From f66b8316669f52e22ec3f5f98c333cac7d53a02e2fed9e4f263f8442466e13e4 Mon Sep 17 00:00:00 2001
From: localhorst <localhorst@mosad.xyz>
Date: Sat, 19 Apr 2025 08:36:19 +0200
Subject: [PATCH 1/2] rework burner fault detection

---
 main/control.c | 40 +++++++++++++++++++++++++++-------------
 1 file changed, 27 insertions(+), 13 deletions(-)

diff --git a/main/control.c b/main/control.c
index 938a1a3..f8c9eb0 100644
--- a/main/control.c
+++ b/main/control.c
@@ -13,9 +13,9 @@
 // Temperature thresholds
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f
-#define CHAMBER_TEMPERATURE_TARGET 80.0f            // Max cutoff temperature
-#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f         // Min threshold for burner enable
-#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f         // Min threshold for burner enable
+#define CHAMBER_TEMPERATURE_TARGET 80.0f             // Max cutoff temperature
+#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f          // Min threshold for burner enable
+#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f          // Min threshold for burner enable
 #define BURNER_FAULT_DETECTION_THRESHOLD (60U * 15U) // Burner fault detection after 15 minutes
 
 static const char *TAG = "smart-oil-heater-control-system-control";
@@ -58,10 +58,17 @@ void initControl(void)
     }
 }
 
+typedef enum _BurnerState
+{
+    BURNER_UNKNOWN,
+    BURNER_FIRED,
+    BURNER_FAULT
+} eBurnerState;
+
 void taskControl(void *pvParameters)
 {
     bool bHeatingInAction = false;
-    bool bBurnerFaultDetected = false;
+    eBurnerState eBurnerState = BURNER_UNKNOWN;
     int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
 
     while (1)
@@ -116,20 +123,27 @@ void taskControl(void *pvParameters)
             }
             else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
             {
-                if (getBurnerError() == FAULT)
+                if (eBurnerState == BURNER_UNKNOWN)
                 {
-                    ESP_LOGW(TAG, "Burner fault detected after timeout!");
-                    bHeatingInAction = false;
-                    bBurnerFaultDetected = true;
-                    sControlState = CONTROL_FAULT_BURNER;
-                    setCirculationPumpState(ENABLED);
-                    setBurnerState(DISABLED);
-                    setSafetyControlState(ENABLED);
+                    if (getBurnerError() == FAULT)
+                    {
+                        ESP_LOGW(TAG, "Burner fault detected after timeout!");
+                        bHeatingInAction = false;
+                        eBurnerState = BURNER_FAULT;
+                        sControlState = CONTROL_FAULT_BURNER;
+                        setCirculationPumpState(ENABLED);
+                        setBurnerState(DISABLED);
+                        setSafetyControlState(ENABLED);
+                    }
+                    else
+                    {
+                        eBurnerState = BURNER_FIRED;
+                    }
                 }
             }
         }
 
-        if (!bHeatingInAction && !bBurnerFaultDetected)
+        if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
         {
             if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
             {

From 2477ccb42a70f1c65dd3897e7c79797a92d682453f0edd91b1c37c701162d30d Mon Sep 17 00:00:00 2001
From: localhorst <localhorst@mosad.xyz>
Date: Sat, 19 Apr 2025 08:48:57 +0200
Subject: [PATCH 2/2] increase threshold

---
 main/control.c | 12 +++++++-----
 1 file changed, 7 insertions(+), 5 deletions(-)

diff --git a/main/control.c b/main/control.c
index f8c9eb0..f540b80 100644
--- a/main/control.c
+++ b/main/control.c
@@ -13,10 +13,10 @@
 // Temperature thresholds
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f
-#define CHAMBER_TEMPERATURE_TARGET 80.0f             // Max cutoff temperature
-#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f          // Min threshold for burner enable
-#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f          // Min threshold for burner enable
-#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 15U) // Burner fault detection after 15 minutes
+#define CHAMBER_TEMPERATURE_TARGET 80.0f            // Max cutoff temperature
+#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f         // Min threshold for burner enable
+#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f         // Min threshold for burner enable
+#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 4U) // Burner fault detection after 4 minutes
 
 static const char *TAG = "smart-oil-heater-control-system-control";
 static eControlState sControlState = CONTROL_STARTING;
@@ -127,7 +127,7 @@ void taskControl(void *pvParameters)
                 {
                     if (getBurnerError() == FAULT)
                     {
-                        ESP_LOGW(TAG, "Burner fault detected after timeout!");
+                        ESP_LOGW(TAG, "Burner fault detected after threshold!");
                         bHeatingInAction = false;
                         eBurnerState = BURNER_FAULT;
                         sControlState = CONTROL_FAULT_BURNER;
@@ -137,6 +137,7 @@ void taskControl(void *pvParameters)
                     }
                     else
                     {
+                        ESP_LOGW(TAG, "No Burner fault detected after threshold!");
                         eBurnerState = BURNER_FIRED;
                     }
                 }
@@ -157,6 +158,7 @@ void taskControl(void *pvParameters)
                      (getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD))
             {
                 ESP_LOGI(TAG, "Enabling burner: Return flow temperature target reached");
+                eBurnerState = BURNER_UNKNOWN;
                 bHeatingInAction = true;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(ENABLED);