Index: firmware/App/Controllers/TemperatureSensors.c =================================================================== diff -u -ra2c32d4d221603054ca9ad7a097112caebf08c4e -rc0160362dc799802ec589d5b6cf4c2bd1face77e --- firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision a2c32d4d221603054ca9ad7a097112caebf08c4e) +++ firmware/App/Controllers/TemperatureSensors.c (.../TemperatureSensors.c) (revision c0160362dc799802ec589d5b6cf4c2bd1face77e) @@ -37,7 +37,6 @@ #define PRIMARY_HEATER_EXT_TEMP_SENSORS_0_DEGREE_RESISTANCE 1000U ///< Primary heater external temperature sensors zero degree resistance. #define COND_SENSORS_TEMP_SENSOR_GAIN 8U ///< Temperature sensor for conductivity gain. - #define COND_SENSORS_TEMP_SENSOR_REF_RESISTANCE 19600U ///< Temperature sensor for conductivity reference resistance. #define COND_SENSORS_TEMP_SENSOR_0_DEGREE_RESISTANCE 1000U ///< Temperature sensor for conductivity zero degree resistance. @@ -78,15 +77,20 @@ #define FPGA_RAW_ADC_READ_INTERVAL_COUNT 8 ///< Time interval in counts to read the raw ADC reads from FPGA. #define TEMPERATURE_SENSORS_ERROR_FLAG_PERSISTENT_PERIOD ( 5 * MS_PER_SECOND ) ///< Temperature sensors error flag persistent period. -/// Temperature sensor self-test states. -typedef enum tempSensors_Self_Test_States -{ - TEMPSENSORS_SELF_TEST_START = 0, ///< Temperature sensors self-test start - TEMPSENSORS_SELF_TEST_ADC_CHECK, ///< Temperature sensors self ADC check - TEMPSENSORS_SELF_TEST_COMPLETE, ///< Temperature sensors self-test complete - NUM_OF_TEMPSENSORS_SELF_TEST_STATES ///< Total number of self-test states -} TEMPSENSORS_SELF_TEST_STATES_T; +#define TEMP_SENSORS_MIN_ALLOWED_DEGREE_C 0.0 ///< Temperature sensors minimum allowed temperature in C. +#define TEMP_SENSORS_MAX_ALLOWED_DEGREE_C 120.0 ///< Temperature sensors maximum allowed temperature in C. +#define NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C 80.0 ///< Non fluid temperature sensors path maximum allowed temperature in C. +#define TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS ( 5 * MS_PER_SECOND ) ///< Temperature sensor out of range persistent period in milliseconds. +// The count cannot be within 0.1V of the rail on both sides therefore: +// ADC count = ((2^12) - 1 / ref voltage) * voltage +// Max allowed voltage = 3.0 - 0.1 = 2.0V +// Min allowed voltage = 0.1 - 0.0 = 0.1V +// Max count = ((2^12) - 1 / ref voltage) * voltage -> ((4096 - 1)/3.0) * (3.0 - 0.1) +// Min count = ((2^12) - 1 / ref voltage) * voltage -> ((4096 - 1)/3.0) * (0.1 - 0.0) +#define TEMP_SENSORS_MAX_ALLOWED_ADC_COUNT 3959U ///< Temperature sensors max allowed ADC count. +#define TEMP_SESNORS_MIN_ALLOWED_ADC_COUNT 137U ///< Temperature sensors min allowed ADC count. + /// Temperature sensor exec states. typedef enum tempSensors_Exec_States { @@ -107,12 +111,11 @@ S32 adcRunningSum; ///< ADC running sum U32 readCount; ///< Read counts from FPGA OVERRIDE_F32_T temperatureValues; ///< Temperature values with override + F32 maxAllowedTemperature; ///< Maximum allowed temperature of the sensor } TEMP_SENSOR_T; // ********** private data ********** -static SELF_TEST_STATUS_T tempSensorsSelfTestResult = SELF_TEST_STATUS_IN_PROGRESS; ///< Self-test result of the TemperatureSensors module. -static TEMPSENSORS_SELF_TEST_STATES_T tempSensorsSelfTestState; ///< TemperatureSensor self-test state. static TEMPSENSORS_EXEC_STATES_T tempSensorsExecState; ///< TemperatureSensor exec state. static TEMP_SENSOR_T tempSensors [ NUM_OF_TEMPERATURE_SENSORS ]; ///< Temperature sensors' data structure. static U32 fpgaRawADCReadInterval = 0; ///< FPGA raw ADC read interval count. @@ -142,16 +145,12 @@ -1.228034E-2, 9.804036E-4, -4.413030E-5, 1.057734E-6, -1.052755E-8 }; ///< Thermocouple inverse coefficient for positive cold junction temperature. -static const U32 TEMP_SENSORS_ADC_MAX_COUNT = ( 1 << TEMP_SENSORS_ADC_BITS ) - 1; ///< ADC 24 bit max count which is (2^24 - 1). static const U32 TEMP_EQUATION_RESISTOR_CALC = 1 << ( TEMP_SENSORS_ADC_BITS - 1 ); ///< Temperature sensors resistor calculation (2^(24 - 1)). static const F32 TEMP_EQUATION_COEFF_A = 3.9083E-3; ///< ADC to temperature conversion coefficient A. static const F32 TEMP_EQUATION_COEFF_B = -5.775E-7; ///< ADC to temperature conversion coefficient B. // ********** private function prototypes ********** -static TEMPSENSORS_SELF_TEST_STATES_T handleSelfTestStart( void ); -static TEMPSENSORS_SELF_TEST_STATES_T handleSelfTestADCCheck( void ); - static TEMPSENSORS_EXEC_STATES_T handleExecStart( void ); static TEMPSENSORS_EXEC_STATES_T handleExecGetADCValues( void ); @@ -162,15 +161,14 @@ static void processHtrsTempSnsrsADCRead( U32 sensorIndex, U16 adc, U32 fpgaError, U32 fpgaCount ); static BOOL isADCReadValid( U32 sensorIndex, U32 fpgaError, U32 fpgaCount ); static void processADCRead( U32 sensorIndex, S32 adc ); -static void publishTemperatureSensorsData( void ); static U32 getPublishTemperatureSensorsDataInterval( void ); +static void publishTemperatureSensorsData( void ); +static void monitorTemperatureSnsrs( U32 sensorIndex, F32 temperature ); /*********************************************************************//** * @brief * The initTemperatureSensors function initializes the module. - * @details Inputs: tempSensorsSelfTestState, tempSensorsExecState, - * elapsedTime, internalHeatersConversionTimer, dataPublicationTimerCounter, - * tempSensors, fpgaRawADCReadInterval + * @details Inputs: none * @details Outputs: tempSensorsSelfTestState, tempSensorsExecState, * elapsedTime, internalHeatersConversionTimer, dataPublicationTimerCounter, * tempSensors, fpgaRawADCReadInterval @@ -181,13 +179,11 @@ U08 i; // Initialize the variables - tempSensorsSelfTestResult = SELF_TEST_STATUS_IN_PROGRESS; - tempSensorsSelfTestState = TEMPSENSORS_SELF_TEST_START; - tempSensorsExecState = TEMPSENSORS_EXEC_STATE_START; - elapsedTime = 0; - internalHeatersConversionTimer = 0; - dataPublicationTimerCounter = 0; - fpgaRawADCReadInterval = 0; + tempSensorsExecState = TEMPSENSORS_EXEC_STATE_START; + elapsedTime = 0; + internalHeatersConversionTimer = 0; + dataPublicationTimerCounter = 0; + fpgaRawADCReadInterval = 0; /* NOTE: The temperature sensors do not have conversion coefficient. * The conversion coefficients are used for the heaters internal temperature sensors and @@ -206,28 +202,34 @@ tempSensors[ TEMPSENSORS_INLET_PRIMARY_HEATER ].gain = PRIMARY_HEATER_EXT_TEMP_SENSORS_GAIN; tempSensors[ TEMPSENSORS_INLET_PRIMARY_HEATER ].refResistance = PRIMARY_HEATER_EXT_TEMP_SENSORS_REF_RESISTANCE; tempSensors[ TEMPSENSORS_INLET_PRIMARY_HEATER ].zeroDegreeResistance = PRIMARY_HEATER_EXT_TEMP_SENSORS_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_INLET_PRIMARY_HEATER ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; tempSensors[ TEMPSENSORS_OUTLET_PRIMARY_HEATER ].gain = PRIMARY_HEATER_EXT_TEMP_SENSORS_GAIN; tempSensors[ TEMPSENSORS_OUTLET_PRIMARY_HEATER ].refResistance = PRIMARY_HEATER_EXT_TEMP_SENSORS_REF_RESISTANCE; tempSensors[ TEMPSENSORS_OUTLET_PRIMARY_HEATER ].zeroDegreeResistance = PRIMARY_HEATER_EXT_TEMP_SENSORS_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_OUTLET_PRIMARY_HEATER ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; // Initialize TD1 and TD2 constants tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].gain = COND_SENSORS_TEMP_SENSOR_GAIN; tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].refResistance = COND_SENSORS_TEMP_SENSOR_REF_RESISTANCE; tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].zeroDegreeResistance = COND_SENSORS_TEMP_SENSOR_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_1 ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].gain = COND_SENSORS_TEMP_SENSOR_GAIN; tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].refResistance = COND_SENSORS_TEMP_SENSOR_REF_RESISTANCE; tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].zeroDegreeResistance = COND_SENSORS_TEMP_SENSOR_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; // Initialize TRo and TDi constants tempSensors[ TEMPSENSORS_OUTLET_REDUNDANT ].gain = TRIMMER_HEATER_EXT_TEMP_SENSORS_GAIN; tempSensors[ TEMPSENSORS_OUTLET_REDUNDANT ].refResistance = TRIMMER_HEATER_EXT_TEMP_SENSORS_REF_RESISTANCE; tempSensors[ TEMPSENSORS_OUTLET_REDUNDANT ].zeroDegreeResistance = TRIMMER_HEATER_EXT_TEMP_SENSORS_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_OUTLET_REDUNDANT ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; tempSensors[ TEMPSENSORS_INLET_DIALYSATE ].gain = TRIMMER_HEATER_EXT_TEMP_SENSORS_GAIN; tempSensors[ TEMPSENSORS_INLET_DIALYSATE ].refResistance = TRIMMER_HEATER_EXT_TEMP_SENSORS_REF_RESISTANCE; tempSensors[ TEMPSENSORS_INLET_DIALYSATE ].zeroDegreeResistance = TRIMMER_HEATER_EXT_TEMP_SENSORS_0_DEGREE_RESISTANCE; + tempSensors[ TEMPSENSORS_INLET_DIALYSATE ].maxAllowedTemperature = TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; // Initialize the heaters internal thermocouples constants tempSensors[ TEMPSENSORS_PRIMARY_HEATER_THERMO_COUPLE ].conversionCoeff = HEATERS_INTERNAL_TC_ADC_TO_TEMP_CONVERSION_COEFF; @@ -239,57 +241,69 @@ // FPGA board temperature conversion coefficient tempSensors[ TEMPSENSORS_FPGA_BOARD_SENSOR ].conversionCoeff = 503.975 / (F32)TWELVE_BIT_RESOLUTION; + tempSensors[ TEMPSENSORS_FPGA_BOARD_SENSOR ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; F32 const conversionCoeff = 1.0 / 13584.0; - // Board temperature sensors conversion coefficient - tempSensors[ TEMPSENSORS_LOAD_CELL_A1_B1 ].conversionCoeff = conversionCoeff; - tempSensors[ TEMPSENSORS_LOAD_CELL_A2_B2 ].conversionCoeff = conversionCoeff; - tempSensors[ TEMPSENSORS_INTERNAL_THDO_RTD ].conversionCoeff = conversionCoeff; - tempSensors[ TEMPSENSORS_INTERNAL_TDI_RTD ].conversionCoeff = conversionCoeff; - tempSensors[ TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_LOAD_CELL_A1_B1 ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_LOAD_CELL_A1_B1 ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + tempSensors[ TEMPSENSORS_LOAD_CELL_A2_B2 ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_LOAD_CELL_A2_B2 ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + + tempSensors[ TEMPSENSORS_INTERNAL_THDO_RTD ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_INTERNAL_THDO_RTD ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + + tempSensors[ TEMPSENSORS_INTERNAL_TDI_RTD ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_INTERNAL_TDI_RTD ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + + tempSensors[ TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR ].conversionCoeff = conversionCoeff; + tempSensors[ TEMPSENSORS_INTERNAL_COND_TEMP_SENSOR ].maxAllowedTemperature = NON_FLUID_PATH_TEMP_SENSORS_MAX_ALLOWED_DEGREE_C; + // Persistent alarms for inlet water high/low temperature - initPersistentAlarm( ALARM_ID_INLET_WATER_HIGH_TEMPERATURE, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD ); - initPersistentAlarm( ALARM_ID_INLET_WATER_LOW_TEMPERATURE, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD ); + initPersistentAlarm( ALARM_ID_INLET_WATER_HIGH_TEMPERATURE, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD, + INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD ); + initPersistentAlarm( ALARM_ID_INLET_WATER_LOW_TEMPERATURE, INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD, + INLET_WATER_TEMPERATURE_PERSISTENCE_PERIOD ); + + // Persistent alarm for the temperature sensors range check + initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_OUT_OF_RANGE, TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS, + TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS ); + + // Persistent alarm for the temperature sensors range check + initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_ADC_OUT_OF_RANGE, TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS, + TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS ); + + // Persistent alarm for the temperature sensors error bit fault check + initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_FAULT, TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS, + TEMP_SENSORS_OUT_OF_RANGE_PERSISTENT_PEROID_MS ); + // Persistent alarm for temperature sensors ADC error // When the FPGA read count does not increment for a period of time, it is considered as an internal error of the temperature sensors // driver. This is internal because FPGA does not error out if the FPGA read count does not increment. - initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, TEMPERATURE_SENSORS_FPGA_ERROR_PERSISTENT_PERIOD, TEMPERATURE_SENSORS_FPGA_ERROR_PERSISTENT_PERIOD ); + initPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, TEMPERATURE_SENSORS_FPGA_ERROR_PERSISTENT_PERIOD, + TEMPERATURE_SENSORS_FPGA_ERROR_PERSISTENT_PERIOD ); } /*********************************************************************//** * @brief * The execTemperatureSensorsSelfTest function runs the TemperatureSensors * POST during the self-test. - * @details Inputs: tempSensorsSelfTestState - * @details Outputs: tempSensorsSelfTestState + * @details Inputs: none + * @details Outputs: none * @return tempSensorsSelfTestState which is the status of the self test *************************************************************************/ SELF_TEST_STATUS_T execTemperatureSensorsSelfTest( void ) { - switch ( tempSensorsSelfTestState ) - { - case TEMPSENSORS_SELF_TEST_START: - tempSensorsSelfTestState = handleSelfTestStart(); - break; + SELF_TEST_STATUS_T status = SELF_TEST_STATUS_IN_PROGRESS; - case TEMPSENSORS_SELF_TEST_ADC_CHECK: - tempSensorsSelfTestState = handleSelfTestADCCheck(); - break; + // TODO implement the calibration processing function. + // It returns a pass for now - case TEMPSENSORS_SELF_TEST_COMPLETE: - // Done with self-test, do nothing - break; + status = SELF_TEST_STATUS_PASSED; - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_TEMPERATURE_SENSORS_INVALID_SELF_TEST_STATE, tempSensorsSelfTestState ); - tempSensorsSelfTestState = TEMPSENSORS_SELF_TEST_COMPLETE; - break; - } - - return tempSensorsSelfTestResult; + return status; } /*********************************************************************//** @@ -304,7 +318,7 @@ // Read the sensors all the time switch ( tempSensorsExecState ) { - case TEMPSENSORS_SELF_TEST_START: + case TEMPSENSORS_EXEC_STATE_START: tempSensorsExecState = handleExecStart(); break; @@ -644,6 +658,12 @@ // Calculate the average F32 const avgADCReads = tempSensors[ sensorIndex ].adcRunningSum >> SHIFT_BITS_BY_2_FOR_AVERAGING; + // Check if the ADC value of the sensor is not out of range + if ( ( (U32)avgADCReads < TEMP_SESNORS_MIN_ALLOWED_ADC_COUNT ) || ( (U32)avgADCReads > TEMP_SENSORS_MAX_ALLOWED_ADC_COUNT ) ) + { + checkPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_ADC_OUT_OF_RANGE, TRUE, sensorIndex, avgADCReads ); + } + // Different sensors have different ADC to temperature conversion methods switch( sensorIndex ) { @@ -688,51 +708,13 @@ // Update the temperature tempSensors[ sensorIndex ].temperatureValues.data = temperature; -} -/*********************************************************************//** - * @brief - * The handleSelfTestStart function transitions the self-test state to - * check ADC. - * @details Inputs: tempSensorsSelfTestResult - * @details Outputs: none - * @return the next state of state machine - *************************************************************************/ -static TEMPSENSORS_SELF_TEST_STATES_T handleSelfTestStart( void ) -{ - tempSensorsSelfTestResult = SELF_TEST_STATUS_IN_PROGRESS; - return TEMPSENSORS_SELF_TEST_ADC_CHECK; + // Monitor the temperature value + monitorTemperatureSnsrs( sensorIndex, temperature ); } /*********************************************************************//** * @brief - * The handleSelfTestADCCheck function checks whether the ADC reads. If the - * reads are above the maximum 24bit ADC count, it will throw an alarm and - * switches to the next state. - * @details Inputs: tempSensorsSelfTestResult - * @details Outputs: tempSensorsSelfTestResult - * @return the next state of the state machine - *************************************************************************/ -static TEMPSENSORS_SELF_TEST_STATES_T handleSelfTestADCCheck( void ) -{ - tempSensorsSelfTestResult = SELF_TEST_STATUS_PASSED; - - S32 const tpiADC = (S32)getFPGATPiTemp(); - - BOOL const isLessThanZero = tpiADC <= 0; - BOOL const isGreaterThanFullScale = tpiADC >= TEMP_SENSORS_ADC_MAX_COUNT; - - if ( ( TRUE == isLessThanZero ) || ( TRUE == isGreaterThanFullScale ) ) - { - tempSensorsSelfTestResult = SELF_TEST_STATUS_FAILED; - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_TEMPERATURE_SENSORS_ADC_FAULT, TEMPSENSORS_SELF_TEST_ADC_CHECK ); - } - - return TEMPSENSORS_SELF_TEST_COMPLETE; -} - -/*********************************************************************//** - * @brief * The handleExecStart function waits for a period of time and switches to * the state that reads the ADC values from FPGA. * @details Inputs: elapsedTime @@ -743,7 +725,7 @@ { TEMPSENSORS_EXEC_STATES_T state = TEMPSENSORS_EXEC_STATE_START; - if ( elapsedTime == 0 ) + if ( 0 == elapsedTime ) { elapsedTime = getMSTimerCount(); } @@ -906,7 +888,31 @@ } } +/*********************************************************************//** + * @brief + * The monitorTemperatureSnsrs function monitors the temperature sensors' + * temperature value and raises an alarm if any of them are out of range + * for more than the specified time. + * @details Inputs: tempSensors + * @details Outputs: tempSensors + * @param sensorIndex the index of the temperature sensor + * @param temperature the temperature value to be checked + * @return none + *************************************************************************/ +static void monitorTemperatureSnsrs( U32 sensorIndex, F32 temperature ) +{ + // The maximum allowed temperature is different for the sensors that are in the fluid path + // with the ones that are not in the fluid path + F32 maxLimit = tempSensors[ sensorIndex ].maxAllowedTemperature; + // Check both temperature and to be in range + if ( ( temperature < TEMP_SENSORS_MIN_ALLOWED_DEGREE_C ) || ( temperature > maxLimit ) ) + { + checkPersistentAlarm( ALARM_ID_DG_TEMPERATURE_SENSOR_OUT_OF_RANGE, TRUE, sensorIndex, temperature ); + } +} + + /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/