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๐Ÿญ Phase 2 Room Controller

Phase 2 Compost
Tunnel Controller

A complete 7-stage automated controller for mushroom compost Phase 2 pasteurisation and conditioning tunnels. Precision temperature, ventilation and fresh-air control with ammonia gas monitoring, intelligent sensor fallback, and full remote management โ€” built specifically for the demands of compost conditioning, not adapted from a grow-room controller.

๐ŸŒก๏ธ 5 PT100 Sensors
๐Ÿงช Ammonia (NHโ‚ƒ) Sensor
๐ŸŒ€ Auto Fresh-Air Damper
โš™๏ธ Ventilation (VFD) Control
๐Ÿ“‹ 7-Stage Automation
โ˜๏ธ Remote Monitoring
Process Automation

7 Stages, Fully Automated

From leveling through pasteurisation, conditioning and cooldown โ€” every stage runs on its own independently configurable setpoints, with automatic advance to the next stage as soon as conditions are met.

โš™๏ธ
Idle
Standby
All outputs off
๐Ÿ“
Leveling
Air differential settling
Auto-advance on stable reading
๐Ÿ”ฅ
Heat-Up
Controlled ramp to target
Auto ventilation correction
โ™จ๏ธ
Pasteurise
Hold at target temperature
Power-loss-safe hold timer
๐ŸŒก๏ธ
Condition
Two-phase: ramp-down then hold
Hot/cold alarm protection
โ„๏ธ
Cooldown
Damper opens to ambient
Signed ramp-rate tracking
๐Ÿ†
Done
Cycle complete
Ready for next batch

Every stage has its own fresh-air %, ventilation speed, target temperature, duration, ramp rate, and auto-advance setting โ€” fully configurable, not fixed defaults. All setpoints persist through power cycles.

Environmental Sensing

5 Temperature Probes + Ammonia Monitoring

Compost pasteurisation and conditioning need more than a single thermometer โ€” multiple sensing points, cross-checked against each other, plus gas monitoring that grow-room controllers don't typically include.

T1
Compost Probe (Primary)
// FIELD-CALIBRATABLE PT100
Primary compost mass temperature probe, individually calibratable in the field.
T2
Compost Probe (Secondary)
// CROSS-CHECK SENSOR
A second compost probe used for cross-checking against the primary โ€” the controller compares both and flags a fault if they disagree beyond a configurable spread.
T3/T4
Air & Reference Probes
// FALLBACK CHAIN
Additional air-temperature reference probes that automatically take over control (with a correction offset) if the primary compost probes fail.
T5
Ambient Reference
// COOLDOWN TARGETING
Dedicated ambient-air reference probe, used to set a dynamic cooldown target relative to outside conditions rather than a fixed number.
NHโ‚ƒ
Ammonia Gas Sensor
// 0-300 PPM RANGE
Continuous ammonia concentration monitoring โ€” a compost-specific parameter most grow-room controllers don't measure at all, logged alongside every other reading.
Reliability

Intelligent Sensor Fallback Chain

If a sensor fails mid-cycle, a basic controller either keeps trusting bad data or shuts down. This system automatically falls back through a prioritised chain of backup sensors โ€” applying a correction offset where needed โ€” and only flags "all sensors failed" if every option is genuinely exhausted.

Automatic ModeAverages both primary compost probes when both are healthy โ€” the most accurate reading available
Single-Sensor FallbackIf one primary probe fails, automatically switches to the surviving one without operator intervention
Offset-Corrected Backup SensorsIf both primary probes fail, falls back to reference probes with a configurable correction offset to maintain control accuracy
Total Failure DetectionOnly raises a full sensor-failure alarm when every fallback option has been exhausted โ€” not on the first sensor hiccup
Sensor Disagreement DetectionFlags a fault automatically if the two primary compost probes disagree by more than a configurable spread
Manual Sensor SelectionOperators can also manually pin control to a specific sensor if needed, overriding the automatic chain
Automated Control

Fresh-Air Damper & Ventilation Drive

FRESH-AIR DAMPER
๐ŸŒ€

Anti-Drift Positioning

The damper always re-homes to fully closed before moving to a new target โ€” eliminating the position drift that can otherwise leave a damper physically open while the system believes it's closed.
Configurable deadband prevents constant micro-adjustments.
VENTILATION DRIVE
โš™๏ธ

Automatic Rate Correction

During Heat-Up, ventilation speed is automatically corrected based on the actual measured heating rate โ€” slowing or speeding airflow to keep the ramp on target instead of running a fixed speed regardless of result.
Manual override available at any time; auto control resumes when override is cleared.
VENTILATION HEALTH
๐Ÿ“ก

Continuous Fault Monitoring

Output current, fault status and communication health are continuously monitored, with configurable over-current and under-current alarm thresholds.
Communication-loss detection prevents acting on stale data.
COOLDOWN STAGE
โ„๏ธ

Ambient-Relative Targeting

Cooldown targets a dynamic setpoint relative to actual outside ambient temperature, rather than a fixed number โ€” adapting automatically to seasonal conditions.
Falls back to a fixed target if the ambient probe is unavailable.
Process Integrity

Power-Loss-Safe Hold Timers

A pasteurisation hold that silently restarts after a brief power blip can ruin a batch without anyone knowing until it's too late. This controller's hold timers are timestamp-based, so a configured clock means the pasteurise and condition hold timers survive power loss and resume exactly where they left off โ€” not from zero.

Pasteurise Hold TimerTimestamp-based โ€” survives power interruptions when the controller clock is configured
Two-Phase Condition StageRamp-down phase followed by a separately timed hold phase, each tracked independently
Condition Hold Temperature GuardDedicated high-temperature and low-temperature alarms during the condition hold, protecting the biological process from drifting outside its safe range
Pasteurise Disagreement AlarmFlags a warning if the two primary compost probes disagree about whether the pasteurisation target has actually been reached
Safety

Comprehensive Alarm System

Eight distinct alarm conditions, each independently configurable, with a dedicated alarm output relay and full alarm history logging.

Over TemperatureConfigurable upper threshold breached
Under TemperaturePasteurise-stage specific lower threshold
Sensor SpreadPrimary compost probes disagree beyond threshold
Slow Heating RateHeat-Up ramp falling behind configured rate
Total Sensor FailureEvery fallback sensor option exhausted
Pasteurise ColdSensors disagree on reaching pasteurise target
Condition HotCondition hold temperature too high
Condition ColdCondition hold temperature too low
Remote Monitoring & Control

Manage Every Batch From Anywhere

Network connectivity, a built-in web dashboard, and cloud telemetry give you visibility and control without needing to be on-site.

Built-In Web DashboardFull status and control accessible from any browser on the local network, no internet required
Cloud TelemetryContinuous data push to a cloud monitoring platform for historical trend analysis and remote visibility
Remote Stage ControlAdvance or set the active stage remotely, toggle auto-advance, or place the system on manual hold
Remote Output OverrideOverride ventilation speed or damper position remotely, with automatic control resuming when override is cleared
Alarm History LogEvery alarm trigger and clear event is timestamped and retained for review
Persistent ConfigurationAll setpoints, calibration data, and stage progress survive power cycles โ€” nothing resets unexpectedly

Ready to Automate Your Phase 2 Tunnel?

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