Index: firmware/App/Controllers/DialInFlow.c
===================================================================
diff -u -rdecd87eaf64e68ee4690c046f48ae47977928729 -r758497628fa5839a2b6661a9d7c32fd3b11db2bd
--- firmware/App/Controllers/DialInFlow.c	(.../DialInFlow.c)	(revision decd87eaf64e68ee4690c046f48ae47977928729)
+++ firmware/App/Controllers/DialInFlow.c	(.../DialInFlow.c)	(revision 758497628fa5839a2b6661a9d7c32fd3b11db2bd)
@@ -8,7 +8,7 @@
 * @file    DialInFlow.c
 *
 * @author  (last)      Sean Nash
-* @date    (last)      16-Nov-2022
+* @date    (last)      21-Dec-2022
 *
 * @author  (original)  Sean
 * @date    (original)  16-Dec-2019
@@ -69,8 +69,9 @@
 #define DIP_MIN_FLOW_RATE                   -1320.0F         ///< Minimum measured BP flow rate allowed.
 #define DIP_MAX_FLOW_VS_SPEED_DIFF_RPM       350.0F          ///< Maximum difference between measured motor speed and speed implied by measured flow.
 #define DIP_MAX_MOTOR_SPEED_WHILE_OFF_RPM    100.0F          ///< Maximum motor speed (RPM) while motor is commanded off.
-#define DIP_MAX_ROTOR_VS_MOTOR_DIFF_RPM      5.0F            ///< Maximum difference in speed between motor and rotor (in rotor RPM).
+#define DIP_MAX_ROTOR_VS_MOTOR_DIFF_RPM      2.0F            ///< Maximum difference in speed between motor and rotor (in rotor RPM).
 #define DIP_MAX_MOTOR_SPEED_ERROR_RPM        300.0F          ///< Maximum difference in speed between measured and commanded RPM.
+#define DIP_MAX_MOTOR_SPEED_VS_TRGT_DIFF_PCT 0.15F           ///< Maximum motor speed vs target difference in percent.
 
 /// Persist time (task intervals) for flow vs. motor speed error condition.
 static const U32 DIP_FLOW_VS_SPEED_PERSIST     = ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL);
@@ -238,6 +239,7 @@
 static void checkDialInPumpMCCurrent( void );
 static void checkDialInPumpFlowRate( void );
 static F32  calcDialInFlow( void );
+static F32  dialysateInPumpRPMFromTargetFlowRate( F32 QdTarget );
 static F32  dialysateInPumpPWMFromTargetFlowRate( F32 QdTarget );
 static BOOL testSetDialInPumpWithPWM( F32 pwm );
 
@@ -407,7 +409,7 @@
     U32 deltaTime = calcTimeBetween( dipRotorRevStartTime, rotTime );
 
     // Calculate rotor speed (in RPM)
-    dialInPumpRotorSpeedRPM.data = ( 1.0 / (F32)deltaTime ) * (F32)MS_PER_SECOND * (F32)SEC_PER_MIN;
+    dialInPumpRotorSpeedRPM.data = ( 1.0F / (F32)deltaTime ) * (F32)MS_PER_SECOND * (F32)SEC_PER_MIN;
     dipRotorRevStartTime = rotTime;
     dialysateInPumpRotorCounter.data++;
 
@@ -826,23 +828,39 @@
 
 /*********************************************************************//**
  * @brief
- * The dialysateInPumpPWMFromTargetFlowRate function calculates a motor PWM setting
+ * The dialysateInPumpRPMFromTargetFlowRate function calculates a motor RPM
  * from the estimator based on target flow rate and tubing wear.
  * @details Inputs: dialInPumpRotorCounter
  * @details Outputs: none
  * @param QdTarget target dialysate flow rate
- * @return Motor PWM value for given target flow rate
+ * @return Motor RPM value for given target flow rate
  *************************************************************************/
-static F32 dialysateInPumpPWMFromTargetFlowRate( F32 QdTarget )
+static F32 dialysateInPumpRPMFromTargetFlowRate( F32 QdTarget )
 {
     U32 r              = getDialInPumpRotorCount();
     U32 rotCount       = CAP( r, DIAL_IN_MAX_ROTOR_COUNT_FOR_WEAR );
     F32 wearFactor     = DIAL_IN_FLOW_WEAR_A_TERM * (F32)rotCount + DIAL_IN_FLOW_WEAR_B_TERM;
     F32 Pest           = DIAL_IN_FLOW_PEST_A_TERM * ( QdTarget * QdTarget ) + DIAL_IN_FLOW_PEST_B_TERM * QdTarget + DIAL_IN_FLOW_PEST_C_TERM;
     F32 alphaTerm      = wearFactor * Pest + DIAL_IN_FLOW_A_ZERO;
     F32 rpmTgt         = QdTarget * DIAL_IN_GEAR_RATIO / ( 2 * DIAL_IN_STROKE_VOLUME * alphaTerm );
-    F32 pwmDC          = DIP_MOTOR_SPEED_RPM_TO_PWM( rpmTgt );
 
+    return rpmTgt;
+}
+
+/*********************************************************************//**
+ * @brief
+ * The dialysateInPumpPWMFromTargetFlowRate function calculates a motor PWM
+ * setting from a given target flow rate.
+ * @details Inputs: none
+ * @details Outputs: none
+ * @param QdTarget target dialysate flow rate
+ * @return Motor PWM value for given RPM
+ *************************************************************************/
+static F32 dialysateInPumpPWMFromTargetFlowRate( F32 QdTarget )
+{
+    F32 rpmTgt = dialysateInPumpRPMFromTargetFlowRate( QdTarget );
+    F32 pwmDC  = DIP_MOTOR_SPEED_RPM_TO_PWM( rpmTgt );
+
     return pwmDC;
 }
 
@@ -1297,7 +1315,8 @@
         F32 deltaMCMotorSpeed = fabs( measMCMotorSpeed - cmdMotorSpeed );
         F32 measRotorSpeed = fabs( getMeasuredDialInPumpRotorSpeed() );
         F32 measMotorSpeedInRotorRPM = measMotorSpeed / DIP_GEAR_RATIO;
-        F32 deltaRotorSpeed = fabs( measRotorSpeed - measMotorSpeedInRotorRPM );
+        F32 deltaRotorSpeed = fabs( measRotorSpeed - measMotorSpeedInRotorRPM );
+        F32 measMotorSpeedDeltaPct = fabs( deltaRotorSpeed / measMotorSpeedInRotorRPM );
 
         // Check measured motor speed vs. commanded motor speed while controlling to target
         if ( ( deltaMotorSpeed > DIP_MAX_MOTOR_SPEED_ERROR_RPM ) || ( deltaMCMotorSpeed > DIP_MAX_MOTOR_SPEED_ERROR_RPM ) )
@@ -1318,7 +1337,7 @@
         }
 
         // Check measured rotor speed vs. measured motor speed while controlling to target
-        if ( deltaRotorSpeed > DIP_MAX_ROTOR_VS_MOTOR_DIFF_RPM )
+        if ( ( deltaRotorSpeed > DIP_MAX_ROTOR_VS_MOTOR_DIFF_RPM ) && ( measMotorSpeedDeltaPct > DIP_MAX_MOTOR_SPEED_VS_TRGT_DIFF_PCT ) )
         {
             if ( ++errorDialInRotorSpeedPersistTimerCtr >= ( getPumpRotorErrorPersistTime( measMotorSpeed, DIP_GEAR_RATIO ) / TASK_PRIORITY_INTERVAL ) )
             {
@@ -1371,7 +1390,7 @@
     {
         F32 flow = (F32)targetDialInFlowRate;
         F32 speed = getMeasuredDialInPumpSpeed();
-        F32 impliedSpeed = ( flow * DIP_ML_PER_MIN_TO_PUMP_RPM_FACTOR * DIP_GEAR_RATIO );
+        F32 impliedSpeed = dialysateInPumpRPMFromTargetFlowRate( flow );
         F32 delta = fabs( speed - impliedSpeed );
 
         if ( delta > DIP_MAX_FLOW_VS_SPEED_DIFF_RPM )