Prototyped voltage-based grid disable

.gitignore

@@ -1 +1 @@
-*.DS_Store
+**.DS_Store

Electronics/PCB (KiCAD)/RevA/CARs/CAR009 - Add connector for External Screen.txt

@@ -1,3 +1,8 @@
 Add a connector for external Nextion screen.  Also need to add a FET (or use debug one) to turn Nextion off when car is off.
 
-Combine METSCI & BATTSCI to free up a serial port.  Still requires QTY2 LTC RS-488 chips.  Need to add another pin to control each chip output input impedance when key is off.
+Combine METSCI & BATTSCI to free up a serial port.  Still requires QTY2 LTC RS-488 chips.  Need to add another pin to control each chip output input impedance when key is off.
+
+VCC
+TX (Nextion)
+RX (Nextion)
+GND

Electronics/PCB (KiCAD)/RevA/CARs/CAR014 - LTC6804 Voltage Errors on certain cells/CAR014 - LTC6804 Voltage Errors on certain cells.txt

@@ -41,3 +41,7 @@ These traces are (accidentally) routed well.  Should still look at optimizing th
 Update: I removed R144 and connected a lead - with series 50 Ohm resistor - directly from the BMS connector's 24+ to R144 (net C12_B).  This is a direct sense to the LTC6804 for C24... but unfortunately it only reduced the measurement error 10 mV (from 33 mV to 23 mV.  Something else is wrong here.
 
 Going to play around with ADC update rate, etc.
+
+...
+
+Solution: There was a short from highest cell on IC to Vin.

Electronics/PCB (KiCAD)/RevA/CARs/CAR015 - HVDC->DC Filtering.txt

@@ -18,7 +18,7 @@ DLW5ATN272SQ2L
 Solutions:
 
 Between Input- & output-:
-Add a ~1nF capacitance between HVDC- & 12V-.  Put QTY2 22 nF in series between these negative leads for safety.
+Add capacitance between HVDC- & 12V-.  Put QTY2 22 nF in series between these negative leads for safety.
 
 Between HVDCDC inputs:
 Add 44 nF

Electronics/PCB (KiCAD)/RevA/CARs/CAR016 - General PCB Cleanup.txt

@@ -10,4 +10,8 @@ If possible, rotate bay 3 fan's wire hole for better wire routing on back of PCB
 
 Reroute HVDC so that pack voltage goes through fuse, then cap, then HVDCDC.
 
-HVDC 8pin screw terminal probably blocked by aluminum shaft that bolts from PDU to IMA battery.
+HVDC 8pin screw terminal probably blocked by aluminum shaft that bolts from PDU to IMA battery.
+
+Remove Redundant Neutral & GND Vias
+
+Move HVDCDC inward 0.1" to prevent interference with enclosure.  Same with cap and fuse.

Electronics/PCB (KiCAD)/RevA/CARs/CAR019 - isoSPI Biasing.txt

@@ -20,4 +20,12 @@ R265 (and related): 1.4 kOhm
 Requirement to achieve 1.0 mA: R267+R265 = 2 kOhm
 Requirement to achieve 0.5 mA: R267+R265 = 4 kOhm
 
-Current should lie between these two values.  Ideally close to - but not more than - 1 mA.
+Current should lie between these two values.  Ideally close to - but not more than - 1 mA.
+
+Solution:
+0.75 mA:
+R267 (and related): 1.00 kOhm
+R265 (and related): 1.65 kOhm (3k3 || 3k3)
+
+Add ground plane under isoSPI to reduce noise
+Change R130 to (22 nF || 100 kOhm), to reduce common mode noise.  Note that R130 is larger than 0805.

Electronics/PCB (KiCAD)/RevA/CARs/CAR020 - Thicker PCB.txt

@@ -0,0 +1 @@
+Make PCB thicker, so it deflects less.

Electronics/PCB (KiCAD)/RevA/CARs/CAR021 - Move Temperature Sensors.txt

@@ -0,0 +1,2 @@
+Add 2nd temp sensor to each LTC6804.
+Move temp sensor closer to cells... they're the warmest by far.

Electronics/PCB (KiCAD)/RevA/Manufacturing/.~lock.LiBCM BOM - RevA.ods#

@@ -0,0 +1 @@
+,master,Chonker.local,19.05.2021 23:44,file:///Users/master/Library/Application%20Support/LibreOffice/4;

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/DC1942.ino

@@ -125,24 +125,22 @@ uint16_t aux_codes[TOTAL_IC][6];
 
 uint8_t tx_cfg[TOTAL_IC][6];
 /*!<
-  The tx_cfg[][6] stores the LTC6804 configuration data that is going to be written
-  to the LTC6804 ICs on the daisy chain. The LTC6804 configuration data that will be
-  written should be stored in blocks of 6 bytes. The array should have the following format:
+  tx_cfg[][6] stores the LTC6804 configuration data to be written
+  to the LTC6804 ICs. The 6 byte array should have the following format:
 
- |  tx_cfg[0][0]| tx_cfg[0][1] |  tx_cfg[0][2]|  tx_cfg[0][3]|  tx_cfg[0][4]|  tx_cfg[0][5]| tx_cfg[1][0] |  tx_cfg[1][1]|  tx_cfg[1][2]|  .....    |
- |--------------|--------------|--------------|--------------|--------------|--------------|--------------|--------------|--------------|-----------|
- |IC1 CFGR0     |IC1 CFGR1     |IC1 CFGR2     |IC1 CFGR3     |IC1 CFGR4     |IC1 CFGR5     |IC2 CFGR0     |IC2 CFGR1     | IC2 CFGR2    |  .....    |
+ |  tx_cfg[0][0]| tx_cfg[0][1] |  tx_cfg[0][2]|  tx_cfg[0][3]|  tx_cfg[0][4]|  tx_cfg[0][5]|
+ |--------------|--------------|--------------|--------------|--------------|--------------|
+ |IC1 CFGR0     |IC1 CFGR1     |IC1 CFGR2     |IC1 CFGR3     |IC1 CFGR4     |IC1 CFGR5     |
 
 */
 
 uint8_t rx_cfg[TOTAL_IC][8];
 /*!<
-  the rx_cfg[][8] array stores the data that is read back from a LTC6804-1 daisy chain.
-  The configuration data for each IC  is stored in blocks of 8 bytes. Below is an table illustrating the array organization:
+  the rx_cfg[][8] array stores the 8 byte configuration data read back from the LTC6804:
 
-|rx_config[0][0]|rx_config[0][1]|rx_config[0][2]|rx_config[0][3]|rx_config[0][4]|rx_config[0][5]|rx_config[0][6]  |rx_config[0][7] |rx_config[1][0]|rx_config[1][1]|  .....    |
-|---------------|---------------|---------------|---------------|---------------|---------------|-----------------|----------------|---------------|---------------|-----------|
-|IC1 CFGR0      |IC1 CFGR1      |IC1 CFGR2      |IC1 CFGR3      |IC1 CFGR4      |IC1 CFGR5      |IC1 PEC High     |IC1 PEC Low     |IC2 CFGR0      |IC2 CFGR1      |  .....    |
+|rx_config[0][0]|rx_config[0][1]|rx_config[0][2]|rx_config[0][3]|rx_config[0][4]|rx_config[0][5]|rx_config[0][6]  |rx_config[0][7] |
+|---------------|---------------|---------------|---------------|---------------|---------------|-----------------|----------------|
+|IC1 CFGR0      |IC1 CFGR1      |IC1 CFGR2      |IC1 CFGR3      |IC1 CFGR4      |IC1 CFGR5      |IC1 PEC High     |IC1 PEC Low     |
 */
 
 //JTS Move to hardware IO file
@@ -333,6 +331,26 @@ void run_command(uint8_t cmd)
           Serial.println(F("A PEC error was detected in the received data"));
         }
         print_cells();
+        
+        //check for full cell(s)   
+        uint16_t cellVoltage_highest = 0;   
+        for (int current_ic = 0 ; current_ic < TOTAL_IC; current_ic++)
+          {
+            for (int i=0; i<12; i++)
+            {
+              if( cell_codes[current_ic][i] > cellVoltage_highest )
+              {
+                cellVoltage_highest = cell_codes[current_ic][i];
+              }
+              if( cell_codes[current_ic][i] > 36750 ) //3.7 volts
+              {
+                Serial.println("Cell " + String(current_ic * 12 + i + 1) + " is full." );
+                turnGridCharger_Off();
+                //tx_cfg[current_ic][i]
+              }
+            }
+          }
+        Serial.println("Highest cell voltage is: " + String(cellVoltage_highest , DEC) );
         delay(500);
       }
       print_menu();
@@ -348,16 +366,13 @@ void run_command(uint8_t cmd)
   
       if( gridEnabled || !(gridPowerPresent) ) //charger is enabled, or unplugged
       {
-        analogWrite(GRIDPWM_PIN,255); //Set power to zero
-        delay(100);
-        digitalWrite(GRIDEN_PIN,LOW); //Turn charger off
-        Serial.println(F("Charger turned off"));
+        turnGridCharger_Off();
       }
       if( !(gridEnabled) && gridPowerPresent ) //charger off & plugged in 
       {
         digitalWrite(GRIDEN_PIN,HIGH); //Turn charger on
         delay(100);
-        for(int ii=255; ii>0; ii--)
+        for(int ii=255; ii>=0; ii--)
         {
           analogWrite(GRIDPWM_PIN,ii);
           delay(2);
@@ -399,16 +414,17 @@ void run_command(uint8_t cmd)
 /*!***********************************
  \brief Initializes the configuration array
  **************************************/
+//JTS2do: This doesn't need to be a 2D array.  Data identical on all LTC, except DCC12:1.
 void init_cfg()
 {
   for (int i = 0; i<TOTAL_IC; i++)
-  {
-    tx_cfg[i][0] = 0xFE;
-    tx_cfg[i][1] = 0x00 ;
-    tx_cfg[i][2] = 0x00 ;
-    tx_cfg[i][3] = 0x00 ;
-    tx_cfg[i][4] = 0x00 ;
-    tx_cfg[i][5] = 0x00 ;
+  {                        // BIT7    BIT6    BIT5    BIT4    BIT3    BIT2    BIT1   BIT0 
+    tx_cfg[i][0] = 0xF6 ;  //GPIO5   GPIO4   GPIO3   GPIO2   GPIO1   REFON   SWTRD  ADCOPT //Enable GPIO pulldown, etc
+    tx_cfg[i][1] = 0x00 ;  //VUV[7]  VUV[6]  VUV[5]  VUV[4]  VUV[3]  VUV[2]  VUV[1] VUV[0] //Undervoltage comparison voltage
+    tx_cfg[i][2] = 0x00 ;  //VOV[3]  VOV[2]  VOV[1]  VOV[0]  VUV[11] VUV[10] VUV[9] VUV[8] 
+    tx_cfg[i][3] = 0x00 ;  //VOV[11] VOV[10] VOV[9]  VOV[8]  VOV[7]  VOV[6]  VOV[5] VOV[4] //Overvoltage comparison voltage 
+    tx_cfg[i][4] = 0x00 ;  //DCC8    DCC7    DCC6    DCC5    DCC4    DCC3    DCC2   DCC1   //Enables discharge on cells 8:1
+    tx_cfg[i][5] = 0x00 ;  //DCTO[3] DCTO[2] DCTO[1] DCTO[0] DCC12   DCC11   DCC10  DCC9   //Discharge timer and cells 12:9
   }
 }
 
@@ -560,3 +576,11 @@ void serial_print_hex(uint8_t data)
   else
     Serial.print((byte)data,HEX);
 }
+
+void turnGridCharger_Off(void)
+{
+  analogWrite(GRIDPWM_PIN,255); //Set power to zero
+  delay(100);
+  digitalWrite(GRIDEN_PIN,LOW); //Turn charger off
+  Serial.println(F("Charger turned off"));
+}

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/LTC68042.cpp

@@ -95,7 +95,6 @@ uint8_t ADAX[2]; //!< GPIO conversion command.
 */
 void LTC6804_initialize()
 {
-  quikeval_SPI_connect();
   spi_enable(SPI_CLOCK_DIV64);
   set_adc(MD_NORMAL,DCP_DISABLED,CELL_CH_ALL,AUX_CH_GPIO1);
 }
@@ -109,7 +108,7 @@ void LTC6804_initialize()
 @param[in] uint8_t CHG Determines which GPIO channels are measured during Auxiliary conversion command
 
  Command Code: \n
-      |command  |  10   |   9   |   8   |   7   |   6   |   5   |   4   |   3   |   2   |   1   |   0   |
+      |command    |  10   |   9   |   8   |   7   |   6   |   5   |   4   |   3   |   2   |   1   |   0   |
       |-----------|-------|-------|-------|-------|-------|-------|-------|-------|-------|-------|-------|
       |ADCV:      |   0   |   1   | MD[1] | MD[2] |   1   |   1   |  DCP  |   0   | CH[2] | CH[1] | CH[0] |
       |ADAX:      |   1   |   0   | MD[1] | MD[2] |   1   |   1   |  DCP  |   0   | CHG[2]| CHG[1]| CHG[0]|
@@ -122,8 +121,8 @@ void set_adc(uint8_t MD, //ADC Mode
 {
   uint8_t md_bits;
 
-  md_bits = (MD & 0x02) >> 1;
-  ADCV[0] = md_bits + 0x02;
+  md_bits = (MD & 0x02) >> 1; //set bit 8 (MD[1]) in ADCV[0]... MD[0] is in ADCV[1] 
+  ADCV[0] = md_bits + 0x02;  //set bit 9 true
   md_bits = (MD & 0x01) << 7;
   ADCV[1] =  md_bits + 0x60 + (DCP<<4) + CH;
 

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/LTC68042.h

@@ -52,7 +52,7 @@ Copyright 2013 Linear Technology Corp. (LTC)
 
 
 #ifndef LTC6804_CS
-#define LTC6804_CS QUIKEVAL_CS
+#define LTC6804_CS SS //Arduino Mega SPI Slave Select line
 #endif
 
 

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/LT_SPI.cpp

@@ -134,25 +134,6 @@ void spi_transfer_block(uint8_t cs_pin, uint8_t *tx, uint8_t *rx, uint8_t length
   output_high(cs_pin);                //! 3) Pull CS high
 }
 
-// Connect SPI pins to QuikEval connector through the Linduino MUX. This will disconnect I2C.
-void quikeval_SPI_connect()
-{
-  pinMode(QUIKEVAL_CS, OUTPUT);
-  output_high(QUIKEVAL_CS); //! 1) Pull Chip Select High
-
-  //! 2) Enable Main SPI
-  pinMode(QUIKEVAL_MUX_MODE_PIN, OUTPUT);
-  digitalWrite(QUIKEVAL_MUX_MODE_PIN, LOW);
-}
-
-// Configure the SPI port for 4MHz SCK.
-// This function or spi_enable() must be called
-// before using the other SPI routines.
-void quikeval_SPI_init(void)  // Initializes SPI
-{
-  spi_enable(SPI_CLOCK_DIV16);  //! 1) Configure the spi port for 4MHz SCK
-}
-
 // Setup the processor for hardware SPI communication.
 // Must be called before using the other SPI routines.
 // Alternatively, call quikeval_SPI_connect(), which automatically

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/LT_SPI.h

@@ -98,14 +98,6 @@ void spi_transfer_block(uint8_t cs_pin,     //!< Chip select pin
                         uint8_t length      //!< Length of array
                        );
 
-//! Connect SPI pins to QuikEval connector through the Linduino MUX. This will disconnect I2C.
-void quikeval_SPI_connect();
-
-//! Configure the SPI port for 4Mhz SCK.
-//! This function or spi_enable() must be called
-//! before using the other SPI routines.
-void quikeval_SPI_init();
-
 //! Setup the processor for hardware SPI communication.
 //! Must be called before using the other SPI routines.
 //! Alternatively, call quikeval_SPI_connect(), which automatically

Firmware/Prototype Building Blocks/LTC6804-2 (addressable)/DC1942/Linduino.h

@@ -54,7 +54,6 @@ OF THIS SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
 //! @{
 
 #define QUIKEVAL_GPIO 9          //!< Linduino QuikEval GPIO pin (QuikEval connector pin 14) connects to Arduino pin 9
-#define QUIKEVAL_CS SS           //!< QuikEval CS pin (SPI chip select on QuikEval connector pin 6) connects to Arduino SS pin.
 #define QUIKEVAL_MUX_MODE_PIN 8  /*!< QUIKEVAL_MUX_MODE_PIN defines the control pin for the QuikEval MUX.
 The I2C port's SCL and the SPI port's SCK signals share the same pin on the Linduino's QuikEval connector.
 Additionally, the I2C port's SDA and the SPI port's MOSI signals share the same pin on the Linduino's QuikEval connector.