/// <summary>
/// Read the flow sensor
/// </summary>
/// <remarks>
/// Engineering Notes: This step is to check if the reading of flow sensor is reasonable.
/// With the pump closed and all valves closed, the flow should be lower than a certain level.
/// Failure on this indicates the reading of flow rate is not correct.
/// </remarks>
/// <param name="details">The string to hold details.</param>
private void TestFlowSensor( DetailsBuilder details )
{
Pump.CloseAllValves( true );
Pump.Stop();
Thread.Sleep( 500 ); // Give the valves a chance to finish closing
// Read the flow rate.
ushort rawFlowCount = Pump.GetRawFlow();
ushort flowVolts = Pump.ConvertRawFlowToVolts( rawFlowCount );
ushort vacuumCounts = Pump.GetRawVacuum();
double vacuumInches = Pump.ConvertRawVacuumToInches( vacuumCounts );
int flowRate = Pump.CalculateFlowRate( flowVolts, vacuumCounts );
// Test flow reading
string flowString = BuildFlowString( rawFlowCount, flowRate, flowVolts );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_FLOW", rawFlowCount.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_FLOW_VOLTS", flowVolts.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_FLOW_RATE", flowRate.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_FLOW_VACUUM", vacuumCounts.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_FLOW_VACUUM_INCHES", vacuumInches.ToString() ) );
// Flow value should be in the range of 0 (0mV) to 186 (600 mV), inclusive.
// INS-3067, 6/26/2013, JMP - changer criteria from 43/128 to 0/186.
ReportDiagnostic( details, DiagnosticResources.FLOW, flowString, ( ( rawFlowCount < 0 ) || ( rawFlowCount > 186 ) ) );
}
/// <summary>
/// Check the vacuum sensor.
/// </summary>
/// <remarks>
/// Engineering Notes: This step is to check if the reading of vacuum sensor is reasonable.
/// After the initialization, the vacuum (negative pressure) should be close to zero.
/// Failure on this test indicates possible issues on vacuum sensor, or A2D converter,
/// or some tubing is blocked by something.
/// </remarks>
/// <param name="details">The string to hold details.</param>
private void TestVacuumSensor(DetailsBuilder details)
{
Pump.CloseAllValves( true );
Thread.Sleep(500); // Give the valves a chance to finish closing
Pump.OpenValve(1, false); // Open solenoid 1
Thread.Sleep(500); // Pause at least 500ms.
// Read the vacuum pressure
ushort vacuumCount = Pump.GetRawVacuum();
int vacuumVoltage = CountToVoltage(vacuumCount);
// Test vacuum readings
// Vacuum count value should be in the range of 62 (200mV) to 128 (410 mV), inclusive.
// The normal vacuum count is 77.
// Report results
string vacuumString = BuildCountAndUnitString(vacuumCount, vacuumVoltage, DiagnosticResources.MILLIVOLTS);
_gdpList.Add(new GeneralDiagnosticProperty("DIAGNOSTIC_VACUUM", vacuumCount.ToString()));
ReportDiagnostic(details, DiagnosticResources.VACUUM, vacuumString, ((vacuumCount < 62) || (vacuumCount > 128)));
}
/// <summary>
/// Check if pump works properly.
/// </summary>
/// <remarks>
/// Engineering Notes: This step is to check if pump works properly.
/// Run pump at two different control voltages, check the flow rate difference between these two cases.
/// </remarks>
/// <param name="details">The string to hold details.</param>
private void TestPump(DetailsBuilder details)
{
// Find a port without a gas cylinder connected.
// If all ports are connected, skip this test.
DockingStation ds = Controller.GetDockingStation();
// First, see if port one is unconnected or is providing FRESH AIR
// Note: we are trying ports in the order of 3-2-1 so as to avoid pulling air through the filter, if possible.
int testPort = -1;
GasEndPoint gasEndPoint = null;
for ( int solenoid = Configuration.DockingStation.NumGasPorts; solenoid >= 1 && testPort <= 0; solenoid-- )
{
gasEndPoint = ds.GasEndPoints.Find(m => m.Position == solenoid);
if (gasEndPoint == null || gasEndPoint.Cylinder.IsFreshAir)
testPort = solenoid;
}
if (testPort <= 0)
{
Log.Debug("TestPump: could not find open solenoid; this test will be skipped.");
return;
}
// Open solenoid valve determined to be unconnected
Pump.CloseAllValves( true );
Thread.Sleep(500); // Give the valves a chance to finish closing
Pump.OpenValve(testPort, false);
// Start pump with pump voltage of 80
Pump.Start(80);
// Wait 3 seconds
Thread.Sleep(3000);
// Read flow 1
ushort flowCount1 = Pump.GetRawFlow();
ushort flowVolts1 = Pump.ConvertRawFlowToVolts( flowCount1 );
ushort vacuumCounts1 = Pump.GetRawVacuum();
int flowRate1 = Pump.CalculateFlowRate( flowVolts1, vacuumCounts1 );
string flowString1 = BuildFlowString(flowCount1, flowRate1, flowVolts1);
// Increase pump voltage to 240
Pump.SetNewPumpVoltage(240);
// Wait 3 seconds
Thread.Sleep(3000);
// Check Pump Error status
int pumpErrorState = Pump.GetPumpErrorState();
// Fail if state is 1
_gdpList.Add(new GeneralDiagnosticProperty("DIAGNOSTIC_PUMP_ERROR_STATUS", pumpErrorState.ToString()));
ReportDiagnostic(details, DiagnosticResources.PUMP_ERROR_STATUS, pumpErrorState.ToString(), (pumpErrorState == 1));
// Read flow 2
ushort flowCount2 = Pump.GetRawFlow();
ushort flowVolts2 = Pump.ConvertRawFlowToVolts( flowCount2 );
ushort vacuumCounts2 = Pump.GetRawVacuum();
int flowRate2 = Pump.CalculateFlowRate( flowVolts2, vacuumCounts2 );
string flowString2 = BuildFlowString(flowCount2, flowRate2, flowVolts2);
// Fail if f2 - f1 < 100 OR f2 - f1 > 450
_gdpList.Add(new GeneralDiagnosticProperty("DIAGNOSTIC_PUMP_F1", flowCount1.ToString()));
_gdpList.Add(new GeneralDiagnosticProperty("DIAGNOSTIC_PUMP_F2", flowCount2.ToString()));
ReportDiagnostic(details, DiagnosticResources.PUMP, flowString1, flowString2, ( flowCount2 - flowCount1 < 100 ) || ( flowCount2 - flowCount1 > 450 ) );
// Stop the pump and close the port used for this test
Pump.CloseValve(testPort);
Thread.Sleep(500);
}
/// <summary>
/// Check for leaks.
/// </summary>
/// <remarks>
/// This is to check if the components in the closed gas delivery system work properly including
/// tubing, 3 solenoid valves, manifolds, check valves, vacuum sensor, flow sensor and pump.
/// The pump failure to operate could also cause this test to fail.
/// If a leakage is found, flow check will be meaningless.
/// </remarks>
/// <param name="details">The details to fill in.</param>
private void TestForLeak(DetailsBuilder details)
{
Pump.CloseAllValves( true );
Thread.Sleep( 500 ); // Give the valves a chance to finish closing
int pumpVoltage = 80; // initial voltage for leak test
bool leakCheck1Failed = true;
ushort vac1Raw;
double vac1Inches;
string vac1String;
const int maxPumpVoltage = 120;
const ushort rawInches40 = 360;
const int inches40 = 40;
const int pumpVoltageIncrement = 10;
//const ushort rawInches55 = 466;
//const int inches55 = 55;
Pump.Start( pumpVoltage ); // start pump with initial voltage
//Suresh 19-JUNE-2012 INS-3067
do
{
// After changing pump voltage, always wait 1 second before reading
// vacuum sensor to give the sensor time to adjust to the change.
Thread.Sleep( 1000 );
// Take vacuum reading (vac1)
vac1Raw = Pump.GetRawVacuum();
vac1Inches = Pump.ConvertRawVacuumToInches( vac1Raw );
vac1String = BuildCountAndUnitString( vac1Raw, vac1Inches, 1, "\"" );
Log.Debug( string.Format( "Vacuum: {0}, Pump voltage: {1}", vac1String, pumpVoltage ) );
// Check vacuum reading against target pressure. Pass after we reach or exceed target.
if ( vac1Raw >= rawInches40 )
{
// Pass if vac1 >= 40 inches of water
leakCheck1Failed = false;
Log.Debug( string.Format( "Leak Check 1 PASSED. (vacuum exeeds {0}\")", inches40 ) );
break;
}
if ( pumpVoltage + pumpVoltageIncrement >= maxPumpVoltage )// if the pump voltage crests above 120
{
Log.Debug( string.Format( "Leak Check 1 FAILED (pump voltage exeeds {0} but vacuum under {1}\")", maxPumpVoltage, inches40 ) );
break;
}
pumpVoltage += pumpVoltageIncrement;
Pump.SetNewPumpVoltage( (byte)pumpVoltage ); // set the new voltage to pump
} while ( true );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_LEAK_CHECK_VAC1", vac1Raw.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_LEAK_CHECK_VAC1_INCHES", vac1Inches.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_LEAK_CHECK_VAC1_PASSED", (!leakCheck1Failed).ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_LEAK_CHECK_VAC1_PUMP_VOLTAGE", pumpVoltage.ToString() ) );
ReportDiagnostic( details, DiagnosticResources.LEAK_CHECK_1, vac1String, leakCheck1Failed );
int vacuumError = Pump.GetVacuumErrorState(); // Check status of Vacuum Error by calling GetVacuumErrState()
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_LEAK_CHECK_VAC_ERROR", vacuumError.ToString() ) );
//Pass no matter what the state is [Vacuum Error Status]. The purpose is to keep the data structure of the report same as previous version.
ReportDiagnostic( details, DiagnosticResources.VACUUM_ERROR_STATUS, vacuumError.ToString(), false );
// Stop pump
Pump.Stop();
//Open Solenoid #1 for 1 second to relieve the pressure
Pump.OpenValve( 1, false );
Thread.Sleep( 1000 ); // 1 sec
Pump.CloseValve( 1 );
}