Index: firmware/App/Modes/ModeHeatDisinfect.c =================================================================== diff -u -re86af65442a36724461317980814f0868bd8c995 -r8b8b9bbb288c06acec1fdf8a2e93248c3d775478 --- firmware/App/Modes/ModeHeatDisinfect.c (.../ModeHeatDisinfect.c) (revision e86af65442a36724461317980814f0868bd8c995) +++ firmware/App/Modes/ModeHeatDisinfect.c (.../ModeHeatDisinfect.c) (revision 8b8b9bbb288c06acec1fdf8a2e93248c3d775478) @@ -19,6 +19,7 @@ #include "DrainPump.h" #include "Heaters.h" #include "LoadCell.h" +#include "ModeFault.h" #include "ModeHeatDisinfect.h" #include "OperationModes.h" #include "Pressures.h" @@ -138,7 +139,7 @@ static U32 dataPublishCounter = 0; ///< Heat Disinfect data publish counter. static CANCELLATION_MODES_T cancellationMode = CANCELLATION_MODE_NONE; ///< Cancellation mode. static U32 rsrvrFillStableTimeCounter = 0; ///< Reservoirs fill stable time counter. -static ALARM_ID_T alarm; ///< Heat disinfect alarm to raise. +static ALARM_ID_T alarmDetectedPendingTrigger; ///< Heat disinfect alarm to raise. static BOOL isDrainPumpInMixDrainOn = FALSE; ///< Flag to show the drain pump is on during mix drain. // ********** private function prototypes ********** @@ -167,7 +168,6 @@ static DG_HEAT_DISINFECT_STATE_T handleHeatDisinfectCancelModeWaterPathState( void ); static DG_HEAT_DISINFECT_STATE_T handleHeatDisinfectCompleteState( void ); -static void resetActuators( void ); static void failHeatDisinfect( 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 ); @@ -215,7 +215,7 @@ *************************************************************************/ void transitionToHeatDisinfectMode( void ) { - resetActuators(); + deenergizeActuators(); initHeatDisinfectMode(); } @@ -363,7 +363,7 @@ if ( DG_MODE_HEAT == getCurrentOperationMode() ) { // Reset all the actuators - resetActuators(); + deenergizeActuators(); // Transition to mode standby requestNewOperationMode( DG_MODE_STAN ); @@ -397,7 +397,7 @@ overallHeatDisinfectTimer = getMSTimerCount(); // Set all the actuators to reset and de-energized state - resetActuators(); + deenergizeActuators(); // Reset the load cells lowest weight prior to starting the run resetReservoirsLowestWeight(); @@ -411,7 +411,7 @@ if ( ( ppiPressure < MIN_INLET_PRESSURE_PSI ) && ( fabs( TDiTemp - TRoTemp ) > MAX_START_STATE_TEMP_SENSORS_DIFF_C ) ) { prevHeatDisinfectState = state; - alarm = ALARM_ID_DG_HEAT_DISINFECT_INLET_PRES_AND_TEMP_SNSRS_OUT; + alarmDetectedPendingTrigger = ALARM_ID_DG_HEAT_DISINFECT_INLET_PRES_AND_TEMP_SNSRS_OUT; state = DG_HEAT_DISINFECT_STATE_CANCEL_BASIC_PATH; } else @@ -582,7 +582,7 @@ // Couldn't get a good water sample after a couple of trials and the disinfect cycle failed else { - alarm = ALARM_ID_DG_HEAT_DISINFECT_INLET_COND_AND_TEMP_OUT; + alarmDetectedPendingTrigger = ALARM_ID_DG_HEAT_DISINFECT_INLET_COND_AND_TEMP_OUT; prevHeatDisinfectState = state; state = DG_HEAT_DISINFECT_STATE_CANCEL_BASIC_PATH; } @@ -635,7 +635,7 @@ // State failed. Cancel heat disinfect mode else { - alarm = ALARM_ID_DG_TEMP_SENSORS_DIFF_OUT_OF_RANGE; + alarmDetectedPendingTrigger = ALARM_ID_DG_TEMP_SENSORS_DIFF_OUT_OF_RANGE; prevHeatDisinfectState = state; state = DG_HEAT_DISINFECT_STATE_CANCEL_BASIC_PATH; } @@ -689,6 +689,18 @@ if ( DG_RESERVOIR_BELOW_TARGET == rsrvr1Status ) { rsrvr1Status = getRsrvrFillStatus( DG_RESERVOIR_1, RSRVRS_FULL_VOL_ML, RSRVRS_FILL_UP_TIMEOUT_MS ); + + // Keep monitoring the status of reservoir 2 as the same time + rsrvr2Status = getRsrvrFillStatus( DG_RESERVOIR_2, RSRVRS_PARTIAL_FILL_VOL_ML, RSRVRS_500ML_FILL_UP_TIMEOUT_MS ); + // Reservoir 2 cannot be filled before reservoir 1 is filled and is overflowing to reservoir 2. If reservoir 2 has already + // reached to target volume, it means reservoir 1's load cell might be reading incorrect values. This situation might continue + // until reservoir 2 is filled up and the tubing might expand or leak. + if ( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) + { + prevHeatDisinfectState = state; + alarmDetectedPendingTrigger = ALARM_ID_DG_INVALID_LOAD_CELL_VALUE; + state = DG_HEAT_DISINFECT_STATE_CANCEL_WATER_PATH; + } } // Once R1 is full, keep monitoring for R2 level and timeout else if( DG_RESERVOIR_REACHED_TARGET == rsrvr1Status ) @@ -763,6 +775,21 @@ if ( DG_RESERVOIR_BELOW_TARGET == rsrvr2Status ) { rsrvr2Status = getRsrvrFillStatus( DG_RESERVOIR_2, RSRVRS_FULL_VOL_ML, RSRVRS_FILL_UP_TIMEOUT_MS ); + + U32 drainPumpRPM = getTargetDrainPumpRPM(); + // Keep monitoring the status of reservoir 1 as the same time + F32 volume = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + // Reservoir 1 cannot be filled before reservoir 2 is filled and is overflowing to reservoir 1. If reservoir 1 has already + // reached to target volume, it means reservoir 2's load cell might be reading incorrect values. This situation might continue + // until reservoir 1 is filled up and the tubing might expand or leak. + // Before checking whether reservoir 1 is filled pre-maturely, we have to make sure reservoir 1 is drained completely to make + // sure the extra volume that is read is not because of previous water that is being drained currently and it is above 500 mL + if ( ( volume > RSRVRS_PARTIAL_FILL_VOL_ML ) && ( 0 == drainPumpRPM ) ) + { + prevHeatDisinfectState = state; + alarmDetectedPendingTrigger = ALARM_ID_DG_INVALID_LOAD_CELL_VALUE; + state = DG_HEAT_DISINFECT_STATE_CANCEL_WATER_PATH; + } } // Once R2 is full, R1 must be partially full else if( DG_RESERVOIR_REACHED_TARGET == rsrvr2Status ) @@ -1472,7 +1499,7 @@ U32 targetRPM = 0; // Stop all the actuators first then decide who should run next - resetActuators(); + deenergizeActuators(); // Check inlet dialysate and redundant outlet temperature sensors F32 TDi = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); //TODO change to TDi @@ -1563,41 +1590,6 @@ /*********************************************************************//** * @brief - * The resetActuators function sets all the actuators to reset and - * de-energized state. - * @details Inputs: none - * @details Outputs: none - * @return none - *************************************************************************/ -static void resetActuators( void ) -{ - // UV reactors will not be used in the heat disinfection since their operating temperature - // range is below 85C and they might be damaged by the high temperature. - turnOffUVReactor( INLET_UV_REACTOR ); - turnOffUVReactor( OUTLET_UV_REACTOR ); - - // De-energize all the valves - setValveState( VPI, VALVE_STATE_CLOSED ); - setValveState( VBF, VALVE_STATE_CLOSED ); - setValveState( VSP, VALVE_STATE_CLOSED ); - setValveState( VPD, VALVE_STATE_OPEN_C_TO_NO ); - setValveState( VPO, VALVE_STATE_NOFILL_C_TO_NO ); - setValveState( VDR, VALVE_STATE_DRAIN_C_TO_NO ); - setValveState( VRC, VALVE_STATE_DRAIN_C_TO_NO ); - setValveState( VRO, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRD, VALVE_STATE_R2_C_TO_NO ); - setValveState( VRI, VALVE_STATE_R1_C_TO_NO ); - setValveState( VRF, VALVE_STATE_R2_C_TO_NO ); - - //TODO add the composition pumps - signalROPumpHardStop(); - signalDrainPumpHardStop(); - stopPrimaryHeater(); - stopTrimmerHeater(); -} - -/*********************************************************************//** - * @brief * The failHeatDisinfect function sets the alarm that failed the heat * disinfect mode. * @details Inputs: alarm, prevHeatDisinfectState @@ -1606,7 +1598,7 @@ *************************************************************************/ static void failHeatDisinfect( void ) { - SET_ALARM_WITH_1_U32_DATA( alarm, prevHeatDisinfectState ) + SET_ALARM_WITH_1_U32_DATA( alarmDetectedPendingTrigger, prevHeatDisinfectState ) } /*********************************************************************//** @@ -1653,7 +1645,8 @@ else if ( TRUE == didTimeout( stateTimer, timeout ) ) { // Failed to fill ontime. Update the previous heat disinfect state and transition to basic cancellation - alarm = ALARM_ID_DG_RESERVOIR_FILL_TIMEOUT; + prevHeatDisinfectState = heatDisinfectState; + alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_FILL_TIMEOUT; status = DG_RESERVOIR_NOT_REACHED_TARGET; } @@ -1690,7 +1683,8 @@ else if ( TRUE == didTimeout( stateTimer, timeout ) ) { // Failed to drain on time. Update the previous heat disinfect state and transition to basic cancellation - alarm = ALARM_ID_DG_RESERVOIR_DRAIN_TIMEOUT; + prevHeatDisinfectState = heatDisinfectState; + alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_DRAIN_TIMEOUT; status = DG_RESERVOIR_NOT_REACHED_TARGET; } @@ -1733,7 +1727,7 @@ else if ( TRUE == didTimeout( rsrvrsVolMonitorTimer, RSRVRS_TARGET_VOL_OUT_TIMEOUT_MS ) ) { areRsrvrsLeaking = FALSE; - alarm = ALARM_ID_DG_RESERVOIR_LEAK_TIMEOUT; + alarmDetectedPendingTrigger = ALARM_ID_DG_RESERVOIR_LEAK_TIMEOUT; status = HEAT_DISINFECT_RSRVRS_LEAK_TIMEOUT; } } @@ -1754,7 +1748,7 @@ if ( TRUE == didTimeout( stateTimer, HEAT_DISINFECT_START_TEMP_TIMOUT_MS ) ) { // Heating up to minimum temperature for heat disinfect failed - alarm = ALARM_ID_DG_HEAT_DISINFECT_TARGET_TEMP_TIMEOUT; + alarmDetectedPendingTrigger = ALARM_ID_DG_HEAT_DISINFECT_TARGET_TEMP_TIMEOUT; status = HEAT_DISINFECT_HEAT_UP_TIMEOUT; } }