'*****************************************************
'** **
'** 24Volt 40A Battery Charger **
'** **
'** Mike Crean Perth Western Australia **
'** mike.crean@y7mail.com **
'** **
'** mgc Start 02/01/2003 **
'** Finish 23/01/2003 **
'** **
'*****************************************************

'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
'@@ @@
'@@ This is a program to drive a MOC into a Triac @@
'@@ using an AT90S8535 AVR micro. @@
'@@ @@
'@@ Demo of using INT0 for zero crossing detection @@
'@@ & Timer0 for Triac control, also shows use of @@
'@@ Urxc ISR for comm's interface & use of ADCs. @@
'@@ @@
'@@ The hardware for this project is reserved & @@
'@@ will not be released. @@
'@@  @@
'@@ This battery charger was developed to charge @@
'@@ 24V 500A/Hr batteries on stationary Gen. Sets. @@
'@@ It has to shut OFF when the prime mover is @@
'@@ cranking (500-800A). It has 4 levels of voltage @@
'@@ Control 25, 27, 28 & 28.5V and 4 levels of @@
'@@ current control 40, 12, 8(variable) & 0A. Some @@
'@@ of the current controls very with battery @@
'@@ condition. It has a float & Triac fail @@
'@@ timer (4min.) @@
'@@  @@
'@@ There are a number of features that could be @@
'@@ added, like|- de-sulfate timer with voltage & @@
'@@ current control @@
'@@ @@
'@@ @@
'@@ Must set up AVR-IDE for AT90S8535 @@
'@@ --------------------------------- @@
'@@  @@
'@@ From Options menu, select compiler, chip & @@
'@@ set to 8535, in communications tab set @@
'@@ Fequency to 8000000 @@
'@@ From the programmer menu set programmer to @@
'@@ STK200/STK300 programmer, Auto Flash tick @@
'@@ only and cable to Parallel @@
'@@ This is for the ISP programmer dongle in the @@
'@@ BASCAVR1.PDF manual (about page 396). @@
'@@ @@
'@@ ** F7 Compile @@
'@@ ** F2 Simulate @@
'@@ ** F4 Send to chip @@
'@@ @@
'@@ ** $sim must be included & compiled when @@
'@@ simulate is run. @@
'@@ ** $sim must be REM out when compiled to @@
'@@ send to chip @@
'@@ @@
'@@ FOR MORE INFORMATION ON IDE set up and @@
'@@ programming, READ THE BASCAVR1.PDF manual or @@
'@@ use HELP @@
'@@ @@
'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@

'$sim
$regfile = "8535def.dat"
$crystal = 8000000
$baud = 9600
Config Adc = Single , Prescaler = Auto
Config Timer0 = Timer , Prescale = 1 '** Sets T0 / rate
 '** Values (1,8,64,256 &
Config Int0 = Falling '** Interrupt 0, PIN 16 (Int0)
Config Portd = Input '** Set Portd to Inputs
Config Portb = Output '** Set Portb to Outputs
Config Portc = Output '** Set Portc to Outputs
Cursor Off

'** Config variables

Dim Rx As Byte , Channel As Byte , Flag27 As Byte , Flag28 As Byte
Dim Flagchk As Byte , Lv As Byte , Mv As Byte , Hv As Byte , Ea As Byte
Dim Eep As Byte , Shit As Byte , Fdcount As Byte , Fdmult As Byte
Dim Startflag As Byte , Stod As Byte , Ep As Byte , Ehv As Byte
Dim Count As Integer , Td As Integer , Tds As Integer , Dcount As Integer
Dim Vd As Single , Amps As Single
Dim W As Word , Stuff As Word , Stuffs As Word , Ftd As Word

Startflag = 0

'** Get Values from Eeprom

Readeeprom Ea , 2
Readeeprom Hv , 3
Readeeprom Mv , 4
Readeeprom Lv , 5
Readeeprom Shit , 6
Readeeprom Fdmult , 7
Readeeprom Stod , 8
Readeeprom Ehv , 9

'** 1st. run after programming, Ea should be 255
'** If Ea > 251 then load defaults to variables & write to Eeprom **

If Ea > 251 Then
 Ea = 145 : Hv = 141 : Mv = 138 : Lv = 130 : Tds = 110 : Shit = 255
 Dcount = 0 : Fdcount = 0 : Fdmult = 240 : Stod = 2 : Ehv = 143
 Writeeeprom Ea , 2
 Waitms 10
 Writeeeprom Hv , 3
 Waitms 10
 Writeeeprom Mv , 4
 Waitms 10
 Writeeeprom Lv , 5
 Waitms 10
 Writeeeprom Shit , 6
 Waitms 10
 Writeeeprom Fdmult , 7
 Waitms 10
 Writeeeprom Stod , 8
 Waitms 10
 Writeeeprom Ehv , 9
 Waitms 10
End If

Ftd = Shit * 100
Flag27 = 0 : Flag28 = 0 : Flagchk = 0 : Startflag = 0 '** Set Flags
On Urxc Rec_isr '** Call Recv. Interrupt service routine
Enable Urxc '** Enable ISR calls
On Timer0 Tim0_isr '** Call Timer0 ISR
Enable Timer0 '** Enable Timer0 ISR calls
Enable Int0 '** Enable Int0 ISR calls
On Int0 Int0_isr '** Call Int0 ISR
Enable Interrupts '** Enable all interrupts
Stop Timer0 '** Stop the Timer
Start Adc '** Start the Adc
Portc = 0 '** Set Portc LOW (0)
Portc.0 = 1 : Portc.2 = 1 : Portc.3 = 1 : Portc.4 = 1 '** Set Portc
Portb = 255 '** Set all bits on Portb High
 '** all bits pulled HIGH with
 '** internal pull up resistors

Portb.2 = 0  '** Pull PortB.2 Low (Triac OFF)

'***** MAIN PROGRAM LOOP *****

Do

 nop

Loop


Getadc:

 '** Read the ADC channels (10 bit ADC) = (0 to 1023 count)

 For Channel = 0 To 7
 W = Getadc(channel) '** Loop to read 8 Adcs
 If Channel = 0 Then Stuff = W / 3 '** Put ADC0 / 3 into Stuff (Amps)
 If Channel = 1 Then Stuffs = W / 3 '** Put ADC1 / 3 into Stuffs (Volts)
 Next Channel

 '** If a start sig. is seen on Pd6

 If Pind.6 = 1 Then '** Turn OFF Charger & Starter ON
 If Startflag = 0 Then
 Portc.0 = 0 : Portc.3 = 1 : Portc.4 = 1
 Wait Stod
 Portc.1 = 1
 Startflag = 1
 Portc.1 = 1
 End If
 End If

 '** If No start sig. on Pd6

 If Pind.6 = 0 Then '** Turn Starter OFF & Charger ON
 If Startflag = 1 Then
 Startflag = 0
 Portc.1 = 0
 Wait Stod
 Portc.0 = 1
 End If
 End If

 If Startflag = 1 Then Goto Starting '** Jump this lot if Starting

 Td = Stuff '** Put Stuff (word) into Td (Integer)
 If Stuffs > Td Then Td = Stuffs

 If Stuffs < Lv Then '** If Batt < 25.5V set to max C/R
 Flag27 = 0 '** C/R is Charge Rate
 Flag28 = 0
 Portc.2 = 0 : Portc.3 = 1 : Portc.4 = 1 '** Set LEDs on Portc
 End If

 If Stuffs > Mv Then '** If Batt > 27V set 27V Flag
 If Flag27 = 0 Then
 If Flagchk = 0 Then
 Flag27 = 1
 Portc.2 = 1 : Portc.3 = 0 : Portc.4 = 1 '** Set LEDs on Portc
 End If
 End If
 End If

 If Stuffs > Hv Then '** If Batt > 28V set 28V Flag
 If Flag27 = 1 Then
 If Flagchk = 0 Then
 If Flag28 = 0 Then
 Flag28 = 1
 Portc.2 = 1 : Portc.3 = 1 : Portc.4 = 0 '** Set LEDs on Portc
 End If
 End If
 End If
 End If

 If Stuffs > Ehv Then '** If Batt > 29V set 28V Flag = 2
 Portb.2 = 0 : '** Turn off Triac
 Waitms 250 '** Wait .25 Sec.
 Portc.0 = 0 '** Turn OFF mains relay TRIAC may be
 Flag28 = 2 '** at FAULT (will cycle every 4 min.)
 Portc.2 = 1 : Portc.3 = 1 : Portc.4 = 1
 '** Turn all LEDs ON to indicate FAULT
 End If

 If Flag28 = 1 Then
 Portb.2 = 0 '** Set Portb.2 LOW Triac OFF
 Flag28 = 2 : Count = 0
 End If

 If Flag28 = 0 Then
 If Td < Tds Then Td = Tds '** Set Td not < Zero Cross or max amps
 If Td > 217 Then Td = 217 '** Set Td not > next Zero Cross
 If Flag27 = 1 Then Td = Ea '** If Batt > 27V Set max Amps to 8
 End If '** value 145

Starting:

Return

Int0_isr: '** Interrupt0 Interrupt Service Routine

Start Timer0 '** Start Timer 0
Gosub Getadc '** Get the Amps & Volts from the ADC
 '** The ADC conversion & other
 '** calculations are in this section
 '** because they take the most time.

Return '** Return to MAIN Program Loop

Tim0_isr: 'Timer0 ISR, called if T0 overflows

If Startflag = 1 Then '** If Startting set Portb Low
 Portb = 0
 Goto Yes_start '** Jump to Yes_start
End If

If Flag28 = 0 Then
 Count = Count + 1 '** Start counter (No. of interrupts)
 '** counts each time T0 overflows
 If Count > Td Then  '** If the count > AD0 / 3 then send
 Count = 0 '** pulses & set count to 0
 Stop Timer0 '** Stop Timer 0
 '** Send 3 pulses to the Triac
  Set Portb.2 '** Turn Portb.2 on (high), PIN 3
 Waitus 100 '** Wait 100 u/s
 Reset Portb.2 '** Turn Portb.2 off (low), PIN 3
 Waitus 100 '** Wait 100 u/s
 Set Portb.2 '** Repeat for 3 pulses
 Waitus 100
 Reset Portb.2
 Waitus 100
 Set Portb.2
 Waitus 100
 Reset Portb.2
 Waitus 100
 End If
End If

If Flag28 = 2 Then '** If 28V Battery Flag is set to 2
 Portb.2 = 0 '** Turn Portb,2 OFF (Triac OFF)
 Dcount = Dcount + 1 '** Set up a 4min. Timer

 If Dcount > Ftd Then
 Dcount = 0 : Fdcount = Fdcount + 1

 If Fdcount > Fdmult Then
 Fdcount = 0 : Dcount = 0 : Flag27 = 0 : Flag28 = 0
 Portc.0 = 1
 Waitms 250
 End If
 End If
End If

Yes_start:

Return '** Return to MAIN Program Loop

Rec_isr:  '** Recv. buffer ISR

Rx = Inkey() '** Get Char (ASCII) from Recv. buffer

If Rx = 63 Then '** 63 = chr ?
 Print : Print " 24V Battery Charger" '** Send to Tx buffer
 Print " -----------------------------"
 Print : Print " | - Get All Values"
 Print " ! - Set Max Amps (40A) value 110 "
 Print " @ - Get Volts & Amps"
 Print " # - Turn 27V & 28V Flags OFF"
 Print " $ - Turn Voltage Flags ON"
 Print " % - Set all Micro values & write to Eeprom"
 Print " ^ - Read Micro values from Eeprom"
End If

If Rx = 124 Then '** 124 = chr |
 Print : Print " Td = " ; Td '** Send Td to Tx buffer
 Print " Count = " ; Count
 Print " Ea = " ; Ea
 Print " Tds = " ; Tds
 Print " W = " ; W
 Print " Stuffs = " ; Stuffs
 Print " Flag27 = " ; Flag27
 Print " Flag28 = " ; Flag28
 Print " FlagChk = " ; Flagchk
 Print " Eight Amp Value = " ; Ea
 Print " Ehv 29V Value = " ; Ehv
 Print " Hv 28V Value = " ; Hv
 Print " Mv 27V Value = " ; Mv
 Print " Lv 25V Value = " ; Lv
 Print " Ftd float time delay = " ; Ftd
 Print " Dcount = " ; Dcount
 Print " Fdt Mult. count (Fdcount) = " ; Fdcount
 Print " Fdmult = " ; Fdmult
 Print " Startflag = " ; Startflag
 Print " PortD.6 = " ; Pind.6
 Print " Stod Start Relay Delay = " ; Stod
End If


If Rx = 33 Then '** 33 = chr !
 Waitms 100 '** Must turn OFF Recv. ISR
 Disable Urxc '** & interrupts if Input is used
 Waitms 50 '** Need short delays
 Disable Interrupts
 Waitms 100
 Input " Enter Tds value " , Tds
 Waitms 100 '** Need short delays
 Enable Urxc '** Must turn Recv. ISR ON to
 Waitms 50 '** enable more Uart ISR's
 Enable Interrupts
 Waitms 100
End If

If Rx = 64 Then '** 64 = chr @
 Vd = Stuffs / 5.0 '** Was 4.75
 Amps = Stuff / 5.8 '** Was 3.26
 Print " Volts = " ; Vd
 Print " Amps. = " ; Amps
End If

If Rx = 35 Then '** 35 chr # - Hold Flags OFF
 Flagchk = 1
 Flag27 = 0
 Flag28 = 0
End If

If Rx = 36 Then '** 36 chr $ - Set Flags to ON
 Flagchk = 0
End If

If Rx = 37 Then '** 37 chr % - Set all volts &
 Waitms 100 '** Amps Values
 Disable Urxc
 Waitms 50
 Disable Interrupts
 Waitms 100
 Print : Print " Max. for any Value is 255"
 Input " Enter Tds max amps (110 = 40A) " , Tds '** Tds max amps (38A) value (110)
 Input " Enter Lv min volts (130 = 25V) " , Lv '** Lv 25V value (130)
 Input " Enter Mv med volts (138 = 27V) " , Mv '** Mv 27V value (138)
 Input " Enter Hv high volts (141 = 28V) " , Hv '** Hv 28V value (141)
 Input " Enter Ehv Extra high volts (143 = 29V) " , Ehv '** Ehv 29V value (143)
 Input " Enter Ea 8A (145 max 250) " , Ea '** Ea 8A value (145)
 Input " Enter Ftd float time delay (255 = 1 Sec.) " , Shit
 '** Ftd float time delay value ( )
 Input " Enter Fdt Mult. (Fdcount) (240=4min.) " , Fdmult
 Input " Stod Start Relay Delay 1 to 255 Sec's " , Stod
 Waitms 50
 Writeeeprom Ea , 2
 Waitms 10
 Writeeeprom Hv , 3
 Waitms 10
 Writeeeprom Mv , 4
 Waitms 10
 Writeeeprom Lv , 5
 Waitms 10
 Writeeeprom Shit , 6
 Ftd = Shit * 100
 Waitms 10
 Writeeeprom Fdmult , 7
 Waitms 10
 Writeeeprom Stod , 8
 Waitms 10
 Writeeeprom Ehv , 9
 Waitms 50
 Enable Urxc '** Must turn Recv. ISR ON to
 Waitms 50 '** enable more Uart ISR's
 Enable Interrupts
 Waitms 100
End If

If Rx = 94 Then '** 94 ^ Read Eeprom values
 Waitms 100 '** Amps Values
 Disable Urxc
 Waitms 50
 Disable Interrupts
 Waitms 100
 Readeeprom Ep , 2
 Print : Print " Low amps (8A=145) Ea = " ; Ep
 Readeeprom Ehv , 9
 Print " Extra high volts (29V = 143) Ehv = " ; Ehv
 Readeeprom Ep , 3
 Print " High volts (28V = 141) Hv = " ; Ep
 Readeeprom Ep , 4
 Print " Med. Volts (27V = 138) Mv = " ; Ep
 Readeeprom Ep , 5
 Print " Low volts (25V = 130) Lv = " ; Ep
 Readeeprom Ep , 6
 Print " Float delay (255 = 255) Shit = " ; Ep
 Readeeprom Ep , 7
 Print " Float Mult. (240 = 240) Fdmult = " ; Ep
 Readeeprom Ep , 8
 Print " Start delay (2sec = 2sec) Stod = " ; Ep
 Print
 Print " Ea = " ; Ea
 Print " Ehv = " ; Ehv
 Print " Hv = " ; Hv
 Print " Mv = " ; Mv
 Print " Lv = " ; Lv
 Print " Shit = " ; Shit
 Print " Ftd = Shit * 100 Ftd = " ; Ftd
 Print " Fdmult = " ; Fdmult
 Print " Stod = " ; Stod
 Waitms 50
 Enable Urxc '** Must turn Recv. ISR ON to
 Waitms 50 '** enable more Uart ISR's
 Enable Interrupts
 Waitms 100
End If

Rx = 0

Return '** Return to MAIN Program Loop

End '** End of program and code space