of the basic BJTs, and I think that probably required circuit modifications... or else I just screwed it up some other way, which is entirely possible!

Thankfully, the through-hole parts were still small enough and easy enough to solder together without supports, and I was able to tuck them into the case.
I used cheap dollar-store nail polish to coat the wires to avoid shorts. Helpful hint - do that AFTER testing... so I've heard from a friend Stuck out tongue winking eye

IR Remote parts tucked into case

The result looks pretty cool. Here I have both lights on for testing. The IR LEDs are sticking out the top - I used some other cheap LEDs to melt holes through the lid by heating up the legs and pushing through. This allows the IR LEDs to be bent around a bit to point towards the target.

IR Remote in case

I've been using it like that for about a little while now, and it has been nicely reliable Slight smile

The only trouble I ran into was that I started this project when it was much colder outside, so as spring weather arrived the hard-coded values made it a little too warm in the house!
And then Daylight savings time meant my timezone offset needed adjusting - the heat turned on and off an hour too late.

But it was easy enough to bring the little box back to my desk and reprogram it with the new values. At the same time I also added a pre-warm step an hour before the wake-up step.

That was yesterday morning, and I thought it was about time I let you know what I've been up to, thus this post Slight smile

Next steps:
* Today I hope to add a web-based UI to allow me to update at least the temperatures, and hopefully also the times, and a web-based control button or two.
-> I'm not sure yet if I'll implement this directly on the Wemos (I'm pretty sure it can handle that easily enough), or if I want to use MQTT for that, maybe via NodeRed on Raspberry Pi that I'm currently already using to monitor my outdoor sensors.

* Next I also hope to add Alexa control
-> I've seen some examples of how this can be done for switches on Arduino/Wemos, so that can be a basic start. Ultimately it would be great to also set the temperature for it that way.

-Nico

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Top Comments

  • beacon_dave
    beacon_dave over 3 years ago +1
    It appears to be the time of year for driving LED projects /challenges-projects/element14-presents/dc-to-daylight/w/documents/27486/dc-to-daylight-07-how-to-drive-leds /challenges-projects/element14…
  • beacon_dave
    beacon_dave over 3 years ago in reply to ntewinkel +1
    Thanks for this. Yes, the air-to-air heat pumps do look a bit questionable when it comes to the return of investment. However if you benefit from the A/C aspect then there is perhaps a better case for…
  • DAB
    DAB over 3 years ago +1
    Good job Nico. My frugalness was confirmed when my local power company began including comparisons of our energy use to other customers. We came in well below the considered good home for power efficiency…
  • DAB
    DAB over 3 years ago

    Good job Nico.

    My frugalness was confirmed when my local power company began including comparisons of our energy use to other customers.

    We came in well below the considered good home for power efficiency.

    Now if I could just train my wife to turn off lights after she leaves a room. After thirty-five years, I have not been successful.

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  • beacon_dave
    beacon_dave over 3 years ago in reply to ntewinkel

    Thanks for this. Yes, the air-to-air heat pumps do look a bit questionable when it comes to the return of investment.

    However if you benefit from the A/C aspect then there is perhaps a better case for them. 

    I was thinking more of the ground (vertical) to water heat pumps which should help overcome the 'below 5 degrees issues' that a lot of people mention with the air-to-air systems, but you lose out on the A/C that way and you have the added cost of a 100m (300ft) bore hole in the back garden to consider, along with the cost of maintaining the 200m of plumbing that goes into it when it decides to spring a leak. May be able to share some of the cost of a bore hole with a neighbour though.

    For such a simple concept, the designs don't look as if they were built for low cost maintenance, or to use standardised parts, so when things do go wrong then I suspect it will be the usual replace the lot rather than repair.

    Compare that to the likes of solar water pre-heating which is really easy - some panels on the roof, a bit of simple  plumbing, a standard central heating circulation pump and a couple of temperature sensors connected to a differential temperature pump control switch. And also really effective all year round. Although the panels may have to compete with roof space against photovoltaic panels for electric.

    The grants here basically appear to buy back you current working gas boiler, and from there you have to purchase a more expensive heat pump system, pay to get it installed, pay increased ongoing maintenance, pay additional costs in electricity to run it, lose space indoors and out and ultimately get a lower performing system, only to be told to reinsulate your house and get a boiler and electric heaters to supplement its output over the winter months.

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  • ntewinkel
    ntewinkel over 3 years ago in reply to beacon_dave

    beacon_dave, I did a little more math and research, in case you were thinking about getting one of these units...

    I went through my electricity bills, and it looks like the payback period is about 6 years - ASSUMING nothing goes wrong in the meantime because the labour warranty was only for 1 year. The Daikin is warranteed for 12 years, so I hope that means it will really keep going that long. Our unit cost $4,000 after rebates and we're saving maybe $700 per year. It seems most new installs are much higher than that now too.

    Given that these units are generally expected to live from 7 to 10 years (edit: that's according to a few websites I looked at), that means we might ultimately not be saving anything, especially if it needs any work in the meantime, which would suck up a full year of savings easily. It's kind of a gamble - you win if the thing lasts past the pay-back period, but it could be very costly if it has issues.

    Given that, and the extra fan noise, it's hard to recommend them.

    On the plus side, it does give us very effective A/C which was a life saver this past summer! And in that respect it saved us not having to buy an A/C unit for the bedrooms.

    I also think the house is more evenly warm over-all. For the art studio, it does also heat up the space much quicker than baseboards.

    So, I suppose it's a luxury item that (hopefully) pays for itself over time.

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  • ntewinkel
    ntewinkel over 3 years ago in reply to beacon_dave

    Oh, I did see an inexpensive (relative term there) mini-split heat pump (Perfect Aire, I think?) at Home Depot (I'm in Canada, so the .ca website) that's a full DIY model and comes with a full 1 year exchange warranty. It's about $1600 CAD but doesn't require any special tools - the line set is made with special connectors so it doesn't need to be vacuumed, and it's guaranteed to not leak. So as long as you also keep your existing heat source this might be an option to start with - depending on your climate it could be great for the shoulder seasons at least, and gives cooling for summer.

    The two little Senville units I have are not really DIY even though they sell them on Amazon. They are a bit cheaper at about $1100 CAD, but if you DIY them there is zero warranty. If you pay a pro, it'll cost far more than the unit itself to install it, AND warranty still doesn't cover labour. So that Home Depot unit seems like a good way to go unless you have a friend in the HVAC business.

    On the bright side, I bought that first Senville unit for the art studio 2 years ago and it has been working perfectly ever since. It was only $800 on sale (included shipping and taxes even!), and I installed it myself due to the lock-down, so it has definitely been worth it there Slight smile

    edit: I kinda forgot a main feature and related to my first post - that Perfect Aire unit comes with built-in WiFi smart control!

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  • ntewinkel
    ntewinkel over 3 years ago in reply to beacon_dave

    Thanks for the videos! I’ve added them to my watch list so I can watch them on the bigger screen at breakfast Grinning  I can definitely use more ideas on how to properly light up LEDs.

    I have a love-hate relationship with heat pumps. I was much more in favour of them before this winter, but now I’m not so sure.

    They work really well when the outside temps are above about 5 degrees Celsius, but below that they struggle - the heat pump gives less output the colder it gets, when the house needs more heating the most. When we had our extended freezing weeks, down to -12 C, the smaller units could not keep up at all. My main house Daikin did ok, but we supplemented with both gas fireplaces on the whole day.

    They also seem to be much less reliable, and expensive to fix. Snow came off the roof at the renovation house , which caused a line to shift just enough to leak, which then killed the compressor when the refrigerant ran out. Cost me more to fix and recharge it than the unit cost to begin with, only to find out after that the compressor was toast. New outdoor unit is on the way.

    This made me much more aware of the repair costs. Baseboard heaters cost more to run, but never need expensive maintenance!

    Given that the life expectancy of a refrigerator is only about 7 to 9 years now, I wonder if heat pumps are similar, given the tech is similar, and maybe even more complicated.

    To replace gas and oil heat, also consider that the air coming from the heat pump tends to be much cooler. That’s more efficient, but sucks if you have radiant floor heat, for example - it’ll feel cold on your feet.

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