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Sprinkler Controller, running a cycle leads to panic and automatic reboot #5740

Open ychieux opened 3 weeks ago

ychieux commented 3 weeks ago

The problem

ESP32 crashes and reboots when running a cycle. I ran the same YAML on an ESP8266 based board and get the same crash/reboot while running an irrigation cycle.

[18:46:56]Guru Meditation Error: Core  1 panic'ed (LoadProhibited). Exception was unhandled.
[18:46:56]
[18:46:56]Core  1 register dump:
[18:46:56]PC      : 0x400e2f44  PS      : 0x00060530  A0      : 0x80205d00  A1      : 0x3ffcd9e0  
[18:46:56]A2      : 0x3ffbc8fc  A3      : 0x00000000  A4      : 0x3ffbca98  A5      : 0x000035c0  
[18:46:56]A6      : 0x3ffcd9c4  A7      : 0x00000000  A8      : 0x800e2f36  A9      : 0x3ffcd9c0  
[18:46:56]A10     : 0x3ffbca68  A11     : 0x00000000  A12     : 0x00002710  A13     : 0x00060f23  
[18:46:56]A14     : 0x00060f20  A15     : 0x00000001  SAR     : 0x0000000a  EXCCAUSE: 0x0000001c  
[18:46:56]EXCVADDR: 0x00000028  LBEG    : 0x40084605  LEND    : 0x4008460d  LCOUNT  : 0x00000027  
[18:46:56]
[18:46:56]
[18:46:56]Backtrace:0x400e2f41:0x3ffcd9e00x40205cfd:0x3ffcda00 0x40205d61:0x3ffcda20 0x400ea350:0x3ffcda40 0x400ec942:0x3ffcda70 0x400f9115:0x3ffcda90 
[18:46:56]
[18:46:56]
[18:46:56]
[18:46:56]
[18:46:56]ELF file SHA256: 0000000000000000
[18:46:56]
[18:46:56]Rebooting...
[18:46:56]ets Jun  8 2016 00:22:57
[18:46:56]
[18:46:56]rst:0xc (SW_CPU_RESET),boot:0x12 (SPI_FAST_FLASH_BOOT)
[18:46:56]configsip: 0, SPIWP:0xee
[18:46:56]clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
[18:46:56]mode:DIO, clock div:2
[18:46:56]load:0x3fff0030,len:1184
[18:46:56]load:0x40078000,len:13132
[18:46:56]load:0x40080400,len:3036
[18:46:56]entry 0x400805e4

Which version of ESPHome has the issue?

2024.4.1

What type of installation are you using?

Home Assistant Add-on

Which version of Home Assistant has the issue?

2024.4.4

What platform are you using?

ESP32

Board

LILYGO T-Relay ESP32 (4ch with ESP32-WROOM-B)

Component causing the issue

Sprinkler Controller

Example YAML snippet

sprinkler:
  - id: lawn_sprinkler_ctrlr
    main_switch: "Start Irrigation Cycle"
    auto_advance_switch: "Irrigation Auto Advance"
    reverse_switch: "Irrigation Reverse"
    multiplier_number: "Irrigation Multiplier"
    repeat_number: "Irrigation Repeat"
    valve_overlap: 5s
    valves:
      - valve_switch: "Flowers Front"
        enable_switch:
          id: enable_switch_valve2
          name: "Enable irrigation for Flowers Front"
          restore_mode: RESTORE_DEFAULT_ON
        run_duration: 10s
        valve_switch_id: irrigation_valve_sw2

      - valve_switch: "Trees"
        enable_switch:
          id: enable_switch_valve3
          name: "Enable irrigation for Trees"
          restore_mode: RESTORE_DEFAULT_ON
        run_duration: 10s
        valve_switch_id: irrigation_valve_sw3

      - valve_switch: "Flowers Back"
        enable_switch:
          id: enable_switch_valve4
          name: "Enable irrigation for Flowers Back"
          restore_mode: RESTORE_DEFAULT_ON
        run_duration: 10s
        valve_switch_id: irrigation_valve_sw4

      # Relay/Valve #1 for Lawn
      - valve_switch: "Lawn"
        enable_switch:
          id: enable_switch_valve1
          name: "Enable irrigation for Lawn"
          restore_mode: RESTORE_DEFAULT_OFF
        run_duration: 10s
        valve_switch_id: irrigation_valve_sw1

button:
  - platform: restart
    id: irrigation_controller_restart_button
    name: "Irrigation Controller Restart Button"

switch:
  - platform: gpio
    pin: 21
    # Garden Irrigation - Valve 1
    id: irrigation_valve_sw1

  - platform: gpio
    pin: 19
    #Garden Irrigation - Valve 2
    id: irrigation_valve_sw2

  - platform: gpio
    pin: 18
    #Garden Irrigation - Valve 3
    id: irrigation_valve_sw3

  - platform: gpio
    pin: 5
    #Garden Irrigation - Valve 4
    id: irrigation_valve_sw4

Anything in the logs that might be useful for us?

[18:46:41][D][switch:012]: 'Start Irrigation Cycle' Turning ON.
[18:46:41][VV][sprinkler:1488]: fsm_transition_ called; state is IDLE
[18:46:41][VV][scheduler:032]: set_timeout(name='Start Irrigation Cyclesm', timeout=5000)
[18:46:41][VV][sprinkler:1651]: Timer 0 started for 5 sec
[18:46:41][D][sprinkler:1427]: CYCLE is starting valve 0 for 10 seconds, cycle 1 of 1
[18:46:41][D][switch:012]: 'irrigation_valve_sw2' Turning ON.
[18:46:41][D][switch:055]: 'irrigation_valve_sw2': Sending state ON
[18:46:41][VV][sprinkler:1531]: fsm_transition_ complete; new state is ACTIVE
[18:46:41][D][switch:055]: 'Start Irrigation Cycle': Sending state ON
[18:46:41][V][json:038]: Attempting to allocate 512 bytes for JSON serialization
[18:46:41][V][json:058]: Size after shrink 80 bytes
[18:46:41][VV][api.service:156]: send_switch_state_response: SwitchStateResponse {
  key: 2268764749
  state: YES
}
[18:46:41][W][component:237]: Component web_server took a long time for an operation (80 ms).
[18:46:41][W][component:238]: Components should block for at most 30 ms.
[18:46:41][D][switch:055]: 'Flowers Front': Sending state ON
[18:46:41][V][json:038]: Attempting to allocate 512 bytes for JSON serialization
[18:46:41][V][json:058]: Size after shrink 72 bytes
[18:46:41][VV][api.service:156]: send_switch_state_response: SwitchStateResponse {
  key: 3963119055
  state: YES
}
[18:46:42][VV][scheduler:226]: Running interval '' with interval=10000 last_execution=16357 (now=26358)
[18:46:46][VV][scheduler:226]: Running timeout 'Start Irrigation Cyclesm' with interval=5000 last_execution=25734 (now=30740)
[18:46:46][VV][sprinkler:1682]: State machine timer expired
[18:46:46][VV][sprinkler:1488]: fsm_transition_ called; state is ACTIVE
[18:46:46][D][sprinkler:1296]: Marking valve 0 complete
[18:46:46][VV][scheduler:032]: set_timeout(name='Start Irrigation Cyclesm', timeout=5000)
[18:46:46][VV][sprinkler:1651]: Timer 0 started for 5 sec
[18:46:46][D][sprinkler:1427]: CYCLE is starting valve 1 for 10 seconds, cycle 1 of 1
[18:46:46][D][switch:012]: 'irrigation_valve_sw3' Turning ON.
[18:46:46][D][switch:055]: 'irrigation_valve_sw3': Sending state ON
[18:46:46][VV][sprinkler:1531]: fsm_transition_ complete; new state is ACTIVE
[18:46:46][W][component:237]: Component sprinkler took a long time for an operation (63 ms).
[18:46:46][W][component:238]: Components should block for at most 30 ms.
[18:46:46][D][switch:055]: 'Trees': Sending state ON
[18:46:46][V][json:038]: Attempting to allocate 512 bytes for JSON serialization
[18:46:46][E][json:043]: Could not allocate memory for JSON document! Requested 512 bytes, largest free heap block: 1396 bytes
[18:46:46][VV][api.service:156]: send_switch_state_response: SwitchStateResponse {
  key: 3882419280
  state: YES
}
[18:46:48][VV][scheduler:226]: Running interval '' with interval=60000 last_execution=4294939677 (now=32382)
[18:46:51][VV][scheduler:226]: Running timeout 'Start Irrigation Cyclesm' with interval=5000 last_execution=30763 (now=35765)
[18:46:51][VV][sprinkler:1682]: State machine timer expired
[18:46:51][VV][sprinkler:1488]: fsm_transition_ called; state is ACTIVE
[18:46:51][D][sprinkler:1296]: Marking valve 1 complete
[18:46:51][VV][scheduler:032]: set_timeout(name='Start Irrigation Cyclesm', timeout=5000)
[18:46:51][VV][sprinkler:1651]: Timer 0 started for 5 sec
[18:46:51][VV][sprinkler:1531]: fsm_transition_ complete; new state is ACTIVE
[18:46:51][D][switch:016]: 'irrigation_valve_sw2' Turning OFF.
[18:46:51][D][switch:055]: 'irrigation_valve_sw2': Sending state OFF
[18:46:51][D][switch:055]: 'Flowers Front': Sending state OFF
[18:46:51][V][json:038]: Attempting to allocate 512 bytes for JSON serialization
[18:46:51][V][json:058]: Size after shrink 72 bytes
[18:46:51][VV][api.service:156]: send_switch_state_response: SwitchStateResponse {
  key: 3963119055
  state: NO
}
[18:46:52][VV][scheduler:226]: Running interval '' with interval=10000 last_execution=26357 (now=36358)
[18:46:56][VV][scheduler:226]: Running timeout 'Start Irrigation Cyclesm' with interval=5000 last_execution=35784 (now=40784)
[18:46:56][VV][sprinkler:1682]: State machine timer expired
[18:46:56][VV][sprinkler:1488]: fsm_transition_ called; state is ACTIVE
[18:46:56][D][sprinkler:1296]: Marking valve 2 complete
[18:46:56][VV][scheduler:032]: set_timeout(name='Start Irrigation Cyclesm', timeout=5000)
[18:46:56][VV][sprinkler:1651]: Timer 0 started for 5 sec
[18:46:56][D][sprinkler:1427]: CYCLE is starting valve 3 for 10 seconds, cycle 1 of 1
[18:46:56][D][switch:012]: 'irrigation_valve_sw1' Turning ON.
[18:46:56][D][switch:055]: 'irrigation_valve_sw1': Sending state ON
[18:46:56][VV][sprinkler:1531]: fsm_transition_ complete; new state is ACTIVE
[18:46:56][W][component:237]: Component sprinkler took a long time for an operation (62 ms).
[18:46:56][W][component:238]: Components should block for at most 30 ms.
[18:46:56][D][switch:055]: 'Lawn': Sending state ON
[18:46:56][V][json:038]: Attempting to allocate 512 bytes for JSON serialization
[18:46:56][V][json:058]: Size after shrink 60 bytes
[18:46:56][VV][api.service:156]: send_switch_state_response: SwitchStateResponse {
  key: 557079219
  state: YES
}
[18:46:56][D][switch:016]: 'irrigation_valve_sw3' Turning OFF.
[18:46:56][D][switch:055]: 'irrigation_valve_sw3': Sending state OFF
[18:46:56]Guru Meditation Error: Core  1 panic'ed (LoadProhibited). Exception was unhandled.
[18:46:56]
[18:46:56]Core  1 register dump:
[18:46:56]PC      : 0x400e2f44  PS      : 0x00060530  A0      : 0x80205d00  A1      : 0x3ffcd9e0  
[18:46:56]A2      : 0x3ffbc8fc  A3      : 0x00000000  A4      : 0x3ffbca98  A5      : 0x000035c0  
[18:46:56]A6      : 0x3ffcd9c4  A7      : 0x00000000  A8      : 0x800e2f36  A9      : 0x3ffcd9c0  
[18:46:56]A10     : 0x3ffbca68  A11     : 0x00000000  A12     : 0x00002710  A13     : 0x00060f23  
[18:46:56]A14     : 0x00060f20  A15     : 0x00000001  SAR     : 0x0000000a  EXCCAUSE: 0x0000001c  
[18:46:56]EXCVADDR: 0x00000028  LBEG    : 0x40084605  LEND    : 0x4008460d  LCOUNT  : 0x00000027  
[18:46:56]
[18:46:56]
[18:46:56]Backtrace:0x400e2f41:0x3ffcd9e00x40205cfd:0x3ffcda00 0x40205d61:0x3ffcda20 0x400ea350:0x3ffcda40 0x400ec942:0x3ffcda70 0x400f9115:0x3ffcda90 
[18:46:56]
[18:46:56]
[18:46:56]
[18:46:56]
[18:46:56]ELF file SHA256: 0000000000000000
[18:46:56]
[18:46:56]Rebooting...
[18:46:56]ets Jun  8 2016 00:22:57
[18:46:56]
[18:46:56]rst:0xc (SW_CPU_RESET),boot:0x12 (SPI_FAST_FLASH_BOOT)
[18:46:56]configsip: 0, SPIWP:0xee
[18:46:56]clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
[18:46:56]mode:DIO, clock div:2
[18:46:56]load:0x3fff0030,len:1184
[18:46:56]load:0x40078000,len:13132
[18:46:56]load:0x40080400,len:3036
[18:46:56]entry 0x400805e4

Additional information

No response

ychieux commented 3 weeks ago

I believe, I found the root cause... the valves' run duration was set to 10sec for testing purposes while the overlap was set to 5s i.e. exactly half the valve run duration. This led to a situation where timers failed when transitioning from valve no 2 to 3.