Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r7d293e18ea5ac0fce443c68525100e44df80b4fd -r72ba5f3c63325b00306b544b2513c03500919d06 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 7d293e18ea5ac0fce443c68525100e44df80b4fd) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 72ba5f3c63325b00306b544b2513c03500919d06) @@ -1,14 +1,14 @@ /************************************************************************** * -* Copyright (c) 2019-2021 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 * -* @author (last) Sean Nash -* @date (last) 12-Nov-2021 +* @author (last) Bill Bracken +* @date (last) 22-Aug-2022 * * @author (original) Dara Navaei * @date (original) 23-Apr-2020 @@ -22,19 +22,22 @@ #include "AlarmMgmt.h" #include "DGDefs.h" +#include "FlowSensors.h" #include "Heaters.h" -#include "InternalADC.h" #include "MessageSupport.h" #include "ModeFill.h" +#include "NVDataMgmt.h" #include "OperationModes.h" -#include "PIControllers.h" +#include "PersistentAlarm.h" +#include "Reservoirs.h" #include "ROPump.h" #include "SafetyShutdown.h" #include "SystemCommMessages.h" #include "TaskGeneral.h" #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" +#include "Voltages.h" /** * @addtogroup Heaters @@ -43,73 +46,56 @@ // ********** private definitions ********** -#define HEATERS_MAX_DUTY_CYCLE 1.00 ///< Heaters max duty cycle (100%). -#define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Heaters minimum duty cycle (0.00%). -#define HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE 0.6 ///< Heaters minimum duty cycle during heat disinfect. +#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 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 MAXIMUM_IDLE_DRAIN_TARGET_TEMPERATURE 58.0 ///< Maximum allowed target temperature for the idle and drain modes. +#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 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. -#define HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Heaters max allowed internal temperature timeout in milliseconds. -#define HEATERS_ON_NO_FLOW_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Heaters on with no flow time out in milliseconds. -#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. +#define HEATERS_ON_NO_FLOW_TIMEOUT_MS ( 10 * 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 DELTA_TEMPERATURE_TIME_COSNTANT_C 8.6 ///< Delta temperature calculated from time constant. -#define MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C 0.25 ///< Maximum allowed temperature deviation from target temperature in C. -#define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.03 ///< Primary heaters duty cycle per temperature in C. -#define RESERVOIR_TEMPERATURE_TIME_CONSTANT_C_PER_MIN 0.512 ///< Reservoir temperature time constant C/min. -#define ULTRAFILTER_TEMPERATURE_TIME_CONSTANT_C_PER_MIN 0.345 ///< Ultrafilter temperature time constant C/min. +#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 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 + 237.5; ///< Primary heaters maximum power (main primary = 475W and small primary = 237.5W). +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 { - F32 targetTemp; ///< Heater target temperature. + 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 targetROFlow; ///< Heater target flow. - U32 heaterOnWithNoFlowTimer; // TODO remove ///< Heater on with no flow timer. - BOOL isFlowBelowMin; ///< Heater flow below minimum flag indicator. + F32 dutyCycle; ///< Heater duty cycle. + F32 targetFlow; ///< Heater target flow. BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. - F32 heaterEfficiency; ///< Heater efficiency during the run. + F32 heaterEstGain; ///< Heater estimation gain during the run. BOOL hasTargetBeenReached; ///< Heater flag to indicate whether the target temperature has been reached. - - 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 calculatedTemperature; ///< Heater calculated temperature. + DG_RESERVOIR_ID_T inactiveRsrvr; ///< Heater inactive reservoir. } HEATER_STATUS_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. -static U32 voltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. -static U32 operationMode = 0; // ********** private function prototypes ********** @@ -121,45 +107,51 @@ static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ); static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); -static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); +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 void setMainPrimaryHeaterPWM( F32 pwm ); static void setSmallPrimaryHeaterPWM( F32 pwm ); static void setTrimmerHeaterPWM( F32 pwm ); static void publishHeatersData( void ); -static void checkPrimaryHeaterTempSensors( void ); -static void checkTrimmerHeaterTempSensors( void ); static void monitorHeatersVoltage( void ); /*********************************************************************//** * @brief * The initHeaters initializes the heaters driver. * @details Inputs: none * @details Outputs: voltageMonitorTimeCounter, heaterStatus, - * hasTreatmentInternalTempBeenSet + * hasTreatmentInternalTempBeenSet, dataPublicationTimerCounter, + * trimmerHeaterControlCounter * @return none *************************************************************************/ void initHeaters( void ) { DG_HEATERS_T heater; + dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; + trimmerHeaterControlCounter = 0; - voltageMonitorTimeCounter = 0; - operationMode = 0; - for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - heatersStatus[ heater ].startHeaterSignal = FALSE; - heatersStatus[ heater ].tempOutOfRangeTimer = 0; - heatersStatus[ heater ].isHeaterTempOutOfRange = FALSE; - heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; - heatersStatus[ heater ].targetTemp = 0.0; - heatersStatus[ heater ].dutycycle = 0.0; - heatersStatus[ heater ].targetROFlow = 0.0; - heatersStatus[ heater ].hasTargetTempChanged = FALSE; - heatersStatus[ heater ].heaterEfficiency = 1.0; // Assuming 100% efficiency during initialization until it is updated - heatersStatus[ heater ].hasTargetBeenReached = FALSE; + 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 persistent alarms + initPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); } /*********************************************************************//** @@ -170,10 +162,12 @@ * @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 + * @return TRUE if the temperature was set otherwise, FALSE *************************************************************************/ -void setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ) +BOOL setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ) { + BOOL result = FALSE; + if( heater < NUM_OF_DG_HEATERS ) { // Assume the target temperature has not changed @@ -184,13 +178,15 @@ { heatersStatus[ heater ].targetTemp = targetTemperature; heatersStatus[ heater ].hasTargetTempChanged = TRUE; - // TODO alarm if temperature if out of range or just reject? + 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; } /*********************************************************************//** @@ -219,9 +215,9 @@ if( heater < NUM_OF_DG_HEATERS ) { - if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) + if ( HEATER_EXEC_STATE_OFF == heatersStatus[ heater ].state ) { - status = TRUE; + status = TRUE; heatersStatus[ heater ].startHeaterSignal = TRUE; } } @@ -307,47 +303,6 @@ /*********************************************************************//** * @brief - * The handleTrimmerHeaterCmd handles a start trimmer heater command from the HD. - * It resets the trimmer heater's state and sets the duty cycle of the trimmer heater. - * @details Inputs: none - * @details Outputs: process command and send back response - * @param heaterCmdPtr pointer to heater command data record - * @return status - *************************************************************************/ -void handleTrimmerHeaterCmd( TRIMMER_HEATER_CMD_T *heaterCmdPtr ) -{ - DG_CMD_RESPONSE_T cmdResponse; - - cmdResponse.commandID = DG_CMD_START_TRIMMER_HEATER; - cmdResponse.rejected = TRUE; - cmdResponse.rejectCode = DG_CMD_REQUEST_REJECT_REASON_NONE; - - if ( TRUE == heaterCmdPtr->startHeater ) - { - if ( ( MINIMUM_TARGET_TEMPERATURE <= heaterCmdPtr->targetTemp ) && ( heaterCmdPtr->targetTemp <= MAXIMUM_TARGET_TEMPERATURE ) ) - { - cmdResponse.rejected = FALSE; -#ifndef DISABLE_HEATERS_AND_TEMPS - heatersStatus[ DG_TRIMMER_HEATER ].targetTemp = heaterCmdPtr->targetTemp; - heatersStatus[ DG_TRIMMER_HEATER ].startHeaterSignal = TRUE; -#endif - } - else - { - cmdResponse.rejectCode = DG_CMD_REQUEST_REJECT_REASON_INVALID_PARAMETER; - } - } - else - { - cmdResponse.rejected = FALSE; - stopHeater( DG_TRIMMER_HEATER ); - } - - sendCommandResponseMsg( &cmdResponse ); -} - -/*********************************************************************//** - * @brief * 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 @@ -358,75 +313,110 @@ *************************************************************************/ void execHeatersMonitor( void ) { -#if 0 // This code is disabled to prevent any heaters monitoring while the driver in in development. DG_HEATERS_T heater; -#ifndef IGNORE_HEATERS_MONITOR - checkPrimaryHeaterTempSensors(); - checkTrimmerHeaterTempSensors(); -#endif - for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - // Check if a heater is on and whether is duty cycle is not zero - if ( ( TRUE == heatersStatus[ heater ].isHeaterOn ) && ( ( heatersStatus[ heater ].dutycycle - HEATERS_MIN_DUTY_CYCLE ) > NEARLY_ZERO ) ) + // Check if the heater is on and if it is, check the flow sensor's status + if ( TRUE == heatersStatus[ heater ].isHeaterOn ) { - // TODO add the function that gets the flow of the new flow sensor for DG. For now it is assumed that trimmer heater flow sensor - // is not 0 so the heater can run if needed - F32 measFlow = ( DG_PRIMARY_HEATER == heater ? getMeasuredROFlowRate() : 50.0 ); - // TODO get the minimum new flow sensor flow sensor - F32 minFlow = ( DG_PRIMARY_HEATER == heater ? MIN_RO_FLOWRATE_LPM : MIN_RO_FLOWRATE_LPM ); - BOOL isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); + ALARM_ID_T alarm; + F32 measFlow; + F32 minFlow; + BOOL isFlowLow; - if ( TRUE == isFlowLow ) + if ( DG_PRIMARY_HEATER == heater ) { - // Check if the flow of the heater is below minimum for the first time - if ( FALSE == heatersStatus[ heater ].isFlowBelowMin ) - { - heatersStatus[ heater ].isFlowBelowMin = TRUE; - heatersStatus[ heater ].heaterOnWithNoFlowTimer = getMSTimerCount(); - } - else if ( TRUE == didTimeout( heatersStatus[ heater ].heaterOnWithNoFlowTimer, HEATERS_ON_NO_FLOW_TIMEOUT_MS ) ) - { - // Heater has been on with no flow time out - stopHeater( heater ); - - ALARM_ID_T alarm = ( DG_PRIMARY_HEATER == heater ? ALARM_ID_DG_PRIMARY_HEATER_ON_WITH_NO_FLOW_TIMEOUT : - ALARM_ID_DG_TRIMMER_HEATER_ON_WITH_NO_FLOW_TIMEOUT ); - activateAlarmNoData( alarm ); - } + alarm = ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; + measFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); + minFlow = MIN_RO_FLOWRATE_LPM; } else { - heatersStatus[ heater ].isFlowBelowMin = FALSE; - heatersStatus[ heater ].heaterOnWithNoFlowTimer = getMSTimerCount(); + 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 ); + } } - monitorHeatersVoltage(); +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_MONITOR ) != SW_CONFIG_ENABLE_VALUE ) #endif + { + monitorHeatersVoltage(); + } // Check for data publication publishHeatersData(); } /*********************************************************************//** * @brief - * The resetHeatersEfficiency function resets the heaters efficiency upon + * The resetHeatersEstimationGain function resets the heaters estimation gain upon * the start of a treatment. * @details Inputs: none * @details Outputs: heaterStatus * @return none *************************************************************************/ -void resetHeatersEfficiency( void ) +void resetHeatersEstimationGain( void ) { - heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency = 1.0; - heatersStatus[ DG_TRIMMER_HEATER ].heaterEfficiency = 1.0; + heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; + heatersStatus[ DG_TRIMMER_HEATER ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; } /*********************************************************************//** * @brief + * The calculateHeaterEstimationGain function calculates the heater estimation + * gain. + * @details Inputs: none + * @details Outputs: heatersStatus + * @return none + *************************************************************************/ +void calculateHeaterEstimationGain( DG_HEATERS_T heater ) +{ +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_EFFICIENCY ) != SW_CONFIG_ENABLE_VALUE ) +#endif + { + F32 heaterEstGain = heatersStatus[ heater ].heaterEstGain; + F32 heaterDutyCycle = heatersStatus[ heater ].dutyCycle; + F32 lastFillTemperature = getAvgFillTemperature(); + F32 primaryTargetTemperature = heatersStatus[ heater ].targetTemp; + BOOL isTempUnderTarget = ( lastFillTemperature < primaryTargetTemperature ? TRUE : FALSE ); + + 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; + } + } + + heaterEstGain = MAX( heaterEstGain, HEATERS_MIN_EST_GAIN ); + heaterEstGain = MIN( heaterEstGain, HEATERS_MAX_EST_GAIN ); + heatersStatus[ heater ].heaterEstGain = heaterEstGain; + } +} + +/*********************************************************************//** + * @brief * The handleHeaterStateOff function handles the heater not running state. * @details Inputs: heaterStatus * @details Outputs: heaterStatus @@ -465,31 +455,37 @@ F32 targetFlow = 0.0; F32 dutyCycle = 0.0; F32 targetTemperature = heatersStatus[ heater ].targetTemp; + DG_OP_MODE_T opMode = getCurrentOperationMode(); - if ( DG_MODE_FILL == getCurrentOperationMode() ) + if ( DG_MODE_FILL == opMode ) { // If the previous average fill flow rate is 0, use the nominal target RO flow from the RO pump - targetFlow = ( getAvgFillFlowRate() - 0.0 > NEARLY_ZERO ? getAvgFillFlowRate() : getTargetROPumpFlowRate() ); + targetFlow = ( getAvgFillFlowRateLPM() - 0.0F > NEARLY_ZERO ? getAvgFillFlowRateLPM() : getTargetROPumpFlowRateLPM() ); dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } - else if ( ( DG_MODE_GENE == getCurrentOperationMode() ) || ( DG_MODE_DRAI == getCurrentOperationMode() ) ) + else if ( ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) { targetTemperature += DELTA_TEMPERATURE_TIME_COSNTANT_C; - // Use target flow rate during Idle and drain - targetFlow = getTargetROPumpFlowRate(); - dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); - state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + targetFlow = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } - else if ( ( DG_MODE_HEAT == getCurrentOperationMode() ) || ( DG_MODE_CHEM == getCurrentOperationMode() ) ) + 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 = getTargetROPumpFlowRate(); + targetFlow = getTargetROPumpFlowRateLPM(); dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } + else + { + // Do nothing the mode that DG is in right now, does not need heaters to be on + } + // Update the calculated target temperature + heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature = targetTemperature; setHeaterDutyCycle( heater, dutyCycle ); return state; @@ -538,7 +534,7 @@ state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; } - // If the heat disifect sensor indicates that the temperature is below target temperature but the target temperature had been reached + // If the heat disinfect 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 ) ) { @@ -569,24 +565,81 @@ *************************************************************************/ static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ) { - HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; + 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(); + if ( ( DG_MODE_FILL == opMode ) || ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) + { + currentTemperature = getReservoirCurrentTemperature(); + dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); + state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; + } + else if ( DG_MODE_HEAT == opMode ) + { + // 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; + } + + // Update the calculated target temperature + // Reset the duty cycle since the reservoir has been switched + heatersStatus[ heater ].calculatedTemperature = currentTemperature; + heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); + heatersStatus[ heater ].targetFlow = targetFlowLPM; + trimmerHeaterControlCounter = 0; + + // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 + dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); + setHeaterDutyCycle( heater, dutyCycle ); + return state; } /*********************************************************************//** * @brief * The handleHeaterStateTrimmerControlToTarget function handles the trimmer - * heater's control to target. - * @details Inputs: heaterStatus - * @details Outputs: heaterStatus + * heater's control to target state. + * @details Inputs: heaterStatus, trimmerHeaterControlCounter + * @details Outputs: heaterStatus, trimmerHeaterControlCounter * @return next state of the state machine *************************************************************************/ static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; + F32 tempDutyCycle = 0.0; + // 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() ) + { + state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; + } + else if ( ++trimmerHeaterControlCounter > TRIMMER_HEATER_CONTROL_CHECK_INTERVAL_COUNT ) + { + // When the trimmer heater is on, its duty cycle is adjusted at the control interval. For this control check, + // dialysate inlet temperature sensor is used rather than the theoretical calculations. + F32 outletRedundantTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); + F32 targetTemperature = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; + F32 targetFlowLPM = heatersStatus[ DG_TRIMMER_HEATER ].targetFlow; + F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, outletRedundantTemperature, targetFlowLPM, TRUE ); + trimmerHeaterControlCounter = 0; + tempDutyCycle = heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle + dutyCycle; + tempDutyCycle = MIN( tempDutyCycle, HEATERS_MAX_DUTY_CYCLE ); + tempDutyCycle = MAX( tempDutyCycle, HEATERS_MIN_DUTY_CYCLE ); + + setHeaterDutyCycle( DG_TRIMMER_HEATER, tempDutyCycle ); + } + return state; } @@ -606,12 +659,12 @@ setMainPrimaryHeaterPWM( pwm ); setSmallPrimaryHeaterPWM( pwm ); } - else if ( DG_TRIMMER_HEATER == heater ) + else if ( DG_TRIMMER_HEATER == heater ) { setTrimmerHeaterPWM( pwm ); } - heatersStatus[ heater ].dutycycle = pwm; + heatersStatus[ heater ].dutyCycle = pwm; } /*********************************************************************//** @@ -627,38 +680,50 @@ *************************************************************************/ 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 dutyCycle; +} + +/*********************************************************************//** + * @brief + * 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 F32 calculateTrimmerHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ) +{ // Get the primary heater's efficiency and the last fill temperature from the ModeFill - F32 heaterEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency; + F32 heaterEstGain = heatersStatus[ DG_TRIMMER_HEATER ].heaterEstGain; + F32 dutyCycle = 0.0; - if ( TRUE == checkEfficiency ) +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_EFFICIENCY ) != SW_CONFIG_ENABLE_VALUE ) +#endif { - F32 lastFillTemperature = getLastFillTemperature(); - - // If the last fill temperature > target temperature, it means the primary heater overshot the duty cycle - // so with its efficiency is toned down for the next fill cycle - // If the heater undershoots the duty cycle, the efficiency increases the duty cycle for the next fill cycle - if ( lastFillTemperature - targetTemperature > MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C ) + if ( TRUE == checkEfficiency ) { - heaterEfficiency -= ( lastFillTemperature - targetTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; + // Do nothing right now. Efficiency will be implemented later if needed } - else if ( lastFillTemperature - targetTemperature <= MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C ) - { - heaterEfficiency += ( lastFillTemperature - targetTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; - } - - // Update the heaters efficiency - heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency = heaterEfficiency; } - // 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 ) * heaterEfficiency; + // 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; + dutyCycle = MIN( dutyCycle, HEATERS_MAX_DUTY_CYCLE ); + dutyCycle = MAX( dutyCycle, ( HEATERS_MAX_DUTY_CYCLE * -1.0F ) ); - // 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 ); - return dutyCycle; } @@ -675,16 +740,14 @@ static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ) { BOOL status = FALSE; - F32 targetFlow = getTargetROPumpFlowRate(); - BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : 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 ) ) { - status = TRUE; - - // Moving back from control to target to ramp. - heatersStatus[ heater ].targetROFlow = targetFlow; + status = TRUE; + heatersStatus[ heater ].targetFlow = targetFlow; heatersStatus[ heater ].hasTargetTempChanged = FALSE; } @@ -701,7 +764,15 @@ *************************************************************************/ 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 ); + } } /*********************************************************************//** @@ -714,7 +785,15 @@ *************************************************************************/ 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 ); + } } /*********************************************************************//** @@ -727,7 +806,15 @@ *************************************************************************/ 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 ); + } } /*********************************************************************//** @@ -744,148 +831,75 @@ { HEATERS_DATA_T data; - data.mainPrimayHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + 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 ].heaterEfficiency * 100; + 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; broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); - - dataPublicationTimerCounter = 0; } } /*********************************************************************//** * @brief - * The checkPrimaryHeaterTempSensors function checks the primary heater's - * thermocouple and cold junction temperature sensors. - * @details Inputs: isPrimaryHeaterTempOutOfRange - * @details Outputs: isPrimaryHeaterTempOutOfRange + * The monitorHeatersVoltage function monitors the heaters' voltages + * @details Inputs: voltageMonitorTimeCounter + * @details Outputs: voltageMonitorTimeCounter * @return none *************************************************************************/ -static void checkPrimaryHeaterTempSensors( void ) +static void monitorHeatersVoltage( void ) { - F32 primaryHeaterInternalTemp = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ); - F32 primaryHeaterColdJunctionTemp = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_COLD_JUNCTION ); - BOOL isTempOut = FALSE; + F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_MAIN_PRIM_HTR_V ); - // Check if the primary heater's internal temperature or the cold junction temperature is above the allowed limit - if ( primaryHeaterInternalTemp > HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C ) +#ifndef _RELEASE_ + if ( SW_CONFIG_ENABLE_VALUE == getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) { - isTempOut = TRUE; - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_PRIMARY_HEATER_INTERNAL_TEMP_OUT_OF_RANGE, primaryHeaterInternalTemp ); + // V3 use CPU based value for Primary, same as Secondary + mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); } - else if ( primaryHeaterColdJunctionTemp > HEATERS_MAX_ALLOWED_COLD_JUNCTION_TEMPERATURE_C ) - { - isTempOut = TRUE; - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_PRIMARY_HEATER_CJ_TEMP_OUT_OF_RANGE, primaryHeaterInternalTemp ); - } +#endif - /*/ If any of the temperatures are above the range - /if ( ( FALSE == isPrimaryHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) - { - stopPrimaryHeater(); - isPrimaryHeaterTempOutOfRange = TRUE; - primaryHeaterTempOutTimer = getMSTimerCount(); - } - // If the primary heaters internal temperature was out for more than the define period, activate the safety shutdown - else if ( ( TRUE == isPrimaryHeaterTempOutOfRange ) && - ( TRUE == didTimeout( primaryHeaterTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) ) - { - isPrimaryHeaterTempOutOfRange = FALSE; - activateSafetyShutdown(); - }*/ -} + F32 smallPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); + F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_TRIM_HTR_V ); -/*********************************************************************//** - * @brief - * The checkTrimmerHeaterTempSensors function checks the trimmer heater's - * thermocouple and cold junction temperature sensors. - * @details Inputs: isTrimmerHeaterTempOutOfRange - * @details Outputs: isTrimmerHeaterTempOutOfRange - * @return none - *************************************************************************/ -static void checkTrimmerHeaterTempSensors( void ) -{ - F32 trimmerHeaterInternalTemp = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ); - F32 trimmerHeaterColdJunctionTemp = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_COLD_JUNCTION ); - BOOL isTempOut = FALSE; + // 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; - // Check if the primary heater's internal temperature or the cold junction temperature is above the allowed limit - if ( trimmerHeaterInternalTemp > HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C ) - { - isTempOut = TRUE; - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_TRIMMER_HEATER_INTERNAL_TEMP_OUT_OF_RANGE, trimmerHeaterInternalTemp ); - } - else if ( trimmerHeaterColdJunctionTemp > HEATERS_MAX_ALLOWED_COLD_JUNCTION_TEMPERATURE_C ) - { - isTempOut = TRUE; - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_TRIMMER_HEATER_CJ_TEMP_OUT_OF_RANGE, trimmerHeaterColdJunctionTemp ); - } + F32 mainPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - mainPriDC ); + F32 smallPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - smallPriDC ); + F32 trimmerExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - trimmerDC ); - // If it is above the range for the first time, stop the trimmer heater - // and set the variables - /*if ( ( FALSE == isTrimmerHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) - { - stopTrimmerHeater(); - isTrimmerHeaterTempOutOfRange = TRUE; - trimmerHeaterTempOutTimer = getMSTimerCount(); - } - // If the trimmer heater internal temperature was out for more than the define period, activate the safety shutdown - else if ( ( TRUE == isTrimmerHeaterTempOutOfRange ) && - ( TRUE == didTimeout( trimmerHeaterTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) ) - { - activateSafetyShutdown(); - }*/ -} + 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 ); -/*********************************************************************//** - * @brief - * The monitorHeatersVoltage function monitors the heaters' voltages - * @details Inputs: voltageMonitorTimeCounter - * @details Outputs: voltageMonitorTimeCounter - * @return none - *************************************************************************/ -static void monitorHeatersVoltage( void ) -{ - if ( ++voltageMonitorTimeCounter >= HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ) + if ( getCurrentOperationMode() != DG_MODE_INIT ) { - 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 - // before applying the PWMs to the heaters. Right now, there is no ADC channel available for the small primary - // heater so the main primary heater's ADC channel is used for the small primary heater as well. - F32 smallPriVoltage = getIntADCVoltageConverted( INT_ADC_PRIMARY_HEATER_24_VOLTS ); - F32 trimmerVoltage = getIntADCVoltageConverted( INT_ADC_TRIMMER_HEATER_24_VOLTS ); + 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 ); - // Voltage to PWM is reverse. If PWM = 0 -> V = 24V - F32 mainPri = 1.0 - heatersStatus[ DG_PRIMARY_HEATER ].dutycycle; - F32 smallPri = 1.0 - heatersStatus[ DG_PRIMARY_HEATER ].dutycycle; - F32 trimmer = 1.0 - heatersStatus[ DG_TRIMMER_HEATER ].dutycycle; - - // Check main primary heater's voltage - // The corresponding voltage of the current PWM must be close to the sensed voltage - if ( fabs( ( HEATERS_MAX_OPERATING_VOLTAGE_V * mainPri ) - mainPriVoltage ) > HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL * mainPriVoltage ) +#ifndef _RELEASE_ + if ( SW_CONFIG_ENABLE_VALUE != getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) +#endif { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, mainPriVoltage ); - } - // Check small primary heater's voltage - if ( fabs( ( HEATERS_MAX_OPERATING_VOLTAGE_V * smallPri ) - smallPriVoltage ) > HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL * smallPriVoltage ) - { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, smallPriVoltage ); - } - // Check trimmer heater's voltage - if ( fabs( ( HEATERS_MAX_OPERATING_VOLTAGE_V * trimmer ) - trimmerVoltage ) > HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL * trimmerVoltage ) - { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, trimmerVoltage ); - } + // 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 ); - voltageMonitorTimeCounter = 0; + checkPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, isPriPowerOut, powerMainPriVoltage, PRIMARY_HEATER_VOLTAGE_TOLERANCE_V ); + } } } @@ -911,7 +925,7 @@ { U32 interval = value / TASK_PRIORITY_INTERVAL; - result = TRUE; + result = TRUE; heatersDataPublishInterval.ovData = interval; heatersDataPublishInterval.override = OVERRIDE_KEY; } @@ -933,7 +947,7 @@ if ( TRUE == isTestingActivated() ) { - result = TRUE; + result = TRUE; heatersDataPublishInterval.override = OVERRIDE_RESET; heatersDataPublishInterval.ovData = heatersDataPublishInterval.ovInitData; }