From effd5c19e9741060fbbc87088cf755789102a08f2c6ece7d33411e4159131bef Mon Sep 17 00:00:00 2001 From: localhorst Date: Thu, 26 Dec 2024 20:27:42 +0100 Subject: [PATCH 1/3] detect burner fault --- README.md | 18 +++++++++--------- main/control.c | 29 +++++++++++++++++++++++++---- main/control.h | 2 +- 3 files changed, 35 insertions(+), 14 deletions(-) diff --git a/README.md b/README.md index bf80127..961d1a3 100644 --- a/README.md +++ b/README.md @@ -131,15 +131,15 @@ wifi_rssi -63 ##### Control Loop - control_state -| Enum eControlState in [control.h](main/control.h) | Value | Description | -|---------------------------------------------------|-------|------------------------------------| -| CONTROL_STARTING | 0 | | -| CONTROL_HEATING | 1 | Burner running | -| CONTROL_OUTDOOR_TOO_WARM | 2 | Heating not needed | -| CONTROL_RETURN_FLOW_TOO_WARM | 3 | Heating not needed | -| CONTROL_BURNER_FAULT | 4 | Burner reported fault | -| CONTROL_FAULT_SAFETY | 5 | Unable to control due safety fault | -| CONTROL_FAULT_SNTP | 6 | Unable to control due SNTP fault | +| Enum eControlState in [control.h](main/control.h) | Value | Description | +|---------------------------------------------------|-------|--------------------------------------------------| +| CONTROL_STARTING | 0 | | +| CONTROL_HEATING | 1 | Burner running | +| CONTROL_OUTDOOR_TOO_WARM | 2 | Heating not needed | +| CONTROL_RETURN_FLOW_TOO_WARM | 3 | Heating not needed | +| CONTROL_FAULT_BURNER | 4 | Burner reported fault after threshold is reached | +| CONTROL_FAULT_SAFETY | 5 | Unable to control due safety fault | +| CONTROL_FAULT_SNTP | 6 | Unable to control due SNTP fault | ##### SNTP Client - sntp_state diff --git a/main/control.c b/main/control.c index eedc877..098111e 100644 --- a/main/control.c +++ b/main/control.c @@ -1,5 +1,6 @@ #include "freertos/FreeRTOS.h" #include "freertos/task.h" +#include "esp_timer.h" #include "esp_log.h" #include "control.h" #include "outputs.h" @@ -12,6 +13,7 @@ #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0 #define CHAMPER_TEMPERATURE_TARGET 70.0 +#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 3U) // Detect burner fault if after 3 minutes no burner start detected static const char *TAG = "smart-oil-heater-control-system-control"; static eControlState sControlState = CONTROL_STARTING; @@ -54,6 +56,9 @@ void initControl(void) void taskControl(void *pvParameters) { bool bHeatingInAction = false; + bool bBurnerFaultDetected = false; + int64_t i64BurnerEnableTimestamp = esp_timer_get_time(); + while (1) { vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS); @@ -64,7 +69,7 @@ void taskControl(void *pvParameters) sControlState = CONTROL_FAULT_SAFETY; if (bHeatingInAction == true) { - ESP_LOGI(TAG, "Control not possible due to safety fault: Disable burner"); + ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner"); bHeatingInAction = false; setCirculationPumpState(ENABLED); setBurnerState(DISABLED); @@ -79,7 +84,7 @@ void taskControl(void *pvParameters) sControlState = CONTROL_FAULT_SNTP; if (bHeatingInAction == true) { - ESP_LOGI(TAG, "Control not possible due to sntp fault: Disable burner"); + ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner"); bHeatingInAction = false; setCirculationPumpState(ENABLED); setBurnerState(DISABLED); @@ -105,12 +110,27 @@ void taskControl(void *pvParameters) { if (bHeatingInAction) { - // TODO: Check burner fault signal here + int64_t i64Delta = esp_timer_get_time() - i64BurnerEnableTimestamp; + + if ((i64Delta / 1000000U) >= BURNER_FAULT_DETECTION_THRESHOLD) + { + if (getBurnerError() == FAULT) + { + ESP_LOGW(TAG, "Detected burner fault after %lli seconds!", (i64Delta / 1000000U)); + ESP_LOGW(TAG, "Control not possible due to burner fault: Disable burner"); + sControlState = CONTROL_FAULT_BURNER; + bHeatingInAction = false; + bBurnerFaultDetected = true; + setCirculationPumpState(ENABLED); + setBurnerState(DISABLED); + setSafetyControlState(ENABLED); + } + } } } } - if (bHeatingInAction == false) + if ((bHeatingInAction == false) && (bBurnerFaultDetected == true)) { if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0)) { @@ -119,6 +139,7 @@ void taskControl(void *pvParameters) setCirculationPumpState(ENABLED); setBurnerState(ENABLED); setSafetyControlState(ENABLED); + i64BurnerEnableTimestamp = esp_timer_get_time(); sControlState = CONTROL_HEATING; } else diff --git a/main/control.h b/main/control.h index d5085ee..ba60d4c 100644 --- a/main/control.h +++ b/main/control.h @@ -9,7 +9,7 @@ typedef enum _ControlState CONTROL_HEATING, CONTROL_OUTDOOR_TOO_WARM, CONTROL_RETURN_FLOW_TOO_WARM, - CONTROL_BURNER_FAULT, + CONTROL_FAULT_BURNER, CONTROL_FAULT_SAFETY, CONTROL_FAULT_SNTP, } eControlState; From 25b0a11694afe3f354520bc4be45c3da08a1fa732a03d0c8b115617bf75410cb Mon Sep 17 00:00:00 2001 From: localhorst Date: Thu, 26 Dec 2024 20:37:19 +0100 Subject: [PATCH 2/3] fix detection state --- main/control.c | 2 +- 1 file changed, 1 insertion(+), 1 deletion(-) diff --git a/main/control.c b/main/control.c index 098111e..cf62ec3 100644 --- a/main/control.c +++ b/main/control.c @@ -130,7 +130,7 @@ void taskControl(void *pvParameters) } } - if ((bHeatingInAction == false) && (bBurnerFaultDetected == true)) + if ((bHeatingInAction == false) && (bBurnerFaultDetected == false)) { if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0)) { From 3c972296ce77c2cbbd6ad2be1ae73e036ab6325a6d697fd9fa9e0c842a71e482 Mon Sep 17 00:00:00 2001 From: Hendrik Schutter Date: Thu, 26 Dec 2024 20:47:21 +0100 Subject: [PATCH 3/3] update example metric --- README.md | 42 +++++++++++++++++++++++------------------- 1 file changed, 23 insertions(+), 19 deletions(-) diff --git a/README.md b/README.md index 961d1a3..3f0f299 100644 --- a/README.md +++ b/README.md @@ -77,31 +77,35 @@ Sntp <|-- Metrics #### Example ``` burner_fault_pending 1 -circulation_pump_enabled 0 -burner_enabled 1 -safety_contact_enabled 1 -chamber_temperature 21.812500 -chamber_temperature_avg10 21.837500 -chamber_temperature_avg60 21.825521 -inlet_flow_temperature 22.437500 -inlet_flow_temperature_avg10 22.437500 -inlet_flow_temperature_avg60 22.434896 -outdoor_temperature 21.937500 -outdoor_temperature_avg10 21.937500 -outdoor_temperature_avg60 21.933594 -return_flow_temperature 22.375000 -return_flow_temperature_avg10 22.375000 -return_flow_temperature_avg60 22.375000 +circulation_pump_enabled 1 +burner_enabled 0 +safety_contact_enabled 0 +chamber_temperature 58.750000 +chamber_temperature_avg10 58.931252 +chamber_temperature_avg60 59.190475 +chamber_temperature_pred60 55.870998 +inlet_flow_temperature 53.875000 +inlet_flow_temperature_avg10 53.900002 +inlet_flow_temperature_avg60 53.994320 +inlet_flow_temperature_pred60 52.848743 +outdoor_temperature 18.000000 +outdoor_temperature_avg10 18.006250 +outdoor_temperature_avg60 18.002840 +outdoor_temperature_pred60 18.050785 +return_flow_temperature 48.625000 +return_flow_temperature_avg10 48.718750 +return_flow_temperature_avg60 48.846592 +return_flow_temperature_pred60 47.383083 chamber_temperature_state 0 outdoor_temperature_state 0 inlet_flow_temperature_state 0 return_flow_temperature_state 0 safety_state 0 -control_state 5 +control_state 3 sntp_state 0 -system_unixtime 1734814285 -uptime_seconds 90 -wifi_rssi -63 +system_unixtime 1735242392 +uptime_seconds 40 +wifi_rssi -74 ``` #### Status Encoding