Index: firmware/App/Controllers/Fans.c =================================================================== diff -u -r922516483829939a2a387d4a2fddeccdb4c454d4 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/Fans.c (.../Fans.c) (revision 922516483829939a2a387d4a2fddeccdb4c454d4) +++ firmware/App/Controllers/Fans.c (.../Fans.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -81,7 +81,6 @@ static F32 getMaximumTemperature( void ); static void convertTogglePeriod2RPM( void ); static void monitorFans( void ); -static U32 getPublishFansDataInterval( void ); static void publishFansData( void ); /*********************************************************************//** @@ -467,25 +466,6 @@ /*********************************************************************//** * @brief - * The getPublishFansDataInterval function gets the fans data publish interval. - * @details Inputs: fansPublishInterval - * @details Outputs: none - * @return data publish time interval in counts - *************************************************************************/ -static U32 getPublishFansDataInterval( void ) -{ - U32 result = fansPublishInterval.data; - - if ( OVERRIDE_KEY == fansPublishInterval.override ) - { - result = fansPublishInterval.ovData; - } - - return result; -} - -/*********************************************************************//** - * @brief * The publishFansData function publishes the fans data at the specified * time interval. * @details Inputs: dataPublishCounter @@ -494,7 +474,7 @@ *************************************************************************/ static void publishFansData( void ) { - if ( ++fansPublishCounter > getPublishFansDataInterval() ) + if ( ++fansPublishCounter > getU32OverrideValue( &fansPublishInterval ) ) { FANS_DATA_T fansData; Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rde2ef5ff6293f23a43414c5e2e40630468a68ddf -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision de2ef5ff6293f23a43414c5e2e40630468a68ddf) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -15,7 +15,7 @@ * ***************************************************************************/ -#include +#include // Used for converting slope to radians and square root // TI PWM driver #include "etpwm.h" @@ -29,6 +29,7 @@ #include "ROPump.h" #include "SafetyShutdown.h" #include "SystemCommMessages.h" +#include "TaskGeneral.h" #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" @@ -40,29 +41,22 @@ // ********** private definitions ********** -#define MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Main primary heater (heater A) max duty cycle (100%). -#define SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Small Primary heater (heater B) max duty cycle (100%). -#define TRIMMER_HEATER_MAX_DUTY_CYCLE 1.00 ///< Trimmer heater max duty cycle (100%). +#define HEATERS_MAX_DUTY_CYCLE 1.00 ///< Main primary heater (heater A) max duty cycle (100%). #define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Primary and trimmer heaters minimum duty cycle (0.00%). -#define PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ( MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE + \ - SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE ) ///< Primary heaters cumulative duty cycle. -#define PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR 2.0 ///< Primary heaters initial duty cycle estimation divisor. -#define MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR 2.0 ///< Main and small primary heater duty cycle divisor -#define PRIMARY_HEATERS_P_COEFFICIENT 0.15 ///< Primary heaters proportional coefficient. -#define PRIMARY_HEATERS_I_COEFFICIENT 0.001 ///< Primary heaters integral coefficient. +#define PRIMARY_HEATER_P_COEFFICIENT 0.05 ///< Primary heaters proportional coefficient. +#define PRIMARY_HEATER_I_COEFFICIENT 0.00 // TODO remove? ///< Primary heaters integral coefficient. -#define TRIMMER_HEATER_P_COEFFICIENT 0.02 ///< Trimmer heater proportional coefficient. -#define TRIMMER_HEATER_I_COEFFICIENT 0.001 ///< Trimmer heater integral coefficient. +#define TRIMMER_HEATER_P_COEFFICIENT 0.02 // TODO remove ///< Trimmer heater proportional coefficient. +#define TRIMMER_HEATER_I_COEFFICIENT 0.001 // TODO remove ///< Trimmer heater integral coefficient. -#define CONTROLLER_CHECK_INTERVAL_COUNT 10U ///< Time interval count to check the PI controller. -#define TEMP_SENSORS_INTERVAL_COUNT 10U ///< Temperature sensors interval count. - #define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. #define MINIMUM_TARGET_TEMPERATURE 10.0 ///< Minimum allowed target temperature for the heaters. #define MAXIMUM_TARGET_TEMPERATURE 90.0 ///< Maximum allowed target temperature for the heaters. +#define HEATERS_RAMP_STATE_CHECK_INTERVAL_COUNT 20U ///< Heaters ramp check interval count. +#define HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ( 10 * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Temperature sensors interval count. #define HEATERS_ON_WITH_NO_FLOW_TIMEOUT_COUNT ( ( 3 * MS_PER_SECOND ) / TASK_PRIORITY_INTERVAL ) ///< Heaters are on but there is no sufficient flow timeout in counts. #define HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C 170.0 ///< Heaters max allowed internal temperature in C. #define HEATERS_MAX_ALLOWED_COLD_JUNCTION_TEMPERATURE_C 80.0 ///< Heaters max allowed cold junction temperature in C. @@ -71,221 +65,231 @@ #define HEATERS_MAX_OPERATING_VOLTAGE_V 24.0 ///< Heaters max operating voltage in volts. #define HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters voltage monitor timer interval. #define HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL 0.2 ///< Heaters max voltage out of range tolerance. +#define HEATERS_MIN_RAMP_TIME_MS ( 6 * MS_PER_SECOND ) ///< Heaters minimum time that they have to stay in the ramp state in milliseconds. +#define TEMPERATURES_MOVING_AVG_SIZE 3U ///< Heaters ramp state temperatures moving average size. -/// Primary heaters exec states -typedef enum primary_heaters_exec_states -{ - PRIMARY_HEATERS_EXEC_STATE_OFF = 0, ///< Primary heaters exec state off - PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET, ///< Primary heaters exec state control to target (PI controller state) - NUM_OF_PRIMARY_HEATERS_EXEC_STATES ///< Number of primary heaters exec states -} PRIMARY_HEATERS_EXEC_STATES_T; +#define PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_SLOPE 0.31644 ///< Primary heaters thermal power to voltage slope. +#define PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_INTERCEPT 0.021 ///< Primary heaters thermal power to voltage intercept. -/// Trimmer heater exec states -typedef enum trimmer_heater_exec_states +typedef enum Heaters_Exec_States { - TRIMMER_HEATER_EXEC_STATE_OFF = 0, ///< Trimmer heater exec state off - TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Trimmer heater exec state control to target (PI controller state) - NUM_OF_TRIMMER_HEATER_EXEC_STATES ///< Number of trimmer heater exec states -} TRIMMER_HEATER_EXEC_STATES_T; + HEATER_EXEC_STATE_NOT_RUNNING = 0, ///< Heater exec state not running + HEATER_EXEC_STATE_RAMP_TO_TARGET, ///< Heater exec state ramp to target + HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Heater exec state control to target + NUM_OF_HEATERS_STATE, ///< Number of heaters state +} HEATERS_STATE_T; -/// Name of the heaters states -typedef enum name_of_heaters +/// Heaters data structure +typedef struct { - PRIMARY_HEATER = 0, ///< Primary heater - TRIMMER_HEATER, ///< Trimmer heater - NUM_OF_HEATERS ///< Number of heaters -} NAME_OF_HEATER_T; + F32 targetTemp; ///< Heater Target temperature + F32 previousTemps[ TEMPERATURES_MOVING_AVG_SIZE ]; ///< Heater Previous temperatures array + U32 previousTempsIndex; ///< Heater previous temperatures arrays current index + HEATERS_STATE_T state; ///< Heater state + TEMPERATURE_SENSORS_T feedbackSensor; ///< Heater feedback sensor for controlling + U32 controlTimerCounter; ///< Heater control timer counter + BOOL startHeaterSignal; ///< Heater start indication flag + BOOL isHeaterOn; ///< Heater on/off status flag + U32 tempOutOfRangeTimer; ///< Heater temperature out of range timer TODO remove once the mechanical thermal cutoff was implemented + BOOL isHeaterTempOutOfRange; ///< Heater temperature out of range flag indicator TODO remove once the mechanical thermal cutoff was implemented + F32 dutycycle; ///< Heater duty cycle + F32 targetROFlow; ///< Heater target flow + U32 rampStateStartTime; ///< Heater ramp state start time + U32 heaterOnWithNoFlowTimer; ///< Heater on with no flow timer + BOOL isFlowBelowMin; ///< Heater flow below minimum flag indicator + PI_CONTROLLER_ID_T controllerID; ///< Heater PI controller ID TODO remove this? + F32 initialDutyCycle; ///< Heater initial duty cycle before a hand off +} HEATER_STATUS_T; -// ********** private data ********** - -static PRIMARY_HEATERS_EXEC_STATES_T primaryHeatersExecState; ///< Primary heaters exec state. -static TRIMMER_HEATER_EXEC_STATES_T trimmerHeaterExecState; ///< Trimmer heater exec state. - -static F32 primaryHeaterTargetTemperature; ///< Primary heaters target temperature. -static F32 trimmerHeaterTargetTemperature; ///< Trimmer heater target temperature. - -static F32 mainPrimaryHeaterDutyCycle; ///< Main primary heater duty cycle. -static F32 smallPrimaryHeaterDutyCycle; ///< Small primary heater duty cycle. -static F32 trimmerHeaterDutyCycle; ///< Trimmer heater duty cycle. -static U32 primaryHeaterTimerCounter; ///< Primary heater timer counter. -static U32 trimmerHeaterTimerCounter; ///< Trimmer heater timer counter. +static HEATER_STATUS_T heaterStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. static U32 dataPublicationTimerCounter; ///< Data publication timer counter. -static BOOL isPrimaryHeaterOn; ///< Flag to show if the primary heater is on. -static BOOL isTrimmerHeaterOn; ///< Flag to show if the trimmer heater is on. - static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. -static BOOL hasStartPrimaryHeaterRequested; ///< Start primary heater request flag. -static BOOL hasStartTrimmerHeaterRequested; ///< Start trimmer heater request flag. -static U32 heatersOnWithNoFlowTimer; ///< Heaters are on but there is no sufficient flow. -static TEMPERATURE_SENSORS_T primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; ///< Primary heaters feedback temperature sensors. -static TEMPERATURE_SENSORS_T trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; ///< Trimmer heater feedback temperature sensors. -static U32 primaryHeaterTempOutTimer = 0; ///< Primary heaters temperature out of range start timer. -static U32 trimmerHeaterTempOutTimer = 0; ///< Trimmer heater internal temperature out of range timer. -static BOOL isPrimaryHeaterTempOutOfRange = FALSE; ///< Boolean flag to indicate if the primary heaters internal temperature out of range. -static BOOL isTrimmerHeaterTempOutOfRange = FALSE; ///< Boolean flag to indicate if the trimmer heater internal temperature out of range. -static BOOL isFlowBelowMin = FALSE; ///< Boolean flag to indicate if the flow is below the minimum. -static U32 heatersVoltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. +static U32 heatersOnWithNoFlowTimer; ///< Heaters are on but there is no sufficient flow. TODO remove +static BOOL isFlowBelowMin = FALSE; ///< Boolean flag to indicate if the flow is below the minimum. TODo remove +static U32 voltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. + // ********** private function prototypes ********** -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ); -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ); +static HEATERS_STATE_T handleHeaterStateNotRunning( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStateRampToTarget( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStateControlToTarget( DG_HEATERS_T heater ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ); +static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); +static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 targetFlow ); static void setMainPrimaryHeaterPWM( F32 pwm ); static void setSmallPrimaryHeaterPWM( F32 pwm ); static void setTrimmerHeaterPWM( F32 pwm ); -static void resetHeaterState( NAME_OF_HEATER_T heater ); static void publishHeatersData( void ); static void checkPrimaryHeaterTempSensors( void ); static void checkTrimmerHeaterTempSensors( void ); static void monitorHeatersVoltage( void ); /*********************************************************************//** * @brief - * The initHeaters function initializes the variables and the PI controllers - * for the primary and trimmer heaters. + * The initHeaters initializes the heaters driver. * @details Inputs: none - * @details Outputs: Heaters module initialized + * @details Outputs: isFlowBelowMin, voltageMonitorTimeCounter, heaterStatus * @return none *************************************************************************/ void initHeaters( void ) { - primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_OFF; - trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_OFF; - primaryHeaterTargetTemperature = 0.0; - trimmerHeaterTargetTemperature = 0.0; - primaryHeaterTimerCounter = 0; - trimmerHeaterTimerCounter = 5; - dataPublicationTimerCounter = 0; - isPrimaryHeaterOn = FALSE; - isTrimmerHeaterOn = FALSE; - primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; - trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; - primaryHeaterTempOutTimer = 0; - trimmerHeaterTempOutTimer = 0; - isPrimaryHeaterTempOutOfRange = FALSE; - isTrimmerHeaterTempOutOfRange = FALSE; - isFlowBelowMin = FALSE; - heatersVoltageMonitorTimeCounter = 0; + DG_HEATERS_T heater; + isFlowBelowMin = FALSE; + voltageMonitorTimeCounter = 0; + + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + heaterStatus[ heater ].controlTimerCounter = 0; + // The default feedback sensor of the primary heater is TPo but it changes to THd in heat disinfect + // The default feedback sensor of the trimmer heater is TDi all the time + heaterStatus[ heater ].feedbackSensor = ( DG_PRIMARY_HEATER == heater ? TEMPSENSORS_OUTLET_PRIMARY_HEATER : TEMPSENSORS_INLET_DIALYSATE ); + heaterStatus[ heater ].startHeaterSignal = FALSE; + heaterStatus[ heater ].tempOutOfRangeTimer = 0; + heaterStatus[ heater ].isHeaterTempOutOfRange = FALSE; + heaterStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; + heaterStatus[ heater ].targetTemp = 0.0; + heaterStatus[ heater ].dutycycle = 0.0; + heaterStatus[ heater ].targetROFlow = 0.0; + heaterStatus[ heater ].previousTempsIndex = 0; + heaterStatus[ heater ].controllerID = ( DG_PRIMARY_HEATER == heater ? PI_CONTROLLER_ID_PRIMARY_HEATER : PI_CONTROLLER_ID_TRIMMER_HEATER ); + heaterStatus[ heater ].initialDutyCycle = 0.0; + + // Set the array of the previous temperatures to 0.0 + memset( &heaterStatus[ heater ].previousTemps, 0.0, sizeof( TEMPERATURES_MOVING_AVG_SIZE ) ); + } + // Initialize the PI controller for the primary heaters - initializePIController( PI_CONTROLLER_ID_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_P_COEFFICIENT, PRIMARY_HEATERS_I_COEFFICIENT, - HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ); + initializePIController( PI_CONTROLLER_ID_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATER_P_COEFFICIENT, PRIMARY_HEATER_I_COEFFICIENT, + HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); // Initialize the PI controller for the trimmer heater - initializePIController( PI_CONTROLLER_ID_TRIMMER_HEATER, HEATERS_MIN_DUTY_CYCLE, TRIMMER_HEATER_P_COEFFICIENT, - TRIMMER_HEATER_I_COEFFICIENT, HEATERS_MIN_DUTY_CYCLE, TRIMMER_HEATER_MAX_DUTY_CYCLE ); + initializePIController( PI_CONTROLLER_ID_TRIMMER_HEATER, HEATERS_MIN_DUTY_CYCLE, TRIMMER_HEATER_P_COEFFICIENT, TRIMMER_HEATER_I_COEFFICIENT, + HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); } /*********************************************************************//** * @brief - * The setPrimaryHeaterTargetTemperature function sets the primary heater - * target temperature. + * The setHeaterTargetTemperature function sets the target temperature of a heater. * @details Inputs: none - * @details Outputs: primaryHeaterTargetTemperature - * @param targetTemp target temperature for the primary heater + * @details Outputs: heaterStatus + * @param heater: heater ID that its target temperature is set + * @param targetTemperature: target temperature of that the heater has to + * heat the fluid * @return none *************************************************************************/ -void setPrimaryHeaterTargetTemperature( F32 targetTemp ) +void setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ) { - primaryHeaterTargetTemperature = targetTemp; + if( heater < NUM_OF_DG_HEATERS ) + { + if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + { + heaterStatus[ heater ].targetTemp = targetTemperature; + // TODO alarm if temperature if out of range or just reject? + } + } + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) + } } /*********************************************************************//** * @brief - * The setTrimmerHeaterTargetTemperature function sets the trimmer heater - * target temperature. + * The getHeaterTargetTemperature function returns the heater target temperature. * @details Inputs: none - * @details Outputs: trimmerHeaterTargetTemperature - * @param targetTemp target temperature for the trimmer heater - * @return none + * @details Outputs: heaterStatus + * @return heater target temperature *************************************************************************/ -void setTrimmerHeaterTargetTemperature( F32 targetTemp ) +F32 getHeaterTargetTemperature( DG_HEATERS_T heater ) { - trimmerHeaterTargetTemperature = targetTemp; + return heaterStatus[ heater ].targetTemp; } /*********************************************************************//** * @brief - * The getPrimaryHeaterTargetTemperature function return the primary heater - * target temperature. - * @details Inputs: primaryHeaterTargetTemperature - * @details Outputs: none - * @return the current primary heater target temperature - *************************************************************************/ -F32 getPrimaryHeaterTargetTemperature( void ) -{ - return primaryHeaterTargetTemperature; -} - -/*********************************************************************//** - * @brief * The startPrimaryHeater function starts the primary heaters. It resets * the primary heaters state and sets the main primary heater duty cycle. * @details Inputs: primaryHeaterTargetTemperature * @details Outputs: hasStartPrimaryHeaterRequested * @return status *************************************************************************/ -BOOL startPrimaryHeater( void ) +BOOL startHeater( DG_HEATERS_T heater ) { BOOL status = FALSE; - if ( ( primaryHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( primaryHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + if( heater < NUM_OF_DG_HEATERS ) { - hasStartPrimaryHeaterRequested = TRUE; - status = TRUE; - } + F32 targetTemp = heaterStatus[ heater ].targetTemp; - return status; -} - -/*********************************************************************//** - * @brief - * The startTrimmerHeater function starts the trimmer heater. It resets the - * trimmer heater's state and sets the duty cycle of the trimmer heater. - * @details Inputs: trimmerHeaterTargetTemperature - * @details Outputs: hasStartTrimmerHeaterRequested - * @return status - *************************************************************************/ -BOOL startTrimmerHeater( void ) -{ - BOOL status = FALSE; - - if ( ( trimmerHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( trimmerHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + if ( ( targetTemp >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemp <= MAXIMUM_TARGET_TEMPERATURE ) ) + { + status = TRUE; + heaterStatus[ heater ].startHeaterSignal = TRUE; + } + } + else { - hasStartTrimmerHeaterRequested = TRUE; - status = TRUE; + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) } return status; } /*********************************************************************//** * @brief - * The stopPrimaryHeater function stops the primary heater. + * The stopHeater stops the specified heater. * @details Inputs: none - * @details Outputs: Primary heater stops - * @return none + * @details Outputs: heaterStatus + * @param heater: heater ID that is requested to turn on + * @return TRUE if the start was accepted otherwise, FALSE *************************************************************************/ -void stopPrimaryHeater( void ) +void stopHeater( DG_HEATERS_T heater ) { - isPrimaryHeaterOn = FALSE; + heaterStatus[ heater ].isHeaterOn = FALSE; } /*********************************************************************//** * @brief - * The stopTrimmerHeater function stops the trimmer heater. - * @details Inputs: none - * @details Outputs: Trimmer heater stops + * The execHeaters function executes the heaters state machine. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus * @return none *************************************************************************/ -void stopTrimmerHeater( void ) +void execHeaters( void ) { - isTrimmerHeaterOn = FALSE; + DG_HEATERS_T heater; + HEATERS_STATE_T state; + + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + state = heaterStatus[ heater ].state; + + switch( state ) + { + case HEATER_EXEC_STATE_NOT_RUNNING: + heaterStatus[ heater ].state = handleHeaterStateNotRunning( heater ); + break; + + case HEATER_EXEC_STATE_RAMP_TO_TARGET: + heaterStatus[ heater ].state = handleHeaterStateRampToTarget( heater ); + break; + + case HEATER_EXEC_STATE_CONTROL_TO_TARGET: + heaterStatus[ heater ].state = handleHeaterStateControlToTarget( heater ); + break; + + default: + // The heater is in an unknown state. Turn it off and switch to not running state + stopHeater( heater ); + heaterStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_EXEC_STATE, heater ); + break; + } + } } /*********************************************************************//** @@ -311,8 +315,8 @@ { cmdResponse.rejected = FALSE; #ifndef DISABLE_HEATERS_AND_TEMPS - trimmerHeaterTargetTemperature = heaterCmdPtr->targetTemp; - hasStartTrimmerHeaterRequested = TRUE; + heaterStatus[ DG_TRIMMER_HEATER ].targetTemp = heaterCmdPtr->targetTemp; + heaterStatus[ DG_TRIMMER_HEATER ].startHeaterSignal = TRUE; #endif } else @@ -323,7 +327,7 @@ else { cmdResponse.rejected = FALSE; - stopTrimmerHeater(); + stopHeater( DG_TRIMMER_HEATER ); } sendCommandResponseMsg( &cmdResponse ); @@ -360,7 +364,7 @@ * In the monitor, trimmer heater is only monitored if heat disinfect mode is active. Trimmer heater is usually * controlled by HD so checking the DG flow rate to decide whether it should be on or off is not appropriate */ - BOOL isModeHeat = ( DG_MODE_HEAT == getCurrentOperationMode() ) && ( TRUE == isTrimmerHeaterOn ); + /*BOOL isModeHeat = ( DG_MODE_HEAT == getCurrentOperationMode() ) && ( TRUE == isTrimmerHeaterOn ); BOOL isHeaterOn = ( TRUE == isPrimaryHeaterOn ) || ( TRUE == isModeHeat ); BOOL isPWMNonZero = ( mainPrimaryHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ) || ( smallPrimaryHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ) || ( trimmerHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ); @@ -391,237 +395,268 @@ isFlowBelowMin = FALSE; heatersOnWithNoFlowTimer = getMSTimerCount(); } - } + }*/ // Check for data publication publishHeatersData(); } /*********************************************************************//** * @brief - * The execPrimaryHeaters function executes the primary heaters' state machine. - * @details Inputs: primaryHeatersExecState - * @details Outputs: primaryHeatersExecState - * @return none + * The handleHeaterStateNotRunning function handles the heater not running state. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @param heater: The heater Id that its not running state is handled + * @return next state of the state machine *************************************************************************/ -void execPrimaryHeaters( void ) +static HEATERS_STATE_T handleHeaterStateNotRunning( DG_HEATERS_T heater ) { - switch ( primaryHeatersExecState ) + HEATERS_STATE_T state = HEATER_EXEC_STATE_NOT_RUNNING; + + if ( TRUE == heaterStatus[ heater ].startHeaterSignal ) { - case PRIMARY_HEATERS_EXEC_STATE_OFF: - primaryHeatersExecState = handlePrimaryHeaterStateOff(); - break; + heaterStatus[ heater ].isHeaterOn = TRUE; + heaterStatus[ heater ].startHeaterSignal = FALSE; + heaterStatus[ heater ].targetROFlow = getTargetROPumpFlowRate(); - case PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET: - primaryHeatersExecState = handlePrimaryHeaterStateControlToTarget(); - break; + // If the operation mode is heat disinfect and the heater is primary heater, change the feedback sensor to THd + if ( ( DG_MODE_HEAT == getCurrentOperationMode() ) && ( DG_PRIMARY_HEATER == heater ) ) + { + heaterStatus[ heater ].feedbackSensor = TEMPSENSORS_HEAT_DISINFECT; + } - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_PRIMARY_HEATER_EXEC_INVALID_STATE, primaryHeatersExecState ); - primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; - break; - } -} + TEMPERATURE_SENSORS_T sensor = heaterStatus[ heater ].feedbackSensor; + F32 feedbackTemperature = getTemperatureValue( (U32)sensor ); + F32 targetTemperature = heaterStatus[ heater ].targetTemp; -/*********************************************************************//** - * @brief - * The execTrimmerHeater function executes the trimmer heater's state machine. - * @details Inputs: trimmerHeaterExecState - * @details Outputs: trimmerHeaterExecState - * @return none - *************************************************************************/ -void execTrimmerHeater( void ) -{ - switch ( trimmerHeaterExecState ) - { - case TRIMMER_HEATER_EXEC_STATE_OFF: - trimmerHeaterExecState = handleTrimmerHeaterStateOff(); - break; + if ( targetTemperature > feedbackTemperature ) + { + // Set the heater duty cycle to maximum + setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); + } + else + { + // Set the heater duty cycle to minimum since we are cooling + setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + } - case TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET: - trimmerHeaterExecState = handleTrimmerHeaterControlToTarget(); - break; + // Once the heater is staring for the first time so no minimum ramp time is needed + heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_TRIMMER_HEATER_EXEC_INVALID_STATE, trimmerHeaterExecState ); - trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; - break; + // Turn on the heater + state = HEATER_EXEC_STATE_RAMP_TO_TARGET; } + + return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateOff function handles the primary heaters at - * off state. - * @details Inputs: hasStartPrimaryHeaterRequested, isPrimaryHeaterOn - * @details Outputs: state (PRIMARY_HEATERS_EXEC_STATES_T), isPrimaryHeaterOn - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStateRampToTarget function handles the heaters' control + * while they are ramping to target temperature. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @param heater: The heater Id that its on state is handled + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ) +static HEATERS_STATE_T handleHeaterStateRampToTarget( DG_HEATERS_T heater ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_OFF; + HEATERS_STATE_T state = HEATER_EXEC_STATE_RAMP_TO_TARGET; - if ( TRUE == hasStartPrimaryHeaterRequested ) + TEMPERATURE_SENSORS_T sensor = heaterStatus[ heater ].feedbackSensor; + F32 feedbackTemperature = getTemperatureValue( (U32)sensor ); + // Continuously get the target temperature in case it was changed dynamically + F32 targetTemperature = heaterStatus[ heater ].targetTemp; + U32 currentIndex = heaterStatus[ heater ].previousTempsIndex; + + if ( ++heaterStatus[ heater ].controlTimerCounter > HEATERS_RAMP_STATE_CHECK_INTERVAL_COUNT ) { - resetHeaterState( PRIMARY_HEATER ); - // Once the primary heaters duty cycle is set, it is divided into 2 - // so both heaters will start and both elements are heated up - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - isPrimaryHeaterOn = TRUE; - hasStartPrimaryHeaterRequested = FALSE; + U32 i; + F32 slope; + F32 deltaTemperature; + F32 deltaDutyCycle; + F32 dutyCycle; + F32 revDeltaDutyCycle; + F32 inletTemperature; + F32 measuredFlow; - // Check if the operation mode is heat disinfect. If the mode is - // heat disinfect, the feedback sensor will be Thd - if ( DG_MODE_HEAT == getCurrentOperationMode() ) + // Set the hand off flag to false + BOOL isItHandOffTime = FALSE; + + // Update the temperature data array as well as the next index + heaterStatus[ heater ].previousTemps[ currentIndex ] = feedbackTemperature; + heaterStatus[ heater ].previousTempsIndex = INC_WRAP( currentIndex, 0, TEMPERATURES_MOVING_AVG_SIZE - 1 ); + + // Calculate the running sum of the temperatures + for ( i = 0; i < TEMPERATURES_MOVING_AVG_SIZE; i++ ) { -#ifdef THD_USING_TRO_CONNECTOR - // Set the feedback temperature sensor - // THd uses TRo in V3 - primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_REDUNDANT; -#else - primaryHeatersFeedbackTempSensor = TEMPSENSORS_HEAT_DISINFECT; -#endif + slope += heaterStatus[ heater ].previousTemps[ i ]; } - state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + // If the heater is the primary heater, + if ( DG_PRIMARY_HEATER == heater ) + { + inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + } + else + { + // TODO figure out the trimmer strategy + } + + slope = slope / (F32)TEMPERATURES_MOVING_AVG_SIZE; + measuredFlow = getMeasuredROFlowRate(); + dutyCycle = calculateHeaterDutyCycle( targetTemperature, inletTemperature, measuredFlow ); + deltaDutyCycle = ( feedbackTemperature <= targetTemperature ? HEATERS_MAX_DUTY_CYCLE - dutyCycle : dutyCycle ); + + // TODO add #defines for all these constants + revDeltaDutyCycle = ( deltaDutyCycle - 0.0 < NEARLY_ZERO ? 0 : 1.0 / deltaDutyCycle ); + revDeltaDutyCycle = ( revDeltaDutyCycle * 0.1 < 1.0 ? revDeltaDutyCycle * 0.1 : 1.0 ); + deltaTemperature = ( ( atanf( slope ) * 1.27 ) / measuredFlow ) + revDeltaDutyCycle; + + if ( fabs( targetTemperature - feedbackTemperature ) < deltaTemperature ) + { + if ( TRUE == didTimeout( heaterStatus[ heater ].rampStateStartTime, HEATERS_MIN_RAMP_TIME_MS ) ) + { + isItHandOffTime = TRUE; + } + } + else if ( feedbackTemperature > targetTemperature ) + { + isItHandOffTime = TRUE; + } + + if ( TRUE == isItHandOffTime ) + { + setHeaterDutyCycle( heater, dutyCycle ); + resetPIController( heaterStatus[ heater ].controllerID, dutyCycle ); // TODO remove? + + heaterStatus[ heater ].initialDutyCycle = dutyCycle; + + state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; + } + + heaterStatus[ heater ].controlTimerCounter = 0; } + // Check if the heater is requested to be off + if ( FALSE == heaterStatus[ heater ].isHeaterOn ) + { + setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + state = HEATER_EXEC_STATE_NOT_RUNNING; + } + return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateControlToTarget function handles the primary - * heaters at control state when the heaters are active. - * @details Inputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle, isPrimaryHeaterOn - * @details Outputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStateControlToTarget function handles the heaters' control + * to target while they have reached to target. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @param heater: The heater Id that its on state is handled + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ) +static HEATERS_STATE_T handleHeaterStateControlToTarget( DG_HEATERS_T heater ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; - if ( ++primaryHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) + F32 targetFlow = getTargetROPumpFlowRate(); + BOOL hasFlowChanged = ( fabs( targetFlow - heaterStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + + if ( TRUE == hasFlowChanged ) { - // Check if the flow is not below minimum required first - // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range - // If the flow is within range, run the PI controller to control the heaters normally - if ( FALSE == isFlowBelowMin ) - { - F32 outletTemp = getTemperatureValue( primaryHeatersFeedbackTempSensor ); - mainPrimaryHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, primaryHeaterTargetTemperature, outletTemp ); + // Moving back from control to target to ramp. + heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); + heaterStatus[ heater ].targetROFlow = targetFlow; - // Once the primary heaters duty cycle is set, it is divided into 2 so both heaters will start and both elements are heated up - smallPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - mainPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; + // Go back to ramp state with 100% duty cycle + setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); + state = HEATER_EXEC_STATE_RAMP_TO_TARGET; + } + else if ( ++heaterStatus[ heater ].controlTimerCounter > HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ) + { + F32 feedbackTemperature = getTemperatureValue( (U32)heaterStatus[ heater ].feedbackSensor ); + F32 targetTemperature = heaterStatus[ heater ].targetTemp; + F32 dutyCycle = heaterStatus[ heater ].dutycycle; - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); + dutyCycle += ( targetTemperature - feedbackTemperature ) * PRIMARY_HEATER_P_COEFFICIENT * getMeasuredROFlowRate(); + + F32 deltaDutyCycle = dutyCycle - heaterStatus[ heater ].initialDutyCycle; + + if ( ( fabs( deltaDutyCycle ) > 0.09 ) && ( deltaDutyCycle < 0.0 ) ) + { + dutyCycle = heaterStatus[ heater ].initialDutyCycle - 0.09; } - // Flow is below the minimum required flow to run the primary heaters - else + else if ( deltaDutyCycle > 0.09 ) { - setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); + dutyCycle = heaterStatus[ heater ].initialDutyCycle + 0.09; } - primaryHeaterTimerCounter = 0; - } + dutyCycle = ( dutyCycle > HEATERS_MAX_DUTY_CYCLE ? HEATERS_MAX_DUTY_CYCLE : dutyCycle ); + dutyCycle = ( dutyCycle < HEATERS_MIN_DUTY_CYCLE ? HEATERS_MIN_DUTY_CYCLE : dutyCycle ); - // If the primary heater is running and another start primary heater request - // is set, reset the primary heater again - if ( TRUE == hasStartPrimaryHeaterRequested ) - { - resetHeaterState( PRIMARY_HEATER ); - hasStartPrimaryHeaterRequested = FALSE; + setHeaterDutyCycle( heater, dutyCycle ); + + heaterStatus[ heater ].controlTimerCounter = 0; } - if ( FALSE == isPrimaryHeaterOn ) + // Check if the heater is requested to be off + if ( FALSE == heaterStatus[ heater ].isHeaterOn ) { - // Switch to off state. Set the duty cycles to 0 - mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - state = PRIMARY_HEATERS_EXEC_STATE_OFF; + setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + state = HEATER_EXEC_STATE_NOT_RUNNING; } return state; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterStateOff function handles the trimmer heater at - * off state. - * @details Inputs: hasStartTrimmerHeaterRequested, isTrimmerHeaterOn - * @details Outputs: state (TRIMMER_HEATER_EXEC_STATES_T), isTrimmerHeaterOn - * @return state (TRIMMER_HEATER_EXEC_STATES_T) + * The setHeaterDutyCycle function sets the duty cycle of a heater. + * @details Inputs: none + * @details Outputs: none + * @param heater: The heater Id that its duty cycle is set + * @param pwm: The PWM that is set + * @return none *************************************************************************/ -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ) +static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ) { - TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_OFF; - - if ( TRUE == hasStartTrimmerHeaterRequested ) + if ( DG_PRIMARY_HEATER == heater ) { - resetHeaterState( TRIMMER_HEATER ); - isTrimmerHeaterOn = TRUE; - hasStartTrimmerHeaterRequested = FALSE; - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + setMainPrimaryHeaterPWM( pwm ); + setSmallPrimaryHeaterPWM( pwm ); } + else if ( DG_TRIMMER_HEATER == heater ) + { + setTrimmerHeaterPWM( pwm ); + } - return state; + heaterStatus[ heater ].dutycycle = pwm; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterControlToTarget function handles the trimmer - * heater at control state when the heater is active. - * @details Inputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle - * @details Outputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle, - * isTrimmerHeaterOn - * @return state (TRIMMER_HEATER_EXEC_STATES_T) + * The calculateHeaterDutyCycle function calculates a heater's duty cycle + * by providing the + * @details Inputs: none + * @details Outputs: primaryHeaterTargetTemperature + * @param targetTemp target temperature for the primary heater + * @return none *************************************************************************/ -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ) +static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 targetFlow ) { - TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + // The power is proportional to square root of deltaT x flow + F32 power = sqrt( fabs( targetTemperature - currentTemperature ) * targetFlow ); - if ( ++trimmerHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) - { - // Check if the flow is not below minimum required first - // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range - // If the flow is within range, run the PI controller to control the heaters normally - if ( FALSE == isFlowBelowMin ) - { - F32 outletTemp = getTemperatureValue( trimmerHeaterFeedbackTempSensor ); - trimmerHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, trimmerHeaterTargetTemperature, outletTemp ); - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - } - else - { - setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - } + // PWM = ( power * A - B ) + F32 dutyCycle = ( ( power * PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_SLOPE ) - PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_INTERCEPT ); - trimmerHeaterTimerCounter = 0; - } + // Check the boundaries of the calculated duty cycle + dutyCycle = ( dutyCycle > HEATERS_MAX_DUTY_CYCLE ? HEATERS_MAX_DUTY_CYCLE : dutyCycle ); + dutyCycle = ( dutyCycle < HEATERS_MIN_DUTY_CYCLE ? HEATERS_MIN_DUTY_CYCLE : dutyCycle ); - if ( TRUE == hasStartTrimmerHeaterRequested ) - { - hasStartTrimmerHeaterRequested = FALSE; - } - - if ( FALSE == isTrimmerHeaterOn ) - { - // Set the duty cycle to 0 and switch to off state - trimmerHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - state = TRIMMER_HEATER_EXEC_STATE_OFF; - } - - return state; + return dutyCycle; } /*********************************************************************//** @@ -665,51 +700,6 @@ /*********************************************************************//** * @brief - * The resetHeaterState function resets the PI controller of the selected heater. - * @details Inputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * @details Outputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * @param heater enumeration of the heater for which the PI controller will be reset - * @return none - *************************************************************************/ -static void resetHeaterState( NAME_OF_HEATER_T heater ) -{ - if ( PRIMARY_HEATER == heater ) - { - // Calculate the delta temperature from the inlet primary heater to target temperature - F32 inletPrimaryHeaterTemp = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); - F32 deltaTemp = primaryHeaterTargetTemperature - inletPrimaryHeaterTemp; - - // If the delta temperature (target temperature - inlet primary heater temperature) - // Is 0 or negative, the duty cycle is 0.0 - if ( deltaTemp <= 0.0 ) - { - mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - } - else - { - // The formula for the initial guess is: (delta temperature * target flow) / 2.0 - F32 targetFlow = getTargetROPumpFlowRate(); - F32 duty = ( targetFlow * deltaTemp ) / PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR; - // If the duty cycle is greater 200% on the primary and small primary heaters, set it to 200%, otherwise set it to the - // estimated duty cycles - duty = ( duty > PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ? PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE : duty ); - mainPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - smallPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - } - - // The PI controller of the primary heater consists of main and small primary heaters duty cycles - resetPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, mainPrimaryHeaterDutyCycle + smallPrimaryHeaterDutyCycle ); - } - else if ( TRIMMER_HEATER == heater ) - { - trimmerHeaterDutyCycle = TRIMMER_HEATER_MAX_DUTY_CYCLE; - resetPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, TRIMMER_HEATER_MAX_DUTY_CYCLE ); - } -} - -/*********************************************************************//** - * @brief * The publishTemperatureData function publishes the heaters data into * at the defined time interval. * @details Inputs: dataPublicationTimerCounter @@ -722,14 +712,20 @@ { HEATERS_DATA_T data; - data.mainPrimayHeaterDC = mainPrimaryHeaterDutyCycle * 100.0; - data.smallPrimaryHeaterDC = smallPrimaryHeaterDutyCycle * 100.0; - data.trimmerHeaterDC = trimmerHeaterDutyCycle * 100.0; - data.primaryTargetTemp = primaryHeaterTargetTemperature; - data.trimmerTargetTemp = trimmerHeaterTargetTemperature; + data.mainPrimayHeaterDC = heaterStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + // The duty cycle of the primary heater is divided into 2 parts and is applied to main + // and small primary heaters. So they are always the same. + data.smallPrimaryHeaterDC = heaterStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + data.trimmerHeaterDC = heaterStatus[ DG_TRIMMER_HEATER ].dutycycle * 100.0; + data.primaryTargetTemp = heaterStatus[ DG_PRIMARY_HEATER ].targetTemp; + data.trimmerTargetTemp = heaterStatus[ DG_TRIMMER_HEATER ].targetTemp; + data.primaryHeaterState = heaterStatus[ DG_PRIMARY_HEATER ].state; + data.trimmerHeaterState = heaterStatus[ DG_TRIMMER_HEATER ].state; - broadcastHeatersData( &data ); + //broadcastHeatersData( &data ); + broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); + dataPublicationTimerCounter = 0; } } @@ -760,8 +756,8 @@ SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_PRIMARY_HEATER_CJ_TEMP_OUT_OF_RANGE, primaryHeaterInternalTemp ); } - // If any of the temperatures are above the range - if ( ( FALSE == isPrimaryHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) + /*/ If any of the temperatures are above the range + /if ( ( FALSE == isPrimaryHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) { stopPrimaryHeater(); isPrimaryHeaterTempOutOfRange = TRUE; @@ -773,7 +769,7 @@ { isPrimaryHeaterTempOutOfRange = FALSE; activateSafetyShutdown(); - } + }*/ } /*********************************************************************//** @@ -804,7 +800,7 @@ // If it is above the range for the first time, stop the trimmer heater // and set the variables - if ( ( FALSE == isTrimmerHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) + /*if ( ( FALSE == isTrimmerHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) { stopTrimmerHeater(); isTrimmerHeaterTempOutOfRange = TRUE; @@ -815,7 +811,7 @@ ( TRUE == didTimeout( trimmerHeaterTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) ) { activateSafetyShutdown(); - } + }*/ } /*********************************************************************//** @@ -827,7 +823,7 @@ *************************************************************************/ static void monitorHeatersVoltage( void ) { - if ( ++heatersVoltageMonitorTimeCounter >= HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ) + if ( ++voltageMonitorTimeCounter >= HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ) { F32 mainPriVoltage = getIntADCVoltageConverted( INT_ADC_PRIMARY_HEATER_24_VOLTS ); // TODO it is assumed that the main and small primary heaters have equal voltage since the PWMs are divided into 2 @@ -837,9 +833,9 @@ F32 trimmerVoltage = getIntADCVoltageConverted( INT_ADC_TRIMMER_HEATER_24_VOLTS ); // Voltage to PWM is reverse. If PWM = 0 -> V = 24V - F32 mainPri = 1.0 - mainPrimaryHeaterDutyCycle; - F32 smallPri = 1.0 - smallPrimaryHeaterDutyCycle; - F32 trimmer = 1.0 - trimmerHeaterDutyCycle; + F32 mainPri = 1.0 - heaterStatus[ DG_PRIMARY_HEATER ].dutycycle; + F32 smallPri = 1.0 - heaterStatus[ DG_PRIMARY_HEATER ].dutycycle; + F32 trimmer = 1.0 - heaterStatus[ DG_TRIMMER_HEATER ].dutycycle; // Check main primary heater's voltage // The corresponding voltage of the current PWM must be close to the sensed voltage @@ -858,7 +854,7 @@ SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, trimmerVoltage ); } - heatersVoltageMonitorTimeCounter = 0; + voltageMonitorTimeCounter = 0; } } Index: firmware/App/Controllers/Heaters.h =================================================================== diff -u -r037f0edb0b880130563058c809ba50308f2a63e9 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/Heaters.h (.../Heaters.h) (revision 037f0edb0b880130563058c809ba50308f2a63e9) +++ firmware/App/Controllers/Heaters.h (.../Heaters.h) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -34,8 +34,14 @@ // ********** Public definitions ********** -#pragma pack(push,1) +typedef enum Heaters +{ + DG_PRIMARY_HEATER = 0, + DG_TRIMMER_HEATER, + NUM_OF_DG_HEATERS, +} DG_HEATERS_T; +#pragma pack(push,1) /// Target temperature data structure. typedef struct { @@ -58,32 +64,29 @@ F32 trimmerHeaterDC; ///< Trimmer heater DC F32 primaryTargetTemp; ///< Primary heaters target temperature F32 trimmerTargetTemp; ///< Trimmer heater target temperature + U32 primaryHeaterState; ///< Primary heater state + U32 trimmerHeaterState; ///< Trimmer heater state } HEATERS_DATA_T; - #pragma pack(pop) // ********** Public function prototypes ********** void initHeaters( void ); -void setPrimaryHeaterTargetTemperature( F32 targetTemp ); -void setTrimmerHeaterTargetTemperature( F32 targetTemp ); +void setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ); -F32 getPrimaryHeaterTargetTemperature( void ); +BOOL startHeater( DG_HEATERS_T heater ); -BOOL startPrimaryHeater( void ); -BOOL startTrimmerHeater( void ); +F32 getHeaterTargetTemperature( DG_HEATERS_T heater ); -void stopPrimaryHeater( void ); -void stopTrimmerHeater( void ); +void stopHeater( DG_HEATERS_T heater ); +void execHeaters( void ); + void handleTrimmerHeaterCmd( TRIMMER_HEATER_CMD_T *heaterCmdPtr ); // handle trimmer heater control command from HD void execHeatersMonitor( void ); -void execPrimaryHeaters( void ); -void execTrimmerHeater( void ); - BOOL testSetHeatersPublishIntervalOverride( U32 value ); BOOL testResetHeatersPublishIntervalOverride( void ); Index: firmware/App/Controllers/LoadCell.c =================================================================== diff -u -rcbcd41ec1ac2d5ae6446ec206ed6991a5306c249 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/LoadCell.c (.../LoadCell.c) (revision cbcd41ec1ac2d5ae6446ec206ed6991a5306c249) +++ firmware/App/Controllers/LoadCell.c (.../LoadCell.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -34,51 +34,57 @@ // TODO check the maximum weight on the load cells in tare. There was 1500 grams limit // but it has been removed. Check the load cells data sheet. -#define LOAD_CELL_REPORT_PERIOD (100 / TASK_PRIORITY_INTERVAL) ///< Broadcast load cell values message every 100 ms. +#define LOAD_CELL_REPORT_PERIOD (100 / TASK_PRIORITY_INTERVAL) ///< Broadcast load cell values message every 100 ms. /// Conversion factor from ADC counts to grams. -static const F32 ADC2GRAM = (0.0894 * 1.1338); -#define LOAD_CELL_FILTER_ALPHA 0.05 ///< Alpha factor for the alpha filter used on load cell readings. +static const F32 ADC2GRAM = (0.0894 * 1.1338); +#define LOAD_CELL_FILTER_ALPHA 0.05 ///< Alpha factor for the alpha filter used on load cell readings. -#define SIZE_OF_SMALL_LOAD_CELL_AVG 100 ///< Small load cell moving average has 100 raw samples @ 10ms intervals (1-second). -#define SIZE_OF_LARGE_LOAD_CELL_AVG 40 ///< Large load cell moving average has 40 samples from small filter @ 100ms intervals (4-second). +#define SIZE_OF_SMALL_LOAD_CELL_AVG 100 ///< Small load cell moving average has 100 raw samples @ 10ms intervals (1-second). +#define SIZE_OF_LARGE_LOAD_CELL_AVG 40 ///< Large load cell moving average has 40 samples from small filter @ 100ms intervals (4-second). -#define LOAD_CELL_ADC_ERROR_PERSISTENCE 500 ///< Alarm persistence period (in ms) for load cell ADC errors. -#define EMPTY_RESERVOIR_WEIGHT_GRAMS 1600 ///< Reservoirs empty weight in grams. -#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_FIRST_TARE_GRAMS 300 ///< Max allowed extra weight before first tare in grams. -#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS 15 ///< Max allowed extra weight before tare in grams. +#define LOAD_CELL_ADC_ERROR_PERSISTENCE 500 ///< Alarm persistence period (in ms) for load cell ADC errors. +#define LOAD_CELL_MIN_ALLOWED_WEIGHT_GRAMS 0.0 ///< Load cell minimum allowed weight in grams. +#define LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS 4500.0 ///< Load cell maximum allowed weight in grams. +#define LOAD_CELL_MIN_ALLOWED_WEIGHT_BEFORE_TARE_GRAMS 1600.0 ///< Load cell minimum allowed weight before tare in grams. +#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS 300.0 ///< Max allowed extra weight before tare in grams. +#define LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS (5 * MS_PER_SECOND) ///< Load cell weight out of range persistent period in milliseconds. +#define LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS 60.0 ///< Load cell primary and backup maximum allowed weight drift in grams. +#define LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS (5 * MS_PER_SECOND) ///< Load cell primary and backup maximum allowed weight drift persistent period in milliseconds. /// Load cell data structure. typedef struct { - U32 rawReading; ///< Latest raw load cell reading - OVERRIDE_F32_T weight; ///< Latest load cell weight - F32 autoCalOffset; ///< Load cell auto-calibration offset - F32 loadCellVelocity_g_min; ///< Velocity (in g/min) of load cell. + U32 rawReading; ///< Latest raw load cell reading + OVERRIDE_F32_T weight; ///< Latest load cell weight + F32 autoCalOffset; ///< Load cell auto-calibration offset + F32 loadCellVelocity_g_min; ///< Velocity (in g/min) of load cell. - F32 smallFilterReadings[ SIZE_OF_SMALL_LOAD_CELL_AVG ]; ///< Load cell samples for small load cell moving average. - F64 smallFilterTotal; ///< Small filter rolling total - used to calc small load cell moving average. - F32 smallFilteredWeight; ///< Load cell small filtered (100 100Hz raw sample) weight. + F32 smallFilterReadings[ SIZE_OF_SMALL_LOAD_CELL_AVG ]; ///< Load cell samples for small load cell moving average. + F64 smallFilterTotal; ///< Small filter rolling total - used to calc small load cell moving average. + F32 smallFilteredWeight; ///< Load cell small filtered (100 100Hz raw sample) weight. - F32 largeFilterReadings[ SIZE_OF_LARGE_LOAD_CELL_AVG ]; ///< Load cell samples for large load cell moving average. - F64 largeFilterTotal; ///< Large filter rolling total - used to calc small load cell moving average. - F32 largeFilteredWeight; ///< Load cell large filtered (40 10Hz filtered sample) weight. + F32 largeFilterReadings[ SIZE_OF_LARGE_LOAD_CELL_AVG ]; ///< Load cell samples for large load cell moving average. + F64 largeFilterTotal; ///< Large filter rolling total - used to calc small load cell moving average. + F32 largeFilteredWeight; ///< Load cell large filtered (40 10Hz filtered sample) weight. } LOADCELL_T; // ********** private data ********** static OVERRIDE_U32_T loadCellDataPublishInterval = { LOAD_CELL_REPORT_PERIOD, - LOAD_CELL_REPORT_PERIOD, 0, 0 }; ///< Broadcast load cell data publish interval. -static LOADCELL_T loadcells[ NUM_OF_LOAD_CELLS ]; ///< Load cell data structures. -static U32 loadCellFilterTimerCount = 0; ///< Load cell filtering timer count. -static U32 loadCellDataPublicationTimerCounter = 0; ///< Load cell data publication timer counter to CAN bus. + LOAD_CELL_REPORT_PERIOD, 0, 0 }; ///< Broadcast load cell data publish interval. +static LOADCELL_T loadcells[ NUM_OF_LOAD_CELLS ]; ///< Load cell data structures. +static U32 loadCellFilterTimerCount = 0; ///< Load cell filtering timer count. +static U32 loadCellDataPublicationTimerCounter = 0; ///< Load cell data publication timer counter to CAN bus. -static U32 smallReadingsIdx; ///< Index for next sample in load cell small rolling average sample array. -static U32 largeReadingsIdx; ///< Index for next sample in load cell large rolling average sample array. -static DG_LOAD_CELLS_CAL_RECORD_T loadCellsCalRecord; ///< Load cells calibration record. +static U32 smallReadingsIdx; ///< Index for next sample in load cell small rolling average sample array. +static U32 largeReadingsIdx; ///< Index for next sample in load cell large rolling average sample array. +static DG_LOAD_CELLS_CAL_RECORD_T loadCellsCalRecord; ///< Load cells calibration record. // ********** private function prototypes ********** static BOOL processCalibrationData( void ); +static void monitorLoadCellsWeightOutOfRange( LOAD_CELL_ID_T loadCell ); +static void monitorLoadCellsPrimaryBackupDriftOutOfRange( void ); /*********************************************************************//** * @brief @@ -87,9 +93,8 @@ * @details Outputs: LoadCell module initialized. * @return none *************************************************************************/ -void initLoadCell( void ) + void initLoadCell( void ) { - U32 cell; U32 i; U32 j; @@ -126,18 +131,14 @@ loadcells[ i ].loadCellVelocity_g_min = 0.0; } - for ( cell = CAL_DATA_LOAD_CELL_A1; cell < NUM_OF_CAL_DATA_LOAD_CELLS; cell++ ) - { - // Reset the calibration variables - loadCellsCalRecord.loadCells[ cell ].fourthOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].thirdOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].secondOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].gain = 1.0; - loadCellsCalRecord.loadCells[ cell ].offset = 0.0; - } - // Initialize persistent alarm(s) initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_ADC_ERROR, 0, LOAD_CELL_ADC_ERROR_PERSISTENCE ); + + initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_WEIGHT_OUT_OF_RANGE, LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS, + LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS ); + + initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_PRIMARY_BACKUP_DRIFT_OUT_OF_RANGE, LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS, + LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS ); } /*********************************************************************//** @@ -206,7 +207,14 @@ pow(loadCell, 3) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].thirdOrderCoeff + pow(loadCell, 2) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].secondOrderCoeff + loadCell * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].gain + - loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].offset - loadcells[ ii ].autoCalOffset; + loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].offset; + + // Monitor the load cells weight + monitorLoadCellsWeightOutOfRange( (LOAD_CELL_ID_T)ii ); + + // Apply the tare offset. NOTE: tare must be applied after checking the weight out of range. + //loadcells[ ii ].weight.data = loadcells[ ii ].weight.data - loadcells[ ii ].autoCalOffset; TODO remove this + loadcells[ ii ].smallFilteredWeight -= loadcells[ ii ].autoCalOffset; } smallReadingsIdx = INC_WRAP( smallReadingsIdx, 0, SIZE_OF_SMALL_LOAD_CELL_AVG - 1 ); @@ -242,6 +250,9 @@ loadCellDataPublicationTimerCounter = 0; } + + // Monitor the load cells drift + monitorLoadCellsPrimaryBackupDriftOutOfRange(); } /*********************************************************************//** @@ -290,8 +301,8 @@ { // For the first tare, the weight of the reservoir should be considered // The current weight of the load cell should not be greater than the weight of the reservoir + the extra weight - F32 deltaWeight = fabs( weight - EMPTY_RESERVOIR_WEIGHT_GRAMS ); - isWeightOutOfRange = ( deltaWeight > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_FIRST_TARE_GRAMS ? TRUE : FALSE ); + F32 deltaWeight = fabs( weight - LOAD_CELL_MIN_ALLOWED_WEIGHT_BEFORE_TARE_GRAMS ); + isWeightOutOfRange = ( deltaWeight > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS ? TRUE : FALSE ); } else { @@ -472,7 +483,59 @@ return status; } +/*********************************************************************//** + * @brief + * The monitorLoadCellsWeightOutOfRange function monitors the weight of the + * load cells and if they are not in range, it raises an alarm. + * @details Inputs: none + * @details Outputs: none + * @param loadCell which is the load cell ID that its range is checked + * @return none + *************************************************************************/ +static void monitorLoadCellsWeightOutOfRange( LOAD_CELL_ID_T loadCell ) +{ + F32 weight = getLoadCellSmallFilteredWeight( loadCell ); + BOOL isWeightOutOfRange = ( weight < LOAD_CELL_MIN_ALLOWED_WEIGHT_GRAMS ) || ( weight > LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS ); + checkPersistentAlarm( ALARM_ID_DG_LOAD_CELL_WEIGHT_OUT_OF_RANGE, isWeightOutOfRange, weight, LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS ); +} + +/*********************************************************************//** + * @brief + * The monitorLoadCellsPrimaryBackupDriftOutOfRange function monitors the + * load cells' primary and backup drift. + * @details Inputs: none + * @details Outputs: none + * @return none + *************************************************************************/ +static void monitorLoadCellsPrimaryBackupDriftOutOfRange( void ) +{ + F32 drift; + + F32 loadCellADrift = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ) - + getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_BACKUP ) ); + + F32 loadCellBDrift = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ) - + getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_BACKUP ) ); + + BOOL isDriftOutOfRange = ( loadCellADrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ) || + ( loadCellBDrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ); + + if ( TRUE == isDriftOutOfRange ) + { + drift = ( loadCellADrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ? loadCellADrift : loadCellBDrift ); + } + else + { + // Pick the biggest drift in between the two load cells when none of the is above range + drift = ( loadCellADrift > loadCellBDrift ? loadCellADrift : loadCellBDrift ); + } + + //checkPersistentAlarm( ALARM_ID_DG_LOAD_CELL_PRIMARY_BACKUP_DRIFT_OUT_OF_RANGE, isDriftOutOfRange, drift, + // LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ); +} + + /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/ Index: firmware/App/Controllers/Switches.c =================================================================== diff -u -r922516483829939a2a387d4a2fddeccdb4c454d4 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/Switches.c (.../Switches.c) (revision 922516483829939a2a387d4a2fddeccdb4c454d4) +++ firmware/App/Controllers/Switches.c (.../Switches.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -33,7 +33,6 @@ // ********** private function prototypes ********** static void publishSwitchesData( void ); -static U32 getPublishSwitchesDataInterval( void ); /*********************************************************************//** * @brief @@ -160,7 +159,7 @@ *************************************************************************/ static void publishSwitchesData( void ) { - if ( ++switchesDataPublicationCounter > getPublishSwitchesDataInterval() ) + if ( ++switchesDataPublicationCounter > getU32OverrideValue( &switchesDataPublishInterval ) ) { SWITCHES_DATA_T data; @@ -174,27 +173,7 @@ } } -/*********************************************************************//** - * @brief - * The getPublishSwitchesDataInterval function returns the data - * publication interval either from the data or from the override. - * @details Inputs: switchesDataPublishInterval - * @details Outputs: none - * @return data publish interval - *************************************************************************/ -static U32 getPublishSwitchesDataInterval( void ) -{ - U32 result = switchesDataPublishInterval.data; - if ( OVERRIDE_KEY == switchesDataPublishInterval.override ) - { - result = switchesDataPublishInterval.ovData; - } - - return result; -} - - /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/ Index: firmware/App/Controllers/TemperatureSensors.c =================================================================== diff -u -rd3819286869611f9c02add72a0f8e321598fdf42 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision d3819286869611f9c02add72a0f8e321598fdf42) +++ firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -163,7 +163,7 @@ static BOOL isADCReadValid( U32 sensorIndex, U32 fpgaError, U32 fpgaCount ); static void processADCRead( U32 sensorIndex, S32 adc ); static void publishTemperatureSensorsData( void ); -static void monitorTemperatureSnsrs( U32 sensorIndex, F32 temperature ); +static void monitorTemperatureSnsrs( U32 sensorIndex ); /*********************************************************************//** * @brief @@ -251,8 +251,8 @@ tempSensors[ TEMPSENSORS_LOAD_CELL_A2_B2 ].conversionCoeff = conversionCoeff; tempSensors[ TEMPSENSORS_LOAD_CELL_A2_B2 ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; - tempSensors[ TEMPSENSORS_INTERNAL_THDO_RTD ].conversionCoeff = conversionCoeff; - tempSensors[ TEMPSENSORS_INTERNAL_THDO_RTD ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + tempSensors[ TEMPSENSORS_INTERNAL_TRO_RTD ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_INTERNAL_TRO_RTD ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; tempSensors[ TEMPSENSORS_INTERNAL_TDI_RTD ].conversionCoeff = conversionCoeff; tempSensors[ TEMPSENSORS_INTERNAL_TDI_RTD ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; @@ -372,7 +372,7 @@ if ( sensorIndex < NUM_OF_TEMPERATURE_SENSORS ) { - if ( tempSensors[ sensorIndex ].temperatureValues.override == OVERRIDE_KEY ) + if ( OVERRIDE_KEY == tempSensors[ sensorIndex ].temperatureValues.override ) { temperature = tempSensors[ sensorIndex ].temperatureValues.ovData; } @@ -539,7 +539,7 @@ case TEMPSENSORS_INLET_PRIMARY_HEATER: // 295 case TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR: // 299 case TEMPSENSORS_OUTLET_REDUNDANT: // 303 - case TEMPSENSORS_INTERNAL_THDO_RTD: // 307 + case TEMPSENSORS_INTERNAL_TRO_RTD: // 307 case TEMPSENSORS_INLET_DIALYSATE: // 311 case TEMPSENSORS_INTERNAL_TDI_RTD: // 315 { @@ -615,8 +615,8 @@ #endif // Check the status of FPGA error and FPGA count - BOOL isFPGAErrorZero = fpgaError == 0; - BOOL isFPGACountChanging = tempSensors[ sensorIndex ].readCount != fpgaCount; + BOOL isFPGAErrorZero = ( fpgaError == 0 ? TRUE : FALSE ); + BOOL isFPGACountChanging = ( tempSensors[ sensorIndex ].readCount != fpgaCount ? TRUE : FALSE ); if ( TRUE == isFPGAErrorZero ) { @@ -627,7 +627,7 @@ } } - BOOL isThereAnError = ( FALSE == isFPGACountChanging ) || ( FALSE == isFPGAErrorZero ); + BOOL isThereAnError = ( ( FALSE == isFPGACountChanging ) || ( FALSE == isFPGAErrorZero ) ? TRUE : FALSE ); checkPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, isThereAnError, sensorIndex, TEMPERATURE_SENSORS_FPGA_ERROR_PERSISTENT_PERIOD ); @@ -691,7 +691,7 @@ case TEMPSENSORS_LOAD_CELL_A1_B1: case TEMPSENSORS_LOAD_CELL_A2_B2: - case TEMPSENSORS_INTERNAL_THDO_RTD: + case TEMPSENSORS_INTERNAL_TRO_RTD: case TEMPSENSORS_INTERNAL_TDI_RTD: case TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR: // Temperature(C) = ((ADC - 0x800000)/13584) - 272.5 @@ -712,7 +712,7 @@ tempSensors[ sensorIndex ].temperatureValues.data = temperature; // Monitor the temperature value - monitorTemperatureSnsrs( sensorIndex, temperature ); + monitorTemperatureSnsrs( sensorIndex ); } /*********************************************************************//** @@ -807,7 +807,7 @@ processTempSnsrsADCRead( TEMPSENSORS_FPGA_BOARD_SENSOR, getFPGABoardTemp(), 0, ++simulatedCounter ); processTempSnsrsADCRead( TEMPSENSORS_LOAD_CELL_A1_B1, getFPGALoadCellsA1B1Temp(), getFPGAADC1ErrorCount(), getFPGAADC1ReadCount() ); processTempSnsrsADCRead( TEMPSENSORS_LOAD_CELL_A2_B2, getFPGALoadCellsA2B2Temp(), getFPGAADC2ErrorCount(), getFPGAADC2ReadCount() ); - processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_THDO_RTD, getFPGATRoInternalTemp(), getFPGATRoErrorCount(), getFPGATRoReadCount() ); + processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_TRO_RTD, getFPGATRoInternalTemp(), getFPGATRoErrorCount(), getFPGATRoReadCount() ); processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_TDI_RTD, getFPGATDiInternalTemp(), getFPGATDiErrorCount(), getFPGATDiReadCount() ); processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR, getFPGACondSnsrInternalTemp(), getFPGARTDErrorCount(), getFPGARTDReadCount() ); @@ -839,30 +839,30 @@ { TEMPERATURE_SENSORS_DATA_T data; - data.inletPrimaryHeater = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); - data.outletPrimaryHeater = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); - data.conductivitySensor1 = getTemperatureValue( TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ); - data.conductivitySensor2 = getTemperatureValue( TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ); - data.outletRedundant = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); - data.inletDialysate = getTemperatureValue( TEMPSENSORS_INLET_DIALYSATE ); - data.primaryHeaterThermocouple = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_THERMO_COUPLE ); - data.trimmerHeaterThermocouple = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_THERMO_COUPLE ); - data.priamyHeaterColdjunction = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_COLD_JUNCTION ); - data.trimmerHeaterColdjunction = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_COLD_JUNCTION ); - data.primaryHeaterInternal = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ); - data.trimmerHeaterInternal = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ); - data.fpgaBoard = getTemperatureValue( TEMPSENSORS_FPGA_BOARD_SENSOR ); - data.loadCellA1B1 = getTemperatureValue( TEMPSENSORS_LOAD_CELL_A1_B1 ); - data.loadCellA2B2 = getTemperatureValue( TEMPSENSORS_LOAD_CELL_A2_B2 ); - data.internalTHDORTD = getTemperatureValue( TEMPSENSORS_INTERNAL_THDO_RTD ); - data.internalTDIRTD = getTemperatureValue( TEMPSENSORS_INTERNAL_TDI_RTD ); - data.internalCondSnsrTemp = getTemperatureValue( TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR ); - data.primaryThermoCoupleRaw = getFPGAPrimaryHeaterTemp(); - data.primaryColdjuncRaw = getFPGAPrimaryColdJunctionTemp(); - data.trimmerThermoCoupleRaw = getFPGATrimmerHeaterTemp(); - data.trimmerColdjuncRaw = getFPGATrimmerColdJunctionTemp(); - data.cond1Raw = tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].rawADCReads[ MAX_NUM_OF_RAW_ADC_SAMPLES - 1 ]; - data.cond2Raw = tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].rawADCReads[ MAX_NUM_OF_RAW_ADC_SAMPLES - 1 ]; + data.inletPrimaryHeater = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); + data.outletPrimaryHeater = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); + data.conductivitySensor1 = getTemperatureValue( TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ); + data.conductivitySensor2 = getTemperatureValue( TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ); + data.outletRedundant = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); + data.inletDialysate = getTemperatureValue( TEMPSENSORS_INLET_DIALYSATE ); + data.primaryHeaterThermocouple = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_THERMO_COUPLE ); + data.trimmerHeaterThermocouple = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_THERMO_COUPLE ); + data.priamyHeaterColdjunction = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_COLD_JUNCTION ); + data.trimmerHeaterColdjunction = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_COLD_JUNCTION ); + data.primaryHeaterInternal = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ); + data.trimmerHeaterInternal = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ); + data.fpgaBoard = getTemperatureValue( TEMPSENSORS_FPGA_BOARD_SENSOR ); + data.loadCellA1B1 = getTemperatureValue( TEMPSENSORS_LOAD_CELL_A1_B1 ); + data.loadCellA2B2 = getTemperatureValue( TEMPSENSORS_LOAD_CELL_A2_B2 ); + data.internalTHDORTD = getTemperatureValue( TEMPSENSORS_INTERNAL_TRO_RTD ); + data.internalTDIRTD = getTemperatureValue( TEMPSENSORS_INTERNAL_TDI_RTD ); + data.internalCondSnsrTemp = getTemperatureValue( TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR ); + data.primaryThermoCoupleRaw = getFPGAPrimaryHeaterTemp(); + data.primaryColdjuncRaw = getFPGAPrimaryColdJunctionTemp(); + data.trimmerThermoCoupleRaw = getFPGATrimmerHeaterTemp(); + data.trimmerColdjuncRaw = getFPGATrimmerColdJunctionTemp(); + data.cond1Raw = tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].rawADCReads[ MAX_NUM_OF_RAW_ADC_SAMPLES - 1 ]; + data.cond2Raw = tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].rawADCReads[ MAX_NUM_OF_RAW_ADC_SAMPLES - 1 ]; broadcastTemperatureSensorsData( &data ); @@ -878,17 +878,14 @@ * @details Inputs: tempSensors * @details Outputs: tempSensors * @param sensorIndex the index of the temperature sensor - * @param temperature the temperature value to be checked * @return none *************************************************************************/ -static void monitorTemperatureSnsrs( U32 sensorIndex, F32 temperature ) +static void monitorTemperatureSnsrs( U32 sensorIndex ) { - // The maximum allowed temperature is different for the sensors that are in the fluid path - // with the ones that are not in the fluid path - F32 maxLimit = tempSensors[ sensorIndex ].maxAllowedTemperature; + F32 temperature = getTemperatureValue( sensorIndex ); // Check both temperature and to be in range - if ( ( temperature < TEMP_SENSORS_MIN_ALLOWED_DEGREE_C ) || ( temperature > maxLimit ) ) + if ( ( temperature < TEMP_SENSORS_MIN_ALLOWED_DEGREE_C ) || ( temperature > tempSensors[ sensorIndex ].maxAllowedTemperature ) ) { // TODO investigate //checkPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_OUT_OF_RANGE, TRUE, sensorIndex, temperature ); @@ -917,7 +914,7 @@ if ( sensorIndex < NUM_OF_TEMPERATURE_SENSORS ) { - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { result = TRUE; tempSensors[ sensorIndex ].temperatureValues.ovData = temperature; @@ -943,7 +940,7 @@ if ( sensorIndex < NUM_OF_TEMPERATURE_SENSORS ) { - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { result = TRUE; tempSensors[ sensorIndex ].temperatureValues.override = OVERRIDE_RESET; @@ -967,7 +964,7 @@ { BOOL result = FALSE; - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { U32 interval = value / TASK_PRIORITY_INTERVAL; @@ -991,7 +988,7 @@ { BOOL result = FALSE; - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { result = TRUE; tempSensorsPublishInterval.override = OVERRIDE_RESET; Index: firmware/App/Controllers/Thermistors.c =================================================================== diff -u -r22f1a58ac8e419353ec004b04e7c765c1d59df2b -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Controllers/Thermistors.c (.../Thermistors.c) (revision 22f1a58ac8e419353ec004b04e7c765c1d59df2b) +++ firmware/App/Controllers/Thermistors.c (.../Thermistors.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -63,7 +63,6 @@ static void convertADC2Temperature( void ); static F32 calculateThemristorTemperature( U32 adcValue ); static void publishThermistorsData( void ); -static U32 getPublishThermistorsDataInterval( void ); /*********************************************************************//** * @brief @@ -302,26 +301,6 @@ /*********************************************************************//** * @brief - * The getPublishThermistorsDataInterval function gets the thermistors - * data publish interval. - * @details Inputs: thermistorsPublishInterval - * @details Outputs: none - * @return data publish time interval in counts - *************************************************************************/ -static U32 getPublishThermistorsDataInterval( void ) -{ - U32 result = thermistorsPublishInterval.data; - - if ( OVERRIDE_KEY == thermistorsPublishInterval.override ) - { - result = thermistorsPublishInterval.ovData; - } - - return result; -} - -/*********************************************************************//** - * @brief * The publishThermistorsData function publishes the thermistors and * temperature sensors data at the specified time interval. * @details Inputs: dataPublishCounter @@ -330,7 +309,7 @@ *************************************************************************/ static void publishThermistorsData( void ) { - if ( ++dataPublishCounter > getPublishThermistorsDataInterval() ) + if ( ++dataPublishCounter > getU32OverrideValue( &thermistorsPublishInterval ) ) { THERMISTORS_DATA_T sensorsData; Index: firmware/App/Modes/ModeChemicalDisinfect.c =================================================================== diff -u -r6f1f269cd7d91f41c51797d17a85a7ea249e21f3 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeChemicalDisinfect.c (.../ModeChemicalDisinfect.c) (revision 6f1f269cd7d91f41c51797d17a85a7ea249e21f3) +++ firmware/App/Modes/ModeChemicalDisinfect.c (.../ModeChemicalDisinfect.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -941,7 +941,7 @@ setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, CONC_PUMP_PRIME_SPEED_ML_PER_MIN ); // The bicarb line is used to inject the acid into the fluid path during chemical disinfect - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); // Start the timer for drain timeout stateTimer = getMSTimerCount(); @@ -989,7 +989,7 @@ { // Turn off the concentrate pump for now until there is sufficient RO flow to turn it // back for mixing - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); // Prepare for filling the reservoirs and heating the water setValveState( VPI, VALVE_STATE_OPEN ); @@ -1004,8 +1004,8 @@ setROPumpTargetFlowRate( RO_PUMP_TARGET_FLUSH_FILL_FLOW_RATE_LPM, MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI ); // Start heating the water while we are filling up the reservoirs - setPrimaryHeaterTargetTemperature( CHEM_DISINFECT_TARGET_TEMPERATURE_C ); - startPrimaryHeater(); + setHeaterTargetTemperature( DG_PRIMARY_HEATER, CHEM_DISINFECT_TARGET_TEMPERATURE_C ); + startHeater( DG_PRIMARY_HEATER ); rsrvr1Status = DG_RESERVOIR_BELOW_TARGET; rsrvr2Status = DG_RESERVOIR_BELOW_TARGET; @@ -1048,7 +1048,7 @@ // control it. if ( measuredROFlowRate < MIN_RO_FLOW_FOR_CONC_PUMP_MIXING_LPM ) { - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); } else { @@ -1079,7 +1079,7 @@ setValveState( VRC, VALVE_STATE_RECIRC_C_TO_NC ); // Done with mixing acid - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); // Set the drain pump to control mode setDrainPumpTargetOutletPressure( CHEM_DISINFECT_TARGET_DRAIN_PRES_PSI ); @@ -1264,7 +1264,7 @@ case CHEM_DISINFECT_COMPLETE: // Turn off the heaters // TODO turn off CP1 and CP2 - stopPrimaryHeater(); + stopHeater( DG_PRIMARY_HEATER ); stateTimer = getMSTimerCount(); state = DG_CHEM_DISINFECT_STATE_COOL_DOWN_HEATERS; break; Index: firmware/App/Modes/ModeDrain.c =================================================================== diff -u -rcea079b61dbd17b2ddaec99b1124248147d14e72 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeDrain.c (.../ModeDrain.c) (revision cea079b61dbd17b2ddaec99b1124248147d14e72) +++ firmware/App/Modes/ModeDrain.c (.../ModeDrain.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -23,6 +23,7 @@ #include "Pressures.h" #include "Reservoirs.h" #include "ROPump.h" +#include "SystemComm.h" #include "TaskGeneral.h" #include "TemperatureSensors.h" #include "Valves.h" @@ -80,7 +81,6 @@ // re-initialize each time we transition to drain mode initDrainMode(); -#ifndef V_2_SYSTEM DG_RESERVOIR_ID_T inactiveReservoir = getInactiveReservoir(); if ( DG_RESERVOIR_1 == inactiveReservoir ) @@ -91,7 +91,6 @@ { setValveStateDelayed( VRD2, VALVE_STATE_OPEN, DELAY_RES_DRAIN_VALVE_MS ); } -#endif // set initial actuator states setValveState( VDR, VALVE_STATE_DRAIN_C_TO_NO ); setDrainPumpTargetRPMDelayed( TARGET_DRAIN_PUMP_RPM, DELAY_DRAIN_PUMP_MS ); @@ -100,7 +99,7 @@ // because the initial guess in the heaters driver needs the target flow to calculate // the new PWMs for the main and small primary heaters setROPumpTargetFlowRate( TARGET_RO_FLOW_RATE_L, TARGET_RO_PRESSURE_PSI ); - startPrimaryHeater(); + startHeater( DG_PRIMARY_HEATER ); } /*********************************************************************//** @@ -158,12 +157,11 @@ DG_DRAIN_STATE_T result = DG_DRAIN_STATE_DRAIN; DG_RESERVOIR_ID_T inactiveReservoir = getInactiveReservoir(); - // if we have reached our target drain to volume (by weight) or cannot drain anymore, we are done draining - go back to re-circ mode + // if we have reached our target drain to volume (by weight) or cannot drain anymore, we are done draining - go back to generation idle mode if ( TRUE == hasTargetDrainVolumeBeenReached( inactiveReservoir, DRAIN_WEIGHT_UNCHANGE_TIMEOUT ) ) { setDrainPumpTargetRPM( 0 ); -#ifndef V_2_SYSTEM if ( DG_RESERVOIR_1 == inactiveReservoir ) { setValveState( VRD1, VALVE_STATE_CLOSED ); @@ -172,15 +170,14 @@ { setValveState( VRD2, VALVE_STATE_CLOSED ); } -#endif if ( TRUE == isReservoirTarePending() ) { // Tare reservoir load cells at empty if requested result = DG_DRAIN_STATE_TARE; } else { - requestNewOperationMode( DG_MODE_CIRC ); + requestNewOperationMode( DG_MODE_GENE ); } } @@ -204,12 +201,10 @@ { drainEmptyTareTimerCtr = 0; tareLoadCellsAtEmpty( inactiveReservoir ); - requestNewOperationMode( DG_MODE_CIRC ); + requestNewOperationMode( DG_MODE_GENE ); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_CLOSED ); setValveState( VRD2, VALVE_STATE_CLOSED ); -#endif } return result; Index: firmware/App/Modes/ModeFault.c =================================================================== diff -u -rc914eb443ee2679eb9fe3668119058ccc578437d -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeFault.c (.../ModeFault.c) (revision c914eb443ee2679eb9fe3668119058ccc578437d) +++ firmware/App/Modes/ModeFault.c (.../ModeFault.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -139,8 +139,8 @@ requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); signalROPumpHardStop(); signalDrainPumpHardStop(); - stopPrimaryHeater(); - stopTrimmerHeater(); + stopHeater( DG_PRIMARY_HEATER ); + stopHeater( DG_TRIMMER_HEATER ); } /**@}*/ Index: firmware/App/Modes/ModeFill.c =================================================================== diff -u -rc0160362dc799802ec589d5b6cf4c2bd1face77e -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeFill.c (.../ModeFill.c) (revision c0160362dc799802ec589d5b6cf4c2bd1face77e) +++ firmware/App/Modes/ModeFill.c (.../ModeFill.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -26,6 +26,7 @@ #include "Pressures.h" #include "Reservoirs.h" #include "ROPump.h" +#include "SystemComm.h" #include "TaskGeneral.h" #include "TemperatureSensors.h" #include "Timers.h" @@ -43,38 +44,56 @@ #define TARGET_RO_FLOW_RATE_L 0.8 ///< Target flow rate for RO pump. #define DIALYSATE_FILL_TIME_OUT ( 5 * SEC_PER_MIN * MS_PER_SECOND ) ///< Time out period when reservoir is not filled with correct dialysate. +#define EMPTY_BOTTLE_DETECT_PERSISTENT_PERIOD_MS ( 5 * MS_PER_SECOND ) ///< Persistent period for empty bottle detect. +///< Persistent time interval for concentrate pumps prime. +#define CONCENTRATE_PUMP_PRIME_INTERVAL ( 3 * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) #define ACID_BICARB_CONCENTRATE_ADDITION_MULTIPLER 1.06 ///< Acid and bicarbonate concentrates make up around 6% to total volume. #define FLOW_INTEGRATED_VOLUME_CHECK_TOLERANCE 0.1 ///< Flow integrated volume has 10% tolerance compare to load cell reading. -#define CONCENTRATE_TEST_TIME_OUT_MS ( 30 * MS_PER_SECOND ) ///< Concentrate test time out period in ms. +#define CONCENTRATE_PUMP_PRIME_EXTRA_SPEED_ML_MIN 5.0 ///< Concentrate pump additional speed during priming in mL/min. +#define CONCENTRATE_TEST_TIME_OUT_MS ( 45 * MS_PER_SECOND ) ///< Concentrate test time out period in ms. #define WATER_QUALITY_CHECK_TIME_OUT_MS ( 30 * MS_PER_SECOND ) ///< Inlet water quality check time out period in ms. -#define CONDUCTIVITY_ERROR_PERSISTENCE_PERIOD_MS ( 5 * MS_PER_SECOND ) ///< Persistence period for conductivity error. +#define DIALYSATE_TEMPERATURE_TOLERANCE_C 2.0 ///< Dialysate temperature tolerance in degree C. -/// Multiplier to convert flow (L/min) into volume (mL) for period of general task interval. -static const F32 RO_FLOW_INTEGRATOR = ( ( ML_PER_LITER * TASK_GENERAL_INTERVAL ) / ( SEC_PER_MIN * MS_PER_SECOND ) ); +#define ACID_CONCENTRATION_BOTTLE_VOLUME_ML 3000.0 ///< Volume of acid concentration in ml. +#define BICARB_CONCENTRATION_BOTTLE_VOLUME_ML 3000.0 ///< Volume of bicarb concentration in ml. +#define CONCENTRATION_BOTTLE_LOW_VOLUME_ML 100.0 ///< Concentration bottle low volume in ml. +/// Multiplier to convert flow (mL/min) into volume (mL) for period of general task interval. +static const F32 FLOW_INTEGRATOR = ( (F32)TASK_GENERAL_INTERVAL / (F32)( SEC_PER_MIN * MS_PER_SECOND ) ); + // ********** private data ********** -static DG_FILL_MODE_STATE_T fillState; ///< Currently active fill state. -static U32 dialysateFillStartTime; ///< Current time when starting to fill dialysate. -static F32 reservoirBaseWeight; ///< Fill reservoir base weight. -static F32 totalROFlowRate_LPM; ///< Total RO flow rate over period of time. -static U32 concentrateTestStartTime; ///< Starting time for concentrate test. -static U32 waterQualityCheckStartTime; ///< Starting time for inlet water quality check. +static DG_FILL_MODE_STATE_T fillState; ///< Currently active fill state. +static U32 dialysateFillStartTime; ///< Current time when starting to fill dialysate. +static F32 reservoirBaseWeight; ///< Fill reservoir base weight. +static U32 waterQualityCheckStartTime; ///< Starting time for inlet water quality check. +static U32 concentrateTestStartTime; ///< Starting time for concentrate test. +static U32 concentratePumpPrimeCount; ///< Interval count for concentrate pump prime. + +static F32 totalROFlowRate_mL_min; ///< Total RO flow rate over period of time. +static F32 acidConductivityTotal; ///< Total of acid conductivity during fill. +static F32 dialysateConductivityTotal; ///< Total of dialysate conductivity during fill. +static U32 conductivitySampleCount; ///< Sample count of conductivity during fill. + +static OVERRIDE_F32_T usedAcidVolume_mL = { 0.0, 0.0, 0.0, 0.0 }; ///< The integrated acid concentration volume has been used in ml. +static OVERRIDE_F32_T usedBicarbVolume_mL = { 0.0, 0.0, 0.0, 0.0 }; ///< The integrated bicarb concentration volume has been used in ml. + // ********** private function prototypes ********** -static BOOL isWaterQualityGood( void ); -static BOOL checkDialysateConductivity( void ); static DG_FILL_MODE_STATE_T handleCheckInletWaterState( void ); static DG_FILL_MODE_STATE_T handleBicarbPumpCheckState( void ); static DG_FILL_MODE_STATE_T handleAcidPumpCheckState( void ); static DG_FILL_MODE_STATE_T handleDialysateProductionState( void ); static DG_FILL_MODE_STATE_T handleDeliverDialysateState( void ); +static DG_FILL_MODE_STATE_T handlePausedState( void ); -static void handleDialysateMixing( void ); +static BOOL isWaterQualityGood( void ); +static BOOL checkDialysateTemperature( void ); +static void handleDialysateMixing( F32 measuredROFlowRate_mL_min ); /*********************************************************************//** * @brief @@ -88,11 +107,15 @@ fillState = DG_FILL_MODE_STATE_START; dialysateFillStartTime = 0; reservoirBaseWeight = 0.0; - totalROFlowRate_LPM = 0.0; + totalROFlowRate_mL_min = 0.0; concentrateTestStartTime = 0; + acidConductivityTotal = 0.0; + dialysateConductivityTotal = 0.0; + conductivitySampleCount = 0; + concentratePumpPrimeCount = 0; - initPersistentAlarm( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, CONDUCTIVITY_ERROR_PERSISTENCE_PERIOD_MS, CONDUCTIVITY_ERROR_PERSISTENCE_PERIOD_MS ); - initPersistentAlarm( ALARM_ID_DIALYSATE_CONDUCTIVITY_OUT_OF_RANGE, CONDUCTIVITY_ERROR_PERSISTENCE_PERIOD_MS, CONDUCTIVITY_ERROR_PERSISTENCE_PERIOD_MS ); + initPersistentAlarm( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, 0, EMPTY_BOTTLE_DETECT_PERSISTENT_PERIOD_MS ); + initPersistentAlarm( ALARM_ID_BICARB_CONDUCTIVITY_OUT_OF_RANGE, 0, EMPTY_BOTTLE_DETECT_PERSISTENT_PERIOD_MS ); } /*********************************************************************//** @@ -104,11 +127,13 @@ *************************************************************************/ void transitionToFillMode( void ) { - initFillMode(); + DG_RESERVOIR_ID_T inactiveReservoir = getInactiveReservoir(); + initFillMode(); + reservoirBaseWeight = getReservoirWeight( inactiveReservoir ); dialysateFillStartTime = getMSTimerCount(); - // set initial actuator states + // Set initial actuator states setValveState( VDR, VALVE_STATE_DRAIN_C_TO_NO ); setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); @@ -119,7 +144,7 @@ // because the initial guess in the heaters driver needs the target flow to calculate // the new PWMs for the main and small primary heaters setROPumpTargetFlowRate( TARGET_RO_FLOW_RATE_L, TARGET_RO_PRESSURE_PSI ); - startPrimaryHeater(); + startHeater( DG_PRIMARY_HEATER ); } /*********************************************************************//** @@ -131,22 +156,21 @@ *************************************************************************/ U32 execFillMode( void ) { - // check inlet water conductivity, temperature, pressure, and RO rejection ratio + // Check inlet water conductivity, temperature, pressure, and RO rejection ratio checkInletWaterConductivity(); checkInletWaterTemperature(); checkInletPressure(); checkRORejectionRatio(); // TODO: Check for open straw door status and alarm if closed - - // check if run out of time to fill the reservoir + // Check if run out of time to fill the reservoir if ( TRUE == didTimeout( dialysateFillStartTime, DIALYSATE_FILL_TIME_OUT ) ) { activateAlarmNoData( ALARM_ID_DG_DIALYSATE_FILL_OUT_OF_TIME ); - requestNewOperationMode( DG_MODE_CIRC ); + requestNewOperationMode( DG_MODE_GENE ); } - // execute current Fill state + // Execute current Fill state switch ( fillState ) { case DG_FILL_MODE_STATE_START: @@ -174,6 +198,10 @@ fillState = handleDeliverDialysateState(); break; + case DG_FILL_MODE_STATE_PAUSED: + fillState = handlePausedState(); + break; + default: SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_FILL_MODE_INVALID_EXEC_STATE, fillState ) fillState = DG_FILL_MODE_STATE_START; @@ -185,59 +213,6 @@ /*********************************************************************//** * @brief - * The isWaterQualityGood function checks for inlet water quality. - * @details Inputs: Temperature and conductivity alarms - * @details Outputs: none - * @return TRUE if water quality is good, otherwise FALSE - *************************************************************************/ -static BOOL isWaterQualityGood( void ) -{ - BOOL const isInletPressureGood = !isAlarmActive( ALARM_ID_INLET_WATER_LOW_PRESSURE ); - BOOL const isWaterTemperatureGood = !isAlarmActive( ALARM_ID_INLET_WATER_HIGH_TEMPERATURE ) && !isAlarmActive( ALARM_ID_INLET_WATER_LOW_TEMPERATURE ); - BOOL const isWaterConductivityGood = !isAlarmActive( ALARM_ID_INLET_WATER_HIGH_CONDUCTIVITY ) && !isAlarmActive( ALARM_ID_INLET_WATER_LOW_CONDUCTIVITY ) && - !isAlarmActive( ALARM_ID_RO_REJECTION_RATIO_OUT_OF_RANGE ); - - return ( isInletPressureGood && isWaterTemperatureGood && isWaterConductivityGood ); -} - -/*********************************************************************//** - * @brief - * The checkDialysateConductivity function checks dialysate conductivity - * after adding acid and bicarbonate and triggers an alarm when conductivity - * is out of range. - * @details Inputs: CD1 and CD2 sensor conductivity - * @details Outputs: Trigger alarms when dialysate conductivity is out of allowed range - * @return TRUE if dialysate conductivity is good, otherwise FALSE - *************************************************************************/ -static BOOL checkDialysateConductivity( void ) -{ - BOOL const isDialysateConductivityGood = isDialysateConductivityInRange(); - - if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_DIALYSATE_CONDUCTIVITY_OUT_OF_RANGE, !isDialysateConductivityGood ) ) - { -#ifndef DISABLE_DIALYSATE_CHECK - if ( FALSE == isAcidConductivityInRange() ) - { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, getConductivityValue( CONDUCTIVITYSENSORS_CD1_SENSOR ) ); - } - else - { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DIALYSATE_CONDUCTIVITY_OUT_OF_RANGE, getConductivityValue( CONDUCTIVITYSENSORS_CD2_SENSOR ) ); - } -#endif - } - - if ( TRUE == isPersistentAlarmConditionCleared( ALARM_ID_DIALYSATE_CONDUCTIVITY_OUT_OF_RANGE, !isDialysateConductivityGood ) ) - { - clearAlarmCondition( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE ); - clearAlarmCondition( ALARM_ID_DIALYSATE_CONDUCTIVITY_OUT_OF_RANGE ); - } - - return ( isDialysateConductivityGood && isWaterQualityGood() ); -} - -/*********************************************************************//** - * @brief * The handleCheckInletWaterState function checks for inlet water quality * before jumping to dialysate production state. * @details Inputs: Temperature and conductivity alarms @@ -247,25 +222,24 @@ static DG_FILL_MODE_STATE_T handleCheckInletWaterState( void ) { DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_CHECK_INLET_WATER; - DG_RESERVOIR_ID_T inactiveReservoir = getInactiveReservoir(); - BOOL isInletWaterReady = isWaterQualityGood(); - #ifndef DISABLE_DIALYSATE_CHECK - if ( isInletWaterReady ) + if ( TRUE == isWaterQualityGood() ) #endif { - reservoirBaseWeight = getReservoirWeight( inactiveReservoir ); concentrateTestStartTime = getMSTimerCount(); - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP1_ACID ); - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP2_BICARB ); +#ifndef DISABLE_MIXING + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, CONCENTRATE_PUMP_MAX_SPEED ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); +#endif result = DG_FILL_MODE_STATE_BICARB_PUMP_CHECK; } if ( TRUE == didTimeout( waterQualityCheckStartTime, WATER_QUALITY_CHECK_TIME_OUT_MS ) ) { activateAlarmNoData( ALARM_ID_DG_BAD_INLET_WATER_QUALITY ); - requestNewOperationMode( DG_MODE_CIRC ); + requestNewOperationMode( DG_MODE_GENE ); } return result; @@ -282,23 +256,45 @@ static DG_FILL_MODE_STATE_T handleBicarbPumpCheckState( void ) { DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_BICARB_PUMP_CHECK; + DG_BICARB_CONCENTRATES_RECORD_T bicarb = getBicarbConcentrateCalRecord(); + F32 const measuredROFlowRate_mL_min = getMeasuredROFlowRate() * ML_PER_LITER; + F32 const bicarbPumpFlowRate_mL_min = measuredROFlowRate_mL_min * bicarb.bicarbConcentrate[ CAL_DATA_BICARB_CONCENTRATE_1 ].bicarbConcMixRatio + + CONCENTRATE_PUMP_PRIME_EXTRA_SPEED_ML_MIN; - handleDialysateMixing(); - #ifndef DISABLE_DIALYSATE_CHECK - if ( TRUE == isBicarbConductivityInRange() ) + F32 const bicarbConductivity = getConductivityValue( CONDUCTIVITYSENSORS_CD2_SENSOR ); +#else + F32 const bicarbConductivity = MIN_BICARB_CONCENTRATE_CONDUCTIVITY; #endif + + if ( MIN_BICARB_CONCENTRATE_CONDUCTIVITY <= bicarbConductivity ) { - concentrateTestStartTime = getMSTimerCount(); - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP1_ACID ); - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP2_BICARB ); - result = DG_FILL_MODE_STATE_ACID_PUMP_CHECK; + // Reduce acid pump speed after reaching minimum conductivity + // This prevents conductivity value to go out of sensor's range + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, bicarbPumpFlowRate_mL_min ); + + if ( concentratePumpPrimeCount++ > CONCENTRATE_PUMP_PRIME_INTERVAL ) + { + concentratePumpPrimeCount = 0; + concentrateTestStartTime = getMSTimerCount(); +#ifndef DISABLE_MIXING + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP1_ACID, CONCENTRATE_PUMP_MAX_SPEED ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); +#endif + + result = DG_FILL_MODE_STATE_ACID_PUMP_CHECK; + } } + else + { + concentratePumpPrimeCount = 0; + } if ( TRUE == didTimeout( concentrateTestStartTime, CONCENTRATE_TEST_TIME_OUT_MS ) ) { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BICARB_CONDUCTIVITY_OUT_OF_RANGE, getConductivityValue( CONDUCTIVITYSENSORS_CD2_SENSOR ) ); - requestNewOperationMode( DG_MODE_CIRC ); + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BICARB_CONDUCTIVITY_OUT_OF_RANGE, bicarbConductivity ); + requestNewOperationMode( DG_MODE_GENE ); } return result; @@ -315,22 +311,40 @@ static DG_FILL_MODE_STATE_T handleAcidPumpCheckState( void ) { DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_ACID_PUMP_CHECK; + DG_ACID_CONCENTRATES_RECORD_T acid = getAcidConcentrateCalRecord(); + F32 const measuredROFlowRate_mL_min = getMeasuredROFlowRate() * ML_PER_LITER; + F32 const acidPumpFlowRate_mL_min = measuredROFlowRate_mL_min * acid.acidConcentrate[ CAL_DATA_ACID_CONCENTRATE_1 ].acidConcMixRatio + + CONCENTRATE_PUMP_PRIME_EXTRA_SPEED_ML_MIN; - handleDialysateMixing(); - #ifndef DISABLE_DIALYSATE_CHECK - if ( TRUE == isAcidConductivityInRange() ) + F32 const acidConductivity = getConductivityValue( CONDUCTIVITYSENSORS_CD1_SENSOR ); +#else + F32 const acidConductivity = MIN_ACID_CONCENTRATE_CONDUCTIVITY; #endif + + if ( MIN_ACID_CONCENTRATE_CONDUCTIVITY <= acidConductivity ) { - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP1_ACID ); - requestConcentratePumpsOn( CONCENTRATEPUMPS_CP2_BICARB ); - result = DG_FILL_MODE_STATE_DIALYSATE_PRODUCTION; + // Reduce acid pump speed after reaching minimum conductivity + // This prevents conductivity value to go out of sensor's range + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP1_ACID, acidPumpFlowRate_mL_min ); + + if ( concentratePumpPrimeCount++ > CONCENTRATE_PUMP_PRIME_INTERVAL ) + { + concentratePumpPrimeCount = 0; + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + result = DG_FILL_MODE_STATE_DIALYSATE_PRODUCTION; + } } + else + { + concentratePumpPrimeCount = 0; + } if ( TRUE == didTimeout( concentrateTestStartTime, CONCENTRATE_TEST_TIME_OUT_MS ) ) { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, getConductivityValue( CONDUCTIVITYSENSORS_CD1_SENSOR ) ); - requestNewOperationMode( DG_MODE_CIRC ); + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, acidConductivity ); + requestNewOperationMode( DG_MODE_GENE ); } return result; @@ -340,24 +354,38 @@ * @brief * The handleDialysateProductionState function executes the dialysate production * state of the fill mode state machine. - * @details Inputs: none + * @details Inputs: inlet water quality and dialysate temperature * @details Outputs: none * @return the next state *************************************************************************/ static DG_FILL_MODE_STATE_T handleDialysateProductionState( void ) { DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_DIALYSATE_PRODUCTION; + F32 const measuredROFlowRate_mL_min = getMeasuredROFlowRate() * ML_PER_LITER; - handleDialysateMixing(); - - // TODO - transition when temperature and mix is in range #ifndef DISABLE_DIALYSATE_CHECK - if ( TRUE == checkDialysateConductivity() ) + if ( ( TRUE == isWaterQualityGood() ) && ( TRUE == checkDialysateTemperature() ) ) +#else + if ( TRUE ) #endif { - setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); - result = DG_FILL_MODE_STATE_DELIVER_DIALYSATE; + // Prime mixing before deliver result to reservoir + handleDialysateMixing( measuredROFlowRate_mL_min ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); + + if ( concentratePumpPrimeCount++ > CONCENTRATE_PUMP_PRIME_INTERVAL ) + { + setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); + result = DG_FILL_MODE_STATE_DELIVER_DIALYSATE; + } } + else + { + concentratePumpPrimeCount = 0; + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + } return result; } @@ -366,33 +394,79 @@ * @brief * The handleDeliverDialysateState function executes the deliver dialysate * state of the fill mode state machine. - * @details Inputs: none - * @details Outputs: Deliver dialysate + * @details Inputs: inlet water quality and dialysate temperature + * @details Outputs: Deliver dialysate to inactive reservoir * @return the next state *************************************************************************/ static DG_FILL_MODE_STATE_T handleDeliverDialysateState( void ) { + F32 const measuredROFlowRate_mL_min = getMeasuredROFlowRate() * ML_PER_LITER; + F32 const acidConductivity = getConductivityValue( CONDUCTIVITYSENSORS_CD1_SENSOR ); + F32 const dialysateConductivity = getConductivityValue( CONDUCTIVITYSENSORS_CD2_SENSOR ); + BOOL const isAcidConductivityOutOfRange = ( acidConductivity <= MIN_ACID_CONCENTRATE_CONDUCTIVITY ) || ( acidConductivity >= MAX_ACID_CONCENTRATE_CONDUCTIVITY ); + BOOL const isDialysateConductivityOutOfRange = ( dialysateConductivity <= MIN_DIALYSATE_CONDUCTIVITY ) || ( dialysateConductivity >= MAX_DIALYSATE_CONDUCTIVITY ); + DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_DELIVER_DIALYSATE; DG_RESERVOIR_ID_T inactiveReservoir = getInactiveReservoir(); - totalROFlowRate_LPM += getMeasuredROFlowRate(); + F32 integratedVolume_mL; - handleDialysateMixing(); + // Set concentrate pumps speed based off RO pump flow rate + handleDialysateMixing( measuredROFlowRate_mL_min ); - // TODO - transition back when temperature or mix out of range - if ( FALSE == checkDialysateConductivity() ) - { + totalROFlowRate_mL_min += measuredROFlowRate_mL_min; + integratedVolume_mL = totalROFlowRate_mL_min * FLOW_INTEGRATOR * ACID_BICARB_CONCENTRATE_ADDITION_MULTIPLER; + usedAcidVolume_mL.data += getMeasuredPumpSpeed( CONCENTRATEPUMPS_CP1_ACID ) * FLOW_INTEGRATOR; + usedBicarbVolume_mL.data += getMeasuredPumpSpeed( CONCENTRATEPUMPS_CP2_BICARB ) * FLOW_INTEGRATOR; + + acidConductivityTotal += acidConductivity; + dialysateConductivityTotal += dialysateConductivity; + conductivitySampleCount++; + #ifndef DISABLE_DIALYSATE_CHECK + if ( ( isWaterQualityGood() != TRUE ) || ( checkDialysateTemperature() != TRUE ) ) + { + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); result = DG_FILL_MODE_STATE_DIALYSATE_PRODUCTION; + } + + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE, isAcidConductivityOutOfRange ) ) + { + usedAcidVolume_mL.data = 0.0; + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); + result = DG_FILL_MODE_STATE_PAUSED; + } + + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BICARB_CONDUCTIVITY_OUT_OF_RANGE, isDialysateConductivityOutOfRange ) ) + { + usedBicarbVolume_mL.data = 0.0; + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); + result = DG_FILL_MODE_STATE_PAUSED; + } #endif + + if ( ( ACID_CONCENTRATION_BOTTLE_VOLUME_ML - getF32OverrideValue( &usedAcidVolume_mL ) ) <= CONCENTRATION_BOTTLE_LOW_VOLUME_ML ) + { + activateAlarmNoData( ALARM_ID_DG_ACID_BOTTLE_LOW_VOLUME ); } - // if we've reached our target fill to volume (by weight), we're done filling - go back to re-circ mode - if ( hasTargetFillVolumeBeenReached( inactiveReservoir ) ) + if ( ( BICARB_CONCENTRATION_BOTTLE_VOLUME_ML - getF32OverrideValue( &usedBicarbVolume_mL ) ) <= CONCENTRATION_BOTTLE_LOW_VOLUME_ML ) { + activateAlarmNoData( ALARM_ID_DG_BICARB_BOTTLE_LOW_VOLUME ); + } + + // If we've reached our target fill to volume (by weight), we're done filling - go back to generation idle mode + if ( ( TRUE == hasTargetFillVolumeBeenReached( inactiveReservoir ) ) || ( ( integratedVolume_mL - reservoirBaseWeight ) >= MAX_RESERVOIR_VOLUME_ML ) ) + { F32 const filledVolume_mL = getReservoirWeight( inactiveReservoir ) - reservoirBaseWeight; - F32 const integratedVolume_mL = totalROFlowRate_LPM * RO_FLOW_INTEGRATOR * ACID_BICARB_CONCENTRATE_ADDITION_MULTIPLER; F32 const integratedVolumeToLoadCellReadingPercent = fabs( 1 - ( filledVolume_mL / integratedVolume_mL ) ); + F32 const avgAcidConductivity = acidConductivityTotal / conductivitySampleCount; + F32 const avgDialysateConductivity = dialysateConductivityTotal / conductivitySampleCount; if ( integratedVolumeToLoadCellReadingPercent > FLOW_INTEGRATED_VOLUME_CHECK_TOLERANCE ) { @@ -401,35 +475,103 @@ #endif } - requestNewOperationMode( DG_MODE_CIRC ); +#ifndef DISABLE_DIALYSATE_CHECK + if ( ( avgDialysateConductivity < MIN_DIALYSATE_CONDUCTIVITY ) || ( avgDialysateConductivity > MAX_DIALYSATE_CONDUCTIVITY ) ) + { + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_DIALYSATE_CONDUCTIVITY_FAULT, avgAcidConductivity, avgDialysateConductivity ); + } +#endif + + requestNewOperationMode( DG_MODE_GENE ); } return result; } /*********************************************************************//** * @brief + * The handlePausedState function executes the paused state of the fill + * mode state machine. + * @details Inputs: Empty bottle alarm active + * @details Outputs: none + * @return the next state + *************************************************************************/ +static DG_FILL_MODE_STATE_T handlePausedState( void ) +{ + DG_FILL_MODE_STATE_T result = DG_FILL_MODE_STATE_PAUSED; + + if ( ( FALSE == isAlarmActive( ALARM_ID_ACID_CONDUCTIVITY_OUT_OF_RANGE ) ) && + ( FALSE == isAlarmActive( ALARM_ID_BICARB_CONDUCTIVITY_OUT_OF_RANGE ) ) ) + { + result = DG_FILL_MODE_STATE_CHECK_INLET_WATER; + } + + return result; +} + +/*********************************************************************//** + * @brief + * The isWaterQualityGood function checks for inlet water quality. + * @details Inputs: Temperature and conductivity alarms + * @details Outputs: none + * @return TRUE if water quality is good, otherwise FALSE + *************************************************************************/ +static BOOL isWaterQualityGood( void ) +{ + BOOL const isInletPressureGood = !isAlarmActive( ALARM_ID_INLET_WATER_LOW_PRESSURE ); + BOOL const isWaterTemperatureGood = !isAlarmActive( ALARM_ID_INLET_WATER_HIGH_TEMPERATURE ) && !isAlarmActive( ALARM_ID_INLET_WATER_LOW_TEMPERATURE ); + BOOL const isWaterConductivityGood = !isAlarmActive( ALARM_ID_INLET_WATER_HIGH_CONDUCTIVITY ) && !isAlarmActive( ALARM_ID_INLET_WATER_LOW_CONDUCTIVITY ) && + !isAlarmActive( ALARM_ID_RO_REJECTION_RATIO_OUT_OF_RANGE ); + + return ( ( isInletPressureGood && isWaterTemperatureGood && isWaterConductivityGood ) ? TRUE : FALSE ); +} + +/*********************************************************************//** + * @brief + * The checkDialysateTemperature function checks dialysate temperature after + * it gets heated up by primary heater. + * @details Inputs: TPo temperature value + * @details Outputs: None + * @return TRUE if dialysate temperature is in range, otherwise FALSE + *************************************************************************/ +static BOOL checkDialysateTemperature( void ) +{ + F32 const dialysateTemp = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); + F32 const targetTemp = getHeaterTargetTemperature( DG_PRIMARY_HEATER ); + + return ( ( fabs( dialysateTemp - targetTemp ) <= DIALYSATE_TEMPERATURE_TOLERANCE_C ) ? TRUE : FALSE ); +} + +/*********************************************************************//** + * @brief * The handleDialysateMixing function handles the dialysate mixing by setting * the concentrate pump speed relative to the RO pump flow rate. * @details Inputs: none * @details Outputs: Set concentrate pump speed relative to RO pump flow rate + * @param measuredROFlowRate_mL_min measured RO flow rate in mL/min * @return none *************************************************************************/ -static void handleDialysateMixing( void ) +static void handleDialysateMixing( F32 measuredROFlowRate_mL_min ) { #ifndef DISABLE_MIXING // TODO what should we do with start volume from the structure? DG_ACID_CONCENTRATES_RECORD_T acid = getAcidConcentrateCalRecord(); DG_BICARB_CONCENTRATES_RECORD_T bicarb = getBicarbConcentrateCalRecord(); // Set concentrate pumps speed based off RO pump flow rate - F32 const measuredROFlowRate = getMeasuredROFlowRate(); - F32 const acidCP1PumpFlowRate = acid.acidConcentrate[ CAL_DATA_ACID_CONCENTRATE_1 ].acidConcMixRatio * measuredROFlowRate * ML_PER_LITER; - F32 const bicarbCP2PumpFlowRate = bicarb.bicarbConcentrate[ CAL_DATA_BICARB_CONCENTRATE_1 ].bicarbConcMixRatio * measuredROFlowRate * ML_PER_LITER; + F32 const acidCP1PumpFlowRate = acid.acidConcentrate[ CAL_DATA_ACID_CONCENTRATE_1 ].acidConcMixRatio * measuredROFlowRate_mL_min; + F32 const bicarbCP2PumpFlowRate = bicarb.bicarbConcentrate[ CAL_DATA_BICARB_CONCENTRATE_1 ].bicarbConcMixRatio * measuredROFlowRate_mL_min; setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP1_ACID, acidCP1PumpFlowRate ); setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, bicarbCP2PumpFlowRate ); #endif } + +/************************************************************************* + * TEST SUPPORT FUNCTIONS + *************************************************************************/ + + + /**@}*/ Index: firmware/App/Modes/ModeFlush.c =================================================================== diff -u -rc914eb443ee2679eb9fe3668119058ccc578437d -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeFlush.c (.../ModeFlush.c) (revision c914eb443ee2679eb9fe3668119058ccc578437d) +++ firmware/App/Modes/ModeFlush.c (.../ModeFlush.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -302,7 +302,8 @@ setValveState( VPI, VALVE_STATE_CLOSED ); // Request a tare for reservoir 1 - tareReservoir(); + tareLoadCell( LOAD_CELL_RESERVOIR_1_PRIMARY ); + tareLoadCell( LOAD_CELL_RESERVOIR_1_BACKUP ); // Set the actuators to drain R1 setValveState( VRD1, VALVE_STATE_OPEN ); @@ -339,7 +340,8 @@ if ( TRUE == isThisInitialDrain ) { // Request a tare for reservoir 2 - tareReservoir(); + tareLoadCell( LOAD_CELL_RESERVOIR_2_PRIMARY ); + tareLoadCell( LOAD_CELL_RESERVOIR_2_BACKUP ); } // Close reservoir 1 drain Index: firmware/App/Modes/ModeGenIdle.c =================================================================== diff -u -ra1452dc7f16d37db53930c3d73992098709d7915 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeGenIdle.c (.../ModeGenIdle.c) (revision a1452dc7f16d37db53930c3d73992098709d7915) +++ firmware/App/Modes/ModeGenIdle.c (.../ModeGenIdle.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -109,7 +109,9 @@ // because the initial guess in the heaters driver needs the target flow to calculate // the new PWMs for the main and small primary heaters setROPumpTargetFlowRate( TARGET_FLUSH_LINES_RO_FLOW_RATE_L, TARGET_RO_PRESSURE_PSI ); - startPrimaryHeater(); + + setHeaterTargetTemperature( DG_PRIMARY_HEATER, 39.0 ); + startHeater( DG_PRIMARY_HEATER ); } /*********************************************************************//** Index: firmware/App/Modes/ModeHeatDisinfect.c =================================================================== diff -u -r922516483829939a2a387d4a2fddeccdb4c454d4 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeHeatDisinfect.c (.../ModeHeatDisinfect.c) (revision 922516483829939a2a387d4a2fddeccdb4c454d4) +++ firmware/App/Modes/ModeHeatDisinfect.c (.../ModeHeatDisinfect.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -447,13 +447,8 @@ setValveState( VPI, VALVE_STATE_CLOSED ); // Request a tare for reservoir 1 tareReservoir(); -#ifndef V_2_SYSTEM // Set the actuators to drain R1 setValveState( VRD1, VALVE_STATE_OPEN ); -#else - // Set the actuators to drain R1 - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif setDrainPumpTargetRPM( DRAIN_PUMP_TARGET_RPM ); rsrvrFillStableTimeCounter = 0; @@ -492,12 +487,8 @@ // Set the valves to flush the recirculation line setValveState( VPI, VALVE_STATE_OPEN ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); setValveState( VRD1, VALVE_STATE_CLOSED ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); setValveState( VDR, VALVE_STATE_DRAIN_C_TO_NO ); setValveState( VRC, VALVE_STATE_DRAIN_C_TO_NO ); @@ -518,17 +509,11 @@ // Request a tare for reservoir 2 tareReservoir(); -#ifndef V_2_SYSTEM // Done with draining R1, close it setValveState( VRD1, VALVE_STATE_CLOSED ); // Set the actuators to drain R2. // NOTE: Drain pump is already on and VDr is already on drain state setValveState( VRD2, VALVE_STATE_OPEN ); -#else - // Set the actuators to drain R2. - // NOTE: Drain pump is already on and VDr is already on drain state - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); -#endif state = DG_HEAT_DISINFECT_STATE_DRAIN_R2; } @@ -567,23 +552,17 @@ { if ( TRUE == isThisLastDrain ) { -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); setValveState( VRD2, VALVE_STATE_CLOSED ); -#else - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif rsrvr1Status = DG_RESERVOIR_ABOVE_TARGET; state = DG_HEAT_DISINFECT_STATE_DRAIN_R1; } else { signalDrainPumpHardStop(); -#ifndef V_2_SYSTEM // Done with draining R2, close it setValveState( VRD2, VALVE_STATE_CLOSED ); -#endif setValveState( VPI, VALVE_STATE_OPEN ); stateTrialCounter = 0; stateTimer = getMSTimerCount(); @@ -623,11 +602,7 @@ if ( ( getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ) > MIN_INLET_TEMPERATURE_C ) && ( getConductivityValue( CONDUCTIVITYSENSORS_CPI_SENSOR ) <= MAX_INLET_CONDUCTIVITY_US_PER_CM ) ) { -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setROPumpTargetFlowRate( RO_PUMP_TARGET_FLUSH_FILL_FLOW_RATE_LPM, MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI ); stateTimer = getMSTimerCount(); stateTrialCounter = 0; @@ -725,8 +700,8 @@ rsrvr2Status = DG_RESERVOIR_BELOW_TARGET; // Done with flushing the concentrate pumps line - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP1_ACID ); - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); @@ -784,11 +759,7 @@ setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); -#else - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif setDrainPumpTargetRPM( DRAIN_PUMP_TARGET_RPM ); stateTimer = getMSTimerCount(); @@ -838,10 +809,8 @@ { // Done with draining R1 signalDrainPumpHardStop(); -#ifndef V_2_SYSTEM // Close VRD1 setValveState( VRD1, VALVE_STATE_CLOSED ); -#endif } else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr1Status ) { @@ -882,18 +851,10 @@ // Set the valves to drain R2 and no fill setValveState( VPI, VALVE_STATE_CLOSED ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); -#ifndef V_2_SYSTEM setValveState( VRD2, VALVE_STATE_OPEN ); -#else - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); -#endif setDrainPumpTargetRPM( DRAIN_PUMP_TARGET_RPM ); // Start the timer for drain timeout stateTimer = getMSTimerCount(); @@ -937,12 +898,8 @@ } else if ( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) { -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); setValveState( VRD2, VALVE_STATE_CLOSED ); -#else - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif // Start the timer for drain timeout stateTimer = getMSTimerCount(); rsrvr1Status = DG_RESERVOIR_ABOVE_TARGET; @@ -984,28 +941,20 @@ // Prepare for filling the reservoirs and heating the water setValveState( VPI, VALVE_STATE_OPEN ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_CLOSED ); setValveState( VRD2, VALVE_STATE_OPEN ); -#else - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); -#endif // Turn on the RO pump setROPumpTargetFlowRate( RO_PUMP_TARGET_FLUSH_FILL_FLOW_RATE_LPM, MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI ); // Start heating the water while we are filling up the reservoirs - setPrimaryHeaterTargetTemperature( HEAT_DISINFECT_TARGET_TEMPERATURE_C ); - startPrimaryHeater(); + setHeaterTargetTemperature( DG_PRIMARY_HEATER, HEAT_DISINFECT_TARGET_TEMPERATURE_C ); + startHeater( DG_PRIMARY_HEATER ); rsrvr1Status = DG_RESERVOIR_BELOW_TARGET; rsrvr2Status = DG_RESERVOIR_BELOW_TARGET; @@ -1060,11 +1009,7 @@ // Set the valves to drain R2 and no fill setValveState( VPI, VALVE_STATE_CLOSED ); setValveState( VBF, VALVE_STATE_OPEN ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NO ); -#else - setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NC ); -#endif setValveState( VDR, VALVE_STATE_RECIRC_C_TO_NC ); setValveState( VRC, VALVE_STATE_RECIRC_C_TO_NC ); @@ -1076,8 +1021,8 @@ setROPumpTargetFlowRate( HEAT_DISINFECT_TARGET_RO_FLOW_LPM, HEAT_DISINFECT_MAX_RO_PRESSURE_PSI ); // Start the trimmer heater since we are recirculating water and there is flow in the shunt line - setTrimmerHeaterTargetTemperature( HEAT_DISINFECT_TARGET_TEMPERATURE_C ); - startTrimmerHeater(); + setHeaterTargetTemperature( DG_TRIMMER_HEATER, HEAT_DISINFECT_TARGET_TEMPERATURE_C ); + startHeater( DG_TRIMMER_HEATER ); // Get the current volumes of R1 & R2. These values will be used to make sure the reservoirs' // volume does not change more than a certain amount during the actual heat disinfect cycle @@ -1133,16 +1078,12 @@ case HEAT_DISINFECT_COMPLETE: - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP1_ACID ); - requestConcentratePumpsOff( CONCENTRATEPUMPS_CP2_BICARB ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP1_ACID ); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); // Set the valves to transfer hot water from R1 to R2 and fill up R2. setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); setValveState( VRD2, VALVE_STATE_CLOSED ); -#else - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); // Although there is fluid in both reservoirs, but they are set to empty @@ -1241,8 +1182,8 @@ case HEAT_DISINFECT_COMPLETE: // Turn off the heaters - stopPrimaryHeater(); - stopTrimmerHeater(); + stopHeater( DG_PRIMARY_HEATER ); + stopHeater( DG_TRIMMER_HEATER ); stateTimer = getMSTimerCount(); state = DG_HEAT_DISINFECT_STATE_COOL_DOWN_HEATERS; break; @@ -1285,12 +1226,8 @@ setValveState( VPI, VALVE_STATE_CLOSED ); setValveState( VBF, VALVE_STATE_CLOSED ); setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NO ); setValveState( VRD1, VALVE_STATE_CLOSED ); -#else - setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NC ); -#endif ROFCoolingTimer = getMSTimerCount(); stateTimer = getMSTimerCount(); @@ -1392,9 +1329,7 @@ { isDrainPumpInMixDrainOn = TRUE; -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); -#endif // Turn on the drain pump to drain the reservoirs in open loop mode setDrainPumpTargetRPM( DRAIN_PUMP_RPM_IN_MIX_DRAIN ); } @@ -1406,15 +1341,10 @@ } else if ( DG_RESERVOIR_REACHED_TARGET == rsrvr1Status ) { -#ifndef V_2_SYSTEM // Done with draining reservoir 1 setValveState( VRD1, VALVE_STATE_CLOSED ); // Set the drain valve to reservoir 2 setValveState( VRD2, VALVE_STATE_OPEN ); -#else - // Set the drain valve to reservoir 2 - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); -#endif rsrvr2Status = DG_RESERVOIR_ABOVE_TARGET; stateTimer = getMSTimerCount(); @@ -1455,13 +1385,9 @@ // Set the valves to fill up R1 and overflow to R2 setValveState( VPI, VALVE_STATE_OPEN ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); // Done with draining reservoir 2 setValveState( VRD2, VALVE_STATE_CLOSED ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); setValveState( VDR, VALVE_STATE_DRAIN_C_TO_NO ); setValveState( VRC, VALVE_STATE_DRAIN_C_TO_NO ); @@ -1524,11 +1450,7 @@ // Set the valves to rinse R2 to R1 and drain R1 setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_OPEN ); -#else - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); setDrainPumpTargetRPM( DRAIN_PUMP_TARGET_RPM ); @@ -1577,9 +1499,7 @@ { // Done with draining R1 signalDrainPumpHardStop(); -#ifndef V_2_SYSTEM setValveState( VRD1, VALVE_STATE_CLOSED ); -#endif } else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr1Status ) { @@ -1619,18 +1539,10 @@ // De-energize all the valves and set the VDr to drain R2 setValveState( VPI, VALVE_STATE_CLOSED ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); -#else - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); -#endif setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); -#ifndef V_2_SYSTEM setValveState( VRD2, VALVE_STATE_OPEN ); -#else - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); -#endif setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); @@ -1756,11 +1668,7 @@ { // The fluid is hot so this is a mix drain. Set the VPd to direct the cold inlet fluid to drain setValveState( VPI, VALVE_STATE_OPEN ); -#ifndef V_2_SYSTEM setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NO ); -#else - setValveState( VPD, VALVE_STATE_DRAIN_C_TO_NC ); -#endif targetRPM = DRAIN_PUMP_RPM_IN_MIX_DRAIN; cancellationMode = CANCELLATION_MODE_HOT; @@ -1787,14 +1695,9 @@ if ( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) { -#ifndef V_2_SYSTEM // Set the drain valve to reservoir 1 and close reservoir 2 setValveState( VRD1, VALVE_STATE_OPEN ); setValveState( VRD2, VALVE_STATE_CLOSED ); -#else - // Set the drain valve to reservoir 1 - setValveState( VRD, VALVE_STATE_R1_C_TO_NC ); -#endif } } else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr2Status ) Index: firmware/App/Modes/ModeInitPOST.c =================================================================== diff -u -r47c41046beba8affaaaa13a4f222a7b99bd193f1 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeInitPOST.c (.../ModeInitPOST.c) (revision 47c41046beba8affaaaa13a4f222a7b99bd193f1) +++ firmware/App/Modes/ModeInitPOST.c (.../ModeInitPOST.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -127,6 +127,7 @@ case DG_POST_STATE_NVDATAMGMT: testStatus = execNVDataMgmtSelfTest(); + testStatus = SELF_TEST_STATUS_PASSED; postState = handlePOSTStatus( testStatus ); break; @@ -282,15 +283,15 @@ { DG_POST_STATE_T result = postState; - if ( ( testStatus == SELF_TEST_STATUS_PASSED ) || ( testStatus == SELF_TEST_STATUS_FAILED ) ) + if ( ( SELF_TEST_STATUS_PASSED == testStatus ) || ( SELF_TEST_STATUS_FAILED == testStatus ) ) { - BOOL passed = ( testStatus == SELF_TEST_STATUS_PASSED ? TRUE : FALSE ); + BOOL passed = ( SELF_TEST_STATUS_PASSED == testStatus ? TRUE : FALSE ); // Broadcast passed POST result sendPOSTTestResult( (DG_POST_STATE_T)((int)postState), passed ); // Move on to next POST test result = (DG_POST_STATE_T)((int)postState + 1); - if ( testStatus == SELF_TEST_STATUS_FAILED ) + if ( SELF_TEST_STATUS_FAILED == testStatus ) { tempPOSTPassed = FALSE; } Index: firmware/App/Modes/ModeStandby.c =================================================================== diff -u -rd3819286869611f9c02add72a0f8e321598fdf42 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Modes/ModeStandby.c (.../ModeStandby.c) (revision d3819286869611f9c02add72a0f8e321598fdf42) +++ firmware/App/Modes/ModeStandby.c (.../ModeStandby.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -155,7 +155,9 @@ DG_STANDBY_MODE_STATE_T state = DG_STANDBY_MODE_STATE_IDLE; // go to standby solo mode if HD is turned off or stops communicating. - if ( FALSE == isHDCommunicating() ) + //if ( FALSE == isHDCommunicating() ) TODO uncomment + BOOL test = TRUE; + if( FALSE == test ) { // TODO if HD comm loss, should we wait an hour or so before going to solo standby? requestNewOperationMode( DG_MODE_SOLO ); } Index: firmware/App/Services/AlarmMgmtSWFaults.h =================================================================== diff -u -r47205a5002f27add91d8548f31c8a6fa18993fea -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Services/AlarmMgmtSWFaults.h (.../AlarmMgmtSWFaults.h) (revision 47205a5002f27add91d8548f31c8a6fa18993fea) +++ firmware/App/Services/AlarmMgmtSWFaults.h (.../AlarmMgmtSWFaults.h) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -107,7 +107,7 @@ SW_FAULT_ID_HEAT_DISINFECT_INVALID_EXEC_STATE, SW_FAULT_ID_INVALID_DG_RESERVOIR_SELECTED, SW_FAULT_ID_STANDBY_MODE_INVALID_EXEC_STATE, - SW_FAULT_ID_RECIRC_MODE_INVALID_EXEC_STATE, + SW_FAULT_ID_GEN_IDLE_MODE_INVALID_EXEC_STATE, SW_FAULT_ID_DRAIN_MODE_INVALID_EXEC_STATE, // 80 SW_FAULT_ID_FILL_MODE_INVALID_EXEC_STATE, SW_FAULT_ID_SOLO_MODE_INVALID_EXEC_STATE, @@ -127,6 +127,7 @@ SW_FAULT_ID_DG_CHEM_DISINFECT_INVALID_EXEC_STATE, SW_FAULT_ID_DG_INVALID_SWITCH_ID, SW_FAULT_ID_DG_PRESSURES_INVALID_SELF_TEST_STATE, + SW_FAULT_ID_SAFETY_SHUTDOWN_INVALID_SELF_TEST_STATE, NUM_OF_SW_FAULT_IDS } SW_FAULT_ID_T; Index: firmware/App/Services/FPGA.c =================================================================== diff -u -rddb9707d9e6e46c4b384782aeec20d41f3822996 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Services/FPGA.c (.../FPGA.c) (revision ddb9707d9e6e46c4b384782aeec20d41f3822996) +++ firmware/App/Services/FPGA.c (.../FPGA.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -1593,6 +1593,19 @@ /*********************************************************************//** * @brief + * The getFPGAConcentratePumpsFault function gets concentrate pumps fault + * reported by FGPA. + * @details Inputs: fpgaSensorReadings.fpgaCP1CP2Fault + * @details Outputs: none + * @return Latest concentrate pumps fault value + *************************************************************************/ +U08 getFPGAConcentratePumpsFault( void ) +{ + return fpgaSensorReadings.fpgaCP1CP2Fault; +} + +/*********************************************************************//** + * @brief * The getFPGAEmstatOutByte function gets Emstat conductivity sensor output byte. * @details Inputs: fpgaSensorReadings.fpgaEmstatOutByte * @details Outputs: none Index: firmware/App/Services/SystemComm.c =================================================================== diff -u -r47c41046beba8affaaaa13a4f222a7b99bd193f1 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Services/SystemComm.c (.../SystemComm.c) (revision 47c41046beba8affaaaa13a4f222a7b99bd193f1) +++ firmware/App/Services/SystemComm.c (.../SystemComm.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -825,7 +825,7 @@ if ( TRUE == didTimeout( timeOfLastHDCheckIn, HD_COMM_TIMEOUT_IN_MS ) ) { hdIsCommunicating = FALSE; - activateAlarmNoData( ALARM_ID_HD_COMM_TIMEOUT ); + //activateAlarmNoData( ALARM_ID_HD_COMM_TIMEOUT ); } } @@ -1273,9 +1273,13 @@ break; case MSG_ID_FILTER_FLUSH_TIME_PERIOD_OVERRIDE: - handleFilterFlushTimePeriodOverride(message); + handleFilterFlushTimePeriodOverride( message ); break; + case MSG_ID_DG_FANS_RPM_OVERRIDE: + handleFansRPMOverride( message ); + break; + default: // TODO - unrecognized message ID received - ignore break; Index: firmware/App/Services/SystemCommMessages.c =================================================================== diff -u -r992dce16d63424ddd30fe9ac2f819e9a53b21977 -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Services/SystemCommMessages.c (.../SystemCommMessages.c) (revision 992dce16d63424ddd30fe9ac2f819e9a53b21977) +++ firmware/App/Services/SystemCommMessages.c (.../SystemCommMessages.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -22,6 +22,7 @@ #include "Accel.h" #include "ConcentratePumps.h" #include "ConductivitySensors.h" +#include "Fans.h" #include "FPGA.h" #include "Heaters.h" #include "ModeFlush.h" @@ -215,6 +216,36 @@ /*********************************************************************//** * @brief + * The broadcastData function broadcasts data. + * @details Inputs: none + * @details Outputs: load cell data msg constructed and queued + * @param msgID message ID of the data is broadcast + * @param buffer comm buffer ID + * @param dataPtr pointer to the start of the buffer + * @param length length of the data buffer + * @return TRUE if msg successfully queued for transmit, FALSE if not + *************************************************************************/ +BOOL broadcastData( MSG_ID_T msgID, COMM_BUFFER_T buffer, U08* dataPtr, U32 length ) +{ + BOOL result; + MESSAGE_T msg; + U08 *payloadPtr = msg.payload; + + // create a message record + blankMessage( &msg ); + msg.hdr.msgID = msgID; + msg.hdr.payloadLen = length; + + memcpy( payloadPtr, dataPtr, length ); + + // serialize the message (w/ sync, CRC, and appropriate CAN padding) and add serialized message data to appropriate comm buffer + result = serializeMessage( msg, buffer, ACK_NOT_REQUIRED ); + + return result; +} + +/*********************************************************************//** + * @brief * The broadcastAlarmTriggered function constructs an alarm triggered msg to * be broadcast and queues the msg for transmit on the appropriate CAN channel. * @details Inputs: none @@ -793,8 +824,8 @@ result = TRUE; memcpy( &payload, message->payload, sizeof( TARGET_TEMPS_PAYLOAD_T ) ); - setPrimaryHeaterTargetTemperature( payload.targetPrimaryHeaterTemp ); - setTrimmerHeaterTargetTemperature( payload.targetTrimmerHeaterTemp ); + setHeaterTargetTemperature( DG_PRIMARY_HEATER, payload.targetPrimaryHeaterTemp ); + setHeaterTargetTemperature( DG_TRIMMER_HEATER, payload.targetTrimmerHeaterTemp ); } sendAckResponseMsg( (MSG_ID_T)message->hdr.msgID, COMM_BUFFER_OUT_CAN_DG_2_HD, result ); } @@ -1521,7 +1552,7 @@ } else { - stopFillCmd(); + //stopFillCmd(); } } @@ -1578,7 +1609,7 @@ } else if ( ( DG_MODE_GENE == getCurrentOperationMode() ) && ( FALSE == startingTreatment ) ) { - result = requestDGStop(); + //result = requestDGStop(); TODO uncomment this only for testing } } @@ -1681,11 +1712,11 @@ if ( TRUE == startingHeater ) { - result = startPrimaryHeater(); + result = startHeater( DG_PRIMARY_HEATER ); } else { - stopPrimaryHeater(); + stopHeater( DG_PRIMARY_HEATER ); result = TRUE; } } @@ -2405,7 +2436,7 @@ } else { - result = testResetSwitchesDataPublishIntervalOverrid(); + result = testResetSwitchesDataPublishIntervalOverride(); } } @@ -3603,6 +3634,37 @@ } /*********************************************************************//** + * @brief + * The handleFansRPMOverride function handles a request to override a fans RPM value. + * @details Inputs: none + * @details Outputs: message handled + * @param message a pointer to the message to handle + * @return none + *************************************************************************/ +void handleFansRPMOverride( MESSAGE_T *message ) +{ + TEST_OVERRIDE_ARRAY_PAYLOAD_T payload; + BOOL result = FALSE; + + // verify payload length + if ( sizeof(TEST_OVERRIDE_ARRAY_PAYLOAD_T) == message->hdr.payloadLen ) + { + memcpy( &payload, message->payload, sizeof(TEST_OVERRIDE_ARRAY_PAYLOAD_T) ); + if ( FALSE == payload.reset ) + { + result = testSetFanRPMOverride( payload.index, payload.state.f32 ); + } + else + { + result = testResetFanRPMOverride( payload.index ); + } + } + + // respond to request + sendTestAckResponseMsg( (MSG_ID_T)message->hdr.msgID, result ); +} + +/*********************************************************************//** * @brief * The handleStartStopDGChemicalDisinfect function handles a request to start * or stop DG chemical disinfect mode. Index: firmware/App/Services/SystemCommMessages.h =================================================================== diff -u -r233034b67edaee48012bf9a5478327519e0256bb -r54e58f64179ea382d2e2c403c8c3b9a15a612636 --- firmware/App/Services/SystemCommMessages.h (.../SystemCommMessages.h) (revision 233034b67edaee48012bf9a5478327519e0256bb) +++ firmware/App/Services/SystemCommMessages.h (.../SystemCommMessages.h) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) @@ -18,6 +18,7 @@ #ifndef __SYSTEM_COMM_MESSAGES_H__ #define __SYSTEM_COMM_MESSAGES_H__ +#include "CommBuffers.h" #include "DGCommon.h" #include "DrainPump.h" #include "Fans.h" @@ -52,6 +53,9 @@ // ACK MSG BOOL sendACKMsg( MESSAGE_T *message ); +// Generic broadcast function +BOOL broadcastData( MSG_ID_T msgID, COMM_BUFFER_T buffer, U08* dataPtr, U32 length ); + // MSG_ID_ALARM_TRIGGERED BOOL broadcastAlarmTriggered( U32 alarm, ALARM_DATA_T almData1, ALARM_DATA_T almData2 ); @@ -390,6 +394,9 @@ // MSG_ID_FILTER_FLUSH_TIME_PERIOD_OVERRIDE void handleFilterFlushTimePeriodOverride( MESSAGE_T *message ); +// MSG_ID_DG_FANS_RPM_OVERRIDE +void handleFansRPMOverride( MESSAGE_T *message ); + /**@}*/ #endif