/// <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>
/// Test the specified solenoid
/// </summary>
/// <param name="details">The string to hold details.</param>
private void TestFlow( DetailsBuilder details, int solenoid )
{
// Validate the solenoid number
if ( solenoid < 1 || solenoid > Configuration.DockingStation.NumGasPorts )
{
Log.Debug( "TestFlow: Invalid solenoid value = " + solenoid.ToString() );
return;
}
Log.Debug( "TestFlow: port=" + solenoid.ToString() );
// Determine whether a cylinder is attached to this port.
// If there is one attached, skip this test.
DockingStation ds = Controller.GetDockingStation();
GasEndPoint gasEndPoint = ds.GasEndPoints.Find(m => m.Position == solenoid);
if (gasEndPoint != null && gasEndPoint.Cylinder.IsFreshAir == false)
{
Log.Debug( "TestFlow: Cylinder attached to port " + solenoid.ToString() + "; SKIPPING THIS TEST." );
return;
}
Pump.DoCheckFlow = true;
// Ensure that only the specified solenoid is open.
Pump.CloseAllValves( true );
Thread.Sleep(500); // Give the valves a chance to finish closing
Pump.OpenValve(solenoid, false); // Open the specified solenoid
Thread.Sleep(500); // Pause at least 500ms.
Pump.SetDesiredFlow( Pump.StandardFlowRate);
Pump.Start( Pump.StandardStartVoltage ); // Turn on the pump.
Thread.Sleep( 3000 ); // Wait for it to stabilize the flow before letting CheckFlow take its first reading.
// CheckFlow could enter an infinite loop if it's unable to
// establish the desired flow rate and we don't tell it to time out.
// We therefore give it a time out of a minute which should be more than sufficient.
ushort rawFlowCounts;
ushort rawVacuumCounts;
Pump.FlowStatus flowStatus = Pump.CheckFlow( new TimeSpan( 0, 1, 0 ), out rawFlowCounts, out rawVacuumCounts );
byte pumpVoltage = Pump.GetPumpVoltage(); // obtain and hold onto final voltage of the pump, to report it to inet.
// Get the flow rate.
ushort flowVolts = Pump.ConvertRawFlowToVolts( rawFlowCounts );
int flowRate = Pump.CalculateFlowRate( flowVolts, rawVacuumCounts ); // Convert that value to mL/min
// Report the results.
string flowString = BuildFlowString(flowRate, flowVolts);
// We create a property for every value used to compute the flow rate, and also the flow rate itself.
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_VACUUM", rawVacuumCounts.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_VACUUM_INCHES", Pump.ConvertRawVacuumToInches( rawVacuumCounts ).ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid, rawFlowCounts.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_VOLTS", flowVolts.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_RATE", flowRate.ToString() ) );
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_PUMP_VOLTS", pumpVoltage.ToString() ) );
// The flow is considered a failure if it's not equal to the StandardFlowRate plus/minus the standardtolerance
bool flowFailed = flowRate < ( Pump.StandardFlowRate - Pump.FLOWRATE_TOLERANCE ) || flowRate > ( Pump.StandardFlowRate + Pump.FLOWRATE_TOLERANCE );
// TODO - we should rename the translation string so that it's prefixed with "CHECK_FLOW" instead of "SOLENOID_FLOW"
ReportDiagnostic( details, details.GetText( "SOLENOID_FLOW_" + solenoid ), flowString, flowFailed );
// Check Pump Error Status -- FAIL IF STATE IS 1
int pumpErrorState = Pump.GetPumpErrorState();
// Report the results.
_gdpList.Add( new GeneralDiagnosticProperty( "DIAGNOSTIC_CHECK_FLOW_" + solenoid + "_PUMP_ERROR", pumpErrorState.ToString() ) );
// TODO - we should rename the translation string so that it's prefixed with "CHECK_FLOW" instead of "SOLENOID_FLOW"
ReportDiagnostic(details, details.GetText("SOLENOID_PUMP_ERROR_" + solenoid), pumpErrorState.ToString(), (pumpErrorState == 1));
// Stop the pump and close the solenoid
Pump.CloseValve(solenoid);
Pump.DoCheckFlow = false;
}
/// <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 );
}