Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r3e26dba2affe762d5ebad791a51e036bd2aa060a -rda1f86ddf735623ba393ca809479157cd66c154c --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 3e26dba2affe762d5ebad791a51e036bd2aa060a) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision da1f86ddf735623ba393ca809479157cd66c154c) @@ -68,23 +68,13 @@ #define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.015F ///< Primary heaters duty cycle per temperature in C. #define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. #define MIN_RO_HEATER_FLOWRATE_LPM 0.2F ///< Minimum target RO heater flow rate in L/min. +#define PRIMARY_HEATER_POWER_TOL 0.1F ///< Primary heater power tolerance. static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184 / SEC_PER_MIN; ///< Water specific heat in J/KgC / 60. static const F32 PRIMARY_HEATERS_MAXIMUM_POWER_WATTS = 475 + 237.5F; ///< Primary heaters maximum power (main primary = 475W and small primary = 237.5W). static const F32 HEATERS_VOLTAGE_TOLERANCE_V = HEATERS_MAX_OPERATING_VOLTAGE_V * HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL; ///< Heaters voltage tolerance in volts. +static const F32 PRIMARY_HEATER_VOLTAGE_TOLERANCE_V = HEATERS_MAX_OPERATING_VOLTAGE_V * PRIMARY_HEATER_POWER_TOL; ///< Primary heater power voltage tolerance in volts. -/// Heaters exec states -typedef enum Heaters_Exec_States -{ - HEATER_EXEC_STATE_OFF = 0, ///< Heater exec state off. - HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET, ///< Heater exec state primary ramp to target. - HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET, ///< Heater exec state primary control to target. - HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET, ///< Heater exec state control to disinfect (heat or chemical) target. - HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET, ///< Heater exec state trimmer ramp to target. - HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET, ///< Heater exec state trimmer control to target. - NUM_OF_HEATERS_STATE, ///< Number of heaters state. -} HEATERS_STATE_T; - /// Heaters data structure typedef struct { @@ -158,6 +148,7 @@ initPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); } @@ -471,7 +462,7 @@ if ( DG_MODE_FILL == opMode ) { // If the previous average fill flow rate is 0, use the nominal target RO flow from the RO pump - targetFlow = ( getAvgFillFlowRateLPM() - 0.0 > NEARLY_ZERO ? getAvgFillFlowRateLPM() : getTargetROPumpFlowRateLPM() ); + targetFlow = ( getAvgFillFlowRateLPM() - 0.0F > NEARLY_ZERO ? getAvgFillFlowRateLPM() : getTargetROPumpFlowRateLPM() ); dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } @@ -492,8 +483,7 @@ } else { - // No other modes are using the heaters - // TODO software fault + // Do nothing the mode that DG is in right now, does not need heaters to be on } // Update the calculated target temperature @@ -607,7 +597,6 @@ heatersStatus[ heater ].calculatedTemperature = currentTemperature; heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); heatersStatus[ heater ].targetFlow = targetFlowLPM; - heatersStatus[ heater ].dutyCycle = 0.0F; trimmerHeaterControlCounter = 0; // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 @@ -667,24 +656,17 @@ *************************************************************************/ static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ) { - // Check if the requested duty cycle is different from what the heater's duty cycle is. - // If the same duty cycle is requested, then it is not needed to send it again. This is to make sure - // the same duty cycle is not sent to the hardware all the time. - if ( fabs( heatersStatus[ heater ].dutyCycle - pwm ) > NEARLY_ZERO ) + if ( DG_PRIMARY_HEATER == heater ) { - if ( DG_PRIMARY_HEATER == heater ) - { - setMainPrimaryHeaterPWM( pwm ); - setSmallPrimaryHeaterPWM( pwm ); - } - else if ( DG_TRIMMER_HEATER == heater ) - { - setTrimmerHeaterPWM( pwm ); - } - - // Updated the heater's information - heatersStatus[ heater ].dutyCycle = pwm; + setMainPrimaryHeaterPWM( pwm ); + setSmallPrimaryHeaterPWM( pwm ); } + else if ( DG_TRIMMER_HEATER == heater ) + { + setTrimmerHeaterPWM( pwm ); + } + + heatersStatus[ heater ].dutyCycle = pwm; } /*********************************************************************//** @@ -735,7 +717,7 @@ { if ( TRUE == checkEfficiency ) { - // TODO Do we need efficiency for the trimmer heater? + // Do nothing right now. Efficiency will be implemented later if needed } } @@ -784,7 +766,15 @@ *************************************************************************/ static void setMainPrimaryHeaterPWM( F32 pwm ) { - etpwmSetCmpA( etpwmREG1, (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); + etpwm_config_reg_t mainPriConfig; + U32 pwmValue = (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ); + + etpwm1GetConfigValue( &mainPriConfig, CurrentValue ); + + if ( mainPriConfig.CONFIG_CMPA != pwmValue ) + { + etpwmSetCmpA( etpwmREG1, pwmValue ); + } } /*********************************************************************//** @@ -797,7 +787,15 @@ *************************************************************************/ static void setSmallPrimaryHeaterPWM( F32 pwm ) { - etpwmSetCmpB( etpwmREG1, (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); + etpwm_config_reg_t smallPriConfig; + U32 pwmValue = (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ); + + etpwm1GetConfigValue( &smallPriConfig, CurrentValue ); + + if ( smallPriConfig.CONFIG_CMPB != pwmValue ) + { + etpwmSetCmpB( etpwmREG1, pwmValue ); + } } /*********************************************************************//** @@ -810,7 +808,15 @@ *************************************************************************/ static void setTrimmerHeaterPWM( F32 pwm ) { - etpwmSetCmpA( etpwmREG3, (U32)( (S32)( ( pwm * (F32)(etpwmREG3->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); + etpwm_config_reg_t trimmerConfig; + U32 pwmValue = (U32)( (S32)( ( pwm * (F32)(etpwmREG3->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ); + + etpwm3GetConfigValue( &trimmerConfig, CurrentValue ); + + if ( trimmerConfig.CONFIG_CMPA != pwmValue ) + { + etpwmSetCmpA( etpwmREG3, pwmValue ); + } } /*********************************************************************//** @@ -854,18 +860,19 @@ *************************************************************************/ static void monitorHeatersVoltage( void ) { - // NOTE: Default to using Primary heater voltage from FPGA - F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_PRIM_HTR_GND_V ); + F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_MAIN_PRIM_HTR_V ); + #ifndef _RELEASE_ if ( SW_CONFIG_ENABLE_VALUE == getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) { // V3 use CPU based value for Primary, same as Secondary - mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_SEC_HTR_V ); + mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); } #endif - F32 smallPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_SEC_HTR_V ); - F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_TRIM_HTR_V ); + F32 smallPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); + F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_TRIM_HTR_V ); + // Voltage to PWM is reverse. If PWM = 0 -> V = 24V F32 mainPriDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle; F32 smallPriDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle; @@ -884,6 +891,17 @@ checkPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isMainPriOut, mainPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isSmallPriOut, smallPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, isTrimmerOut, trimmerDC, HEATERS_VOLTAGE_TOLERANCE_V ); + +#ifndef _RELEASE_ + if ( SW_CONFIG_ENABLE_VALUE != getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) +#endif + { + // If the system is DVT, check the primary heater's power line voltage + F32 powerMainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_POWER_PRIM_HTR_V ); + BOOL isPriPowerOut = ( fabs( powerMainPriVoltage - HEATERS_MAX_OPERATING_VOLTAGE_V ) > PRIMARY_HEATER_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + + checkPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, isPriPowerOut, powerMainPriVoltage, PRIMARY_HEATER_VOLTAGE_TOLERANCE_V ); + } } }