Index: firmware/App/Controllers/TemperatureSensors.c =================================================================== diff -u -r63d007f32b08efe97a08915e304affd3d9759cd2 -r08eb8944c4db804b373cf37a78a761b01f00e649 --- firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision 63d007f32b08efe97a08915e304affd3d9759cd2) +++ firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision 08eb8944c4db804b373cf37a78a761b01f00e649) @@ -8,7 +8,7 @@ * @file TemperatureSensors.c * * @author (last) Dara Navaei -* @date (last) 18-Jan-2023 +* @date (last) 13-Jun-2023 * * @author (original) Dara Navaei * @date (original) 08-Apr-2020 @@ -59,14 +59,15 @@ #define MAX_ALLOWED_TEMP_DELTA_BETWEEN_SENSORS 2U ///< Maximum allowed temperature delta between sensors. #define SHIFT_BITS_BY_2 2U ///< Shift bits by 2 to create a 4 for averaging 4 samples. #define SHIFT_BITS_BY_2_FOR_AVERAGING 2U ///< Shift the ADCs of the temperature sensors by 2 to average them. -#define INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ( 5 * MS_PER_SECOND ) ///< Inlet water temperature sensors timeout in milliseconds. +#define INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ( 30 * MS_PER_SECOND ) ///< Inlet water temperature sensors timeout in milliseconds. #define INLET_WATER_TEMP_OUT_OF_RANGE_CLEAR_MS ( 1 * MS_PER_SECOND ) ///< Inlet water temperature sensors out of range clear in milliseconds. #define MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE 24.0F ///< Low range minimum water input temperature. #define MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE 26.0F ///< Low range maximum water input temperature. #define MIN_WATER_TEMPERATURE_WARNING_HIGH_RANGE 35.0F ///< High range minimum water input temperature. #define MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE 37.0F ///< High range maximum water input temperature. +#define MAX_CLEANING_MODE_WATER_TEMPERATURE_WARNING_HIGH_RANGE 45.0F ///< High range maximum cleaning mode water input temperature. #define HEATERS_INTERNAL_TEMPERTURE_CALCULATION_INTERVAL 20U ///< Time interval that is used to calculate the heaters internal temperature. #define HEATERS_INTERNAL_TC_ADC_TO_TEMP_CONVERSION_COEFF 0.25F ///< Heaters internal temperature sensors ADC to temperature conversion coefficient. @@ -119,9 +120,7 @@ OVERRIDE_F32_T temperatureValues; ///< Temperature values with override F32 maxAllowedTemp; ///< Maximum allowed temperature of the sensor U32 alarmStartTime; ///< Alarm start time - U08 sensorErrorBitStatus; ///< Temperature sensor error bit status BOOL fpgaErrorStatus; ///< Temperature sensor FPGA error status - BOOL adcErrorStatus; ///< Temperature sensor ADC error status S32 baroTempSnsrDiff; ///< Barometric sensor temperature difference } TEMP_SENSOR_T; @@ -184,12 +183,6 @@ static const U32 TWO_TO_POWER_OF_8 = ( 1 << 8 ); ///< 2^8. static const U32 TWO_TO_POWER_OF_23 = ( 1 << 23 ); ///< 2^23. -// The count cannot be within 0.1V of the rail on both sides therefore: -// Maximum ADC count -> (2^24) * ( 3.0V - 0.1V ) / 3V -// Minimum ADC count -> (2^24) * ( 0.1V - 0.0V ) / 3V -static const U32 TEMP_SENSORS_MAX_ADC_COUNT = ( BITS_24_FULL_SCALE * ( 3.0F - 0.1F ) ) / 3.0F; ///< Temperature sensors max allowed ADC count. -static const U32 TEMP_SESNORS_MIN_ADC_COUNT = ( BITS_24_FULL_SCALE * ( 0.1F - 0.0F ) ) / 3.0F; ///< Temperature sensors min allowed ADC count. - // ********** private function prototypes ********** static TEMPSENSORS_EXEC_STATES_T handleExecStart( void ); @@ -324,16 +317,15 @@ tempSensors[ TEMPSENSORS_BAROMETRIC_TEMP_SENSOR ].maxAllowedTemp = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; // Persistent alarms for inlet water high/low temperature - initPersistentAlarm( ALARM_ID_INLET_WATER_TEMPERATURE_IN_LOW_RANGE, INLET_WATER_TEMP_OUT_OF_RANGE_CLEAR_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE, INLET_WATER_TEMP_OUT_OF_RANGE_CLEAR_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_LOW_RANGE, INLET_WATER_TEMP_OUT_OF_RANGE_CLEAR_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE, INLET_WATER_TEMP_OUT_OF_RANGE_CLEAR_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_HIGH, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_LOW, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS, INLET_WATER_TEMP_OUT_OF_RANGE_TIMEOUT_MS ); // Persistent alarm for the temperature sensors range check initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_OUT_OF_RANGE, TEMP_SENSORS_OUT_OF_RANGE_TIME_OUT_MS, TEMP_SENSORS_OUT_OF_RANGE_TIME_OUT_MS ); // Persistent alarm for the temperature sensors range check - initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, TEMP_SENSORS_OUT_OF_RANGE_TIME_OUT_MS, TEMP_SENSORS_OUT_OF_RANGE_TIME_OUT_MS ); initPersistentAlarm( ALARM_ID_DG_DIALYSATE_TEMPERATURE_SENSORS_OUT_OF_RANGE, 0, DIALYSATE_TEMP_SNSRS_OUT_OF_RANGE_TIMEOUT_MS ); // Initialize the FPGA persistent alarms @@ -421,56 +413,79 @@ *************************************************************************/ void checkInletWaterTemperature( void ) { -#ifndef _RELEASE_ - if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_WATER_QUALITY_CHECK ) != SW_CONFIG_ENABLE_VALUE ) -#endif + F32 temperature = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); + + if ( VALVE_STATE_OPEN == getValveStateName( VPI ) ) { - DG_OP_MODE_T opMode = getCurrentOperationMode(); - F32 temperature = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); - BOOL isWaterTempInHighRange = ( temperature > MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ? TRUE : FALSE ); - BOOL isWaterTempInLowRange = ( temperature < MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE ? TRUE : FALSE ); - switch( opMode ) +#ifndef _RELEASE_ + if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_WATER_QUALITY_CHECK ) != SW_CONFIG_ENABLE_VALUE ) +#endif { - case DG_MODE_GENE: - case DG_MODE_FILL: - case DG_MODE_DRAI: - if ( TRUE == isAlarmActive( ALARM_ID_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE ) ) + if ( getTestConfigStatus( TEST_CONFIG_DISABLE_INLET_WATER_TEMP_CHECK ) != TRUE ) + { + DG_OP_MODE_T opMode = getCurrentOperationMode(); + BOOL isWaterTempInHighRange = ( temperature > MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ? TRUE : FALSE ); + BOOL isWaterTempInLowRange = ( temperature < MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE ? TRUE : FALSE ); + + switch( opMode ) { - isWaterTempInHighRange = ( temperature <= MIN_WATER_TEMPERATURE_WARNING_HIGH_RANGE ? FALSE : TRUE ); - } + case DG_MODE_GENE: + case DG_MODE_FILL: + case DG_MODE_DRAI: + case DG_MODE_STAN: + if ( TRUE == isAlarmActive( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE ) ) + { + isWaterTempInHighRange = ( temperature <= MIN_WATER_TEMPERATURE_WARNING_HIGH_RANGE ? FALSE : TRUE ); + } - // Per PRS 406 - checkPersistentAlarm( ALARM_ID_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE, isWaterTempInHighRange, temperature, MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); + // Per PRS 406 + checkPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE, isWaterTempInHighRange, temperature, + MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); - if ( TRUE == isAlarmActive( ALARM_ID_INLET_WATER_TEMPERATURE_IN_LOW_RANGE ) ) - { - isWaterTempInLowRange = ( temperature >= MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE ? FALSE : TRUE ); - } + if ( TRUE == isAlarmActive( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_LOW_RANGE ) ) + { + isWaterTempInLowRange = ( temperature >= MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE ? FALSE : TRUE ); + } - // Per PRS 405 - checkPersistentAlarm( ALARM_ID_INLET_WATER_TEMPERATURE_IN_LOW_RANGE, isWaterTempInLowRange, temperature, MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE ); - break; + // Per PRS 405 + checkPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_LOW_RANGE, isWaterTempInLowRange, temperature, + MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE ); + break; - case DG_MODE_FLUS: - case DG_MODE_HEAT: - case DG_MODE_CHEM: - case DG_MODE_INIT: - case DG_MODE_STAN: - case DG_MODE_CHFL: - if ( VALVE_STATE_OPEN == getValveStateName( VPI ) ) - { - // Per PRS 557 - checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_HIGH, isWaterTempInHighRange, temperature, MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); - checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_LOW, isWaterTempInLowRange, temperature, MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE ); - } - break; + case DG_MODE_FLUS: + case DG_MODE_HEAT: + case DG_MODE_HCOL: + case DG_MODE_CHEM: + case DG_MODE_CHFL: + case DG_MODE_ROPS: + isWaterTempInHighRange = ( temperature > MAX_CLEANING_MODE_WATER_TEMPERATURE_WARNING_HIGH_RANGE ? TRUE : FALSE ); + // Per PRS 557 + checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_HIGH, isWaterTempInHighRange, temperature, + MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); + checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_LOW, isWaterTempInLowRange, temperature, + MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE ); + break; - default: - // NOTE: Do nothing in the rest of the modes - break; + default: + // NOTE: Do nothing in the rest of the modes + break; + } + } } } + else + { + // VPI is closed - clear all alarms + checkPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_HIGH_RANGE, FALSE, temperature, + MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); + checkPersistentAlarm( ALARM_ID_DG_INLET_WATER_TEMPERATURE_IN_LOW_RANGE, FALSE, temperature, + MIN_WATER_TEMPERATURE_WARNING_LOW_RANGE ); + checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_HIGH, FALSE, temperature, + MAX_WATER_TEMPERATURE_WARNING_HIGH_RANGE ); + checkPersistentAlarm( ALARM_ID_DG_CLEANING_MODE_INLET_WATER_TEMP_TOO_LOW, FALSE, temperature, + MAX_WATER_TEMPERATURE_WARNING_LOW_RANGE ); + } } /*********************************************************************//** @@ -683,58 +698,10 @@ *************************************************************************/ static void processTempSnsrsADCRead( U32 sensorIndex, U32 adc ) { - // Some of the temperature sensors have an MSB bit that is used as an error flag. This flag will be a TRUE by default. - BOOL isErrorBitNotValid = FALSE; - S32 convertedADC = (S32)( adc & MASK_OFF_U32_MSB ); + S32 convertedADC = (S32)( adc & MASK_OFF_U32_MSB ); - switch( sensorIndex ) - { - case TEMPSENSORS_LOAD_CELL_A1_B1: - case TEMPSENSORS_LOAD_CELL_A2_B2: - case TEMPSENSORS_CONDUCTIVITY_SENSOR_1: - case TEMPSENSORS_CONDUCTIVITY_SENSOR_2: - case TEMPSENSORS_OUTLET_PRIMARY_HEATER: - case TEMPSENSORS_INLET_PRIMARY_HEATER: - case TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR: - case TEMPSENSORS_OUTLET_REDUNDANT: - case TEMPSENSORS_INTERNAL_TRO_RTD: - case TEMPSENSORS_INLET_DIALYSATE: - case TEMPSENSORS_INTERNAL_TDI_RTD: - case TEMPSENSORS_HEAT_DISINFECT: - case TEMPSENSORS_INTERNAL_THD_RTD: - { - U08 i; - - // Shift bits by 31 to right to check the error bit status - tempSensors[ sensorIndex ].sensorErrorBitStatus = adc >> SHIFT_BITS_BY_31; - - for ( i = 0; i < NUM_OF_TEMPERATURE_SENSORS; i++ ) - { - // If that bit is a 1, there is either CRC error or Status error that are ored on top of each other - // NOTE: only a few sensors have the error bit available but for simplicity, all the sensors are looped. - // This variable is zeroed in the init function and the sensors that do not use this bit are never checked (and set) to - // any other values so those sensors will never trigger this fault. - // If any of the sensors have this bit to be 1, set the error occurred be 1 - if ( tempSensors[ i ].sensorErrorBitStatus > 0 ) - { - isErrorBitNotValid = TRUE; - } - } - } - break; - - default: - // Do nothing. FPGA board temperature sensor does not have error flag bit - // If a wrong temperature sensor name is picked, the function that converts - // ADC counts to temperature raises an alarm. - break; - } - - if ( FALSE == isErrorBitNotValid ) - { - // Make sure the error bit is not true before - processADCRead( sensorIndex, convertedADC ); - } + // Make sure the error bit is not true before + processADCRead( sensorIndex, convertedADC ); } /*********************************************************************//** @@ -770,10 +737,8 @@ *************************************************************************/ static void processADCRead( U32 sensorIndex, S32 adc ) { - U08 i; F32 temperature; F32 avgADCReads; - BOOL isADCNotValid = FALSE; U32 index = tempSensors[ sensorIndex ].adcNextIndex; S32 indexValue = tempSensors[ sensorIndex ].rawADCReads [ index ]; @@ -783,23 +748,6 @@ tempSensors[ sensorIndex ].adcRunningSum = tempSensors[ sensorIndex ].adcRunningSum - indexValue + adc; avgADCReads = tempSensors[ sensorIndex ].adcRunningSum >> SHIFT_BITS_BY_2_FOR_AVERAGING; // Calculate the average - // Check if the average ADC is within the accepted range - tempSensors[ sensorIndex ].adcErrorStatus = ( ( (U32)avgADCReads < TEMP_SESNORS_MIN_ADC_COUNT ) || - ( (U32)avgADCReads > TEMP_SENSORS_MAX_ADC_COUNT ) ? TRUE : FALSE ); - - for ( i = 0; i < NUM_OF_TEMPERATURE_SENSORS; i++ ) - { - // Loop through the temperature sensors and check the ADC range except the heater's temperature sensors. They are only - // used to display the temperature inside the heaters - if ( ( i != TEMPSENSORS_PRIMARY_HEATER_THERMO_COUPLE ) && ( i != TEMPSENSORS_TRIMMER_HEATER_THERMO_COUPLE ) && - ( i != TEMPSENSORS_PRIMARY_HEATER_COLD_JUNCTION ) && ( i != TEMPSENSORS_TRIMMER_HEATER_COLD_JUNCTION ) ) - { - isADCNotValid |= tempSensors[ sensorIndex ].adcErrorStatus; - } - } - - checkPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, isADCNotValid, sensorIndex, avgADCReads ); - // Different sensors have different ADC to temperature conversion methods switch( sensorIndex ) { @@ -895,13 +843,11 @@ *************************************************************************/ static TEMPSENSORS_EXEC_STATES_T handleExecGetADCValues( void ) { - U32 errorCount = 0; U32 readCount = 0; - errorCount = (U32)getFPGARTDErrorCount(); readCount = (U32)getFPGARTDReadCount(); - checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TWO_WIRE_ADC_TEMP_SENSORS, errorCount, readCount ); + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TWO_WIRE_ADC_TEMP_SENSORS, readCount ); processTempSnsrsADCRead( TEMPSENSORS_INLET_PRIMARY_HEATER, getFPGATPiTemp() ); processTempSnsrsADCRead( TEMPSENSORS_OUTLET_PRIMARY_HEATER, getFPGATPoTemp() ); processTempSnsrsADCRead( TEMPSENSORS_CONDUCTIVITY_SENSOR_1, getFPGACD1Temp() ); @@ -912,36 +858,36 @@ if ( ( getHardwareConfigStatus() != HW_CONFIG_BETA ) && ( getCurrentOperationMode() != DG_MODE_INIT ) ) #endif { - errorCount = (U32)getFPGATHdErrorCount(); readCount = (U32)getFPGATHdReadCount(); - checkFPGAPersistentAlarms( FPGA_PERS_ERROR_THD_ADC_TEMP_SENSORS, errorCount, readCount ); + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_THD_ADC_TEMP_SENSORS, readCount ); processTempSnsrsADCRead( TEMPSENSORS_HEAT_DISINFECT, getFPGATHdTemp() ); + + // Make sure the baro sensor coefficients are not corrupted + checkBaroSensorCRC(); + processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_THD_RTD, getFPGATHdInternalTemp() ); // Make sure the baro sensor coefficients are not corrupted checkBaroSensorCRC(); baroConvConsts.refTemperature = getFPGABaroReferenceTemperature(); baroConvConsts.temperatureCoeff = getFPGABaroTempCoeffOfTemperature(); - errorCount = getFPGABaroErrorCount(); readCount = getFPGABaroReadCount(); - checkFPGAPersistentAlarms( FPGA_PERS_ERROR_BARO_SENSOR, errorCount, readCount ); + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_BARO_SENSOR, readCount ); processTempSnsrsADCRead( TEMPSENSORS_BAROMETRIC_TEMP_SENSOR, getFPGABaroTemperature() ); } - errorCount = (U32)getFPGATRoErrorCount(); readCount = (U32)getFPGATRoReadCount(); - checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TRO_ADC_TEMP_SENSORS, errorCount, readCount ); + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TRO_ADC_TEMP_SENSORS, readCount ); processTempSnsrsADCRead( TEMPSENSORS_OUTLET_REDUNDANT, getFPGATRoTemp() ); processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_TRO_RTD, getFPGATRoInternalTemp() ); - errorCount = (U32)getFPGATDiErrorCount(); readCount = (U32)getFPGATDiReadCount(); - checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TDI_ADC_TEMP_SENSORS, errorCount, readCount ); + checkFPGAPersistentAlarms( FPGA_PERS_ERROR_TDI_ADC_TEMP_SENSORS, readCount ); processTempSnsrsADCRead( TEMPSENSORS_INLET_DIALYSATE, getFPGATDiTemp() ); processTempSnsrsADCRead( TEMPSENSORS_INTERNAL_TDI_RTD, getFPGATDiInternalTemp() ); @@ -1043,17 +989,9 @@ case TEMPSENSORS_OUTLET_REDUNDANT: case TEMPSENSORS_INLET_DIALYSATE: case TEMPSENSORS_FPGA_BOARD_SENSOR: - case TEMPSENSORS_LOAD_CELL_A1_B1: - case TEMPSENSORS_LOAD_CELL_A2_B2: - case TEMPSENSORS_INTERNAL_TRO_RTD: - case TEMPSENSORS_INTERNAL_TDI_RTD: - case TEMPSENSORS_INTERNAL_THD_RTD: - case TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR: case TEMPSENSORS_BAROMETRIC_TEMP_SENSOR: - // All the temperature sensors are monitored except the heaters' temperature sensors. - // The heaters' temperature sensors are only broadcast for information + // All other temperature sensors are only broadcast for logging/dialin purposes. temperature = getTemperatureValue( sensorId ); - // Check both temperature and to be in range if ( ( ( temperature < TEMP_SENSORS_MIN_ALLOWED_DEGREE_C ) || ( temperature > tempSensors[ sensorId ].maxAllowedTemp ) ) && ( getCurrentOperationMode() != DG_MODE_INIT ) )