mppt.ino

//ARDUINO MPPT SOLAR CHARGE CONTROLLER (Version-3)
//Author: Debasish Dutta/deba168
//          www.opengreenenergy.in
// This code was wrote for an arduino Nano based Solar MPPT charge controller.
// This code is a modified version of sample code from www.timnolan.com
// updated 06/07/2015
// Adapted for Arduino Pro mini on my project on 11/2016
#include "LCD.h" 
#include "TimerOne.h"
#include "LiquidCrystal_I2C.h"
#include "Wire.h" 
 
// A0 - Voltage divider (solar)
// A1 - ACS 712 Out
// A2 - Voltage divider (battery)
// A4 - LCD SDA
// A5 - LCD SCL
// D5 - LCD back control button
// D6 - Load Control
// D8 - 2104 MOSFET driver SD
// D9 - 2104 MOSFET driver IN
// D11- Green LED
// D12- Blue LED
// D13- Red LED
 
#define LOAD_ALGORITHM 0
#define SOL_VOLTS_CHAN 0
#define BAT_VOLTS_CHAN 1
#define SOL_AMPS_CHAN 2
#define AVG_NUM 8
#define SOL_VOLTS_SCALE 0.024900275
#define BAT_VOLTS_SCALE 0.024926075
#define SOL_AMPS_SCALE  0.024506081
#define PWM_PIN 9
#define PWM_ENABLE_PIN 8
#define PWM_FULL 1023
#define PWM_MAX 100
#define PWM_MIN 60
#define PWM_START 90
#define PWM_INC 1
#define TRUE 1
#define FALSE 0
#define ON TRUE
#define OFF FALSE
#define TURN_ON_MOSFETS digitalWrite(PWM_ENABLE_PIN, HIGH)
#define TURN_OFF_MOSFETS digitalWrite(PWM_ENABLE_PIN, LOW)
#define ONE_SECOND 50000
#define LOW_SOL_WATTS 5.00
#define MIN_SOL_WATTS 1.00
#define MIN_BAT_VOLTS 11.00
#define MAX_BAT_VOLTS 14.10
#define BATT_FLOAT 13.60
#define HIGH_BAT_VOLTS 13.00
#define LVD 11.5
#define OFF_NUM 9
#define LED_GREEN 11
#define LED_BLUE 12
#define LED_RED 13
#define LOAD_PIN 6
#define BACK_LIGHT_PIN 5      
 
byte battery_icons[6][8]=
{{
  0b01110,
  0b11011,
  0b10001,
  0b10001,
  0b10001,
  0b10001,
  0b11111,
  0b00000,
},
{
  0b01110,
  0b11011,
  0b10001,
  0b10001,
  0b10001,
  0b11111,
  0b11111,
  0b00000,
},
{
  0b01110,
  0b11011,
  0b10001,
  0b10001,
  0b11111,
  0b11111,
  0b11111,
  0b00000,
},
{
  0b01110,
  0b11011,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b00000,
},
{
  0b01110,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b00000,
},
{
  0b01110,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b11111,
  0b00000,
}};
#define SOLAR_ICON 6
byte solar_icon[8] =
{
  0b11111,
  0b10101,
  0b11111,
  0b10101,
  0b11111,
  0b10101,
  0b11111,
  0b00000
};
#define PWM_ICON 7
byte _PWM_icon[8]=
{
  0b11101,
  0b10101,
  0b10101,
  0b10101,
  0b10101,
  0b10101,
  0b10111,
  0b00000,
};
byte backslash_char[8]=
{
  0b10000,
  0b10000,
  0b01000,
  0b01000,
  0b00100,
  0b00100,
  0b00010,
  0b00000,
};
float sol_amps;
float sol_volts;
float bat_volts;
float sol_watts;
float old_sol_watts = 0;
unsigned int seconds = 0;
unsigned int prev_seconds = 0;
unsigned int interrupt_counter = 0;
unsigned long time = 0;
int delta = PWM_INC;
int pwm = 0;
int back_light_pin_State = 0;
boolean load_status = false;
enum charger_mode {off, on, bulk, bat_float} charger_state;
LiquidCrystal_I2C lcd(0x27, 2, 1, 0, 4, 5, 6, 7, 3, POSITIVE);  
 
void setup()
{
  pinMode(PWM_ENABLE_PIN, OUTPUT);
  TURN_OFF_MOSFETS;
  charger_state = off;
  lcd.begin(20,4);
  lcd.backlight();
  for (int batchar = 0; batchar < 6; ++batchar)
  {
    lcd.createChar(batchar, battery_icons[batchar]);
  }
  lcd.createChar(PWM_ICON,_PWM_icon);
  lcd.createChar(SOLAR_ICON,solar_icon);
  lcd.createChar('\\', backslash_char);
  pinMode(LED_RED, OUTPUT);
  pinMode(LED_GREEN, OUTPUT);
  pinMode(LED_BLUE, OUTPUT);
  Timer1.initialize(20);
  Timer1.pwm(PWM_PIN, 0);
  Timer1.attachInterrupt(callback);
  Serial.begin(9600);
  pwm = PWM_START;
  pinMode(BACK_LIGHT_PIN, INPUT);
  pinMode(LOAD_PIN,OUTPUT);
  digitalWrite(LOAD_PIN,LOW);
  digitalWrite(BACK_LIGHT_PIN,LOW);
  lcd.setCursor(0, 0);
  lcd.print("SOL");
  lcd.setCursor(4, 0);
  lcd.write(SOLAR_ICON);
  lcd.setCursor(8, 0);
  lcd.print("BAT");
}
 
void loop()
{
  read_data();
  run_charger();
 // print_data();
  load_control();
  led_output();
  lcd_display();
}
 
int read_adc(int channel)
{
  int sum = 0;
  int temp;
  int i;
 
  for (i=0; i<AVG_NUM; i++) { temp = analogRead(channel); sum += temp; delayMicroseconds(50); } return(sum / AVG_NUM); } void read_data(void) { sol_amps = (read_adc(SOL_AMPS_CHAN) * SOL_AMPS_SCALE -13.51); sol_volts = read_adc(SOL_VOLTS_CHAN) * SOL_VOLTS_SCALE; bat_volts = read_adc(BAT_VOLTS_CHAN) * BAT_VOLTS_SCALE; sol_watts = sol_amps * sol_volts ; } void callback() { if (interrupt_counter++ > ONE_SECOND)
  {
    interrupt_counter = 0;
    seconds++;
  }
}
 
void set_pwm_duty(void)
{
 
  if (pwm > PWM_MAX)
  {
    pwm = PWM_MAX;
  }
  else if (pwm < PWM_MIN)
  {
    pwm = PWM_MIN;
  }
  if (pwm < PWM_MAX)
  {
    Timer1.pwm(PWM_PIN,(PWM_FULL * (long)pwm / 100), 20);
  }
  else if (pwm == PWM_MAX)
  {
    Timer1.pwm(PWM_PIN,(PWM_FULL - 1), 20);
}
}   
 
void run_charger(void)
{
  static int off_count = OFF_NUM;
  switch (charger_state)
  {
    case on:
      if (sol_watts < MIN_SOL_WATTS) { charger_state = off; off_count = OFF_NUM; TURN_OFF_MOSFETS; } else if (bat_volts > (BATT_FLOAT - 0.1))
      {
        charger_state = bat_float;
      }
      else if (sol_watts < LOW_SOL_WATTS)
      {
        pwm = PWM_MAX;
        set_pwm_duty();
      }
      else
      {
        pwm = ((bat_volts * 10) / (sol_volts / 10)) + 5;
        charger_state = bulk;
      }
      break;
 
    case bulk:
      if (sol_watts < MIN_SOL_WATTS) { charger_state = off; off_count = OFF_NUM; TURN_OFF_MOSFETS; } else if (bat_volts > BATT_FLOAT)
      {
        charger_state = bat_float;
      }
      else if (sol_watts < LOW_SOL_WATTS) { charger_state = on; TURN_ON_MOSFETS; } else { if (old_sol_watts >= sol_watts)
        {
          delta = -delta;
        }
        pwm += delta;
        old_sol_watts = sol_watts;
        set_pwm_duty();
      }
      break;
 
    case bat_float:
      if (sol_watts < MIN_SOL_WATTS) { charger_state = off; off_count = OFF_NUM; TURN_OFF_MOSFETS; set_pwm_duty(); } else if (bat_volts > BATT_FLOAT)
      {
        TURN_OFF_MOSFETS;
        pwm = PWM_MAX;
        set_pwm_duty();
      }
      else if (bat_volts < BATT_FLOAT)
      {
        pwm = PWM_MAX;
        set_pwm_duty();
        TURN_ON_MOSFETS;
        if (bat_volts < (BATT_FLOAT - 0.1)) { charger_state = bulk; } } break; case off: TURN_OFF_MOSFETS; if (off_count > 0)
      {
        off_count--;
      }
      else if ((bat_volts > BATT_FLOAT) && (sol_volts > bat_volts))
      {
        charger_state = bat_float;
        TURN_ON_MOSFETS;
      }
      else if ((bat_volts > MIN_BAT_VOLTS) && (bat_volts < BATT_FLOAT) && (sol_volts > bat_volts))
      {
        charger_state = bulk;
        TURN_ON_MOSFETS;
      }
      break;
    default:
      TURN_OFF_MOSFETS;
      break;
  }
}
 
void load_control()
{
#if LOAD_ALGORITHM == 0
  load_on(sol_watts < MIN_SOL_WATTS && bat_volts > LVD);
#else
  load_on(sol_watts > MIN_SOL_WATTS && bat_volts > BATT_FLOAT);
#endif
}
 
void load_on(boolean new_status)
{
  if (load_status != new_status)
  {
    load_status = new_status;
    digitalWrite(LOAD_PIN, new_status ? HIGH : LOW);
  }
}
 
void print_data(void)  // you can skip this part)
{
  Serial.print(seconds,DEC);
  Serial.print("      ");
  Serial.print("Charging = ");
  if (charger_state == on) Serial.print("on   ");
  else if (charger_state == off) Serial.print("off  ");
  else if (charger_state == bulk) Serial.print("bulk ");
  else if (charger_state == bat_float) Serial.print("float");
  Serial.print("      ");
 
  Serial.print("pwm = ");
  if(charger_state == off)
  Serial.print(0,DEC);
  else
  Serial.print(pwm,DEC);
  Serial.print("      ");
 
  Serial.print("Current (panel) = ");
  Serial.print(sol_amps);
  Serial.print("      ");
 
  Serial.print("Voltage (panel) = ");
  Serial.print(sol_volts);
  Serial.print("      ");
 
  Serial.print("Power (panel) = ");
  Serial.print(sol_volts);
  Serial.print("      ");
 
  Serial.print("Battery Voltage = ");
  Serial.print(bat_volts);
  Serial.print("      ");
 
  Serial.print("\n\r");
  //delay(1000);
}
 
void light_led(char pin)
{
  static char last_lit;
  if (last_lit == pin)
      return;
  if (last_lit != 0)
      digitalWrite(last_lit, HIGH);
  digitalWrite(pin, LOW);
  last_lit = pin;
}
 
void led_output(void)
{
  static char last_lit;
  if(bat_volts > 14.1 )
      light_led(LED_BLUE);
  else if(bat_volts > 11.9)
      light_led(LED_GREEN);
  else
      light_led(LED_RED);
}
void lcd_display()
{
  static bool current_backlight_state = -1;
  back_light_pin_State = digitalRead(BACK_LIGHT_PIN);
  if (current_backlight_state != back_light_pin_State)
  {
    current_backlight_state = back_light_pin_State;
    if (back_light_pin_State == HIGH)
      lcd.backlight();
    else
      lcd.noBacklight();
  }
 
  if (back_light_pin_State == HIGH)
  {
    time = millis();
  }
 
 lcd.setCursor(0, 1);
 lcd.print(sol_volts);
 lcd.print("V ");
 lcd.setCursor(0, 2);
 lcd.print(sol_amps);
 lcd.print("A");
 lcd.setCursor(0, 3);
 lcd.print(sol_watts);
 lcd.print("W ");
 lcd.setCursor(8, 1);
 lcd.print(bat_volts);
 lcd.setCursor(8,2);
 
 if (charger_state == on)
 lcd.print("on   ");
 else if (charger_state == off)
 lcd.print("off  ");
 else if (charger_state == bulk)
 lcd.print("bulk ");
 else if (charger_state == bat_float)
 {
 lcd.print("     ");
 lcd.setCursor(8,2);
 lcd.print("float");
 }
 
 int pct = 100.0*(bat_volts - 11.3)/(12.7 - 11.3);
 if (pct < 0) pct = 0; else if (pct > 100)
     pct = 100;
 
 lcd.setCursor(12,0);
 lcd.print((char)(pct*5/100));
 
 lcd.setCursor(8,3);
 pct = pct - (pct%10);
 lcd.print(pct);
 lcd.print("%  ");
 
 lcd.setCursor(15,0);
 lcd.print("PWM");
 lcd.setCursor(19,0);
 lcd.write(PWM_ICON);
 lcd.setCursor(15,1);
 lcd.print("   ");
 lcd.setCursor(15,1);
 if( charger_state == off)
 lcd.print(0);
 else
 lcd.print(pwm);
 lcd.print("% ");
 
 lcd.setCursor(15,2);
 lcd.print("Load");
 lcd.setCursor(15,3);
 if (load_status)
 {
    lcd.print("On  ");
 }
 else
 {
   lcd.print("Off ");
 }
 spinner();
 backLight_timer();
}
 
void backLight_timer()
{
  if((millis() - time) <= 15000)
      lcd.backlight();
  else
      lcd.noBacklight();
}
void spinner(void)
{
  static int cspinner;
  static char spinner_chars[] = { '*','*', '*', ' ', ' '};
  cspinner++;
  lcd.print(spinner_chars[cspinner%sizeof(spinner_chars)]);
}