suppress heating in summer

Reviewed-on: #23

main/control.c

@@ -13,10 +13,11 @@
 // 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 13.0f          // Min threshold for burner enable
+#define CIRCULATION_PUMP_TEMPERATURE_THRESHOLD 30.0f // Min threshold of chamber for circulation pump 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;
@@ -61,14 +62,14 @@ void initControl(void)
 void taskControl(void *pvParameters)
 {
     bool bHeatingInAction = false;
-    bool bBurnerFaultDetected = false;
+    eBurnerState eBurnerState = BURNER_UNKNOWN;
     int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
 
     while (1)
     {
         vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
 
-        // Handle safety faults
+        // Check for safety faults
         if (getSafetyState() != SAFETY_NO_ERROR)
         {
             ESP_LOGW(TAG, "Control not possible due to safety fault!");
@@ -77,14 +78,13 @@ void taskControl(void *pvParameters)
             {
                 ESP_LOGW(TAG, "Disabling burner due to safety fault");
                 bHeatingInAction = false;
-                setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
                 setSafetyControlState(ENABLED);
             }
             continue;
         }
 
-        // Handle SNTP faults
+        // Check for SNTP faults
         if (getSntpState() != SYNC_SUCCESSFUL)
         {
             ESP_LOGW(TAG, "Control not possible due to SNTP fault!");
@@ -93,48 +93,20 @@ void taskControl(void *pvParameters)
             {
                 ESP_LOGW(TAG, "Disabling burner due to SNTP fault");
                 bHeatingInAction = false;
-                setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
                 setSafetyControlState(ENABLED);
             }
             continue;
         }
 
-        // Get current temperature entry
         sControlTemperatureEntry currentControlEntry = getCurrentTemperatureEntry();
 
-        if (bHeatingInAction)
-        {
-            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
-                (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
-            {
-                ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
-                bHeatingInAction = false;
-                setCirculationPumpState(ENABLED);
-                setBurnerState(DISABLED);
-                setSafetyControlState(ENABLED);
-            }
-            else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
-            {
-                if (getBurnerError() == FAULT)
-                {
-                    ESP_LOGW(TAG, "Burner fault detected after timeout!");
-                    bHeatingInAction = false;
-                    bBurnerFaultDetected = true;
-                    sControlState = CONTROL_FAULT_BURNER;
-                    setCirculationPumpState(ENABLED);
-                    setBurnerState(DISABLED);
-                    setSafetyControlState(ENABLED);
-                }
-            }
-        }
-
-        if (!bHeatingInAction && !bBurnerFaultDetected)
+        // Enable burner if outdoor temperature is low and return flow temperature is cooled down
+        if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
         {
             if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
             {
                 // ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
-                setCirculationPumpState(DISABLED);
                 setBurnerState(DISABLED);
                 setSafetyControlState(DISABLED);
                 sControlState = CONTROL_OUTDOOR_TOO_WARM;
@@ -143,8 +115,8 @@ 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);
                 setSafetyControlState(ENABLED);
                 i64BurnerEnableTimestamp = esp_timer_get_time();
@@ -152,10 +124,56 @@ void taskControl(void *pvParameters)
             }
             else
             {
+                // ESP_LOGI(TAG, "Return flow temperature too warm: Disabling heating");
                 sControlState = CONTROL_RETURN_FLOW_TOO_WARM;
             }
         }
-    }
+
+        // Disable burner if target temperature is reached or a fault occurred
+        if (bHeatingInAction)
+        {
+            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
+                (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
+            {
+                ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
+                bHeatingInAction = false;
+                setBurnerState(DISABLED);
+                setSafetyControlState(ENABLED);
+            }
+            else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
+            {
+                if (eBurnerState == BURNER_UNKNOWN)
+                {
+                    if (getBurnerError() == FAULT)
+                    {
+                        // ESP_LOGW(TAG, "Burner fault detected: Disabling burner");
+                        bHeatingInAction = false;
+                        eBurnerState = BURNER_FAULT;
+                        sControlState = CONTROL_FAULT_BURNER;
+                        setBurnerState(DISABLED);
+                        setSafetyControlState(ENABLED);
+                    }
+                    else
+                    {
+                        // ESP_LOGI(TAG, "No burner fault detected: Marking burner as fired");
+                        eBurnerState = BURNER_FIRED;
+                    }
+                }
+            }
+        }
+
+        // Manage circulation pump
+        if (getChamberTemperature().fCurrentValue <= CIRCULATION_PUMP_TEMPERATURE_THRESHOLD)
+        {
+            // ESP_LOGI(TAG, "Burner cooled down: Disabling circulation pump");
+            setCirculationPumpState(DISABLED);
+        }
+        else
+        {
+            // ESP_LOGI(TAG, "Burner heated: Enabling circulation pump");
+            setCirculationPumpState(ENABLED);
+        }
+    } // End of while(1)
 }
 
 eControlState getControlState(void)

main/control.h

@@ -14,6 +14,13 @@ typedef enum _ControlState
     CONTROL_FAULT_SNTP,
 } eControlState;
 
+typedef enum _BurnerState
+{
+    BURNER_UNKNOWN, // Burner is disabled or state after enabling is still unkown
+    BURNER_FIRED,   // Burner fired successfully
+    BURNER_FAULT    // Burner was unable to fire successfully
+} eBurnerState;
+
 typedef enum _ControlWeekday
 {
     MONDAY,