Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r54f45c387430e440ab4607451fc84dea61f273f1 -r027b218c2a53ceae7aa040071944c5e70c391fc2 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 54f45c387430e440ab4607451fc84dea61f273f1) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 027b218c2a53ceae7aa040071944c5e70c391fc2) @@ -1,735 +1,780 @@ /************************************************************************** * -* Copyright (c) 2019-2020 Diality Inc. - All Rights Reserved. +* Copyright (c) 2020-2022 Diality Inc. - All Rights Reserved. * * THIS CODE MAY NOT BE COPIED OR REPRODUCED IN ANY FORM, IN PART OR IN * WHOLE, WITHOUT THE EXPLICIT PERMISSION OF THE COPYRIGHT OWNER. * -* @file Heaters.c +* @file Heaters.c * -* @author (last) Quang Nguyen -* @date (last) 26-Aug-2020 +* @author (last) Dara Navaei +* @date (last) 04-Aug-2022 * -* @author (original) Dara Navaei -* @date (original) 23-Apr-2020 +* @author (original) Dara Navaei +* @date (original) 23-Apr-2020 * ***************************************************************************/ -#include +#include // Used for converting slope to radians and square root +// TI PWM driver #include "etpwm.h" #include "AlarmMgmt.h" +#include "DGDefs.h" +#include "FlowSensors.h" #include "Heaters.h" +#include "MessageSupport.h" +#include "ModeFill.h" +#include "NVDataMgmt.h" +#include "OperationModes.h" +#include "PersistentAlarm.h" +#include "Reservoirs.h" #include "ROPump.h" -#include "PIControllers.h" +#include "SafetyShutdown.h" #include "SystemCommMessages.h" #include "TaskGeneral.h" +#include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" +#include "Voltages.h" -#ifdef ENABLE_DIP_SWITCHES -#include "mibspi.h" -#include "FPGA.h" -#endif - /** * @addtogroup Heaters * @{ */ // ********** private definitions ********** -#define MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE 0.89 ///< Main primary heater (heater A) max duty cycle (89%). -#define SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE 0.50 ///< Small Primary heater (heater B) max duty cycle (50%). -#define TRIMMER_HEATER_MAX_DUTY_CYCLE 0.50 ///< Trimmer heater max duty cycle (50%). -#define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Primary and trimmer heaters minimum duty cycle (0.00%). +#define HEATERS_MAX_DUTY_CYCLE 1.00F ///< Heaters max duty cycle (100%). +#define HEATERS_MIN_DUTY_CYCLE 0.00F ///< Heaters minimum duty cycle (0.00%). +#define HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE 0.6F ///< Heaters minimum duty cycle during heat disinfect. +#define HEATERS_MIN_EST_GAIN 0.2F ///< Heaters minimum estimation gain. +#define HEATERS_MAX_EST_GAIN 5.0F ///< Heaters maximum estimation gain. +#define HEATERS_NEUTRAL_EST_GAIN 1.0F ///< Heaters neutral estimation gain. -#define PRIMARY_HEATERS_P_COEFFICIENT 0.02 ///< Primary heaters proportional coefficient. -#define PRIMARY_HEATERS_I_COEFFICIENT 0.001 ///< Primary heaters integral coefficient. +#define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. -#define TRIMMER_HEATER_P_COEFFICIENT 0.02 ///< Trimmer heater proportional coefficient. -#define TRIMMER_HEATER_I_COEFFICIENT 0.001 ///< Trimmer heater integral coefficient. +#define MINIMUM_TARGET_TEMPERATURE 10.0F ///< Minimum allowed target temperature for the heaters. +#define MAXIMUM_TARGET_TEMPERATURE 90.0F ///< Maximum allowed target temperature for the heaters. -#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_ON_NO_FLOW_TIMEOUT_MS ( 5 * MS_PER_SECOND ) ///< Heaters on with no flow time out in milliseconds. +#define HEATERS_MAX_OPERATING_VOLTAGE_V 24.0F ///< Heaters max operating voltage in volts. +#define HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ( 2 * MS_PER_SECOND ) ///< Heaters voltage out of range time out in milliseconds. +#define HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL 0.2F ///< Heaters max voltage out of range tolerance. +#define TRIMMER_HEATER_MAX_POWER_W 66.5F ///< Trimmer heater maximum power in Watts. +#define TRIMMER_HEATER_CONTROL_CHECK_INTERVAL_COUNT ( ( 30 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. -#define HEATERS_DATA_PUBLISH_INTERVAL (500 / TASK_GENERAL_INTERVAL ) ///< Heaters data publish interval. +#define DELTA_TEMPERATURE_TIME_COSNTANT_C 8.6F ///< Delta temperature calculated from time constant. +#define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.015F ///< Primary heaters duty cycle per temperature in C. +#define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. -#define SMALL_PRIMARY_AND_TRIMMER_HEATERS_POST_TARGET_TEMPERATURE 40U ///< Small primary and trimmer heaters target temperature during POST. -#define MAIN_PRIMARY_HEATER_POST_TARGET_TEMPERATURE 35U ///< Main primary heater target temperature during POST. -#define HEATERS_POST_HEAT_UP_TIME_SECONDS 50U ///< The time that the heaters are heated up to reach to the target temperature during POST. -#define HEATERS_POST_TEMPERATURE_TOLERANCE 1U ///< Tolerance of the sensors to the target temperature during POST. +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. -#define MINIMUM_TARGET_TEMPERATURE 10U ///< Minimum allowed target temperature for the heaters. -#define MAXIMUM_TARGET_TEMPERATURE 90U ///< Maximum allowed target temperature for the heaters. - -/// Heaters self test enums -typedef enum heaters_self_test_states +/// Heaters exec states +typedef enum Heaters_Exec_States { - HEATERS_SELF_TEST_START = 0, ///< Heaters self test start state - HEATERS_SELF_TEST_SMALL_PRIMARY_AND_TRIMMER_HEATERS, ///< Heaters self test small primary and trimmer heaters state - HEATERS_SELF_TEST_MAIN_PRIMARY_HEATER, ///< Heaters self test start main primary state - HEATERS_SELF_TEST_COMPLETE, ///< Heaters self test complete state - NUM_OF_HEATERS_SELF_TEST_STATES ///< Number of heaters self test states -} HEATERS_SELF_TEST_STATES_T ; + 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; -/// Primary heaters exec states -typedef enum primary_heaters_exec_states +/// Heaters data structure +typedef struct { - 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; + F32 targetTemp; ///< Heater target temperature. + HEATERS_STATE_T state; ///< Heater state. + BOOL startHeaterSignal; ///< Heater start indication flag. + BOOL isHeaterOn; ///< Heater on/off status flag. + F32 dutycycle; ///< Heater duty cycle. + F32 targetFlow; ///< Heater target flow. + BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. + F32 heaterEstGain; ///< Heater estimation gain during the run. + BOOL hasTargetBeenReached; ///< Heater flag to indicate whether the target temperature has been reached. + F32 calculatedTemperature; ///< Heater calculated temperature. + DG_RESERVOIR_ID_T inactiveRsrvr; ///< Heater inactive reservoir. +} HEATER_STATUS_T; -/// Trimmer heater exec states -typedef enum trimmer_heater_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; +static HEATER_STATUS_T heatersStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. +static U32 dataPublicationTimerCounter; ///< Data publication timer counter. +static U32 trimmerHeaterControlCounter; ///< Trimmer heater control counter. +static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. -/// Name of the heaters states -typedef enum name_of_heaters -{ - PRIMARY_HEATER = 0, ///< Primary heater - TRIMMER_HEATER, ///< Trimmer heater - NUM_OF_HEATERS ///< Number of heaters -} NAME_OF_HEATER_T; - -// ********** private data ********** - -static SELF_TEST_STATUS_T heatersSelfTestResult; ///< Heaters self test results. -static HEATERS_SELF_TEST_STATES_T heatersSelfTestState; ///< Heaters self test state. -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 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 U32 selfTestElapsedTime; ///< Self test elapsed time variable. -static BOOL hasStartPrimaryHeaterRequested; ///< Start primary heater request flag. -static BOOL hasStartTrimmerHeaterRequested; ///< Start trimmer heater request flag. - // ********** private function prototypes ********** -static HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestStart( void ); -static HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestSmallPrimaryAndTrimmerHeaters( void ); -static HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestMainPrimaryHeater( void ); +static HEATERS_STATE_T handleHeaterStateOff( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStatePrimaryRampToTarget( void ); +static HEATERS_STATE_T handleHeaterStatePrimaryControlToTarget( void ); +static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ); +static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ); -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ); -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ); +static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); +static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); +static F32 calculateTrimmerHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); +static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ); - 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 U32 getPublishHeatersDataInterval( void ); +static void monitorHeatersVoltage( void ); -// TODO: Remove the below code. FOR TESTING ONLY -#define PRIMARY_HEATER_MIBSPI1_PORT_MASK 0x00000002 // (CS1 - re-purposed as input GPIO) -#define TOGGLEPRIMAYHEATER() ( ( mibspiREG1->PC2 & PRIMARY_HEATER_MIBSPI1_PORT_MASK ) != 0 ) -//TODO: Remove the above code. FOR TESTING ONLY - /*********************************************************************//** * @brief - * The initHeaters function initializes the variables and the PI controllers - * for the primary and trimmer heaters. - * @details - * Inputs : none - * Outputs : Heaters module initialized + * The initHeaters initializes the heaters driver. + * @details Inputs: none + * @details Outputs: voltageMonitorTimeCounter, heaterStatus, + * hasTreatmentInternalTempBeenSet, dataPublicationTimerCounter, + * trimmerHeaterControlCounter * @return none *************************************************************************/ void initHeaters( void ) { - heatersSelfTestState = HEATERS_SELF_TEST_START; - 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; - selfTestElapsedTime = 0; + DG_HEATERS_T heater; + dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; + trimmerHeaterControlCounter = 0; - // 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, MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE + SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE ); + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + heatersStatus[ heater ].targetTemp = 0.0; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; + heatersStatus[ heater ].dutycycle = 0.0; + heatersStatus[ heater ].targetFlow = 0.0; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + heatersStatus[ heater ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; + heatersStatus[ heater ].hasTargetBeenReached = FALSE; + } - // 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 ); + // Initialize the persistent alarms + initPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, + HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + + initPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, + HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + + initPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, + HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + + initPersistentAlarm( ALARM_ID_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 ); } /*********************************************************************//** * @brief - * The setPrimaryHeaterTargetTemperature function sets the primary heater - * target temperature. - * @details - * Inputs : none - * Outputs : primaryHeaterTargetTemperature - * @param targetTemp target temperature for the primary heater - * @return none + * The setHeaterTargetTemperature function sets the target temperature of a heater. + * @details Inputs: none + * @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 TRUE if the temperature was set otherwise, FALSE *************************************************************************/ -void setPrimaryHeaterTargetTemperature( F32 targetTemp ) +BOOL setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ) { - primaryHeaterTargetTemperature = targetTemp; + BOOL result = FALSE; + + if( heater < NUM_OF_DG_HEATERS ) + { + // Assume the target temperature has not changed + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + + // Check if the requested temperature is within the allowed range + if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + { + heatersStatus[ heater ].targetTemp = targetTemperature; + heatersStatus[ heater ].hasTargetTempChanged = TRUE; + result = TRUE; + } + } + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) + } + + return result; } /*********************************************************************//** * @brief - * The setTrimmerHeaterTargetTemperature function sets the trimmer heater - * target temperature. - * @details - * Inputs : none - * Outputs : trimmerHeaterTargetTemperature - * @param targetTemp target temperature for the trimmer heater - * @return none + * The getHeaterTargetTemperature function returns the heater target temperature. + * @details Inputs: none + * @details Outputs: heaterStatus + * @return heater target temperature *************************************************************************/ -void setTrimmerHeaterTargetTemperature( F32 targetTemp ) +F32 getHeaterTargetTemperature( DG_HEATERS_T heater ) { - trimmerHeaterTargetTemperature = targetTemp; + return heatersStatus[ heater ].targetTemp; } /*********************************************************************//** * @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 - * Outputs : hasStartPrimaryHeaterRequested + * @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 ) { -#ifndef DISABLE_HEATERS_AND_TEMPS - hasStartPrimaryHeaterRequested = TRUE; -#endif - status = TRUE; + if ( HEATER_EXEC_STATE_OFF == heatersStatus[ heater ].state ) + { + status = TRUE; + heatersStatus[ heater ].startHeaterSignal = TRUE; + } } - - 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 - * Outputs : hasStartTrimmerHeaterRequested - * @return status - *************************************************************************/ -BOOL startTrimmerHeater( void ) -{ - BOOL status = FALSE; - - if ( ( trimmerHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( trimmerHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + else { -#ifndef DISABLE_HEATERS_AND_TEMPS - hasStartTrimmerHeaterRequested = TRUE; -#endif - 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. - * @details - * Inputs : none - * Outputs : Primary heater stops - * @return none + * The stopHeater stops the specified heater. + * @details Inputs: 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 ) { - mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - isPrimaryHeaterOn = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; } /*********************************************************************//** * @brief - * The stopTrimmerHeater function stops the trimmer heater. - * @details - * Inputs : none - * 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 ) { - trimmerHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - isTrimmerHeaterOn = FALSE; + DG_HEATERS_T heater; + HEATERS_STATE_T state; + + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + state = heatersStatus[ heater ].state; + + switch( state ) + { + case HEATER_EXEC_STATE_OFF: + heatersStatus[ heater ].state = handleHeaterStateOff( heater ); + break; + + case HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStatePrimaryRampToTarget(); + break; + + case HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStatePrimaryControlToTarget(); + break; + + case HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET: + heatersStatus[ heater ].state = handleHeaterStateControlToDisinfectTarget( heater ); + break; + + case HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStateTrimmerRampToTarget(); + break; + + case HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStateTrimmerControlToTarget(); + break; + + default: + // The heater is in an unknown state. Turn it off and switch to not running state + stopHeater( heater ); + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_EXEC_STATE, heater ); + break; + } + + // Check if the heater is requested to be off + if ( FALSE == heatersStatus[ heater ].isHeaterOn ) + { + setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + } + } } /*********************************************************************//** * @brief - * The execHeatersMonitor function turns off the heaters when RO pump is not on. - * @details - * Inputs : none - * Outputs : Turns off the heaters when RO pump is not on + * The execHeatersMonitor function monitors the status of the heaters. + * The internal temperature sensors and the voltages of the heaters are + * monitored. The flow is continuously checked and if there is no flow + * for a period of time, the heaters are turned off. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus * @return none *************************************************************************/ void execHeatersMonitor( void ) { - // If the RO pump is not on, turn off the heaters - if ( ! isReverseOsmosisPumpOn() ) + DG_HEATERS_T heater; + + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { -#ifndef ENABLE_DIP_SWITCHES -#ifndef EMC_TEST_BUILD - stopPrimaryHeater(); // TODO - this is so immediate - if other module requests RO pump on and start heater, this monitor may stop the heater request before RO pump has a chance to start - stopTrimmerHeater(); + // Check if the heater is on and if it is, check the flow sensor's status + if ( TRUE == heatersStatus[ heater ].isHeaterOn ) + { + ALARM_ID_T alarm; + F32 measFlow; + F32 minFlow; + BOOL isFlowLow; + + if ( DG_PRIMARY_HEATER == heater ) + { + alarm = ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; + measFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); + minFlow = MIN_RO_FLOWRATE_LPM; + } + else + { + alarm = ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON; + measFlow = getMeasuredFlowRateLPM( DIALYSATE_FLOW_SENSOR ); + minFlow = MIN_DIALYSATE_FLOWRATE_LPM; + } + + isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); + + checkPersistentAlarm( alarm, isFlowLow, measFlow, minFlow ); + } + else + { + checkPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, FALSE, 0.0, 0.0 ); + checkPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, FALSE, 0.0, 0.0 ); + } + } + +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_MONITOR ) != SW_CONFIG_ENABLE_VALUE ) #endif -#endif + { + monitorHeatersVoltage(); } + + // Check for data publication + publishHeatersData(); } /*********************************************************************//** * @brief - * The execHeatersSelfTest function executes the heaters' self test state machine. - * @details - * Inputs : heatersSelfTestState - * Outputs : heatersSelfTestState - * @return heatersSelfTestState + * The resetHeatersEstimationGain function resets the heaters estimation gain upon + * the start of a treatment. + * @details Inputs: none + * @details Outputs: heaterStatus + * @return none *************************************************************************/ -SELF_TEST_STATUS_T execHeatersSelfTest( void ) +void resetHeatersEstimationGain( void ) { - switch ( heatersSelfTestState ) - { - case HEATERS_SELF_TEST_START: - heatersSelfTestState = handleHeatersSelfTestStart(); - break; - - case HEATERS_SELF_TEST_SMALL_PRIMARY_AND_TRIMMER_HEATERS: - heatersSelfTestState = handleHeatersSelfTestSmallPrimaryAndTrimmerHeaters(); - break; - - case HEATERS_SELF_TEST_MAIN_PRIMARY_HEATER: - heatersSelfTestState = handleHeatersSelfTestMainPrimaryHeater(); - break; - - case HEATERS_SELF_TEST_COMPLETE: - // POST is done. Do nothing - break; - - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_SELF_TEST_INVALID_STATE, heatersSelfTestState ); - heatersSelfTestState = HEATERS_SELF_TEST_COMPLETE; - break; - } - - return heatersSelfTestResult; + heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; + heatersStatus[ DG_TRIMMER_HEATER ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; } /*********************************************************************//** * @brief - * The execPrimaryHeaters function executes the primary heaters' state machine. - * @details - * Inputs : primaryHeatersExecState - * Outputs : primaryHeatersExecState + * The calculateHeaterEstimationGain function calculates the heater estimation + * gain. + * @details Inputs: none + * @details Outputs: heatersStatus * @return none *************************************************************************/ -void execPrimaryHeaters( void ) +void calculateHeaterEstimationGain( DG_HEATERS_T heater ) { - switch ( primaryHeatersExecState ) +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_EFFICIENCY ) != SW_CONFIG_ENABLE_VALUE ) +#endif { - case PRIMARY_HEATERS_EXEC_STATE_OFF: - primaryHeatersExecState = handlePrimaryHeaterStateOff(); - break; + F32 heaterEstGain = heatersStatus[ heater ].heaterEstGain; + F32 heaterDutyCycle = heatersStatus[ heater ].dutycycle; + F32 lastFillTemperature = getAvgFillTemperature(); + F32 primaryTargetTemperature = heatersStatus[ heater ].targetTemp; + BOOL isTempUnderTarget = ( lastFillTemperature < primaryTargetTemperature ? TRUE : FALSE ); - case PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET: - primaryHeatersExecState = handlePrimaryHeaterStateControlToTarget(); - break; + if ( TRUE == isTempUnderTarget ) + { + if ( heaterDutyCycle < HEATERS_MAX_DUTY_CYCLE ) + { + heaterEstGain += ( primaryTargetTemperature - lastFillTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; + } + } + else + { + if ( heaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ) + { + heaterEstGain -= ( lastFillTemperature - primaryTargetTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; + } + } - 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; + heaterEstGain = MAX( heaterEstGain, HEATERS_MIN_EST_GAIN ); + heaterEstGain = MIN( heaterEstGain, HEATERS_MAX_EST_GAIN ); + heatersStatus[ heater ].heaterEstGain = heaterEstGain; } } /*********************************************************************//** * @brief - * The execTrimmerHeater function executes the trimmer heater's state machine. - * @details - * Inputs : trimmerHeaterExecState - * Outputs : trimmerHeaterExecState - * @return none + * The handleHeaterStateOff 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 execTrimmerHeater( void ) +static HEATERS_STATE_T handleHeaterStateOff( DG_HEATERS_T heater ) { - switch ( trimmerHeaterExecState ) + HEATERS_STATE_T state = HEATER_EXEC_STATE_OFF; + + if ( TRUE == heatersStatus[ heater ].startHeaterSignal ) { - case TRIMMER_HEATER_EXEC_STATE_OFF: - trimmerHeaterExecState = handleTrimmerHeaterStateOff(); - break; + heatersStatus[ heater ].isHeaterOn = TRUE; + heatersStatus[ heater ].startHeaterSignal = FALSE; - case TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET: - trimmerHeaterExecState = handleTrimmerHeaterControlToTarget(); - break; - - 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; + // Depending on which heater is called, go to different states + state = ( heater == DG_PRIMARY_HEATER ? HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET : HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET ); } + + return state; } /*********************************************************************//** * @brief - * The handleHeatersSelfTestStart function starts the small primary and - * the trimmer heaters for self test. - * @details - * Inputs : heatersSelfTestResult, selfTestElapsedTime - * Outputs : heatersSelfTestResult, selfTestElapsedTime - * @return state (HEATERS_SELF_TEST_STATES_T) + * The handleHeaterStatePrimaryRampToTarget function handles the primary heaters' + * control while they are ramping to target temperature. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestStart( void ) +static HEATERS_STATE_T handleHeaterStatePrimaryRampToTarget( void ) { - // Code temporarily disabled since POST is not tested yet - // TODO once POST is tested and implemented, remove #ifndef -#ifndef _VECTORCAST_ - heatersSelfTestResult = SELF_TEST_STATUS_PASSED; - return HEATERS_SELF_TEST_COMPLETE; -#else - heatersSelfTestResult = SELF_TEST_STATUS_IN_PROGRESS; - setSmallPrimaryHeaterPWM( SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE ); - setTrimmerHeaterPWM( TRIMMER_HEATER_MAX_DUTY_CYCLE ); - selfTestElapsedTime = getMSTimerCount(); + HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; + DG_HEATERS_T heater = DG_PRIMARY_HEATER; + F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + F32 targetFlow = 0.0; + F32 dutyCycle = 0.0; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; + DG_OP_MODE_T opMode = getCurrentOperationMode(); - return HEATERS_SELF_TEST_SMALL_PRIMARY_AND_TRIMMER_HEATERS; -#endif + 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() ); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + } + else if ( ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) + { + targetTemperature += DELTA_TEMPERATURE_TIME_COSNTANT_C; + targetFlow = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + } + else if ( ( DG_MODE_HEAT == opMode ) || ( DG_MODE_CHEM == opMode ) ) + { + // If the mode is any of the disinfects, especially heat, use the target flow rate instead of the avg. flow + // Most of the times the heater should be running at 100% duty cycle since the target temperature is 81 C + targetFlow = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; + } + else + { + // No other modes are using the heaters + // TODO software fault + } + + // Update the calculated target temperature + heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature = targetTemperature; + setHeaterDutyCycle( heater, dutyCycle ); + + return state; } /*********************************************************************//** * @brief - * The handleHeatersSelfTestSmallPrimaryAndTrimmerHeaters function checks if - * the time on the small primary and trimmer heaters has elapsed. If time has - * elapsed, it checks the thermocouple temperature shared among the two - * heaters. If they are in range, it sets the main primary heater and transitions - * to the next state. If it fails, it sets an alarm and fails the test. - * @details - * Inputs : heatersSelfTestResult, selfTestElapsedTime - * Outputs : heatersSelfTestResult, selfTestElapsedTime - * @return state (HEATERS_SELF_TEST_STATES_T) + * The handleHeaterStatePrimaryControlToTarget function handles the primary + * heaters' control to target while the heater is targeting to reach to temperature. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestSmallPrimaryAndTrimmerHeaters( void ) +static HEATERS_STATE_T handleHeaterStatePrimaryControlToTarget( void ) { - HEATERS_SELF_TEST_STATES_T state = HEATERS_SELF_TEST_SMALL_PRIMARY_AND_TRIMMER_HEATERS; + HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + DG_HEATERS_T heater = DG_PRIMARY_HEATER; - if ( didTimeout( selfTestElapsedTime, HEATERS_POST_HEAT_UP_TIME_SECONDS ) ) + if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) { - setSmallPrimaryHeaterPWM( 0 ); - setTrimmerHeaterPWM( 0 ); - - F32 convertedTemperature = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ); - - if ( fabs( convertedTemperature - SMALL_PRIMARY_AND_TRIMMER_HEATERS_POST_TARGET_TEMPERATURE ) > HEATERS_POST_TEMPERATURE_TOLERANCE ) - { - //TODO alarm - // TODO POST failed - heatersSelfTestResult = SELF_TEST_STATUS_FAILED; - state = HEATERS_SELF_TEST_COMPLETE; - } - else - { - setMainPrimaryHeaterPWM( MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE ); - selfTestElapsedTime = getMSTimerCount(); - state = HEATERS_SELF_TEST_MAIN_PRIMARY_HEATER; - } + state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; } return state; } /*********************************************************************//** * @brief - * The handleHeatersSelfTestMainPrimaryHeater function checks if the time - * on the main primary heater has elapsed. When the time has elapsed, it - * checks to ensure the thermocouple temperature is within the tolerance - * of the target temperature. It then transitions to the complete state. - * @details - * Inputs : heatersSelfTestResult - * Outputs : heatersSelfTestResult - * @return state (HEATERS_SELF_TEST_STATES_T) + * The handleHeaterStateControlToDisinfectTarget function handles the + * heaters' control to target while the operation mode is heat or chemical + * disinfects. + * @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 HEATERS_SELF_TEST_STATES_T handleHeatersSelfTestMainPrimaryHeater( void ) +static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DG_HEATERS_T heater ) { - HEATERS_SELF_TEST_STATES_T state = HEATERS_SELF_TEST_MAIN_PRIMARY_HEATER; + HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; - if ( didTimeout( selfTestElapsedTime, HEATERS_POST_HEAT_UP_TIME_SECONDS ) ) + F32 heatDisinfectSensorTemp = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); + + // Check if the heaters control conditions have changed, if yes, switch back to ramp to target + if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) { - setMainPrimaryHeaterPWM( 0 ); + state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; + } - F32 convertedTemperature = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ); + // If the heat disifect sensor indicates that the temperature is below target temperature but the target temperature had been reached + // before turn on the heaters with 100% power + if ( ( heatDisinfectSensorTemp <= heatersStatus[ heater ].targetTemp ) && ( TRUE == heatersStatus[ heater ].hasTargetBeenReached ) ) + { + heatersStatus[ heater ].hasTargetBeenReached = FALSE; + setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); + } - if ( fabs( convertedTemperature - MAIN_PRIMARY_HEATER_POST_TARGET_TEMPERATURE ) > HEATERS_POST_TEMPERATURE_TOLERANCE ) - { - //TODO alarm - // TODO POST failed - heatersSelfTestResult = SELF_TEST_STATUS_FAILED; - } - else - { - heatersSelfTestResult = SELF_TEST_STATUS_PASSED; - } - - state = HEATERS_SELF_TEST_COMPLETE; + // If we have reached to target temperature, turn off the heaters + if ( heatDisinfectSensorTemp > heatersStatus[ heater ].targetTemp ) + { + // Set the flag to true for the next run + heatersStatus[ heater ].hasTargetBeenReached = TRUE; + // The primary heater are not turned off but it is set to a minimum duty cycle so the temperature is kept + // above the target + setHeaterDutyCycle( heater, HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE ); } return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateOff function handles the primary heaters at - * off state. - * @details - * Inputs : hasStartPrimaryHeaterRequested, isPrimaryHeaterOn - * Outputs : state (PRIMARY_HEATERS_EXEC_STATES_T), isPrimaryHeaterOn - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStateTrimmerRampToTarget function handles the trimmer + * heater's ramp to target. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ) +static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_OFF; + HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; + DG_HEATERS_T heater = DG_TRIMMER_HEATER; + F32 currentTemperature = 0.0; + F32 targetFlowLPM = getTargetDialysateFlowLPM(); + F32 dutyCycle = 0.0; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; + DG_OP_MODE_T opMode = getCurrentOperationMode(); - // TODO for testing only. remove -#ifdef DEBUG_ENABLED -#ifdef ENABLE_DIP_SWITCHES -#ifndef EMC_TEST_BUILD - if ( TOGGLEPRIMAYHEATER() ) + if ( ( DG_MODE_FILL == opMode ) || ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) { - setPrimaryHeaterTargetTemperature( 37 ); - startPrimaryHeater(); - F32 pumpPWM = 1; - etpwmSetCmpB( etpwmREG2, (U32)( (S32)( ( pumpPWM * (F32)(etpwmREG2->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - F32 fanPWM = 0.25; - etpwmSetCmpA( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - etpwmSetCmpB( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - hasStartPrimaryHeaterRequested = TRUE; + currentTemperature = getReservoirCurrentTemperature(); + dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); + state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; } -#endif -#endif -#endif - // TODO remove this code for testing - - if ( hasStartPrimaryHeaterRequested ) + else if ( DG_MODE_HEAT == opMode ) { - resetHeaterState( PRIMARY_HEATER ); - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - isPrimaryHeaterOn = TRUE; - hasStartPrimaryHeaterRequested = FALSE; - state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + // If the mode is heat disinfect, use the target flow rate instead of the avg. flow + // Most of the times the heater should be running at 100% duty cycle since the target temperature is 81 C and + // it is far from the inlet temperature. + currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + targetFlowLPM = getTargetROPumpFlowRateLPM(); + dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, FALSE ); + state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } - publishHeatersData(); + // Update the calculated target temperature + heatersStatus[ heater ].calculatedTemperature = currentTemperature; + heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); + heatersStatus[ heater ].targetFlow = targetFlowLPM; + trimmerHeaterControlCounter = 0; + setHeaterDutyCycle( heater, dutyCycle ); return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateControlToTarget function handles the primary - * heaters at control state when the heaters are active. - * @details - * Inputs : primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle, isPrimaryHeaterOn - * Outputs : primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStateTrimmerControlToTarget function handles the trimmer + * heater's control to target state. + * @details Inputs: heaterStatus, trimmerHeaterControlCounter + * @details Outputs: heaterStatus, trimmerHeaterControlCounter + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ) +static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; - if ( ++primaryHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) + // If the inactive reservoir has changed from the last run transition to ramp state to recalculate the + // duty cycle for the next delivery + if ( heatersStatus[ DG_TRIMMER_HEATER ].inactiveRsrvr != getInactiveReservoir() ) { - F32 outletTemp = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); - mainPrimaryHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, primaryHeaterTargetTemperature, outletTemp ); - - if ( mainPrimaryHeaterDutyCycle >= MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE ) - { - // The duty cycle from the PI controller was greater than max duty cycle of the main primary - // heater. So subtract the remaining from the max main primary heater duty cycle and set - // the rest to the small primary heater - smallPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle - MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE; - mainPrimaryHeaterDutyCycle = MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE; - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - } - else - { - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - } - primaryHeaterTimerCounter = 0; + state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; } - - publishHeatersData(); - - // TODO remove this code -#ifdef DEBUG_ENABLED -#ifdef ENABLE_DIP_SWITCHES -#ifndef EMC_TEST_BUILD - if ( !TOGGLEPRIMAYHEATER() ) + else if ( ++trimmerHeaterControlCounter > TRIMMER_HEATER_CONTROL_CHECK_INTERVAL_COUNT ) { - stopPrimaryHeater(); - F32 pumpPWM = 0; - etpwmSetCmpB( etpwmREG2, (U32)( (S32)( ( pumpPWM * (F32)(etpwmREG2->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - F32 fanPWM = 0; - etpwmSetCmpA( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - etpwmSetCmpB( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - } -#endif -#endif -#endif - // TODO Remove this code + // When the trimmer heater is on, its duty cycle is adjusted at the control interval. For this control check, + // dialysate inlet temperature sensor is used rather than the theoretical calculations. + F32 outletRedundantTemperature = getTemperatureValue( TEMPSENSORS_INLET_DIALYSATE ); // TODO Change to TRo in DVT + F32 targetTemperature = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; + F32 targetFlowLPM = heatersStatus[ DG_TRIMMER_HEATER ].targetFlow; + F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, outletRedundantTemperature, targetFlowLPM, TRUE ); - if ( ! isPrimaryHeaterOn ) - { - state = PRIMARY_HEATERS_EXEC_STATE_OFF; + trimmerHeaterControlCounter = 0; + setHeaterDutyCycle( DG_TRIMMER_HEATER, ( heatersStatus[ DG_TRIMMER_HEATER ].dutycycle + dutyCycle ) ); } return state; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterStateOff function handles the trimmer heater at - * off state. - * @details - * Inputs : hasStartTrimmerHeaterRequested, isTrimmerHeaterOn - * 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; - - // TODO for testing only. remove -#ifdef DEBUG_ENABLED -#ifdef ENABLE_DIP_SWITCHES -#ifndef EMC_TEST_BUILD - if ( TOGGLEPRIMAYHEATER() ) + // 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 ) { - setTrimmerHeaterTargetTemperature( 38 ); - startTrimmerHeater(); - //F32 pumpPWM = 1; - //etpwmSetCmpB( etpwmREG2, (U32)( (S32)( ( pumpPWM * (F32)(etpwmREG2->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //temporaryStartROPump(); - //temporaryStartFan(); - //F32 fanPWM = 0.25; - //etpwmSetCmpA( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //etpwmSetCmpB( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //temporaryStartROPump(); - //temporaryStartFan(); - } -#endif -#endif -#endif - // TODO remove this code for testing + if ( DG_PRIMARY_HEATER == heater ) + { + setMainPrimaryHeaterPWM( pwm ); + setSmallPrimaryHeaterPWM( pwm ); + } + else if ( DG_TRIMMER_HEATER == heater ) + { + setTrimmerHeaterPWM( pwm ); + } - if ( hasStartTrimmerHeaterRequested ) - { - resetHeaterState( TRIMMER_HEATER ); - isTrimmerHeaterOn = TRUE; - hasStartTrimmerHeaterRequested = FALSE; - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + // Updated the heater's information + heatersStatus[ heater ].dutycycle = pwm; } +} - publishHeatersData(); +/*********************************************************************//** + * @brief + * The calculatePrimaryHeaterDutyCycle function calculates the primary + * heater's duty cycle. + * @details Inputs: none + * @details Outputs: none + * @param targetTemperature target temperature of the heater + * @oaram currentTemperature current inlet temperature of the heater + * @param flow current flow + * @return calculated duty cycle + *************************************************************************/ +static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ) +{ + // Duty cycle = ( 69.73 * flow rate * deltaT / primary heater maximum power ) ^ 1/2 + // Multiply the duty cycle to the heater efficiency + F32 dutyCycle = sqrt( ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * fabs( targetTemperature - currentTemperature ) * flow ) / PRIMARY_HEATERS_MAXIMUM_POWER_WATTS ); + dutyCycle *= heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain; + dutyCycle = MIN( dutyCycle, HEATERS_MAX_DUTY_CYCLE ); + dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); - return state; + return dutyCycle; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterControlToTarget function handles the trimmer - * heater at control state when the heater is active. - * @details - * Inputs : trimmerHeaterTimerCounter, trimmerHeaterDutyCycle - * Outputs : trimmerHeaterTimerCounter, trimmerHeaterDutyCycle, isTrimmerHeaterOn - * @return state (TRIMMER_HEATER_EXEC_STATES_T) + * The calculateTrimmerHeaterDutyCycle function calculates the trimmer + * heater's duty cycle. + * @details Inputs: none + * @details Outputs: none + * @param targetTemperature target temperature of the heater + * @oaram currentTemperature current inlet temperature of the heater + * @param flow current flow + * @param check efficiency flag to indicate whether to consider heater's + * efficiency + * @return calculated duty cycle *************************************************************************/ -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ) +static F32 calculateTrimmerHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ) { - TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + // Get the primary heater's efficiency and the last fill temperature from the ModeFill + F32 heaterEstGain = heatersStatus[ DG_TRIMMER_HEATER ].heaterEstGain; + F32 dutyCycle = 0.0; - if ( ++trimmerHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_EFFICIENCY ) != SW_CONFIG_ENABLE_VALUE ) +#endif { - F32 outletTemp = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANCY ); - trimmerHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, trimmerHeaterTargetTemperature, outletTemp ); - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - trimmerHeaterTimerCounter = 0; + if ( TRUE == checkEfficiency ) + { + // TODO Do we need efficiency for the trimmer heater? + } } - publishHeatersData(); + // Duty cycle = ( 69.73 * flow rate * deltaT / primary heater maximum power ) and multiply the duty cycle to the heater efficiency + dutyCycle = ( ( flow * WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * + ( targetTemperature - currentTemperature ) ) / TRIMMER_HEATER_MAX_POWER_W ) * heaterEstGain; - // TODO remove this code -#ifdef DEBUG_ENABLED -#ifdef ENABLE_DIP_SWITCHES -#ifndef EMC_TEST_BUILD - if ( !TOGGLEPRIMAYHEATER() ) - { - stopTrimmerHeater(); - //F32 pumpPWM = 0; - //etpwmSetCmpB( etpwmREG2, (U32)( (S32)( ( pumpPWM * (F32)(etpwmREG2->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //temporaryStartROPump(); - //temporaryStartFan(); - //F32 fanPWM = 0; - //etpwmSetCmpA( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //etpwmSetCmpB( etpwmREG6, (U32)( (S32)( ( fanPWM * (F32)(etpwmREG6->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); - //temporaryStopROPump(); - //temporaryStopFan(); - } -#endif -#endif -#endif - // TODO Remove this code + // Check the boundaries of the calculated duty cycle + dutyCycle = MIN( dutyCycle, HEATERS_MAX_DUTY_CYCLE ); + dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); - if ( ! isTrimmerHeaterOn ) + return dutyCycle; +} + +/*********************************************************************//** + * @brief + * The haveHeaterControlConditionsChanged function checks whether the heater + * control conditions have changed or not. If the control conditions have + * changed it sets the changes the control parameters accordingly. + * @details Inputs: heaterStatus, operationMode + * @details Outputs: heaterStatus, operationMode + * @param heater: The heater Id that its on state is handled + * @return TRUE if the control conditions have changed otherwise, FALSE + *************************************************************************/ +static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ) +{ + BOOL status = FALSE; + F32 targetFlow = ( DG_PRIMARY_HEATER == heater ? getTargetROPumpFlowRateLPM() : getTargetDialysateFlowLPM() ); + BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + + // Check if the target flow has changed or the target temperature has changed. + if ( ( TRUE == hasFlowChanged ) || ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) ) { - state = TRIMMER_HEATER_EXEC_STATE_OFF; + status = TRUE; + heatersStatus[ heater ].targetFlow = targetFlow; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; } - return state; + return status; } /*********************************************************************//** * @brief * The setMainPrimaryHeaterPWM function sets the PWM of the main primary heater. - * @details - * Inputs : none - * Outputs : Sets the PWM duty cycle for the main primary heater + * @details Inputs: none + * @details Outputs: Sets the PWM duty cycle for the main primary heater * @param pwm PWM duty cycle to set for 1st primary heater element * @return none *************************************************************************/ @@ -741,9 +786,8 @@ /*********************************************************************//** * @brief * The setSmallPrimaryHeaterPWM function sets the PWM of the small primary heater. - * @details - * Inputs : none - * Outputs : Sets the PWM duty cycle for the small primary heater + * @details Inputs: none + * @details Outputs: Sets the PWM duty cycle for the small primary heater * @param pwm PWM duty cycle to set for 2nd primary heater element * @return none *************************************************************************/ @@ -755,9 +799,8 @@ /*********************************************************************//** * @brief * The setTrimmerHeaterPWM function sets the PWM of the trimmer heater. - * @details - * Inputs : none - * Outputs : Sets the PWM duty cycle for the trimmer heater + * @details Inputs: none + * @details Outputs: Sets the PWM duty cycle for the trimmer heater * @param pwm PWM duty cycle to set for trimmer heater * @return none *************************************************************************/ @@ -768,82 +811,73 @@ /*********************************************************************//** * @brief - * The resetHeaterState function resets the PI controller of the selected heater. - * @details - * Inputs : mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * Outputs : mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * @param heater enumeration of the heater for which the PI controller will be reset + * The publishTemperatureData function publishes the heaters data into + * at the defined time interval. + * @details Inputs: dataPublicationTimerCounter + * @details Outputs: dataPublicationTimerCounter * @return none *************************************************************************/ -static void resetHeaterState( NAME_OF_HEATER_T heater ) +static void publishHeatersData( void ) { - if ( heater == PRIMARY_HEATER ) + if ( ++dataPublicationTimerCounter >= getU32OverrideValue( &heatersDataPublishInterval ) ) { - mainPrimaryHeaterDutyCycle = MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE; - resetPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE ); - } - else if ( heater == TRIMMER_HEATER ) - { - trimmerHeaterDutyCycle = TRIMMER_HEATER_MAX_DUTY_CYCLE; - resetPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, TRIMMER_HEATER_MAX_DUTY_CYCLE ); - } -} + HEATERS_DATA_T data; -/*********************************************************************//** - * @brief - * The getPublishHeatersDataInterval function gets the publish interval. - * @details - * Inputs : heatersDataPublishInterval - * Outputs : none - * @return result - *************************************************************************/ -U32 getPublishHeatersDataInterval( void ) -{ - U32 result = heatersDataPublishInterval.data; + data.mainPrimayHeaterDC = heatersStatus[ 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 = heatersStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + data.trimmerHeaterDC = heatersStatus[ DG_TRIMMER_HEATER ].dutycycle * 100.0; + data.primaryTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].targetTemp; + data.trimmerTargetTemp = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; + data.primaryHeaterState = heatersStatus[ DG_PRIMARY_HEATER ].state; + data.trimmerHeaterState = heatersStatus[ DG_TRIMMER_HEATER ].state; + data.primaryEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain * 100; + data.primaryCalcTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature; + data.trimmerCalcCurrentTemp = heatersStatus[ DG_TRIMMER_HEATER ].calculatedTemperature; + dataPublicationTimerCounter = 0; - if ( OVERRIDE_KEY == heatersDataPublishInterval.override ) - { - result = heatersDataPublishInterval.ovData; + broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); } - - return result; } /*********************************************************************//** * @brief - * The publishTemperatureData function publishes the temperature sensors - * data into the USB debug port at the defined time interval. - * @details - * Inputs : dataPublicationTimerCounter - * Outputs : Broadcast temperature sensors' data + * The monitorHeatersVoltage function monitors the heaters' voltages + * @details Inputs: voltageMonitorTimeCounter + * @details Outputs: voltageMonitorTimeCounter * @return none *************************************************************************/ -static void publishHeatersData( void ) +static void monitorHeatersVoltage( void ) { - if ( ++dataPublicationTimerCounter >= getPublishHeatersDataInterval() ) + // NOTE: Default to using Primary heater voltage from FPGA + F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_PRIM_HTR_V );; +#ifndef _RELEASE_ + if ( SW_CONFIG_ENABLE_VALUE == getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) { - broadcastHeatersData( (U32)(mainPrimaryHeaterDutyCycle*100), (U32)(smallPrimaryHeaterDutyCycle*100), (U32)(trimmerHeaterDutyCycle*100) ); - //NOTE: This section will be removed -#ifdef DEBUG_ENABLED -#ifdef HEATERS_DEBUG - { - char debugTempStr[ 256 ]; - sprintf( debugTempStr, "TPo: %6.2f, PriCJ: %6.2f, PriTC: %6.2f, TpriInt: %6.2f, TRo: %6.2f, TriCJ: %6.2f, TriTC: %6.2f, TtriInt: %6.2f\r\n", - getTemperatureValue ( TEMPSENSORS_OUTLET_PRIMARY_HEATER ), - getTemperatureValue ( TEMPSENSORS_PRIMARY_HEATER_COLD_JUNCTION ), - getTemperatureValue ( TEMPSENSORS_PRIMARY_HEATER_THERMO_COUPLE ), - getTemperatureValue ( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ), - getTemperatureValue ( TEMPSENSORS_OUTLET_REDUNDANCY ), - getTemperatureValue ( TEMPSENSORS_TRIMMER_HEATER_COLD_JUNCTION ), - getTemperatureValue ( TEMPSENSORS_TRIMMER_HEATER_THERMO_COUPLE ), - getTemperatureValue ( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ) ); - - sendDebugData ( (U08*)debugTempStr, strlen(debugTempStr) ); + // V3 use CPU based value for Primary, same as Secondary + mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_SEC_HTR_V ); } #endif -#endif - dataPublicationTimerCounter = 0; - } + F32 smallPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_SEC_HTR_V ); + F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_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; + F32 trimmerDC = heatersStatus[ DG_TRIMMER_HEATER ].dutycycle; + + F32 mainPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0 - mainPriDC ); + F32 smallPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0 - smallPriDC ); + F32 trimmerExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0 - trimmerDC ); + + BOOL isMainPriOut = ( fabs( mainPriExpectedVoltage - mainPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + BOOL isSmallPriOut = ( fabs( smallPriExpectedVoltage - smallPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + BOOL isTrimmerOut = ( fabs( trimmerExpectedVoltage - trimmerVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + + 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 ); } @@ -856,20 +890,19 @@ * @brief * The testSetHeatersPublishIntervalOverride function overrides the heaters * publish data time interval. - * @details - * Inputs : heatersDataPublishInterval - * Outputs : heatersDataPublishInterval + * @details Inputs: heatersDataPublishInterval + * @details Outputs: heatersDataPublishInterval * @return result *************************************************************************/ BOOL testSetHeatersPublishIntervalOverride( U32 value ) { BOOL result = FALSE; - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { - U32 interval = value / TASK_GENERAL_INTERVAL; + U32 interval = value / TASK_PRIORITY_INTERVAL; - result = TRUE; + result = TRUE; heatersDataPublishInterval.ovData = interval; heatersDataPublishInterval.override = OVERRIDE_KEY; } @@ -881,18 +914,17 @@ * @brief * The testResetHeatersPublishIntervalOverride function resets the heaters * publish time interval to its previous time interval. - * @details - * Inputs : heatersDataPublishInterval - * Outputs : heatersDataPublishInterval + * @details Inputs: heatersDataPublishInterval + * @details Outputs: heatersDataPublishInterval * @return result *************************************************************************/ BOOL testResetHeatersPublishIntervalOverride( void ) { BOOL result = FALSE; - if ( isTestingActivated() ) + if ( TRUE == isTestingActivated() ) { - result = TRUE; + result = TRUE; heatersDataPublishInterval.override = OVERRIDE_RESET; heatersDataPublishInterval.ovData = heatersDataPublishInterval.ovInitData; }