Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rede98c647eb388e121bdd7c07dc8ef134c04e5bd -r59357d3831aa60f17ccdfbe0eef1a005935b9a58 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision ede98c647eb388e121bdd7c07dc8ef134c04e5bd) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 59357d3831aa60f17ccdfbe0eef1a005935b9a58) @@ -8,7 +8,7 @@ * @file Heaters.c * * @author (last) Dara Navaei -* @date (last) 03-Feb-2023 +* @date (last) 20-May-2023 * * @author (original) Dara Navaei * @date (original) 23-Apr-2020 @@ -69,8 +69,9 @@ #define TRIMMER_HEATER_MAX_POWER_W 66.5F ///< Trimmer heater maximum power in Watts. #define TRIMMER_HEATER_INITIAL_CONTROL_INTERVAL_COUNT ( ( 10 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater initial control interval count. #define TRIMMER_HEATER_CONTROL_INTERVAL_COUNT ( ( 30 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. +#define TRIMMER_HEATER_MIN_DIALYSATE_FLOWRATE_LPM 0.00F ///< Trimmer heater minimum dialysate flow rate in L/min. -#define DELTA_TEMPERATURE_TIME_COSNTANT_C 8.6F ///< Delta temperature calculated from time constant. +#define DELTA_TEMPERATURE_TIME_CONSTANT_C 8.6F ///< Delta temperature calculated from time constant. #define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.015F ///< Primary heaters duty cycle per temperature in C. #define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. #define MIN_RO_HEATER_FLOWRATE_LPM 0.2F ///< Minimum target RO heater flow rate in L/min. @@ -80,24 +81,25 @@ static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184 / SEC_PER_MIN; ///< Water specific heat in J/KgC / 60. static const F32 PRIMARY_HEATERS_MAXIMUM_POWER_WATTS = 475 + 237.5F; ///< Primary heaters maximum power (main primary = 475W and small primary = 237.5W). static const F32 HEATERS_VOLTAGE_TOLERANCE_V = HEATERS_MAX_OPERATING_VOLTAGE_V * HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL; ///< Heaters voltage tolerance in volts. -static const F32 PRIMARY_HEATER_VOLTAGE_TOLERANCE_V = HEATERS_MAX_OPERATING_VOLTAGE_V * PRIMARY_HEATER_POWER_TOL; ///< Primary heater power voltage tolerance in volts. /// Heaters data structure typedef struct { - F32 targetTemp; ///< Heater target temperature. + F32 targetTempC; ///< Heater target temperature. HEATERS_STATE_T state; ///< Heater state. BOOL startHeaterSignal; ///< Heater start indication flag. BOOL isHeaterOn; ///< Heater on/off status flag. OVERRIDE_F32_T dutyCycle; ///< Heater duty cycle. - F32 targetFlow; ///< Heater target flow. + F32 targetFlowLPM; ///< Heater target flow in L/min to calculate the duty cycle. + F32 nomTargetFlowLPM; ///< Heater nominal target flow in L/min. BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. F32 heaterEstGain; ///< Heater estimation gain during the run. - F32 calculatedTemperature; ///< Heater calculated temperature. + F32 calculatedTemperatureC; ///< Heater calculated temperature. DG_RESERVOIR_ID_T inactiveRsrvr; ///< Heater inactive reservoir. U32 controlIntervalCounter; ///< Heater control interval counter. BOOL isThisFirstControl; ///< Heater is this first control interval. BOOL useLastDutyCycle; ///< Heater has use previous duty cycle been requested flag. + F32 prevDiaTargetFlowLPM; ///< Heater previous target dialysate flow in L/min. } HEATER_STATUS_T; static HEATER_STATUS_T heatersStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. @@ -113,7 +115,7 @@ static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ); static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ); -static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); +static void setHeaterDutyCycle( DG_HEATERS_T heater ); static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); static F32 calculateTrimmerHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ); @@ -140,29 +142,30 @@ for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - heatersStatus[ heater ].targetTemp = 0.0F; + heatersStatus[ heater ].targetTempC = 0.0F; heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; heatersStatus[ heater ].startHeaterSignal = FALSE; heatersStatus[ heater ].isHeaterOn = FALSE; - heatersStatus[ heater ].dutyCycle.data = 0.0F; - heatersStatus[ heater ].dutyCycle.ovData = 0.0F; - heatersStatus[ heater ].dutyCycle.ovInitData = 0.0F; + heatersStatus[ heater ].dutyCycle.data = HEATERS_MIN_DUTY_CYCLE; + heatersStatus[ heater ].dutyCycle.ovData = HEATERS_MIN_DUTY_CYCLE; + heatersStatus[ heater ].dutyCycle.ovInitData = HEATERS_MIN_DUTY_CYCLE; heatersStatus[ heater ].dutyCycle.override = 0; - heatersStatus[ heater ].targetFlow = 0.0F; + heatersStatus[ heater ].targetFlowLPM = 0.0F; + heatersStatus[ heater ].nomTargetFlowLPM = 0.0F; heatersStatus[ heater ].hasTargetTempChanged = FALSE; heatersStatus[ heater ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; heatersStatus[ heater ].controlIntervalCounter = 0; heatersStatus[ heater ].isThisFirstControl = TRUE; heatersStatus[ heater ].useLastDutyCycle = FALSE; + heatersStatus[ heater ].prevDiaTargetFlowLPM = 0.0F; } // Initialize the persistent alarms initPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); // Initialize the FPGA persistent alarm initFPGAPersistentAlarm( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, ALARM_ID_DG_MAIN_PRIMARY_HEATER_FPGA_FAULT, @@ -191,7 +194,7 @@ // Check if the requested temperature is within the allowed range if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) { - heatersStatus[ heater ].targetTemp = targetTemperature; + heatersStatus[ heater ].targetTempC = targetTemperature; heatersStatus[ heater ].hasTargetTempChanged = TRUE; result = TRUE; } @@ -213,7 +216,7 @@ *************************************************************************/ F32 getHeaterTargetTemperature( DG_HEATERS_T heater ) { - return heatersStatus[ heater ].targetTemp; + return heatersStatus[ heater ].targetTempC; } /*********************************************************************//** @@ -274,7 +277,15 @@ *************************************************************************/ void stopHeater( DG_HEATERS_T heater ) { - heatersStatus[ heater ].isHeaterOn = FALSE; + if( heater < NUM_OF_DG_HEATERS ) + { + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; + } + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) + } } /*********************************************************************//** @@ -330,7 +341,8 @@ // Check if the heater is requested to be off if ( FALSE == heatersStatus[ heater ].isHeaterOn ) { - setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + heatersStatus[ heater ].dutyCycle.data = HEATERS_MIN_DUTY_CYCLE; + setHeaterDutyCycle( heater ); heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; } } @@ -362,16 +374,16 @@ if ( DG_PRIMARY_HEATER == heater ) { - alarm = ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; + alarm = ALARM_ID_DG_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; measFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); minFlow = MIN_RO_HEATER_FLOWRATE_LPM; isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); } else { - alarm = ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON; + alarm = ALARM_ID_DG_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON; measFlow = getMeasuredRawFlowRateLPM( DIALYSATE_FLOW_SENSOR ); - minFlow = MIN_DIALYSATE_FLOWRATE_LPM; + minFlow = TRIMMER_HEATER_MIN_DIALYSATE_FLOWRATE_LPM; isFlowLow = ( measFlow > minFlow ? FALSE : TRUE ); } @@ -381,11 +393,11 @@ { if ( DG_PRIMARY_HEATER == heater ) { - checkPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); + checkPersistentAlarm( ALARM_ID_DG_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); } else { - checkPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); + checkPersistentAlarm( ALARM_ID_DG_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); } } } @@ -432,7 +444,7 @@ F32 heaterEstGain = heatersStatus[ heater ].heaterEstGain; F32 heaterDutyCycle = heatersStatus[ heater ].dutyCycle.data; F32 lastFillTemperature = getAvgFillTemperature(); - F32 primaryTargetTemperature = heatersStatus[ heater ].targetTemp; + F32 primaryTargetTemperature = heatersStatus[ heater ].targetTempC; BOOL isTempUnderTarget = ( lastFillTemperature < primaryTargetTemperature ? TRUE : FALSE ); if ( TRUE == isTempUnderTarget ) @@ -507,48 +519,50 @@ HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; DG_HEATERS_T heater = DG_PRIMARY_HEATER; F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); - F32 targetFlow = 0.0F; + F32 targetFlowLPM = 0.0F; F32 dutyCycle = 0.0F; - F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 targetTemperature = heatersStatus[ heater ].targetTempC; DG_OP_MODE_T opMode = getCurrentOperationMode(); if ( DG_MODE_FILL == opMode ) { // If the previous average fill flow rate is 0, use the nominal target RO flow from the RO pump - targetFlow = ( getAvgFillFlowRateLPM() - 0.0F > NEARLY_ZERO ? getAvgFillFlowRateLPM() : getTargetROPumpFlowRateLPM() ); - dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); - state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + targetFlowLPM = ( getAvgFillFlowRateLPM() > NEARLY_ZERO ? getAvgFillFlowRateLPM() : getTargetROPumpFlowRateLPM() ); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlowLPM, TRUE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } else if ( ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) { - targetTemperature += DELTA_TEMPERATURE_TIME_COSNTANT_C; - targetFlow = getTargetROPumpFlowRateLPM(); - dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + targetTemperature += DELTA_TEMPERATURE_TIME_CONSTANT_C; + targetFlowLPM = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlowLPM, FALSE ); state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } else if ( ( DG_MODE_HEAT == opMode ) || ( DG_MODE_CHEM == opMode ) ) { // If the mode is any of the disinfects, specially heat, use the target flow rate instead of the avg. flow // Most of the times the heater should be running at 100% duty cycle since the target temperature is far from // the inlet temperature - targetFlow = getTargetROPumpFlowRateLPM(); + targetFlowLPM = getTargetROPumpFlowRateLPM(); inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_OUTLET_PRIMARY_HEATER ); - dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlowLPM, FALSE ); state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } else { // Calculate the energy equation and set the duty cycle // This is for other modes (i.e. standby or service) - targetFlow = getTargetROPumpFlowRateLPM(); - dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); - state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + targetFlowLPM = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlowLPM, FALSE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } // Update the calculated target temperature and flow - heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature = targetTemperature; - heatersStatus[ DG_PRIMARY_HEATER ].targetFlow = targetFlow; - setHeaterDutyCycle( heater, dutyCycle ); + heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperatureC = targetTemperature; + heatersStatus[ DG_PRIMARY_HEATER ].targetFlowLPM = targetFlowLPM; + heatersStatus[ DG_PRIMARY_HEATER ].nomTargetFlowLPM = getTargetROPumpFlowRateLPM(); + heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle.data = dutyCycle; + setHeaterDutyCycle( heater ); return state; } @@ -572,16 +586,16 @@ } else if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) { - F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); - F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 inletTemperature = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); + F32 targetTemperature = heatersStatus[ heater ].targetTempC; F32 targetFlow = getTargetROPumpFlowRateLPM(); F32 dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); - heatersStatus[ heater ].calculatedTemperature = targetTemperature; - heatersStatus[ heater ].targetFlow = targetFlow; - heatersStatus[ heater ].hasTargetTempChanged = FALSE; - - setHeaterDutyCycle( heater, dutyCycle ); + heatersStatus[ heater ].calculatedTemperatureC = targetTemperature; + heatersStatus[ heater ].targetFlowLPM = targetFlow; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + heatersStatus[ heater ].dutyCycle.data = dutyCycle; + setHeaterDutyCycle( heater ); } return state; @@ -601,22 +615,28 @@ { HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; F32 currentTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); - F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 targetTemperature = heatersStatus[ heater ].targetTempC; if ( currentTemperature < targetTemperature ) { - setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_MAX_DUTY_CYCLE ); - setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_MAX_DUTY_CYCLE ); + heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle.data = HEATERS_MAX_DUTY_CYCLE; + heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle.data = HEATERS_MAX_DUTY_CYCLE; + setHeaterDutyCycle( DG_TRIMMER_HEATER ); + setHeaterDutyCycle( DG_PRIMARY_HEATER ); } else if ( currentTemperature - targetTemperature < HEATERS_DISINFECT_TEMPERATURE_DRIFT_C ) { - setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_DISINFECT_DUTY_CYCLE ); - setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_DISINFECT_DUTY_CYCLE ); + heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle.data = HEATERS_DISINFECT_DUTY_CYCLE; + heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle.data = HEATERS_DISINFECT_DUTY_CYCLE; + setHeaterDutyCycle( DG_TRIMMER_HEATER ); + setHeaterDutyCycle( DG_PRIMARY_HEATER ); } else { - setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_MIN_DUTY_CYCLE ); - setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE ); + heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle.data = HEATERS_MIN_DUTY_CYCLE; + heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle.data = HEATERS_MIN_DUTY_CYCLE; + setHeaterDutyCycle( DG_TRIMMER_HEATER ); + setHeaterDutyCycle( DG_PRIMARY_HEATER ); } return state; @@ -637,7 +657,7 @@ F32 currentTemperature = 0.0F; F32 targetFlowLPM = getTargetDialysateFlowLPM(); F32 dutyCycle = 0.0F; - F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 targetTemperature = heatersStatus[ heater ].targetTempC; DG_OP_MODE_T opMode = getCurrentOperationMode(); if ( ( DG_MODE_FILL == opMode ) || ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) @@ -659,29 +679,28 @@ // If the mode is heat disinfect, use the target flow rate instead of the avg. flow // Most of the times the heater should be running at 100% duty cycle since the target temperature is 81 C and // it is far from the inlet temperature. - currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + currentTemperature = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); targetFlowLPM = getTargetROPumpFlowRateLPM(); dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, FALSE ); state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } else { // If not any of the above modes, just calculate the energy equation based on TRo - currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_OUTLET_REDUNDANT ); + currentTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; } // Update the calculated target temperature // Reset the duty cycle since the reservoir has been switched - heatersStatus[ heater ].calculatedTemperature = currentTemperature; - heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); - heatersStatus[ heater ].targetFlow = targetFlowLPM; - heatersStatus[ heater ].isThisFirstControl = TRUE; - // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 - dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); - setHeaterDutyCycle( heater, dutyCycle ); + heatersStatus[ heater ].calculatedTemperatureC = currentTemperature; + heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); + heatersStatus[ heater ].targetFlowLPM = targetFlowLPM; + heatersStatus[ heater ].isThisFirstControl = TRUE; + heatersStatus[ heater ].dutyCycle.data = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); + setHeaterDutyCycle( heater ); return state; } @@ -699,35 +718,50 @@ HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; F32 tempDutyCycle = 0.0F; DG_HEATERS_T heater = DG_TRIMMER_HEATER; + F32 targetFlowLPM = getTargetDialysateFlowLPM(); U32 controlInterval = ( TRUE == heatersStatus[ heater ].isThisFirstControl ? TRIMMER_HEATER_INITIAL_CONTROL_INTERVAL_COUNT : TRIMMER_HEATER_CONTROL_INTERVAL_COUNT ); - // If the inactive reservoir has changed from the last run transition to ramp state to recalculate the + // If the inactive reservoir has changed from the last run, transition to ramp state to recalculate the // duty cycle for the next delivery if ( heatersStatus[ heater ].inactiveRsrvr != getInactiveReservoir() ) { state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; } - else if ( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval ) + else if ( ( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval ) || + ( fabs( heatersStatus[ heater ].prevDiaTargetFlowLPM - targetFlowLPM ) > NEARLY_ZERO ) ) { - // Reset the control counter + // Check if it is time for another control interval or the current target flow is different from the previous flow and + // we need to reset the control counter heatersStatus[ heater ].controlIntervalCounter = 0; heatersStatus[ heater ].isThisFirstControl = FALSE; // When the trimmer heater is on, its duty cycle is adjusted at the control interval. For this control check, // dialysate inlet temperature sensor is used rather than the theoretical calculations. - F32 outletRedundantTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); - F32 targetTemperature = heatersStatus[ heater ].targetTemp; - F32 targetFlowLPM = heatersStatus[ heater ].targetFlow; - F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, outletRedundantTemperature, targetFlowLPM, TRUE ); + F32 dialysateInletTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); + F32 targetTemperature = heatersStatus[ heater ].targetTempC; + F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, dialysateInletTemperature, targetFlowLPM, TRUE ); - tempDutyCycle = heatersStatus[ heater ].dutyCycle.data + dutyCycle; + if ( fabs( heatersStatus[ heater ].prevDiaTargetFlowLPM - targetFlowLPM ) > NEARLY_ZERO ) + { + // If the current flow is different from the previous flow, restart the duty cycle as the controller is restarting itself + // Set it as it is the first control so the control interval is shorter since it is the first guess with the new dialysate flow + tempDutyCycle = dutyCycle; + heatersStatus[ heater ].isThisFirstControl = TRUE; + } + else + { + tempDutyCycle = heatersStatus[ heater ].dutyCycle.data + dutyCycle; + } + tempDutyCycle = MIN( tempDutyCycle, HEATERS_MAX_DUTY_CYCLE ); tempDutyCycle = MAX( tempDutyCycle, HEATERS_MIN_DUTY_CYCLE ); - - setHeaterDutyCycle( heater, tempDutyCycle ); + heatersStatus[ heater ].dutyCycle.data = tempDutyCycle; + setHeaterDutyCycle( heater ); } + heatersStatus[ heater ].prevDiaTargetFlowLPM = targetFlowLPM; + return state; } @@ -740,14 +774,13 @@ * @param pwm: The PWM that is set * @return none *************************************************************************/ -static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ) +static void setHeaterDutyCycle( DG_HEATERS_T heater ) { if ( heater < NUM_OF_DG_HEATERS ) { F32 duty; - heatersStatus[ heater ].dutyCycle.data = pwm; - duty = getHeaterDutyCycle( heater ); + duty = getHeaterDutyCycle( heater ); if ( DG_PRIMARY_HEATER == heater ) { @@ -772,7 +805,7 @@ * @details Inputs: none * @details Outputs: none * @param targetTemperature target temperature of the heater - * @oaram currentTemperature current inlet temperature of the heater + * @param currentTemperature current inlet temperature of the heater * @param flow current flow * @return calculated duty cycle *************************************************************************/ @@ -797,7 +830,7 @@ * @details Inputs: none * @details Outputs: none * @param targetTemperature target temperature of the heater - * @oaram currentTemperature current inlet temperature of the heater + * @param currentTemperature current inlet temperature of the heater * @param flow current flow * @param check efficiency flag to indicate whether to consider heater's * efficiency @@ -841,13 +874,13 @@ { BOOL status = FALSE; F32 targetFlow = ( DG_PRIMARY_HEATER == heater ? getTargetROPumpFlowRateLPM() : getTargetDialysateFlowLPM() ); - BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].nomTargetFlowLPM ) > NEARLY_ZERO ? TRUE : FALSE ); // Check if the target flow has changed or the target temperature has changed. if ( TRUE == hasFlowChanged ) { - status = TRUE; - heatersStatus[ heater ].targetFlow = targetFlow; + status = TRUE; + heatersStatus[ heater ].targetFlowLPM = targetFlow; } return status; @@ -949,14 +982,16 @@ data.mainPrimayHeaterDC = getHeaterDutyCycle( DG_PRIMARY_HEATER ) * FRACTION_TO_PERCENT_FACTOR; data.smallPrimaryHeaterDC = getHeaterDutyCycle( DG_PRIMARY_HEATER ) * FRACTION_TO_PERCENT_FACTOR; data.trimmerHeaterDC = getHeaterDutyCycle( DG_TRIMMER_HEATER ) * FRACTION_TO_PERCENT_FACTOR; - data.primaryTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].targetTemp; - data.trimmerTargetTemp = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; + data.primaryTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].targetTempC; + data.trimmerTargetTemp = heatersStatus[ DG_TRIMMER_HEATER ].targetTempC; data.primaryHeaterState = heatersStatus[ DG_PRIMARY_HEATER ].state; data.trimmerHeaterState = heatersStatus[ DG_TRIMMER_HEATER ].state; data.primaryEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain * FRACTION_TO_PERCENT_FACTOR; - data.primaryCalcTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature; - data.trimmerCalcCurrentTemp = heatersStatus[ DG_TRIMMER_HEATER ].calculatedTemperature; + data.primaryCalcTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperatureC; + data.trimmerCalcCurrentTemp = heatersStatus[ DG_TRIMMER_HEATER ].calculatedTemperatureC; data.trimmerUseLastDC = (U32)heatersStatus[ DG_TRIMMER_HEATER ].useLastDutyCycle; + data.previsouFlow = heatersStatus[ DG_TRIMMER_HEATER ].prevDiaTargetFlowLPM; + data.controlCounter = heatersStatus[ DG_TRIMMER_HEATER ].controlIntervalCounter; dataPublicationTimerCounter = 0; broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); @@ -999,9 +1034,8 @@ else #endif { - // TODO this is not working on DVT-002 - // If the system is DVT, check the FPGA persistent alarm of the main primary heater's voltage ADC - //checkFPGAPersistentAlarms( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, getFPGAHeaterGateADCErrorCount(), getFPGAHeaterGateADCReadCount() ); + // If the system is DVT, check the FPGA persistent alarm of the main primary heater's voltage ADC + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, getFPGAHeaterGateADCReadCount() ); } isMainPriOut = ( fabs( mainPriExpectedVoltage - mainPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); @@ -1013,17 +1047,6 @@ checkPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isMainPriOut, mainPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isSmallPriOut, smallPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, isTrimmerOut, trimmerDC, HEATERS_VOLTAGE_TOLERANCE_V ); - -#ifndef _RELEASE_ - if ( getHardwareConfigStatus() != HW_CONFIG_BETA ) -#endif - { - // If the system is DVT, check the primary heater's power line voltage - F32 powerMainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_POWER_PRIM_HTR_V ); - BOOL isPriPowerOut = ( fabs( powerMainPriVoltage - HEATERS_MAX_OPERATING_VOLTAGE_V ) > PRIMARY_HEATER_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); - - checkPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, isPriPowerOut, powerMainPriVoltage, PRIMARY_HEATER_VOLTAGE_TOLERANCE_V ); - } } } @@ -1052,6 +1075,11 @@ result = TRUE; heatersStatus[ (DG_HEATERS_T)heater ].dutyCycle.ovData = value; heatersStatus[ (DG_HEATERS_T)heater ].dutyCycle.override = OVERRIDE_KEY; + + if ( TRUE == heatersStatus[ (DG_HEATERS_T)heater ].isHeaterOn ) + { + setHeaterDutyCycle( (DG_HEATERS_T)heater ); + } } } @@ -1075,6 +1103,8 @@ result = TRUE; heatersStatus[ (DG_HEATERS_T)heater ].dutyCycle.override = OVERRIDE_RESET; heatersStatus[ (DG_HEATERS_T)heater ].dutyCycle.ovData = heatersStatus[ (DG_HEATERS_T)heater ].dutyCycle.ovInitData; + setHeaterDutyCycle( (DG_HEATERS_T)heater ); + } return result;