Merge pull request 'fix/burner-fault-detection' (#23) from fix/burner-fault-detection into feature/summer-mode

Reviewed-on: #23

main/control.c

@@ -8,26 +8,31 @@
 #include "safety.h"
 #include "sntp.h"
 
-#define PERIODIC_INTERVAL 1U // run control loop every 1sec
+#define PERIODIC_INTERVAL 1U // Run control loop every 1 second
 
-#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0
+// Temperature thresholds
-#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0
+#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
-#define CHAMPER_TEMPERATURE_TARGET 80.0
+#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f
-#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 3U) // Detect burner fault if after 3 minutes no burner start detected
+#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;
 
+// Control table for daily schedules
 static sControlDay aControlTable[] = {
-    {MONDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {MONDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {TUESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {TUESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {WEDNESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {WEDNESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {FRIDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{23, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {FRIDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{23, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {SATURDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{23, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {SATURDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{23, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
-    {SUNDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}},
+    {SUNDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
 };
 
+// Function prototypes
 void taskControl(void *pvParameters);
 eControlWeekday getCurrentWeekday(void);
 sControlTemperatureEntry getCurrentTemperatureEntry(void);
@@ -53,28 +58,31 @@ 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();
 
-    time_t now;
-
     while (1)
     {
-        // Get the current time
-        time(&now);
-        ESP_LOGW(TAG, "Control loop time: %lli", now);
         vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
 
+        // Handle safety faults
         if (getSafetyState() != SAFETY_NO_ERROR)
         {
-            //ESP_LOGW(TAG, "Control not possible due to safety fault!");
+            ESP_LOGW(TAG, "Control not possible due to safety fault!");
             sControlState = CONTROL_FAULT_SAFETY;
-            if (bHeatingInAction == true)
+            if (bHeatingInAction)
             {
-                ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner");
+                ESP_LOGW(TAG, "Disabling burner due to safety fault");
                 bHeatingInAction = false;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -83,13 +91,14 @@ void taskControl(void *pvParameters)
             continue;
         }
 
+        // Handle SNTP faults
         if (getSntpState() != SYNC_SUCCESSFUL)
         {
-            ESP_LOGW(TAG, "Control not possible due to sntp fault!");
+            ESP_LOGW(TAG, "Control not possible due to SNTP fault!");
             sControlState = CONTROL_FAULT_SNTP;
-            if (bHeatingInAction == true)
+            if (bHeatingInAction)
             {
-                ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner");
+                ESP_LOGW(TAG, "Disabling burner due to SNTP fault");
                 bHeatingInAction = false;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -98,48 +107,58 @@ void taskControl(void *pvParameters)
             continue;
         }
 
+        // Get current temperature entry
         sControlTemperatureEntry currentControlEntry = getCurrentTemperatureEntry();
-        // ESP_LOGI(TAG, "Control Entry Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", currentControlEntry.timestamp.hour, currentControlEntry.timestamp.minute, currentControlEntry.fChamberTemperature, currentControlEntry.fReturnFlowTemperature);
 
-        if (bHeatingInAction == true)
+        if (bHeatingInAction)
         {
-            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
+            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
+                (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
             {
-                ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner");
+                ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
                 bHeatingInAction = false;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
                 setSafetyControlState(ENABLED);
             }
-            else
+            else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
             {
-                if (bHeatingInAction)
+                if (eBurnerState == BURNER_UNKNOWN)
                 {
-                    int64_t i64Delta = esp_timer_get_time() - i64BurnerEnableTimestamp;
+                    if (getBurnerError() == FAULT)
-
-                    if ((i64Delta / 1000000U) >= BURNER_FAULT_DETECTION_THRESHOLD)
                     {
-                        if (getBurnerError() == FAULT)
+                        ESP_LOGW(TAG, "Burner fault detected after threshold!");
-                        {
+                        bHeatingInAction = false;
-                            ESP_LOGW(TAG, "Detected burner fault after %lli seconds!", (i64Delta / 1000000U));
+                        eBurnerState = BURNER_FAULT;
-                            ESP_LOGW(TAG, "Control not possible due to burner fault: Disable burner");
+                        sControlState = CONTROL_FAULT_BURNER;
-                            sControlState = CONTROL_FAULT_BURNER;
+                        setCirculationPumpState(ENABLED);
-                            bHeatingInAction = false;
+                        setBurnerState(DISABLED);
-                            bBurnerFaultDetected = true;
+                        setSafetyControlState(ENABLED);
-                            setCirculationPumpState(ENABLED);
+                    }
-                            setBurnerState(DISABLED);
+                    else
-                            setSafetyControlState(ENABLED);
+                    {
-                        }
+                        ESP_LOGW(TAG, "No Burner fault detected after threshold!");
+                        eBurnerState = BURNER_FIRED;
                     }
                 }
             }
         }
 
-        if ((bHeatingInAction == false) && (bBurnerFaultDetected == false))
+        if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
         {
-            if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0))
+            if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
             {
-                ESP_LOGI(TAG, "Return Flow Target Temperature reached: Enable Burner");
+                // ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
+                setCirculationPumpState(DISABLED);
+                setBurnerState(DISABLED);
+                setSafetyControlState(DISABLED);
+                sControlState = CONTROL_OUTDOOR_TOO_WARM;
+            }
+            else if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) &&
+                     (getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD))
+            {
+                ESP_LOGI(TAG, "Enabling burner: Return flow temperature target reached");
+                eBurnerState = BURNER_UNKNOWN;
                 bHeatingInAction = true;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(ENABLED);
@@ -165,71 +184,36 @@ eControlWeekday getCurrentWeekday(void)
     time_t now;
     struct tm *timeinfo;
 
-    // Get the current time
     time(&now);
-    timeinfo = localtime(&now); // Convert to local time
+    timeinfo = localtime(&now);
 
-    // Get the day of the week (0 = Sunday, 1 = Monday, ..., 6 = Saturday)
     int day = timeinfo->tm_wday;
-
+    return (eControlWeekday)((day == 0) ? 6 : day - 1);
-    // Adjust so that Monday = 0, Sunday = 6
-    if (day == 0)
-    {
-        day = 6; // Sunday becomes 6
-    }
-    else
-    {
-        day -= 1; // Shift other days to make Monday = 0
-    }
-
-    return (eControlWeekday)day;
 }
 
 sControlTemperatureEntry getCurrentTemperatureEntry(void)
 {
     sControlTemperatureEntry result = aControlTable[0].aTemperatureEntries[0];
     eControlWeekday currentDay = getCurrentWeekday();
+
     time_t now;
     struct tm timeinfo;
-
-    // Get the current time
     time(&now);
-    // Convert to local time structure
     localtime_r(&now, &timeinfo);
-    // Extract hour and minute
-    int hour = timeinfo.tm_hour;  // Hour (0-23)
-    int minute = timeinfo.tm_min; // Minute (0-59)u
 
-    // ESP_LOGI(TAG, "Current Day: %i Hour: %i Minute: %i", currentDay, hour, minute);
+    int hour = timeinfo.tm_hour;
+    int minute = timeinfo.tm_min;
 
     for (int i = 0; i < sizeof(aControlTable) / sizeof(aControlTable[0]); i++)
     {
-        /// loops through days
-        // ESP_LOGI(TAG, "Day %d: %d", i + 1, aControlTable[i].day);
-        // int numberOfEntries = aControlTable[i].entryCount;
-        // ESP_LOGI(TAG, "Number of entries: %i", numberOfEntries);
-
         for (int j = 0; j < aControlTable[i].entryCount; j++)
         {
-            if ((aControlTable[i].day) > currentDay)
+            if ((aControlTable[i].day > currentDay) ||
+                (aControlTable[i].day == currentDay && aControlTable[i].aTemperatureEntries[j].timestamp.hour > hour) ||
+                (aControlTable[i].day == currentDay && aControlTable[i].aTemperatureEntries[j].timestamp.hour == hour && aControlTable[i].aTemperatureEntries[j].timestamp.minute >= minute))
             {
-                // ESP_LOGI(TAG, "DAY Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
+                return aControlTable[i].aTemperatureEntries[j];
-                return result;
             }
-
-            if ((aControlTable[i].day == currentDay) && (aControlTable[i].aTemperatureEntries[j].timestamp.hour > hour))
-            {
-                // ESP_LOGI(TAG, "HOUR Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
-                return result;
-            }
-
-            if ((aControlTable[i].day == currentDay) && (aControlTable[i].aTemperatureEntries[j].timestamp.hour == hour) && (aControlTable[i].aTemperatureEntries[j].timestamp.minute == minute))
-            {
-                // ESP_LOGI(TAG, "MINUTE Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
-                return result;
-            }
-
-            // ESP_LOGI(TAG, "SET Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
             result = aControlTable[i].aTemperatureEntries[j];
         }
     }

main/inputs.c

@@ -17,7 +17,7 @@ const uint8_t uBurnerFaultPin = 19U;
 const uint8_t uDS18B20Pin = 4U;
 
 const onewire_addr_t uChamperTempSensorAddr = 0xd00000108cd01d28;
-const onewire_addr_t uOutdoorTempSensorAddr = 0x78000000c6c2f728;
+const onewire_addr_t uOutdoorTempSensorAddr = 0xd70000108a9b9128;
 const onewire_addr_t uInletFlowTempSensorAddr = 0x410000108b8c0628;
 const onewire_addr_t uReturnFlowTempSensorAddr = 0x90000108cc77c28;
 
@@ -189,12 +189,12 @@ void taskInput(void *pvParameters)
 
             if (ds18x20_scan_devices(uDS18B20Pin, uOneWireAddresses, MAX_DN18B20_SENSORS, &sSensorCount) != ESP_OK)
             {
-               // ESP_LOGE(TAG, "1-Wire device scan error!");
+                ESP_LOGE(TAG, "1-Wire device scan error!");
             }
 
             if (!sSensorCount)
             {
-               // ESP_LOGW(TAG, "No 1-Wire devices detected!");
+                ESP_LOGW(TAG, "No 1-Wire devices detected!");
             }
             else
             {
@@ -203,14 +203,14 @@ void taskInput(void *pvParameters)
                 if (sSensorCount > MAX_DN18B20_SENSORS)
                 {
                     sSensorCount = MAX_DN18B20_SENSORS;
-                   // ESP_LOGW(TAG, "More 1-Wire devices found than expected!");
+                    ESP_LOGW(TAG, "More 1-Wire devices found than expected!");
                 }
 
                 for (size_t iReadLoop = 0; iReadLoop < ONE_WIRE_LOOPS; iReadLoop++)
                 {
                     if (ds18x20_measure_and_read_multi(uDS18B20Pin, uOneWireAddresses, sSensorCount, fDS18B20Temps) != ESP_OK)
                     {
-                      //  ESP_LOGE(TAG, "1-Wire devices read error");
+                        ESP_LOGE(TAG, "1-Wire devices read error");
                         vTaskDelay(PERIODIC_INTERVAL * 100U / portTICK_PERIOD_MS); // Wait 100ms if bus error occurred
                     }
                     else

main/safety.c

@@ -85,7 +85,7 @@ void checkSensorSanity(void)
 
         if (sCurrentMeasurement.state == MEASUREMENT_FAULT)
         {
-            //ESP_LOGE(TAG, "%s Sensor not found!", sanityChecks[i].name);
+            ESP_LOGE(TAG, "%s Sensor not found!", sanityChecks[i].name);
             sanityChecks[i].state = SENSOR_NOT_FOUND;
             sSafetyState = SAFETY_SENSOR_ERROR;
         }