private void checkHeaterTemps(
List<ZoneState> zones, double heaterOutputLimit, SystemState state, List<Integer> nodes) {
for (ZoneState zone : zones) {
Unit unit = zone.getTopUnit();
double setpoint = unit.getSetpoint();
double lowerLimit = setpoint - unit.getLoWarn();
double upperLimit = setpoint + unit.getHiWarn();
double upperAlarm = setpoint + unit.getHiAlarm();
double lowerAlarm = setpoint - unit.getLoAlarm();
// test action with heaterFlag
switch (zone.getTopHeaterFlag()) {
case OFF:
zone.setTopColor(GRAY);
yellowFlag = true;
break;
case SET:
zone.setTopColor(WHITE);
yellowFlag = true;
break;
case POWER:
zone.setTopColor(WHITE);
yellowFlag = true;
if (zone.getTopPercentOP() < heaterOutputLimit) zone.setTopHeaterFlag(HeaterFlag.HEATING);
break;
case HEATING:
zone.setTopColor(WHITE);
yellowFlag = true;
if (zone.getTopTemp() > lowerLimit && zone.getTopTemp() < upperLimit) {
zone.setTopHeaterFlag(HeaterFlag.ACTIVE);
}
break;
case ACTIVE:
if (zone.getTopTemp() < lowerAlarm || zone.getTopTemp() > upperAlarm) {
redZone = true;
if (!zone.getTopColor().equals(RED)) {
zone.setTopColor(RED);
if (state.equals(SystemState.SYSTEM_STATE_RUN_STARTUP)
|| state.equals(SystemState.SYSTEM_STATE_RUN)) {
OvenManager.getInstance().startCooldown(LightTowerState.ALARM_COOLDOWN.getTower());
log.error(
"Zone: "
+ zone.getId()
+ " top heater out of alarm band: "
+ zone.getTopTemp());
}
}
} else if (zone.getTopTemp() < lowerLimit || zone.getTopTemp() > upperLimit) {
yellowFlag = true;
if (zone.getTopColor().equals(GREEN)) {
zone.setTopColor(YELLOW);
if (state.equals(SystemState.SYSTEM_STATE_RUN)) {
CanComm.sendSystemState(
SystemState.SYSTEM_STATE_RUN_PAUSE, Can.OpId.OPER_SET.ordinal(), nodes);
CanComm.setLightTower(Equip.LightTowerState.WARNING.getTower());
log.error(
"Zone: "
+ zone.getId()
+ " top heater out of warning band: "
+ zone.getTopTemp());
}
}
} else {
zone.setTopColor(GREEN);
}
break;
default:
break;
}
if (zone.isHeatZone()) {
unit = zone.getBottomUnit();
setpoint = unit.getSetpoint();
upperLimit = setpoint + unit.getHiWarn();
lowerLimit = setpoint - unit.getLoWarn();
upperAlarm = setpoint + unit.getHiAlarm();
lowerAlarm = setpoint - unit.getLoAlarm();
// test action with heaterFlag
switch (zone.getBottomHeaterFlag()) {
case OFF:
zone.setBottomColor(GRAY);
yellowFlag = true;
break;
case SET:
zone.setBottomColor(WHITE);
yellowFlag = true;
break;
case POWER:
zone.setBottomColor(WHITE);
yellowFlag = true;
if (zone.getBottomPercentOP() < heaterOutputLimit)
zone.setBottomHeaterFlag(HeaterFlag.HEATING);
break;
case HEATING:
zone.setBottomColor(WHITE);
yellowFlag = true;
if (zone.getBottomTemp() > lowerLimit && zone.getBottomTemp() < upperLimit) {
zone.setBottomHeaterFlag(HeaterFlag.ACTIVE);
}
break;
case ACTIVE:
if (zone.getBottomTemp() < lowerAlarm || zone.getBottomTemp() > upperAlarm) {
redZone = true;
if (!zone.getBottomColor().equals(RED)) {
zone.setBottomColor(RED);
if (state.equals(SystemState.SYSTEM_STATE_RUN_STARTUP)
|| state.equals(SystemState.SYSTEM_STATE_RUN)) {
OvenManager.getInstance()
.startCooldown(LightTowerState.ALARM_COOLDOWN.getTower());
log.error(
"Zone: "
+ zone.getId()
+ " bottom heater out of alarm band: "
+ zone.getBottomTemp());
}
}
} else if (zone.getBottomTemp() < lowerLimit || zone.getBottomTemp() > upperLimit) {
yellowFlag = true;
if (zone.getBottomColor().equals(GREEN)) {
zone.setBottomColor(YELLOW);
if (state.equals(SystemState.SYSTEM_STATE_RUN)) {
CanComm.sendSystemState(
SystemState.SYSTEM_STATE_RUN_PAUSE, Can.OpId.OPER_SET.ordinal(), nodes);
CanComm.setLightTower(Equip.LightTowerState.WARNING.getTower());
log.error(
"Zone: "
+ zone.getId()
+ " bottom heater out of warning band: "
+ zone.getBottomTemp());
}
}
} else {
zone.setBottomColor(GREEN);
}
break;
default:
break;
}
}
}
}
private void startCooldown(
IoModule ioModule,
ParamManager paramManager,
List<ZoneState> zones,
List<BeltState> beltStates,
List<RailState> railStates,
double cooldownTemp,
Config config,
List<Integer> nodes) {
if (ioModule.getOutput(Can.OutputIO.IOM_HEAT_CONTACTOR) == 1) {
// Turn off heat contactor and disable alarms
paramManager.setAlarms(ALARM_DISABLED);
CanComm.sendCmdSetpoint(
Can.BoardType.BOARD_TYPE_IOM.getStartNum(),
0,
Can.CmdSetpoint.SETPOINT_HEAT_CONTACTOR,
0);
log.info("Delayed Cooldown -- Heat Contactor Off...");
}
// gray out heat zones on GUI
for (ZoneState zone : zones) {
zone.setTopHeaterFlag(Equip.HeaterFlag.OFF);
paramManager.zeroHeaterSetpoint(true, zone);
zone.setTopColor(GRAY);
if (zone.isHeatZone()) {
zone.setBottomHeaterFlag(Equip.HeaterFlag.OFF);
paramManager.zeroHeaterSetpoint(false, zone);
zone.setBottomColor(GRAY);
}
}
// gray out belts on GUI
for (BeltState beltState : beltStates) {
beltState.setColor(GRAY);
}
// gray out rails on GUI
for (RailState railState : railStates) {
railState.setColor(GRAY);
}
// test if zone heaters are above cooldown temperature
boolean belowTemp = true;
for (ZoneState zone : zones) {
if (zone.getTopTemp() > cooldownTemp) {
belowTemp = false;
break;
}
if (zone.getBottomTemp() > cooldownTemp && zone.isHeatZone()) {
belowTemp = false;
break;
}
}
if (belowTemp) {
// complete cooldown after all zones less than cooldown temp
if (OvenState.getInstance().getLightTower() == LightTowerState.COOLDOWN.getTower()) {
CanComm.setLightTower(Equip.LightTowerState.TOWER_OFF.getTower());
}
// set all belts to speed of zero
for (int i = 0; i < config.getNumBelts(); i++) {
BeltState beltState = beltStates.get(i);
paramManager.zeroBeltSetpoint(beltState);
}
// turn off fan contactor
CanComm.sendCmdSetpoint(
Can.BoardType.BOARD_TYPE_IOM.getStartNum(), 0, Can.CmdSetpoint.SETPOINT_FAN_CONTACTOR, 0);
CanComm.sendSystemState(
SystemState.SYSTEM_STATE_OVEN_OFF, Can.OpId.OPER_SET.ordinal(), nodes);
log.info("Cooldown complete - Fan Contactor Off...");
}
}