localhorst/smart-oil-heating-control-system
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Smart Oil Heating Control System

ESP32-based control system for oil-fired central heating with schedule-based temperature management, safety monitoring, and Prometheus metrics export.

Features

  • Schedule Control: Day/night temperature targets per weekday
  • Summer Mode: Automatic heating disable based on outdoor temperature
  • Safety Monitoring: Sensor sanity checks with automatic safe-state fallback
  • Prometheus Metrics: HTTP endpoint at port 9100

Prometheus Metrics

curl http://X.X.X.X:9100/metrics

Example

burner_fault_pending 1
circulation_pump_enabled 1
burner_enabled 0
safety_contact_enabled 1
chamber_temperature 37.250000
chamber_temperature_avg10 37.237499
chamber_temperature_avg60 37.438541
chamber_temperature_damped 42.185040
chamber_temperature_pred60 36.638443
inlet_flow_temperature 35.625000
inlet_flow_temperature_avg10 35.618752
inlet_flow_temperature_avg60 35.415627
inlet_flow_temperature_damped 39.431259
inlet_flow_temperature_pred60 36.078678
outdoor_temperature 14.687500
outdoor_temperature_avg10 14.662500
outdoor_temperature_avg60 14.646875
outdoor_temperature_damped 9.169084
outdoor_temperature_pred60 14.660233
return_flow_temperature 39.937500
return_flow_temperature_avg10 40.087502
return_flow_temperature_avg60 41.146873
return_flow_temperature_damped 32.385151
return_flow_temperature_pred60 37.311958
chamber_temperature_state 0
outdoor_temperature_state 0
inlet_flow_temperature_state 0
return_flow_temperature_state 0
safety_state 0
control_state 3
control_current_weekday 5
control_current_entry_time 17100
control_current_entry_chamber_temperature 80.000000
control_current_entry_return_flow_temperature 30.000000
sntp_state 0
system_unixtime 1762012743
uptime_seconds 465229
wifi_rssi -72

Status Encoding

Digital Themperatur Sensor DS10B20
  • chamber_temperature_state
  • outdoor_temperature_state
  • inlet_flow_temperature_state
  • return_flow_temperature_state
Enum eSensorErrorState in safety.h Value Description
SENSOR_NO_ERROR 0
SENSOR_TOO_HIGH 1 Sanity check failed
SENSOR_TOO_LOW 2 Sanity check failed
SENSOR_UNCHANGED 3 Sanity check failed
SENSOR_NOT_FOUND 4 No Communication
Safety Loop
  • safety_state
Enum eSafetyState in safety.h Value Description
SAFETY_NO_ERROR 0
SAFETY_SENSOR_ERROR 1 At least one sensor failed
SAFETY_INTERNAL_ERROR 2 Internal error
Control Loop
  • control_state
Enum eControlState in 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
Enum eSntpState in sntp.h Value Description
SYNC_SUCCESSFUL 0
SYNC_NOT_STARTED 1
SYNC_FAILED 2

Hardware

Function ESP32 PLC ES32C14
Output CirculationPump IO27 Relay 1 NC1
Output Burner Fire Signal IO14 Relay 2 NC2
Output Safety Contact (powers Burner) IO12 Relay 3 NC2
Input Burner Fault IO19 Digital Input IN1
Input Temperature DS10B20 IO04 1-Wire

Configuration

All parameters configurable via idf.py menuconfig:

  • WiFi credentials and static IP
  • GPIO pin assignments
  • 1-Wire sensor addresses
  • Temperature thresholds and limits
  • Heating schedule (day/night per weekday)
  • Damping factors

Building

idf.py set-target esp32
idf.py menuconfig  # Configure settings
idf.py build flash monitor