//------------------------------------------------------------------------------------------------------

//

// Arduino Peak Power Tracking Solar Charger by Ram Sankar Pillai (www.aaram-engineering.com)

// Project started Feb 19th 2015.

//

// This software implements Tim Nolan's (www.timnolan.com) Peak Power Tracking Solar Charger using the
Arduino IDE

//

// 5/1/09 v1.00 First development version by Tim Nolan. Just getting something to work.

//

// 19/Feb/2014 code modified to suit Ram Sankar Pillai's hardware design.

// 06/Mar/2015 code modified to suit Ram Sankar Pillai's pro PCB, included LED indication

// included EEPROM storage of watt hours

// 08/Mar/2015 introduced PWM indication on LCD display

// released for production use.

//------------------------------------------------------------------------------------------------------

#include <LiquidCrystal.h> // using the liquid crystal library

//#include <EEPROM.h>

LiquidCrystal lcd(7,8,0,1,2,3);

//------------------------------------------------------------------------------------------------------

// definitions

#define SOL_VOLTS_CHAN A0 // the adc channel to read solar volts

#define SOL_AMPS_CHAN A3 // the adc channel to read solar amps

#define BAT_VOLTS_CHAN A2 // the adc channel to read battery volts

#define FAN_PIN A1 // LM 35 Temperature is connected to pin A3

#define AVG_NUM 10 // number of iterations of the adc routine to average the adc readings

#define SOL_AMPS_SCALE 37 // the scaling value for raw adc reading to get solar amps scaled by 60 - (Scale
by 54 for MAX4173T, 22 for MAX4173F, 11 for MAX4173H)
#define SOL_VOLTS_SCALE 28 // the scaling value for raw adc reading to get solar volts scaled by 27

#define BAT_VOLTS_SCALE 28 // the scaling value for raw adc reading to get battery volts scaled by 27

#define PWM_PIN 9 // the output pin for the pwm

//#define PWM_ENABLE_PIN 8 // pin used to control shutoff function of the IR2104 MOSFET driver

#define PWM_FULL 1023 // the actual value used by the Timer1 routines for 100% pwm duty cycle

#define PWM_MAX 100 // the value for pwm duty cyle 0-100%

#define PWM_MIN 60 // the value for pwm duty cyle 0-100%

#define PWM_START 90 // the value for pwm duty cyle 0-100%

#define PWM_INC 1 //the value the increment to the pwm value for the ppt algorithm

#define TRUE 1

#define FALSE 0

#define ON TRUE

#define OFF FALSE

//#define TURN_ON_MOSFETS digitalWrite(PWM_ENABLE_PIN, HIGH) // enable MOSFET driver

//#define TURN_OFF_MOSFETS digitalWrite(PWM_ENABLE_PIN, LOW) // disable MOSFET driver

#define ONE_SECOND 50000 //count for number of interrupt in 1 second on interrupt period of 20us

#define LOW_SOL_WATTS 5.00 //value of solar watts scaled by 100 so this is 5.00 watts

#define MIN_SOL_WATTS 1.00 //value of solar watts scaled by 100 so this is 1.00 watts

#define MIN_BAT_VOLTS 11.00 //value of battery voltage scaled by 100 so this is 11.00 volts

#define MAX_BAT_VOLTS 14.10 //value of battery voltage scaled by 100 so this is 14.10 volts

#define HIGH_BAT_VOLTS 13.60 //value of battery voltage scaled by 100 so this is 13.00 volts

#define OFF_NUM 9 // number of iterations of off charger state

#define yellowLed 10

#define greenLed 11

#define redLed 12

byte solar[8] = //icon for termometer

0b11111,

0b10101,

0b11111,
 0b10101,

0b11111,

0b10101,

0b11111,

0b00000

};

byte battery[8]=

0b01110,

0b11011,

0b10001,

0b10001,

0b11111,

0b11111,

0b11111,

0b11111,

};

//------------------------------------------------------------------------------------------------------

// global variables

float pwm = 0; //pwm duty cycle 0-100%

float sol_amps; // solar amps scaled by 100

float sol_volts; // solar volts scaled by 100

float bat_volts; // battery volts scaled by 100

float sol_watts; // solar watts scaled by 100

int delta = PWM_INC; // variable used to modify pwm duty cycle for the ppt algorithm

float old_sol_watts = 0; // solar watts from previous time through ppt routine scaled by 100
float watts, wattHours;

int disp_page=1; //LCD Display page counter

unsigned long prev_millis, pwm_disp_millis;

double msec, last_msec, elasped_msec, elasped_time, ampSecs, wattSecs;

enum charger_mode {

off, on, bulk, bat_float }

charger_state; // enumerated variable that holds state for charger state machine

//------------------------------------------------------------------------------------------------------

// This routine is automatically called at powerup/reset

//------------------------------------------------------------------------------------------------------

void setup() // run once, when the sketch starts

//

// bitClear(ADCSRA,ADPS0) ;

// bitClear(ADCSRA,ADPS1) ;

// bitSet(ADCSRA,ADPS2) ;

TCCR1B = TCCR1B & B11111000 | B00000001; // set timer 1 divisor to 1 for PWM frequency of 31372.55 Hz

wattHours = 1000;

analogWrite(PWM_PIN,0); // setup pwm on PWM pin, 0% duty cycle

pwm = PWM_START; //starting value for pwm

charger_state = on; // start with charger state as on

pinMode(yellowLed, OUTPUT);

pinMode(greenLed, OUTPUT);

pinMode(redLed, OUTPUT);

pinMode(FAN_PIN,OUTPUT);

digitalWrite(yellowLed,LOW);

digitalWrite(greenLed,LOW);

digitalWrite(redLed,LOW);
 digitalWrite(FAN_PIN,HIGH);

lcd.begin(16, 2); // set up coulumns and rows for LCD. Using a 20x4 display.

lcd.createChar(1,solar);

lcd.createChar(2,battery);

//------------------------------------------------------------------------------------------------------

// This routine reads and averages the analog inputs for this system, solar volts, solar amps and

// battery volts. It is called with the adc channel number (pin number) and returns the average adc

// value as an integer.

//------------------------------------------------------------------------------------------------------

int read_adc(int channel){

int sum = 0;

int temp;

int i;

for (i=0; i<AVG_NUM; i++) { // loop through reading raw adc values AVG_NUM number of times

temp = analogRead(channel); // read the input pin

sum += temp; // store sum for averaging

delayMicroseconds(50); // pauses for 50 microseconds

return(sum / AVG_NUM); // divide sum by AVG_NUM to get average and return it

//------------------------------------------------------------------------------------------------------

// This routine uses the Timer1.pwm function to set the pwm duty cycle. The routine takes the value in

// the variable pwm as 0-100 duty cycle and scales it to get 0-1034 for the Timer1 routine.

// There is a special case for 100% duty cycle. Normally this would be have the top MOSFET on all the time

// but the MOSFET driver IR2104 uses a charge pump to generate the gate voltage so it has to keep running
// all the time. So for 100% duty cycle I set the pwm value to 1023 - 1 so it is on 99.9% almost full on

// but is switches enough to keep the charge pump on IR2104 working.

//------------------------------------------------------------------------------------------------------

void set_pwm_duty(void) {

if (pwm > PWM_MAX) { // check limits of PWM duty cyle and set to
PWM_MAX

pwm = PWM_MAX;

else if (pwm < PWM_MIN) { // if pwm is less than PWM_MIN then set it to PWM_MIN

pwm = PWM_MIN;

if (pwm < PWM_MAX) {

analogWrite(PWM_PIN,(PWM_FULL * (long)pwm / 100)); // use Timer1 routine to set pwm duty cycle at 20uS
period

else if (pwm == PWM_MAX) { // if pwm set to 100% it will be on full but we have

analogWrite(PWM_PIN,(PWM_FULL - 1)); // keep switching so set duty cycle at 99.9% and slow down to
1000uS period

//------------------------------------------------------------------------------------------------------

//This routine prints the data to the LCD

//------------------------------------------------------------------------------------------------------

void lcd_display1(void) {

lcd.clear();

lcd.setCursor(0, 0);
lcd.write(1);

//lcd.print(" ");

lcd.print(sol_volts,1);

lcd.print("V ");

if ((sol_amps*sol_volts) < 10.0 && (sol_amps*sol_volts) > 0.0) {

lcd.print("0");

lcd.print(sol_amps*sol_volts,0);

else if ((sol_amps*sol_volts) >= 10.0) {

lcd.print(sol_amps*sol_volts,0);

else {

lcd.print("00");

lcd.print("W ");

if ((sol_amps) < 10.0 && sol_amps >0) {

lcd.print("0");

lcd.print(sol_amps,1);

else if (sol_amps >= 10){

lcd.print(sol_amps,1);

else {

lcd.print("00.0");

lcd.print("A");

//lcd.print(sol_amps,1);
//lcd.print("A");

lcd.setCursor(0, 1);

lcd.write(2);

//lcd.print(" ");

lcd.print(bat_volts,1);

lcd.print("V ");

if ((sol_amps*bat_volts) < 10.0 && (sol_amps*bat_volts) > 0.0) {

lcd.print("0");

lcd.print(sol_amps*bat_volts,0);

else if ((sol_amps*bat_volts) >= 10.0) {

lcd.print(sol_amps*bat_volts,0);

else {

lcd.print("00");

lcd.print("W ");

if (disp_page==1){

lcd.print(wattHours,0);

lcd.setCursor(15,1);

lcd.print("h");

if(disp_page==2) {

lcd.print(pwm,0);

lcd.setCursor(15,1);

lcd.print("%");
 }

//------------------------------------------------------------------------------------------------------

// This routine reads all the analog input values for the system. Then it multiplies them by the scale

// factor to get actual value in volts or amps. Then it adds on a rounding value before dividing to get

// the result scaled by 100 to give a fractional value of two decimal places. It also calculates the input

// watts from the solar amps times the solar voltage and rounds and scales that by 100 (2 decimal places) also.

//------------------------------------------------------------------------------------------------------

void read_data(void) {

//sol_volts = read_adc(SOL_VOLTS_CHAN)*0.0282; //old PCB value

//bat_volts = read_adc(BAT_VOLTS_CHAN)*0.0276; //old pcb value

sol_volts = read_adc(SOL_VOLTS_CHAN)*0.02705;

bat_volts = read_adc(BAT_VOLTS_CHAN)*0.02613;

sol_amps = (read_adc(SOL_AMPS_CHAN));

sol_amps = (sol_amps/1023.0)*5000;

sol_amps = 0.9*((sol_amps-2500)/66); //Sensitivity is 66mV

sol_amps = sol_amps-1.2; // ======= ACS712 error compensation value

sol_watts = sol_volts*sol_amps;

// temperature = (read_adc(TEMP_ADC)*0.488);

//------------------------------------------------------------------------------------------------------

// This routine calculates Watt Hours produced

//------------------------------------------------------------------------------------------------------

void power(void)

{
 msec = millis();

elasped_msec = msec - last_msec; //Calculate how long has past since last call of this function

elasped_time = elasped_msec / 1000.0; // 1sec=1000 msec

watts = bat_volts*sol_amps; //Watts now

ampSecs = (sol_amps*elasped_time); //AmpSecs since last measurement

wattSecs = ampSecs * sol_volts; //WattSecs since last measurement

// ampHours = ampHours + ampSecs/3600; // 1 hour=3600sec //Total ampHours since program started

wattHours = wattHours + wattSecs/3600; // 1 hour=3600sec //Total wattHours since program started

last_msec = msec; //Store 'now' for next time

//------------------------------------------------------------------------------------------------------

// This routine to indicate charger state using Green, Yellow, and red LEDs

//------------------------------------------------------------------------------------------------------

void ledIndication(void) {

if (charger_state == off){

digitalWrite(greenLed,LOW);

digitalWrite(yellowLed,LOW);

digitalWrite(redLed,HIGH);

else if ((charger_state == bulk) || (charger_state == on)) {

digitalWrite(greenLed,LOW);

digitalWrite(yellowLed,HIGH);

digitalWrite(redLed,LOW);

else if (charger_state == bat_float) {

digitalWrite(greenLed,HIGH);
 digitalWrite(yellowLed,LOW);

digitalWrite(redLed,LOW);

//------------------------------------------------------------------------------------------------------

// This routine is the charger state machine. It has four states on, off, bulk and float.

// It's called once each time through the main loop to see what state the charger should be in.

// The battery charger can be in one of the following four states:

//

// On State - this is charger state for MIN_SOL_WATTS < solar watts < LOW_SOL_WATTS. This state is probably

// happening at dawn and dusk when the solar watts input is too low for the bulk charging state but not

// low enough to go into the off state. In this state we just set the pwm = 100% to get the most of low

// amount of power available.

// Bulk State - this is charger state for solar watts > MIN_SOL_WATTS. This is where we do the bulk of the battery

// charging and where we run the Peak Power Tracking alogorithm. In this state we try and run the maximum
amount

// of current that the solar panels are generating into the battery.

// Float State - As the battery charges it's voltage rises. When it gets to the MAX_BAT_VOLTS we are done with the

// bulk battery charging and enter the battery float state. In this state we try and keep the battery voltage

// at MAX_BAT_VOLTS by adjusting the pwm value. If we get to pwm = 100% it means we can't keep the battery

// voltage at MAX_BAT_VOLTS which probably means the battery is being drawn down by some load so we need
to back

// into the bulk charging mode.

// Off State - This is state that the charger enters when solar watts < MIN_SOL_WATTS. The charger goes into this

// state when it gets dark and there is no more power being generated by the solar panels. The MOSFETs are
turned

// off in this state so that power from the battery doesn't leak back into the solar panel. When the charger off

// state is first entered all it does is decrement off_count for OFF_NUM times. This is done because if the battery

// is disconnected (or battery fuse is blown) it takes some time before the battery voltage changes enough so we
can tell

// that the battery is no longer connected. This off_count gives some time for battery voltage to change so we can
// tell this.

//------------------------------------------------------------------------------------------------------

void run_charger(void) {

static int off_count = OFF_NUM;

switch (charger_state) {

case on:

if (sol_watts < MIN_SOL_WATTS) { //if watts input from the solar panel is less than

charger_state = off; //the minimum solar watts then it is getting dark so

off_count = OFF_NUM; //go to the charger off state

analogWrite(PWM_PIN,0);

else if (bat_volts > MAX_BAT_VOLTS) { // > 14.1V else if the battery voltage has gotten above the float

charger_state = bat_float; //battery float voltage go to the charger battery float state

else if (sol_watts < LOW_SOL_WATTS) { //else if the solar input watts is less than low solar watts

pwm = PWM_MAX; //it means there is not much power being generated by the solar panel

set_pwm_duty(); //so we just set the pwm = 100% so we can get as much of this power
as possible

} //and stay in the charger on state

else {

pwm = ((bat_volts * 10) / (sol_volts / 10)) + 5; //else if we are making more power than low solar watts figure
out what the pwm

charger_state = bulk; //value should be and change the charger to bulk state

break;

case bulk:

if (sol_watts < MIN_SOL_WATTS) { //if watts input from the solar panel is less than

charger_state = off; //the minimum solar watts then it is getting dark so

 off_count = OFF_NUM; //go to the charger off state

else if (bat_volts > MAX_BAT_VOLTS) { //else if the battery voltage has gotten above the float

charger_state = bat_float; //battery float voltage go to the charger battery float state

else if (sol_watts < LOW_SOL_WATTS) { //else if the solar input watts is less than low solar watts

charger_state = on; //it means there is not much power being generated by the solar panel

//so go to charger on state

else { // this is where we do the Peak Power Tracking ro Maximum Power Point algorithm

if (old_sol_watts >= sol_watts) { // if previous watts are greater change the value of

delta = -delta; // delta to make pwm increase or decrease to maximize watts

pwm += delta; // add delta to change PWM duty cycle for PPT algorythm

old_sol_watts = sol_watts; // load old_watts with current watts value for next time

set_pwm_duty(); // set pwm duty cycle to pwm value

break;

case bat_float:

if (sol_watts < MIN_SOL_WATTS) { //if watts input from the solar panel is less than

charger_state = off; //the minimum solar watts then it is getting dark so

off_count = OFF_NUM; //go to the charger off state

set_pwm_duty();

analogWrite(PWM_PIN,0);

else if (bat_volts > MAX_BAT_VOLTS) { //since we're in the battery float state if the battery voltage

pwm -= 1; //is above the float voltage back off the pwm to lower it

set_pwm_duty();
 }

else if (bat_volts < MAX_BAT_VOLTS) { //else if the battery voltage is less than the float voltage

pwm += 1; //increment the pwm to get it back up to the float voltage

set_pwm_duty();

if (pwm >= 100) { //if pwm gets up to 100 it means we can't keep the battery at

charger_state = bulk; //float voltage so jump to charger bulk state to charge the battery

break;

case off: //when we jump into the charger off state, off_count is set with OFF_NUM

if (off_count > 0) { //this means that we run through the off state OFF_NUM of times with out doing

off_count--; //anything, this is to allow the battery voltage to settle down to see if the

} //battery has been disconnected

else if ((bat_volts > HIGH_BAT_VOLTS) && (bat_volts < MAX_BAT_VOLTS) && (sol_volts > bat_volts)) {

charger_state = bat_float; //if battery voltage is still high and solar volts are high

set_pwm_duty(); //change charger state to battery float

else if ((bat_volts > MIN_BAT_VOLTS) && (bat_volts < MAX_BAT_VOLTS) && (sol_volts > bat_volts)) {

pwm = PWM_START; //if battery volts aren't quite so high but we have solar volts

set_pwm_duty(); //greater than battery volts showing it is day light then

charger_state = on; //change charger state to on so we start charging

} //else stay in the off state

break;

default:

analogWrite(PWM_PIN,0);

break;

}
}

//------------------------------------------------------------------------------------------------------

// Main loop.

// Right now the number of times per second that this main loop runs is set by how long the printing to

// the serial port takes. You can speed that up by speeding up the baud rate.

// You can also run the commented out code and the charger routines will run once a second.

//------------------------------------------------------------------------------------------------------

void loop() // run over and over again

read_data(); //read data from inputs

power();

run_charger(); //run the charger state machine

// delay(50);

// read_data();

if ((millis() > (prev_millis+ 1500))) { // do this stuff every five seconds

prev_millis = millis();

ledIndication();

lcd_display1();

if (sol_amps > 2) {

digitalWrite(FAN_PIN,HIGH);

else{

digitalWrite(FAN_PIN,LOW);

if (disp_page==1) disp_page=2;

else disp_page=1;