Index: firmware/App/Modes/ModeChemicalDisinfect.c =================================================================== diff -u -re82ddb85a3b3a1fc5d591d8cca0d006597fd94cf -r6127d594f1673bd75ffe7be22eec69a2f39e025d --- firmware/App/Modes/ModeChemicalDisinfect.c (.../ModeChemicalDisinfect.c) (revision e82ddb85a3b3a1fc5d591d8cca0d006597fd94cf) +++ firmware/App/Modes/ModeChemicalDisinfect.c (.../ModeChemicalDisinfect.c) (revision 6127d594f1673bd75ffe7be22eec69a2f39e025d) @@ -57,9 +57,20 @@ // Drain R1 & R2 states defines #define DRAIN_PUMP_TARGET_RPM 2400 ///< Drain pump target RPM during drain. #define DRAIN_WEIGHT_UNCHANGE_TIMEOUT ( 6 * MS_PER_SECOND ) ///< Time period of unchanged weight during draining before timeout. +#define RSRVRS_DRAIN_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 drain timeout in ms. +#define RSRVRS_INITIAL_DRAIN_TIME_OUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 initial drain time out in milliseconds. +// Fill R1 & R2 state defines +#define RSRVRS_FULL_STABLE_TIME_COUNT ( ( 4 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Reservoirs 1 & 2 full stable time in counts. +#define RSRVRS_FILL_UP_TIMEOUT_MS ( 8 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 full fill up timeout in ms. +#define RSRVRS_PARTIAL_FILL_UP_TIMEOUT_MS ( 7 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 partial fill up timeout in ms. +#define RSRVRS_ALMOST_FULL_FILL_UP_TIMEOUT_MS ( 1 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 partial fill up timeout in ms. +#define RESERVOIR_FULL_VOLUME_CHANGE_LIMIT_ML 5.0F +#define RESERVOIR_MINIMUM_FULL_VOLUME_ML 1700.0F +#define RSRVRS_FILL_TO_FULL_STABLE_TIME_COUNT ( ( 2 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Reservoirs 1 & 2 full stable time in counts. + // Flush drain path state defines -#define FLUSH_DRAIN_WAIT_TIME_MS ( 30 * MS_PER_SECOND ) ///< Flush Drain path wait time in milliseconds. +#define FLUSH_DRAIN_WAIT_TIME_MS ( 60 * MS_PER_SECOND ) ///< Flush Drain path wait time in milliseconds. #define MIN_INLET_TEMPERATURE_C 20.0F ///< Minimum water inlet temperature in C. TODO: set to 24.0 #define MAX_INLET_TEMPERATURE_C 35.0F ///< Maximum water inlet temperature in C. #define MAX_INLET_CONDUCTIVITY_US_PER_CM 2000.0F ///< Maximum water inlet conductivity in us/cm @@ -68,65 +79,66 @@ #define INLET_WATER_CHECK_FAILURE_TIMEOUT_MS ( 10 * MS_PER_SECOND ) ///< Timer for inlet water check failures before alarm // Flush circulation path state defines -#define RO_PUMP_TARGET_FLUSH_FILL_FLOW_RATE_LPM 0.5F ///< RO pump target flow rate during flush/fill in L/min. +#define RO_PUMP_TARGET_FLUSH_FLOW_RATE_LPM 0.8F ///< RO pump target flow rate during flush/fill in L/min. #define MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI 130 ///< Maximum RO pump pressure during flush/fill states in psi. #define FLUSH_CICRCULATION_WAIT_TIME_MS ( 30 * MS_PER_SECOND ) ///< Flush/rinse circulation path wait time in milliseconds. #define FLUSH_CICRCULATION_ADDITIONAL_WAIT_TIME_MS ( 60 * MS_PER_SECOND ) ///< Flush/rinse circulation path additional wait time in milliseconds. #define MAX_FLUSH_CIRC_TEMP_SENSOR_DIFF_C 3.0F ///< Maximum flush circulation temperature difference tolerance in C. #define NUM_OF_TEMP_SENSORS_TO_AVG 2.0F ///< Number of temperature sensors to average to check the difference. -#define MAX_FLUSH_CIRC_CONDUCTIVITY_US_PER_CM 1000.0F ///< Maximum allowed conductivity in flush circulation state in us/cm TODO: set to 100.0 +#define MAX_FLUSH_CIRC_CONDUCTIVITY_US_PER_CM 2000.0F ///< Maximum allowed conductivity in flush circulation state in us/cm TODO: set to 100.0 #define MAX_ALLOWED_FLUSH_CIRC_PERIODS 3 ///< Number of flush circulation periods to wait for sensors to come into range -// RO pump speed and pressure during entire disinfect cycle -#define CHEM_DISINFECT_TARGET_RO_FLOW_LPM 0.5F ///< Chemical disinfect target RO flow rate in L/min. -#define CHEM_DISINFECT_MAX_RO_PRESSURE_PSI 130 ///< Chemical disinfect maximum RO pressure in psi. - // Prime acid line #define PRIME_ACID_LINE_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Priming acid line timeout in milliseconds. #define DISINFECTANT_PUMP_PRIME_SPEED_ML_PER_MIN 19.0F ///< Disinfectant pump prime speed in ml/min. -#define MIN_PRIME_ACID_CONDUCTIVITY_US_PER_CM 2.0F ///< Minimum conductivity that indicates acid is in the line in uS/cm. TODO: set to 600.0 -#define PRIME_ACID_STEADY_CONDUCTIVITY_TIME_MS ( ( 10 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Minimum time that a steady conductivity of acid must be read in milliseconds. TODO: set to 10 sec +#define MIN_PRIME_ACID_CONDUCTIVITY_US_PER_CM 0.0F //3000.0F ///< Minimum conductivity that indicates acid is in the line in uS/cm. TODO: set to 600.0 +#define PRIME_ACID_STEADY_CONDUCTIVITY_TASK_INT ( ( 10 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Minimum time that a steady conductivity of acid must be read in task intervals. #define RO_PUMP_TARGET_PRIME_DISINECTANT_FLOW_RATE_LPM 0.8F ///< ROP flow rate for disinfectant prime +#define DISINFECTANT_MIX_RATIO_PRIME 19.0F ///< Disinfectant mixing ratio during prime, water/disinfectant. #define MAX_RO_PUMP_PRIME_DISINFECTANT_PRESSURE_PSI 130.0F ///< ROP max pressure for disinfectant prime // Stabilize disinfectant mixing and begin to fill tanks with disinfectant #define MAX_ALLOWED_DISINFECTANT_FLUSH_PERIODS 2 #define MIN_RO_FLOW_FOR_CONC_PUMP_MIXING_LPM 0.3F ///< Minimum RO flow rate that is need to be able to turn on the concentrate pump for mixing. -#define DISINFECTANT_PUMP_FILL_SPEED_ML_PER_MIN 7.5F ///< Disinfectant pump fill speed in ml/min. +#define DISINFECTANT_PUMP_FILL_SPEED_ML_PER_MIN 7.61F +#define DISINFECTANT_MIX_RATIO_FILL 65.67F ///< Disinfectant mixing ratio during fill, water/disinfectant. #define RO_PUMP_TARGET_FILL_DISINECTANT_FLOW_RATE_LPM 0.5F ///< ROP flow rate for disinfectant prime #define MAX_RO_PUMP_FILL_DISINFECTANT_PRESSURE_PSI 130.0F ///< ROP max pressure for disinfectant fill #define FLUSH_DISINFECTANT_INITIAL_WAIT_TIME ( 30 * MS_PER_SECOND ) ///< Initial time to wait for temperature and conductivity to reach target in disinfectant flush state #define FLUSH_DISINFECTANT_ADDITIONAL_WAIT_TIME ( 60 * MS_PER_SECOND ) ///< Additional time to wait for temperature and conductivity to reach target in disinfectant flush state -#define MAX_DISINFECT_FLUSH_CYCLE_PERIODS 2 ///< Number of allowed periods to check conductivity and temperature in disinfectant flush state +#define MAX_DISINFECT_FLUSH_CYCLE_PERIODS 2 ///< Number of allowed periods to check conductivity and temperature in disinfectant flush state +// RO pump speed and pressure during disinfect cycle +#define CHEM_DISINFECT_TARGET_RO_FLOW_LPM 0.5F ///< Chemical disinfect target RO flow rate in L/min. +#define CHEM_DISINFECT_MAX_RO_PRESSURE_PSI 130 ///< Chemical disinfect maximum RO pressure in psi. + // Contuctivity and temperature absolute limits during disinfection -#define MIN_DISINFECT_CONDUCTIVITY_US_PER_CM 5.0F ///< Minimum conductivity for mixed disinfect fluid in us/cm TODO: set to 150.0 -#define MAX_DISINFECT_CONDUCTIVITY_US_PER_CM 5000.0F ///< Minimum conductivity for mixed disinfect fluid in us/cm TODO: set to 650.0 -#define MIN_DISINFECT_TD2_TEMPERATURE_C 25.0F ///< Minimum temperature for mixed disinfect fluid at outlet of heater in dec C TODO: set to 35.0 -#define MAX_DISINFECT_TD2_TEMPERATURE_C 45.0F ///< Maximum temperature for mixed disinfect fluid at outlet of heater in dec C TODO: set to 45.0 +#define MIN_DISINFECT_CONDUCTIVITY_US_PER_CM 0.0F //1000.0F ///< Minimum conductivity for mixed disinfect fluid in us/cm TODO: set to 150.0 +#define MAX_DISINFECT_CONDUCTIVITY_US_PER_CM 50000.0F ///< Minimum conductivity for mixed disinfect fluid in us/cm TODO: set to 650.0 +#define MIN_DISINFECT_TPO_TEMPERATURE_C 35.0F ///< Minimum temperature for mixed disinfect fluid at outlet of heater in dec C TODO: set to 35.0 +#define MAX_DISINFECT_TPO_TEMPERATURE_C 45.0F ///< Maximum temperature for mixed disinfect fluid at outlet of heater in dec C TODO: set to 45.0 +#define MIN_MAX_CONDUCTIVITY_WAIT_TIME_MS ( 10 * MS_PER_SECOND ) // Initial disinfectant fill of R1 and R2 -#define RSRVRS_FULL_VOL_ML 1500.0F ///< Reservoirs 1 & 2 full volume in mL. TODo original value was 1900 -#define RSRVRS_PARTIAL_FILL_VOL_ML 500.0F ///< Reservoirs 1 & 2 partial volume in mL. -#define RSRVRS_FULL_STABLE_TIME_COUNT ( ( 4 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Reservoirs 1 & 2 full stable time in counts. -#define RSRVRS_FILL_UP_TIMEOUT_MS ( 6 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 full fill up timeout in ms. -#define RSRVRS_BOTH_FILL_UP_TIMEOUT_MS ( 12 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 partial fill up timeout in ms. -#define RSRVRS_PARTIAL_FILL_UP_TIMEOUT_MS ( 5 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 partial fill up timeout in ms. -#define RSRVRS_INITIAL_DRAIN_TIME_OUT_MS ( 3 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 initial drain time out in milliseconds. -#define RSRVRS_DRAIN_TIMEOUT_MS ( 3 * SEC_PER_MIN * MS_PER_SECOND ) ///< Reservoirs 1 & 2 drain timeout in ms. +#define RSRVRS_FULL_VOL_ML 1750.0F ///< Reservoirs 1 & 2 full volume in mL. TODo original value was 1900 +#define RSRVRS_PARTIAL_FILL_VOL_ML 1000.0F ///< Reservoirs 1 & 2 partial volume in mL. TODO: remove +#define RSRVRS_LEAK_VOL_TIMEOUT_MS ( 30 * MS_PER_SECOND ) +#define RSRVRS_MAX_LEAK_VOL_CHANGE_ML 100.0F; // Parameters controlling chemical disinfect -#define CHEM_DISINFECT_TIME_MS ( 12 * SEC_PER_MIN * MS_PER_SECOND ) ///< Chemical disinfect time in ms. +#define TARGET_CHEM_DISINFECT_TIME_MS ( 12 * SEC_PER_MIN * MS_PER_SECOND ) ///< Expected chemical disinfect time in ms. #define CHEM_DISINFECT_START_TEMP_TIMEOUT_MS ( 6 * SEC_PER_MIN * MS_PER_SECOND ) ///< Chemical disinfect reaching to minimum temperature timeout in milliseconds. -#define CHEM_DISINFECT_TARGET_TEMPERATURE_C 28.0F ///< Chemical disinfect target water temperature in C. // TODO this has not been decided -#define CHEM_DISINFECT_HEATER_CONTROL_TEMPERATURE_C 40.0F ///< Chemical disinfect heater control water temperature in C. // TODO this used to 30.0 -#define DISINFECT_CYCLE_PERIOD_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Time for each disinfectant filling and partial draining cycle +#define CHEM_DISINFECT_TARGET_TEMPERATURE_C 32.0F ///< Chemical disinfect target water temperature in C. // TODO this should be 35 +#define CHEM_DISINFECT_HEATER_CONTROL_TEMPERATURE_C 45.0F ///< Chemical disinfect heater control water temperature in C. +#define DISINFECT_CYCLE_PERIOD_MS ( 3 * SEC_PER_MIN * MS_PER_SECOND ) ///< Time for each disinfectant filling and partial draining cycle +#define REQUIRED_DISINFECT_CYCLES 2 // A PI control loop is used control the DRP speed while the tank is filling and draining, to maintain a constant level of disinfectant in the tank -#define DRP_VOLUME_CONTROL_TARGET_VOLUME_ML 1500.0F ///< Tank level to maintain using DRP volume control +#define RESERVOIR_VOLUME_BELOW_FULL_ML 250.0F ///< Volume to maintain in reservoir relative to full volume TODO: set to 100 or 150 +#define DRP_VOLUME_CONTROL_TARGET_VOLUME_ML 1700.0F ///< Tank level to maintain using DRP volume control, default value #define DRP_VOLUME_CONTROL_INTERVAL_MS ( MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Update rate for DRP volume control in ms. #define DRP_VOLUME_CONTROL_P_COEFFICIENT -0.8F ///< P term for DRP volume control. -#define DRP_VOLUME_CONTROL_I_COEFFICIENT 0.02F ///< I term for DRP volume control. +#define DRP_VOLUME_CONTROL_I_COEFFICIENT 0.1F ///< I term for DRP volume control. #define MIN_DRP_VOLUME_CONTROL_RPM 350.0F ///< Minimum DRP RPM for volume control. The minimum value allowed by the pump driver is 300 RPM #define MAX_DRP_VOLUME_CONTROL_RPM 1500.0F ///< Maximum DRP RPM for volume control. The maximum recommended value is 2400 RPM @@ -140,19 +152,6 @@ NUM_OF_CANCELLATION_MODES ///< Number of cancellation modes. } CANCELLATION_MODE_T; -/// Chemical disinfect status -typedef enum Chemical_disinfect_status -{ - CHEM_DISINFECT_IN_PROGRESS = 0, ///< Chemical disinfect in progress. - CHEM_DISINFECT_RSRVRS_LEAK_TIMEOUT, ///< Chemical disinfect reservoirs leak timeout. - CHEM_DISINFECT_HEAT_UP_TIMEOUT, ///< Chemical disinfect heat up timeout. - CHEM_DISINFECT_HEATER_OUTLET_TEMPERATURE_OUT_OF_RANGE, - CHEM_DISINFECT_DISINFECTANT_CONDUCTIVITY_OUT_OF_RANGE, - CHEM_DISINFECT_DISINFECT_TEMPERATURE_LOW, - CHEM_DISINFECT_COMPLETE, ///< Chemical disinfect complete. - NUM_OF_CHEM_DISINFECT_STATUS ///< Number of chemical disinfect status. -} CHEM_DISINFECT_STATUS_T; - /// Non-volatile write structure typedef struct { @@ -168,7 +167,6 @@ static U32 overallChemDisinfectTimer = 0; ///< Chemical disinfect cycle total timer. static U32 stateTimer = 0; ///< Chemical disinfect state timer to be used in different states. static U32 stateTrialCounter = 0; ///< Chemical disinfect state trial counter to be used for retries in different states. -static BOOL areTempSensorsInRange = FALSE; ///< Chemical disinfect temperature sensors in/out range flag. /// Boolean flag to check whether draining R1 and R2 is at the end of the chemical disinfect cycle or in the beginning. So the drain states can be reused. static BOOL isThisLastDrain = FALSE; static BOOL haveInletWaterChecksPassed = FALSE; ///< Chemical disinfect inlet water checks flag @@ -177,20 +175,29 @@ static DG_RESERVOIR_STATUS_T rsrvr2Status = NUM_OF_DG_RESERVOIR_STATUS; ///< Reservoir 2 status. static F32 R1ChemDisinfectVol = 0.0; ///< Reservoir 1 full volume during chemical disinfect. static F32 R2ChemDisinfectVol = 0.0; ///< Reservoir 2 full volume during chemical disinfect. -static U32 chemDisinfectTimer = 0; ///< Chemical disinfect timer. -static U32 chemDisinfectWarmupTimer = 0; ///< Chemical disinfect warmup timer. -static BOOL isPartialDisinfectInProgress = FALSE; ///< Chemical disinfect partial complete/in progess flag. +static BOOL isRsrvrLeaking = FALSE; static U32 rsrvrsVolMonitorTimer = 0; +static U32 chemDisinfectR1Timer = 0; ///< Chemical disinfect timer for reservoir 1. +static U32 chemDisinfectR2Timer = 0; ///< Chemical disinfect timer for reservoir 1. +static U32 chemDisinfectWarmupTimer = 0; ///< Chemical disinfect warmup timer. +static BOOL isPartialR1DisinfectInProgress = FALSE; ///< Chemical disinfect R1 partial complete/in progess flag. +static BOOL isPartialR2DisinfectInProgress = FALSE; ///< Chemical disinfect R2 partial complete/in progess flag. +static U32 DisinfectCycleCounter = 0; static U32 drpControlTimerCounter = 0; -static BOOL areRsrvrsLeaking = FALSE; ///< Reservoir 1 & 2 leak check flag during chemical disinfect. static U32 dataPublishCounter = 0; ///< Chemical Disinfect data publish counter. +static BOOL areTempSensorsInRange; static CANCELLATION_MODE_T cancellationMode = CANCELLATION_MODE_NONE; ///< Cancellation mode. static U32 rsrvrFillStableTimeCounter; ///< Reservoirs fill stable time counter. static ALARM_ID_T alarmDetectedPendingTrigger; ///< Chemical disinfect alarm to raise. static U32 flushCircWaitTime; ///< Variable time period to wait in flush circulation state to check sensor values static U32 flushDisinfectantWaitTime; ///< Variable time period to wait in disinfectant flush state to check sensor values static U32 primeAcidSteadyStateCounter = 0; ///< Prime acid steady state counter. +static U32 minMaxConductivityWaitTimer = 0; static BOOL haveDrainParamsBeenInit[ NUM_OF_DG_RESERVOIRS ]; ///< Boolean flag to indicate whether the drain parameters have been reset or not. +static U32 rsrvrFillToFullStableTimeCounter = 0; +static F32 R1FullVolume = 0.0; +static F32 R2FullVolume = 0.0; +static F32 disinfectantMixRatio = 0.0; static DISINFECT_NV_OPS_T disinfectNVOps; ///< Disinfect non-volatile memory operations. // ********** private function prototypes ********** @@ -203,17 +210,21 @@ static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectPrimeDisinfectantState( void ); static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectDisinfectantFlushState( void ); static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectFillWithDisinfectantState( void ); -static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectR1DisinfectantFillR2DrainState( void ); -static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectR2DisinfectantFillR1DrainState( void ); +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectDisinfectR1ToR2State( void ); +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectPartialDrainR1FillR2ToR1State( void ); +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectDisinfectR2ToR1State( void ); +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectPartialDrainR2FillR1ToR2State( void ); static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectCancelModeBasicPathState(void); static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectCancelModeWaterPathState(void); static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectCompleteState(void); static void failChemicalDisinfect( void ); static DG_RESERVOIR_STATUS_T getRsrvrFillStatus( DG_RESERVOIR_ID_T r, F32 targetVol, U32 timeout ); static DG_RESERVOIR_STATUS_T getRsrvrDrainStatus( DG_RESERVOIR_ID_T r, U32 drainSteadyStateTimeout, U32 timeout ); +static DG_RESERVOIR_STATUS_T getRsrvrFillToFullStatus( DG_RESERVOIR_ID_T r, U32 timeout ); static void controlDRPByReservoirVolume( DG_RESERVOIR_ID_T r, BOOL initialize ); -static CHEM_DISINFECT_STATUS_T getChemicalDisinfectStatus( void ); +static void handleDisinfectantMixing( F32 measuredROFlowRate_mL_min, F32 disinfectantMixingRatio ); +static void chemicalDisinfectTimerUpdate( DG_RESERVOIR_ID_T r ); static void publishChemicalDisinfectData( void ); static void monitorModeChemicalDisinfect( void ); static void writeDisinfectDataToNV( void ); @@ -246,12 +257,14 @@ R2ChemDisinfectVol = 0.0; overallChemDisinfectTimer = 0; chemDisinfectWarmupTimer = 0; - chemDisinfectTimer = 0; + chemDisinfectR1Timer = 0; + chemDisinfectR2Timer = 0; cancellationMode = CANCELLATION_MODE_NONE; rsrvrFillStableTimeCounter = 0; - isPartialDisinfectInProgress = FALSE; - // numberOfPostDisinfectRinses = 0; + isPartialR1DisinfectInProgress = FALSE; + isPartialR2DisinfectInProgress = FALSE; primeAcidSteadyStateCounter = 0; + disinfectantMixRatio = 0.0; chemDisinfectUIState = CHEM_DISINFECT_UI_STATE_NOT_RUNNING; haveDrainParamsBeenInit[ DG_RESERVOIR_1 ] = FALSE; haveDrainParamsBeenInit[ DG_RESERVOIR_2 ] = FALSE; @@ -324,14 +337,22 @@ chemDisinfectState = handleChemicalDisinfectFillWithDisinfectantState(); break; - case DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN: - chemDisinfectState = handleChemicalDisinfectR2DisinfectantFillR1DrainState(); + case DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2: + chemDisinfectState = handleChemicalDisinfectDisinfectR1ToR2State(); break; - case DG_CHEM_DISINFECT_STATE_R1_DISINFECTANT_FILL_R2_DRAIN: - chemDisinfectState = handleChemicalDisinfectR1DisinfectantFillR2DrainState(); + case DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R1_FILL_R2_TO_R1: + chemDisinfectState = handleChemicalDisinfectPartialDrainR1FillR2ToR1State(); break; + case DG_CHEM_DISINFECT_STATE_DISINFECT_R2_TO_R1: + chemDisinfectState = handleChemicalDisinfectDisinfectR2ToR1State(); + break; + + case DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R2_FILL_R1_TO_R2: + chemDisinfectState = handleChemicalDisinfectPartialDrainR2FillR1ToR2State(); + break; + case DG_CHEM_DISINFECT_STATE_CANCEL_BASIC_PATH: chemDisinfectState = handleChemicalDisinfectCancelModeBasicPathState(); break; @@ -516,9 +537,10 @@ tareLoadCell( LOAD_CELL_RESERVOIR_2_PRIMARY ); tareLoadCell( LOAD_CELL_RESERVOIR_2_BACKUP ); + setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); + setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); setValveState( VRD2, VALVE_STATE_CLOSED ); setValveState( VPI, VALVE_STATE_OPEN ); - setValveState( VRD2, VALVE_STATE_CLOSED ); setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); stateTrialCounter = 0; @@ -559,10 +581,12 @@ { if ( TRUE == haveInletWaterChecksPassed ) { - // set pumps and valves for next state, flush disinfectant line + // set pumps and valves for next state, flush circulation setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); - setROPumpTargetFlowRateLPM( RO_PUMP_TARGET_FLUSH_FILL_FLOW_RATE_LPM, MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI ); - + setROPumpTargetFlowRateLPM( RO_PUMP_TARGET_FLUSH_FLOW_RATE_LPM, MAX_RO_PUMP_FLUSH_FILL_PRESSURE_PSI ); + // Start heating the water while we are flushing + setHeaterTargetTemperature( DG_PRIMARY_HEATER, CHEM_DISINFECT_HEATER_CONTROL_TEMPERATURE_C ); + startHeater( DG_PRIMARY_HEATER ); turnOnUVReactor( INLET_UV_REACTOR ); turnOnUVReactor( OUTLET_UV_REACTOR ); @@ -632,7 +656,7 @@ ++stateTrialCounter; if ( stateTrialCounter < MAX_ALLOWED_FLUSH_CIRC_PERIODS ) { - stateTimer = getMSTimerCount(); + stateTimer = getMSTimerCount(); flushCircWaitTime = FLUSH_CICRCULATION_ADDITIONAL_WAIT_TIME_MS; } @@ -647,19 +671,20 @@ { alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_CONDUCTIVITY_IN_HIGH_RANGE; //ALARM_ID_DG_NEW_CON; } - prevChemDisinfectState = state; - state = DG_CHEM_DISINFECT_STATE_CANCEL_BASIC_PATH; + prevChemDisinfectState = state; + state = DG_CHEM_DISINFECT_STATE_CANCEL_BASIC_PATH; } } else - { // Set the valves for the prime disinfectant state - setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); - setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); - // Set the acid dispense pump speed + { + setROPumpTargetFlowRateLPM( RO_PUMP_TARGET_PRIME_DISINECTANT_FLOW_RATE_LPM, MAX_RO_PUMP_PRIME_DISINFECTANT_PRESSURE_PSI ); + // Set the acid dispense pump speed at the priming rate setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, DISINFECTANT_PUMP_PRIME_SPEED_ML_PER_MIN ); requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); - state = DG_CHEM_DISINFECT_STATE_PRIME_DISINFECTANT; - stateTimer = getMSTimerCount(); + disinfectantMixRatio = DISINFECTANT_MIX_RATIO_PRIME; + + state = DG_CHEM_DISINFECT_STATE_PRIME_DISINFECTANT; + stateTimer = getMSTimerCount(); } } @@ -687,38 +712,32 @@ // Set the chemical disinfect state that is published on the UI chemDisinfectUIState = CHEM_DISINFECT_UI_STATE_MIX_WATER_AND_ACID; + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + if ( cd2Conductivity <= MIN_PRIME_ACID_CONDUCTIVITY_US_PER_CM ) { primeAcidSteadyStateCounter = 0; } - // Check if the acid conductivity value has been above the threshold for the specified time period - else if ( ++primeAcidSteadyStateCounter >= PRIME_ACID_STEADY_CONDUCTIVITY_TIME_MS ) + else { - // Turn off the concentrate pump - requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + // Check if the acid conductivity value has been above the threshold for the specified time period + if ( ++primeAcidSteadyStateCounter >= PRIME_ACID_STEADY_CONDUCTIVITY_TASK_INT ) + { - // Prepare for filling the reservoirs and heating the water + // Turn off the concentrate pump + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + // Turn on the RO pump and concentrate pump to the disinfectant fill rates + setROPumpTargetFlowRateLPM( RO_PUMP_TARGET_FILL_DISINECTANT_FLOW_RATE_LPM, MAX_RO_PUMP_FILL_DISINFECTANT_PRESSURE_PSI ); + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, DISINFECTANT_PUMP_FILL_SPEED_ML_PER_MIN ); + requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); - setValveState( VRD1, VALVE_STATE_CLOSED ); - setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NC ); - setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); - - // Turn on the RO pump and concentrate pump - setROPumpTargetFlowRateLPM( RO_PUMP_TARGET_FILL_DISINECTANT_FLOW_RATE_LPM, MAX_RO_PUMP_FILL_DISINFECTANT_PRESSURE_PSI ); - setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, DISINFECTANT_PUMP_FILL_SPEED_ML_PER_MIN ); - requestConcentratePumpOn( CONCENTRATEPUMPS_CP2_BICARB ); - - // Start heating the water while we are filling up the reservoirs - setHeaterTargetTemperature( DG_PRIMARY_HEATER, CHEM_DISINFECT_HEATER_CONTROL_TEMPERATURE_C ); - startHeater( DG_PRIMARY_HEATER ); - - flushDisinfectantWaitTime = FLUSH_DISINFECTANT_INITIAL_WAIT_TIME; - stateTrialCounter = 0; - state = DG_CHEM_DISINFECT_STATE_DISINFECTANT_FLUSH; - stateTimer = getMSTimerCount(); + disinfectantMixRatio = DISINFECTANT_MIX_RATIO_FILL; + flushDisinfectantWaitTime = FLUSH_DISINFECTANT_INITIAL_WAIT_TIME; + stateTrialCounter = 0; + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_DISINFECTANT_FLUSH; + } } - if ( TRUE == didTimeout( stateTimer, PRIME_ACID_LINE_TIMEOUT_MS ) ) { prevChemDisinfectState = state; @@ -749,31 +768,50 @@ // Set the chemical disinfect that is published on the UI chemDisinfectUIState = CHEM_DISINFECT_UI_STATE_MIX_WATER_AND_ACID; + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + if ( TRUE == didTimeout( stateTimer, flushDisinfectantWaitTime ) ) { - CHEM_DISINFECT_STATUS_T status = getChemicalDisinfectStatus(); - if ( ( CHEM_DISINFECT_HEATER_OUTLET_TEMPERATURE_OUT_OF_RANGE == status ) || - ( CHEM_DISINFECT_DISINFECTANT_CONDUCTIVITY_OUT_OF_RANGE == status ) ) + F32 TdiTemp = getTemperatureValue( TEMPSENSORS_INLET_DIALYSATE ); + F32 cd2Conductivity = getConductivityValue( (U32)CONDUCTIVITYSENSORS_CD2_SENSOR ); + F32 TPoTemp = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); + BOOL isCD2OutofRange = ( cd2Conductivity < MIN_DISINFECT_CONDUCTIVITY_US_PER_CM || cd2Conductivity > MAX_DISINFECT_CONDUCTIVITY_US_PER_CM ); + BOOL isTPoOutofRange = ( TPoTemp < MIN_DISINFECT_TPO_TEMPERATURE_C || TPoTemp > MAX_DISINFECT_TPO_TEMPERATURE_C ); + if ( ( TRUE == isCD2OutofRange ) || ( TRUE == isTPoOutofRange ) ) { // Check if we have exceeded the number of trials. If not, try another time ++stateTrialCounter; if (stateTrialCounter < MAX_ALLOWED_DISINFECTANT_FLUSH_PERIODS ) { stateTimer = getMSTimerCount(); - flushDisinfectantWaitTime = FLUSH_DISINFECTANT_ADDITIONAL_WAIT_TIME; + flushDisinfectantWaitTime = FLUSH_DISINFECTANT_ADDITIONAL_WAIT_TIME; } else { - // fail, alarm has already been set - prevChemDisinfectState = state; - state = DG_CHEM_DISINFECT_STATE_CANCEL_BASIC_PATH; + if ( ( TRUE == isTPoOutofRange ) ) + { + alarmDetectedPendingTrigger = ALARM_ID_DG_CHEM_DISINFECT_TARGET_TEMP_TIMEOUT; + } + else + { + alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_CONDUCTIVITY_IN_HIGH_RANGE; //ALARM_ID_DG_NEW_CON; TODO + } + state = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; } } else { - // No changes in valves and pumps for next state + // Prepare for filling the reservoirs; fill reservoir 1 and overflow it into reservoir 2 + setValveState( VPO, VALVE_STATE_FILL_C_TO_NC ); + setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); + setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); + setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); + setValveState( VRD1, VALVE_STATE_CLOSED ); + setValveState( VRD2, VALVE_STATE_CLOSED ); + rsrvr1Status = DG_RESERVOIR_BELOW_TARGET; rsrvr2Status = DG_RESERVOIR_BELOW_TARGET; + isPartialR1DisinfectInProgress = FALSE; stateTimer = getMSTimerCount(); state = DG_CHEM_DISINFECT_STATE_FILL_WITH_DISINFECTANT; } @@ -799,45 +837,36 @@ static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectFillWithDisinfectantState( void ) { DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_FILL_WITH_DISINFECTANT; + + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + // First reservoir 1 must be full if ( DG_RESERVOIR_BELOW_TARGET == rsrvr1Status ) { - rsrvr1Status = getRsrvrFillStatus( DG_RESERVOIR_1, RSRVRS_FULL_VOL_ML, RSRVRS_FILL_UP_TIMEOUT_MS ); + // If R1 is not full, keep monitoring for R1 level and timeout + rsrvr1Status = getRsrvrFillToFullStatus( DG_RESERVOIR_1, RSRVRS_FILL_UP_TIMEOUT_MS ); } // Once reservoir 1 is full, check the status of reservoir 2 since the water overflows to reservoir 2 else if ( DG_RESERVOIR_REACHED_TARGET == rsrvr1Status ) { - rsrvr2Status = getRsrvrFillStatus( DG_RESERVOIR_2, RSRVRS_FULL_VOL_ML, RSRVRS_BOTH_FILL_UP_TIMEOUT_MS ); - - // If R1 is not full, keep monitoring for R1 level and timeout // Once R1 is full, keep monitoring for R2 level and timeout + rsrvr2Status = getRsrvrFillStatus( DG_RESERVOIR_2, RSRVRS_FULL_VOL_ML, RSRVRS_PARTIAL_FILL_UP_TIMEOUT_MS ); + chemicalDisinfectTimerUpdate( DG_RESERVOIR_1 ); + // Once R2 is full, transition to the next state if ( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) { - // Set the actuators to flush R2 and drain R1 state - // Set the valves to drain R1 and fill R2 - setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); - setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); - setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD1, VALVE_STATE_OPEN ); - // Set both reservoirs status - rsrvr1Status = DG_RESERVOIR_ABOVE_TARGET; - rsrvr2Status = DG_RESERVOIR_ABOVE_TARGET; + // go to the next disinfect configuration cycle, fill R1 and drain R2 + setValveState( VRD2, VALVE_STATE_OPEN ); // Set the drain pump to control mode - controlDRPByReservoirVolume( DG_RESERVOIR_1, TRUE ); //Initialize the PI controller for DRP + controlDRPByReservoirVolume( DG_RESERVOIR_2, TRUE ); //Initialize the PI controller for DRP - /* ??? I am not sure whether we should monitor the reservoir volumes for leaks - // Get the current volumes of R1 & R2. These values will be used to make sure the reservoirs' - // volume does not change more than a certain amount during the actual chemical disinfect cycle - rsrvrsVolMonitorTimer = getMSTimerCount(); - */ - R1ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); - R2ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); - chemDisinfectWarmupTimer = getMSTimerCount(); - isPartialDisinfectInProgress = FALSE; - stateTimer = getMSTimerCount(); - - state = DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN; + chemDisinfectWarmupTimer = getMSTimerCount(); + isPartialR1DisinfectInProgress = FALSE; + R1ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + isRsrvrLeaking = FALSE; + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2; } else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr2Status ) { @@ -867,52 +896,73 @@ * chemDisinfectUIState * @return next state of the chemical disinfect state machine *************************************************************************/ -static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectR2DisinfectantFillR1DrainState( void ) +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectDisinfectR1ToR2State( void ) { - DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN; - CHEM_DISINFECT_STATUS_T status = getChemicalDisinfectStatus(); + DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2; + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + // Set the chemical disinfect that is published on the UI chemDisinfectUIState = CHEM_DISINFECT_UI_STATE_DISINFECT_DEVICE; - if ( CHEM_DISINFECT_COMPLETE == status) + chemicalDisinfectTimerUpdate( DG_RESERVOIR_1 ); + if ( TRUE == didTimeout( chemDisinfectR1Timer, DISINFECT_CYCLE_PERIOD_MS ) ) { - // turn pumps and valves off - stopHeater( DG_PRIMARY_HEATER ); - setValveState( VPI, VALVE_STATE_CLOSED ); - setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); - setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); - setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD1, VALVE_STATE_CLOSED ); - signalROPumpHardStop(); - signalDrainPumpHardStop(); - requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + // Set the actuators to fill R2 and drain R1 state + setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); + setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); + setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); + setValveState( VRD1, VALVE_STATE_OPEN ); + setValveState( VRD2, VALVE_STATE_CLOSED ); - state = DG_CHEM_DISINFECT_STATE_COMPLETE; + rsrvr2Status = DG_RESERVOIR_BELOW_TARGET; + + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R1_FILL_R2_TO_R1; } - if ( TRUE == didTimeout( stateTimer, DISINFECT_CYCLE_PERIOD_MS ) ) + else { - // go to the next disinfect configuration cycle - setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); - setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); - setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD1, VALVE_STATE_CLOSED ); - setValveState( VRD2, VALVE_STATE_OPEN ); - - stateTimer = getMSTimerCount(); - state = DG_CHEM_DISINFECT_STATE_R1_DISINFECTANT_FILL_R2_DRAIN; + controlDRPByReservoirVolume( DG_RESERVOIR_2, FALSE ); } + + return state; +} + +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectPartialDrainR1FillR2ToR1State( void ) +{ + DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R1_FILL_R2_TO_R1; + + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + + // First reservoir 2 must be full + if ( DG_RESERVOIR_BELOW_TARGET == rsrvr2Status ) + { + // If R2 is not full, keep monitoring for R2 level and timeout + rsrvr2Status = getRsrvrFillToFullStatus( DG_RESERVOIR_2, RSRVRS_ALMOST_FULL_FILL_UP_TIMEOUT_MS ); + } + if ( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) + { + isPartialR2DisinfectInProgress = FALSE; + R2ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); + isRsrvrLeaking = FALSE; + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_DISINFECT_R2_TO_R1; + } + else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr2Status ) + { + prevChemDisinfectState = state; + state = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; + } else { controlDRPByReservoirVolume( DG_RESERVOIR_1, FALSE ); } - return state; } /*********************************************************************//** * @brief - * The handleChemicalDisinfectR1DisinfectantFillR2DrainState function handles the + * The handleChemicalDisinfectR2DisinfectantFillR1DrainState function handles the * chemical disinfect R1 to R2 state. The state runs reservoir 1 to reservoir 2 * chemical disinfect. If the reservoirs leak or it cannot reach to temperature * within a certain period of time, it transitions to water cancellation. @@ -923,50 +973,91 @@ * chemDisinfectUIState * @return next state of the chemical disinfect state machine *************************************************************************/ -static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectR1DisinfectantFillR2DrainState( void ) +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectDisinfectR2ToR1State( void ) { - DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_R1_DISINFECTANT_FILL_R2_DRAIN; - CHEM_DISINFECT_STATUS_T status = getChemicalDisinfectStatus(); + DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_DISINFECT_R2_TO_R1; // Set the chemical disinfect that is published on the UI chemDisinfectUIState = CHEM_DISINFECT_UI_STATE_DISINFECT_DEVICE; - if ( CHEM_DISINFECT_COMPLETE == status) + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + + chemicalDisinfectTimerUpdate( DG_RESERVOIR_2 ); + + if ( TRUE == didTimeout( chemDisinfectR2Timer, DISINFECT_CYCLE_PERIOD_MS ) ) { - // turn pumps and valves off - stopHeater( DG_PRIMARY_HEATER ); - setValveState( VPI, VALVE_STATE_CLOSED ); - setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); - setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); - setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD2, VALVE_STATE_CLOSED ); - signalROPumpHardStop(); - signalDrainPumpHardStop(); - requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + if ( REQUIRED_DISINFECT_CYCLES == ++DisinfectCycleCounter ) + { + //Disinfect is complete + // turn pumps and valves off + stopHeater( DG_PRIMARY_HEATER ); + setValveState( VPI, VALVE_STATE_CLOSED ); + setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); + setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); + setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); + setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); + setValveState( VRD2, VALVE_STATE_CLOSED ); + setValveState( VRD1, VALVE_STATE_CLOSED ); + signalROPumpHardStop(); + signalDrainPumpHardStop(); + requestConcentratePumpOff( CONCENTRATEPUMPS_CP2_BICARB ); + rsrvr1Status = DG_RESERVOIR_ABOVE_TARGET; + rsrvr2Status = DG_RESERVOIR_ABOVE_TARGET; + isThisLastDrain = TRUE; + state = DG_CHEM_DISINFECT_STATE_DRAIN_R1; + } + else + { + // go to the next disinfect configuration cycle, fill R1 and drain R2 + setValveState( VRF, VALVE_STATE_R1_C_TO_NC ); + setValveState( VRI, VALVE_STATE_R2_C_TO_NC ); + setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); + setValveState( VRD1, VALVE_STATE_CLOSED ); + setValveState( VRD2, VALVE_STATE_OPEN ); + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R2_FILL_R1_TO_R2; + } + } + else + { + controlDRPByReservoirVolume( DG_RESERVOIR_1, FALSE ); + } - state = DG_CHEM_DISINFECT_STATE_COMPLETE; + return state; +} + +static DG_CHEM_DISINFECT_STATE_T handleChemicalDisinfectPartialDrainR2FillR1ToR2State( void ) +{ + DG_CHEM_DISINFECT_STATE_T state = DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R2_FILL_R1_TO_R2; + + handleDisinfectantMixing( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) * ML_PER_LITER, disinfectantMixRatio ); + + // First reservoir 1 must be full + if ( DG_RESERVOIR_BELOW_TARGET == rsrvr1Status ) + { + // If R1 is not full, keep monitoring for R1 level and timeout + rsrvr1Status = getRsrvrFillToFullStatus( DG_RESERVOIR_1, RSRVRS_ALMOST_FULL_FILL_UP_TIMEOUT_MS ); } - else if ( TRUE == didTimeout( stateTimer, DISINFECT_CYCLE_PERIOD_MS ) ) + if ( DG_RESERVOIR_REACHED_TARGET == rsrvr1Status ) { - // go to the next disinfect configuration cycle - setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); - setValveState( VRO, VALVE_STATE_R2_C_TO_NC ); - setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD1, VALVE_STATE_OPEN ); - setValveState( VRD2, VALVE_STATE_CLOSED ); - stateTimer = getMSTimerCount(); - state = DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN; + isPartialR1DisinfectInProgress = FALSE; + R1ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + isRsrvrLeaking = FALSE; + stateTimer = getMSTimerCount(); + state = DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2; } + else if ( DG_RESERVOIR_NOT_REACHED_TARGET == rsrvr1Status ) + { + prevChemDisinfectState = state; + state = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; + } else { controlDRPByReservoirVolume( DG_RESERVOIR_2, FALSE ); } - return state; } - /*********************************************************************//** * @brief * The handleChemicalDisinfectCancelModeBasicPathState function handles the @@ -1199,6 +1290,95 @@ /*********************************************************************//** * @brief + * The getRsrvrFillStatus function checks whether the target reservoir + * is full or not. If the fill times out, it sets the state machine to + * complete and exits the chemical disinfect mode. + * @details Inputs: rsrvrFillStableTimeCounter, alarm, stateTimer + * @details Outputs: none + * @param r is DG_RESERVOIR_1 or DG_RESERVOIR_2 + * @param targetVol is the target fill volume + * @param timeout is the fill up timeout + * @return the status of the reservoirs during filling + *************************************************************************/ +static DG_RESERVOIR_STATUS_T getRsrvrFillToFullStatus( DG_RESERVOIR_ID_T r, U32 timeout ) +{ + DG_RESERVOIR_STATUS_T status = DG_RESERVOIR_BELOW_TARGET; + F32 currentVolume = 0.0; + F32 filteredVolume = 0.0; + + if ( DG_RESERVOIR_1 == r ) + { + currentVolume = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + filteredVolume = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + } + else if ( DG_RESERVOIR_2 == r ) + { + currentVolume = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); + filteredVolume = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); + } + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_INVALID_DG_RESERVOIR_SELECTED, r ) + } + + // Check the volume of the reservoir against the previous volume + if ( ( currentVolume > RESERVOIR_MINIMUM_FULL_VOLUME_ML ) && ( fabs( currentVolume - filteredVolume ) < RESERVOIR_FULL_VOLUME_CHANGE_LIMIT_ML ) ) + { + if ( ++rsrvrFillToFullStableTimeCounter >= RSRVRS_FILL_TO_FULL_STABLE_TIME_COUNT ) + { + status = DG_RESERVOIR_REACHED_TARGET; + rsrvrFillToFullStableTimeCounter = 0; + if ( DG_RESERVOIR_1 == r ) + { + R1FullVolume = currentVolume; + } + else if ( DG_RESERVOIR_2 == r ) + { + R2FullVolume = currentVolume; + } + // Set the state timer in case it needs to be used for another timeout check + stateTimer = getMSTimerCount(); + } + } + else if ( TRUE == didTimeout( stateTimer, timeout ) ) + { + // Failed to fill ontime. Update the previous chemical disinfect state and transition to basic cancellation + prevChemDisinfectState = chemDisinfectState; + alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_FILL_TIMEOUT; + status = DG_RESERVOIR_NOT_REACHED_TARGET; + } + else + { + rsrvrFillToFullStableTimeCounter = 0; + } + return status; +} + +/*********************************************************************//** + * @brief + * The handleDisinfectantMixing function handles the disinfectant mixing by setting + * the concentrate pump speed relative to the RO pump flow rate. + * @details Inputs: none + * @details Outputs: Set concentrate pump speed relative to RO pump flow rate + * @param measuredROFlowRate_mL_min measured RO flow rate in mL/min + * + * @return none + *************************************************************************/ +static void handleDisinfectantMixing( F32 measuredROFlowRate_mL_min, F32 disinfectantMixingRatio ) +{ + // Set concentrate pumps speed based off RO pump flow rate. The ratio is water/disinfectant + F32 disinfectantCP2PumpFlowRate = measuredROFlowRate_mL_min / disinfectantMixingRatio; + + // Cap to the maximum allowed concentrate pumps rate + disinfectantCP2PumpFlowRate = MIN( disinfectantCP2PumpFlowRate, CONCENTRATE_PUMP_MAX_SPEED ); + + disinfectantCP2PumpFlowRate = MAX( disinfectantCP2PumpFlowRate, 0.0F ); + + setConcentratePumpTargetSpeed( CONCENTRATEPUMPS_CP2_BICARB, disinfectantCP2PumpFlowRate ); +} + +/*********************************************************************//** + * @brief * The controlDRPByReservoirVolume function implements the volume control of the * drain pump to maintain a specified volume in one of the reservoirs. * @details Inputs: stateTimer, reservoir, initialize flag, control volume, @@ -1229,10 +1409,18 @@ if ( DG_RESERVOIR_1 == r ) { actVolume = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + if ( R1FullVolume > 0.0 ) + { + tgtVolume = R1FullVolume - RESERVOIR_VOLUME_BELOW_FULL_ML; + } } else if ( DG_RESERVOIR_2 == r ) { actVolume = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); + if ( R2FullVolume > 0.0 ) + { + tgtVolume = R2FullVolume - RESERVOIR_VOLUME_BELOW_FULL_ML; + } } else { @@ -1256,64 +1444,11 @@ * @details Outputs: areRsrvrsLeaking, areRsrvrsLeaking * @return status of the chemical disinfect (i.e in progress, complete) *************************************************************************/ -static CHEM_DISINFECT_STATUS_T getChemicalDisinfectStatus( void ) +static void chemicalDisinfectTimerUpdate( DG_RESERVOIR_ID_T r ) { - CHEM_DISINFECT_STATUS_T status = CHEM_DISINFECT_IN_PROGRESS; - - // Update the variables + // Update the disinfect temperature F32 TdiTemp = getTemperatureValue( TEMPSENSORS_INLET_DIALYSATE ); - F32 cd2Conductivity = getConductivityValue( (U32)CONDUCTIVITYSENSORS_CD2_SENSOR ); - F32 TD2Temp = getTemperatureValue( TEMPSENSORS_CONDUCTIVITY_SENSOR_2 ); - BOOL isCD2OutofRange = ( cd2Conductivity < MIN_DISINFECT_CONDUCTIVITY_US_PER_CM || cd2Conductivity > MAX_DISINFECT_CONDUCTIVITY_US_PER_CM ); - BOOL isTD2OutofRange = ( TD2Temp < MIN_DISINFECT_TD2_TEMPERATURE_C || TD2Temp > MAX_DISINFECT_TD2_TEMPERATURE_C ); - - /* this section is for monitoring the tank volumes for possible leaks. It is currently disabled pending decision whether to use it - BOOL isR1OutOfRange = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ) - R1ChemDisinfectVol ) > RSRVRS_MAX_TARGET_VOL_CHANGE_ML; - BOOL isR2OutOfRange = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ) - R2ChemDisinfectVol ) > RSRVRS_MAX_TARGET_VOL_CHANGE_ML; - // Check if either reservoir 1 or reservoir 2 are losing volume more than allowed volume - if ( ( TRUE == isR1OutOfRange ) || ( TRUE == isR2OutOfRange ) ) - { - // If the leak is the first time after a while, set the flag and start the timer - if ( FALSE == areRsrvrsLeaking ) - { - areRsrvrsLeaking = TRUE; - rsrvrsVolMonitorTimer = getMSTimerCount(); - } - // If the volume is out of range and it has timed out, exit - else if ( TRUE == didTimeout( rsrvrsVolMonitorTimer, RSRVRS_TARGET_VOL_OUT_TIMEOUT_MS ) ) - { - areRsrvrsLeaking = FALSE; - alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_LEAK_TIMEOUT; - status = CHEM_DISINFECT_RSRVRS_LEAK_TIMEOUT; - - } - } - - // Reservoirs are in range - else - { - areRsrvrsLeaking = FALSE; - } - */ - - // set the tank volumes for logging - R1ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); - R2ChemDisinfectVol = getLoadCellLargeFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); - - // For the following checks, if multiple failures occur at the same time, the last one will take precedence - // Check if the acid conductivity and temperature are within range - if ( TRUE == isCD2OutofRange ) - { - alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_CONDUCTIVITY_IN_HIGH_RANGE; //ALARM_ID_DG_NEW_CON; TODO - status = CHEM_DISINFECT_DISINFECTANT_CONDUCTIVITY_OUT_OF_RANGE; - } - if ( ( TRUE == isTD2OutofRange ) ) - { - alarmDetectedPendingTrigger = ALARM_ID_DG_CHEM_DISINFECT_TARGET_TEMP_TIMEOUT; - status = CHEM_DISINFECT_HEATER_OUTLET_TEMPERATURE_OUT_OF_RANGE; - } - // If the coldest spot which is TDi is less than minimum chemical disinfect temperature, // reset the chemical disinfect timers and check whether heating up has timed out if ( TdiTemp < CHEM_DISINFECT_TARGET_TEMPERATURE_C ) @@ -1322,32 +1457,32 @@ { // Heating up to minimum temperature for chemical disinfect failed alarmDetectedPendingTrigger = ALARM_ID_DG_CHEM_DISINFECT_TARGET_TEMP_TIMEOUT; - status = CHEM_DISINFECT_HEAT_UP_TIMEOUT; + chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; } - else - { - // Keep reseting the disinfect timer so the elapsed time is always 0 until disinfect truly starts - chemDisinfectTimer = getMSTimerCount(); - isPartialDisinfectInProgress = FALSE; - status = CHEM_DISINFECT_DISINFECT_TEMPERATURE_LOW; - } + if ( DG_RESERVOIR_1 == r ) + { + chemDisinfectR1Timer = getMSTimerCount(); + } + else if ( DG_RESERVOIR_2 == r ) + { + chemDisinfectR2Timer = getMSTimerCount(); + } } - else if ( isPartialDisinfectInProgress != TRUE ) + else { - // The temperature of the coldest spot is in range to start the disinfect timer - chemDisinfectTimer = getMSTimerCount(); - isPartialDisinfectInProgress = TRUE; + if ( ( DG_RESERVOIR_1 == r ) && ( isPartialR1DisinfectInProgress != TRUE ) ) + { + // The temperature of the coldest spot is in range to start the disinfect timer + chemDisinfectR1Timer = getMSTimerCount(); + isPartialR1DisinfectInProgress = TRUE; + } + if ( ( DG_RESERVOIR_2 == r ) && ( isPartialR2DisinfectInProgress != TRUE ) ) + { + // The temperature of the coldest spot is in range to start the disinfect timer + chemDisinfectR2Timer = getMSTimerCount(); + isPartialR2DisinfectInProgress = TRUE; + } } - - // If chemical disinfect temperature has been reached, check if this stage of chemical disinfect is done - if ( ( TRUE == isPartialDisinfectInProgress ) && ( TRUE == didTimeout( chemDisinfectTimer, CHEM_DISINFECT_TIME_MS ) ) ) - { - // Done with this stage of chemical disinfect. Reset the variables - status = CHEM_DISINFECT_COMPLETE; - isPartialDisinfectInProgress = FALSE; - } - - return status; } /*********************************************************************//** @@ -1371,11 +1506,10 @@ data.cancellationMode = (U32)cancellationMode; //If the mode is in the actual chemical disinfect states, publish the elapsed time, otherwise publish 0 to avoid confusion - if ( ( DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN == chemDisinfectState ) || - ( DG_CHEM_DISINFECT_STATE_R1_DISINFECTANT_FILL_R2_DRAIN == chemDisinfectState ) ) + if ( TRUE ) { - uiData.chemDisinfectTargetTime = CHEM_DISINFECT_TIME_MS; - uiData.chemDisinfectCountdownTime = calcTimeSince( chemDisinfectTimer ); + uiData.chemDisinfectTargetTime = TARGET_CHEM_DISINFECT_TIME_MS; + uiData.chemDisinfectCountdownTime = calcTimeSince( chemDisinfectR1Timer ); data.R1FillLevel = R1ChemDisinfectVol; data.R2FillLevel = R2ChemDisinfectVol; } @@ -1413,7 +1547,42 @@ static void monitorModeChemicalDisinfect( void ) { - BOOL hasConductivityFailed = TRUE; + // Reservoir leak detection. Perform check if no pending alarm. + if ( ( DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2 == chemDisinfectState ) || ( DG_CHEM_DISINFECT_STATE_DISINFECT_R2_TO_R1 == chemDisinfectState ) ) + { + BOOL isRsrvrVolumeOutOfRange = FALSE; + if ( DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2 == chemDisinfectState ) + { + isRsrvrVolumeOutOfRange = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ) - R1ChemDisinfectVol ) > RSRVRS_MAX_LEAK_VOL_CHANGE_ML; + } + else if ( DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2 == chemDisinfectState ) + { + isRsrvrVolumeOutOfRange = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ) - R2ChemDisinfectVol ) > RSRVRS_MAX_LEAK_VOL_CHANGE_ML; + } + if ( ( TRUE == isRsrvrVolumeOutOfRange ) ) + { + // If the leak is the first time after a while, set the flag and start the timer + if ( FALSE == isRsrvrLeaking ) + { + isRsrvrLeaking = TRUE; + rsrvrsVolMonitorTimer = getMSTimerCount(); + } + // If the volume is out of range and it has timed out, set the alarm + else if ( TRUE == didTimeout( rsrvrsVolMonitorTimer, RSRVRS_LEAK_VOL_TIMEOUT_MS ) ) + { + isRsrvrLeaking = FALSE; + alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_LEAK_TIMEOUT; + chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; + } + } + // Reservoirs are in range + else + { + isRsrvrLeaking = FALSE; + } + } + + BOOL hasConductivityFailed = TRUE; #ifndef _RELEASE_ if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_CAPS_MONITOR ) != SW_CONFIG_ENABLE_VALUE ) @@ -1432,7 +1601,6 @@ alarmDetectedPendingTrigger = ALARM_ID_DG_DIALYSATE_OR_CONC_CAP_NOT_IN_PROPER_POSITION; } } - // In all states, check inlet temperature, inlet pressure, and inlet conductivity. haveInletWaterChecksPassed= TRUE; @@ -1455,7 +1623,7 @@ inletWaterChecksFailTimer = getMSTimerCount(); } haveInletWaterChecksPassed= FALSE; // set flag for flush drain state - if ( TRUE == didTimeout( inletWaterChecksFailTimer, INLET_WATER_CHECK_FAILURE_TIMEOUT_MS ) ) + if ( TRUE == didTimeout( inletWaterChecksFailTimer, INLET_WATER_CHECK_FAILURE_TIMEOUT_MS ) ) { // alarm unless in the start, drain, or flush drain states switch( chemDisinfectState ) @@ -1466,20 +1634,22 @@ case DG_CHEM_DISINFECT_STATE_FLUSH_DRAIN: break; - case DG_CHEM_DISINFECT_STATE_FLUSH_CIRCULATION: case DG_CHEM_DISINFECT_STATE_PRIME_DISINFECTANT: case DG_CHEM_DISINFECT_STATE_DISINFECTANT_FLUSH: prevChemDisinfectState = chemDisinfectState; alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_TEMPERATURE_IN_LOW_RANGE; //ALARM_ID_NEW_WAT; chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_BASIC_PATH; - break; + break; + case DG_CHEM_DISINFECT_STATE_FILL_WITH_DISINFECTANT: - case DG_CHEM_DISINFECT_STATE_R2_DISINFECTANT_FILL_R1_DRAIN: - case DG_CHEM_DISINFECT_STATE_R1_DISINFECTANT_FILL_R2_DRAIN: + case DG_CHEM_DISINFECT_STATE_DISINFECT_R1_TO_R2: + case DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R1_FILL_R2_TO_R1: + case DG_CHEM_DISINFECT_STATE_DISINFECT_R2_TO_R1: + case DG_CHEM_DISINFECT_STATE_PARTIAL_DRAIN_R2_FILL_R1_TO_R2: prevChemDisinfectState = chemDisinfectState; alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_TEMPERATURE_IN_LOW_RANGE; //ALARM_ID_NEW_WAT; chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; - break; + break; } } } @@ -1489,6 +1659,34 @@ inletWaterChecksFailTimer = 0; } + if ( chemDisinfectState > DG_CHEM_DISINFECT_STATE_FLUSH_DRAIN ) + { + // Disinfect conditions check + F32 cd2Conductivity = getConductivityValue( (U32)CONDUCTIVITYSENSORS_CD2_SENSOR ); + F32 TPoTemp = getTemperatureValue( TEMPSENSORS_OUTLET_PRIMARY_HEATER ); + BOOL isCD2OutofRange = ( cd2Conductivity < MIN_DISINFECT_CONDUCTIVITY_US_PER_CM || cd2Conductivity > MAX_DISINFECT_CONDUCTIVITY_US_PER_CM ); + BOOL isTPoOutofRange = ( TPoTemp < MIN_DISINFECT_TPO_TEMPERATURE_C || TPoTemp > MAX_DISINFECT_TPO_TEMPERATURE_C ); + // set the tank volumes for logging + + if ( TRUE != isCD2OutofRange ) + { + minMaxConductivityWaitTimer = 0; + } + else if ( 0 == minMaxConductivityWaitTimer ) + { + minMaxConductivityWaitTimer = getMSTimerCount(); + } + else if ( TRUE == didTimeout( minMaxConductivityWaitTimer, MIN_MAX_CONDUCTIVITY_WAIT_TIME_MS ) ) + { + alarmDetectedPendingTrigger = ALARM_ID_INLET_WATER_CONDUCTIVITY_IN_HIGH_RANGE; //ALARM_ID_DG_NEW_CON; TODO + chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; + } + if ( ( TRUE == isTPoOutofRange ) ) + { + alarmDetectedPendingTrigger = ALARM_ID_DG_CHEM_DISINFECT_TARGET_TEMP_TIMEOUT; + chemDisinfectState = DG_CHEM_DISINFECT_STATE_CANCEL_WATER_PATH; + } + } } /*********************************************************************//**