168 lines
5.4 KiB
Markdown
168 lines
5.4 KiB
Markdown
# smart-oil-heating-control-system
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## Software
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### Design
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```mermaid
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classDiagram
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Inputs <|-- Control
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Outputs <|-- Control
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Sntp <|-- Control
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Inputs <|-- Safety
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Outputs <|--|> Safety
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Inputs <|-- Metrics
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Outputs <|-- Metrics
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Control <|-- Metrics
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Safety <|-- Metrics
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Sntp <|-- Metrics
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class Inputs{
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+initInputs()
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-taskInput()
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+getChamberTemperature()
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+getOutdoorTemperature()
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+getInletFlowTemperature()
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+getReturnFlowTemperature()
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+getBurnerError()
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}
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class Outputs{
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+initOutputs()
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+getCirculationPumpState()
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+setCirculationPumpState()
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+getBurnerState()
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+setBurnerState()
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+getSafetyControlState()
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+setSafetyControlState()
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}
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class Control{
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+taskControl()
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-controlTable
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+getControlState()
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}
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class Safety{
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+initSafety()
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-taskSafety()
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-setSafeState()
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-checkSensorSanity()
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+getSensorSanityStates()
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+getSafetyState()
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}
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class Wifi{
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+initWifi()
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}
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class Sntp{
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+initSntp()
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+getSntpState()
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}
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class Metrics{
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+initMetrics()
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-taskMetrics()
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-metrics
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+event_handler()
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+connect_wifi()
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+setMetrics()
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}
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```
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### Prometheus Metrics
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`curl http://X.X.X.X:9100/metrics`
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#### Example
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```
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burner_fault_pending 1
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circulation_pump_enabled 1
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burner_enabled 0
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safety_contact_enabled 0
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chamber_temperature 58.750000
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chamber_temperature_avg10 58.931252
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chamber_temperature_avg60 59.190475
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chamber_temperature_pred60 55.870998
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inlet_flow_temperature 53.875000
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inlet_flow_temperature_avg10 53.900002
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inlet_flow_temperature_avg60 53.994320
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inlet_flow_temperature_pred60 52.848743
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outdoor_temperature 18.000000
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outdoor_temperature_avg10 18.006250
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outdoor_temperature_avg60 18.002840
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outdoor_temperature_pred60 18.050785
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return_flow_temperature 48.625000
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return_flow_temperature_avg10 48.718750
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return_flow_temperature_avg60 48.846592
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return_flow_temperature_pred60 47.383083
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chamber_temperature_state 0
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outdoor_temperature_state 0
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inlet_flow_temperature_state 0
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return_flow_temperature_state 0
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safety_state 0
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control_state 3
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sntp_state 0
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system_unixtime 1735242392
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uptime_seconds 40
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wifi_rssi -74
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```
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#### Status Encoding
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##### Digital Themperatur Sensor DS10B20
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- chamber_temperature_state
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- outdoor_temperature_state
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- inlet_flow_temperature_state
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- return_flow_temperature_state
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| Enum eSensorErrorState in [safety.h](main/safety.h) | Value | Description |
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|-----------------------------------------------------|-------|---------------------|
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| SENSOR_NO_ERROR | 0 | |
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| SENSOR_TOO_HIGH | 1 | Sanity check failed |
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| SENSOR_TOO_LOW | 2 | Sanity check failed |
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| SENSOR_UNCHANGED | 3 | Sanity check failed |
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| SENSOR_NOT_FOUND | 4 | No Communication |
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##### Safety Loop
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- safety_state
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| Enum eSafetyState in [safety.h](main/safety.h) | Value | Description |
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|------------------------------------------------|-------|----------------------------|
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| SAFETY_NO_ERROR | 0 | |
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| SAFETY_SENSOR_ERROR | 1 | At least one sensor failed |
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| SAFETY_INTERNAL_ERROR | 2 | Internal error |
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##### Control Loop
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- control_state
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| Enum eControlState in [control.h](main/control.h) | Value | Description |
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|---------------------------------------------------|-------|--------------------------------------------------|
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| CONTROL_STARTING | 0 | |
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| CONTROL_HEATING | 1 | Burner running |
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| CONTROL_OUTDOOR_TOO_WARM | 2 | Heating not needed |
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| CONTROL_RETURN_FLOW_TOO_WARM | 3 | Heating not needed |
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| CONTROL_FAULT_BURNER | 4 | Burner reported fault after threshold is reached |
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| CONTROL_FAULT_SAFETY | 5 | Unable to control due safety fault |
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| CONTROL_FAULT_SNTP | 6 | Unable to control due SNTP fault |
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##### SNTP Client
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- sntp_state
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| Enum eSntpState in [sntp.h](main/sntp.h) | Value | Description |
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|------------------------------------------|-------|-------------|
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| SYNC_SUCCESSFUL | 0 | |
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| SYNC_NOT_STARTED | 1 | |
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| SYNC_FAILED | 2 | |
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## Hardware
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| Function | ESP32 | PLC ES32C14 |
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|---------------------------------------|-------|-------------------|
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| Output CirculationPump | IO27 | Relay 1 NC1 |
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| Output Burner Fire Signal | IO14 | Relay 2 NC2 |
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| Output Safety Contact (powers Burner) | IO12 | Relay 3 NC2 |
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| Input Burner Fault | IO19 | Digital Input IN1 |
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| Input Temperature DS10B20 | IO04 | 1-Wire |
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