Power Monitor with Serial UART

//--------------------------------------------------------------------------------------
// Mains AC Non-Invasive Energy Monitor (2 channel)
// Last revision 27th Oct 2010
// Licence: GNU GPL
// By Trystan Lea (updated to support two channel energy monitoring by Glyn Hudson)
// Serial UART library 'Easy Transfer' by Bill Porter.
//--------------------------------------------------------------------------------------
//--------------------------------------------------------------------------------------
// VARIABLE DECLERATION
//--------------------------------------------------------------------------------------
  //--ENERGY MEASURMENT VARIABLES------------------------------

  //Power measurement/time variables
  unsigned long t_now, t_diff, t_last, t_culm, ethsend;

  //Heater power culmative totals
  unsigned long timeH = 0, timeL = 0, heaterH = 0, heaterL = 0;
  float KWH_H = 0, KWH_L = 0;

  //kwhTotal is cumulative kwh today.
  double Solarkwh =0.0;
  double Mainskwh =0.0;

  //Variables for calculating heater power
  double sd6 ;

//--------------------------------------------------------------------------------------
// EMON
//--------------------------------------------------------------------------------------

// include the library code:
#include <LiquidCrystal.h>  // initialize the library with the numbers of the interface pins
LiquidCrystal lcd(8, 9, 10, 11, 12, 13);

#include <EasyTransfer.h>
  EasyTransfer ET; //for easy transfer
struct SEND_DATA_STRUCTURE{
  double sd1f;
  double sd2f;
  double sd3f;
  double sd4f;
  double sd5f;
  double sd6f;
  double sd7f;
};
SEND_DATA_STRUCTURE mydata;  //for easy transfer

int menuState = 0;
int menu = 0;
int menuintro = 0;

int wavelengths = 3000;   //number of wavelengths to sample
int inPinV = 1;           //Analog input pin number that voltage signal is connected to
int inPinI_1 = 3;         //Analog input pin number that current signal is connected to. Channel 1
int inPinI_2 = 2;         //Analog input pin number that current signal is connected to. Channel 2
int menupin = 2;          //Arduino pin 1 goes to pushbutton for menu
int RelayOn = 4;          //Arduino pin 4 goes to the opto isolator (full power)
int HRelayOn = 3;         //Arduino pin 3 goes to opto isolator (half power)
int led_on = 6;           //Arduino pin 6 goes to panel LED


//channel 1
double VCAL = 1.28348;              //Voltage calibration scaler
double ICAL_1 = 0.05815;            //Current calibration scaler
double ICAL_2 = 0.05806;

double PHASECAL = 2.3;                        //Shifts voltage relative to current,
                                              //subtracting any phase shifting caused by components

int emon_timeout = 2000;                       //how long to wait ms if something goes wrong.


class Channel
{
  public:
    void emon_calc(int,double);                //create pulse function
    double realPower,                          //Output variables
       apparentPower,
       powerFactor,
       Vrms,
       Irms,
       whInc,
       wh;

  private: // Variable declaration for emon_calc procedure
   int lastSampleV,sampleV;                          //sample_ holds the raw analog read value, lastSample_ holds the last sample_
    int lastSampleI,sampleI;

    double lastFilteredV,filteredV;                   //Filtered_ is the raw analog value minus the DC offset
    double lastFilteredI, filteredI;

    double phaseShiftedV;                             //Holds the calibrated phase shifted voltage.

    double sqV,sumV,sqI,sumI,instP,sumP;              //sq = squared, sum = Sum, inst = instantaneous

    int startV;                                       //Instantaneous voltage at start of sample window.

    boolean lastVCross, checkVCross;                  //Used to measure number of times threshold is crossed.
    int crossCount;                                   // ''

    unsigned long lwhtime, whtime;                    //used to calculate energy used.

};

Channel ch1,ch2;    //create two incidence of class channel for the two channels

//--------------------------------------------------------------------------------------
// SETUP
//--------------------------------------------------------------------------------------
void setup()
{
   lcd.begin(16, 2); // set up the LCD's number of columns and rows:

   Serial.begin(9600);
   ET.begin(details(mydata), &Serial); //easy transfer
   randomSeed(analogRead(0));  //easy transfer

   pinMode(RelayOn,OUTPUT); // this sets the pin named RelayOn to be an output
   pinMode(HRelayOn,OUTPUT); // this sets the pin named RelayOn to be an output
   pinMode(menupin, INPUT); // this sets the pin named menupin to be an input
   pinMode (led_on, OUTPUT); //this sets the pin named led_on to be an output

   t_culm = (3600000 * 12);       //On first run, advances the 24hr timer by 12hrs (so can restart at midday!)
   //t_culm = (3600000 * 23.75);  //FOR TESTING ONLY

   digitalWrite(RelayOn,HIGH);   //Switches relay off
   digitalWrite(HRelayOn,HIGH);  //Switches relay off

   //Introduces 15 second delay to allow caps to charge up
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("  Please Wait  ");
    lcd.setCursor(0, 1);
    lcd.print("Initialising....");
    delay (15000);
}

unsigned long wtime;

//--------------------------------------------------------------------------------------
// MAIN LOOP
//--------------------------------------------------------------------------------------
void loop()
{
  //-------------------------------------------------------------------------------------------
  // 1) Calculate energy monitor values
  //-------------------------------------------------------------------------------------------
  ch1.emon_calc(inPinI_1,ICAL_1);  //Energy Monitor calc function for channel 1, pass Arduino analog in pin nummber and calibration coefficient
  ch2.emon_calc(inPinI_2,ICAL_2);  //Energy Monitor calc function, for channel 2, pass Arduino analog in pin nummber and calibration coefficient

if (ch1.realPower < 0)  {   //Stops the solar channel reading negative (invertor anomaly)
   (ch1.realPower = 0);  }

  //--ENERGY MEASURMENT CALCULATION----------------

 //Power measurement
  t_now = millis();
    if ( t_now > t_last ) {   //check to see if millis has overflowed back to zero (after approx 49 days)
      t_diff = t_now - t_last; } //if not, the time each emon cycle takes
        else {  //if millis has reset...
          t_diff = 4127; }   //t_diff = (the amount of time each average emon cycle takes), again dealing with the millis reset.
  t_culm += t_diff;
  t_last = t_now;

  if ( t_culm > (3600000 * 24)){ //check to see if 24hrs has elapsed
  Solarkwh = 0; // RESET
  Mainskwh = 0; // RESET
  t_culm = 0;   // RESET
  heaterH = 0;  // RESET
  timeH = 0;    // RESET
  heaterL = 0;  // RESET
  timeL = 0;    // RESET
  ethsend = 0;  // RESET
  }

 //Calculate kW's diverted to heater per 24hrs
   if (digitalRead(RelayOn) == LOW) timeH += t_diff;
   if (digitalRead(HRelayOn) == LOW) timeL += t_diff;
   heaterH = (1.09 * timeH);    // units Ws;  (long math)
   heaterL = (0.545 * timeL);
   KWH_H = heaterH / 3.6e6;     // units KWH    3.6e6 = (3600.0 * 1000.0)
   KWH_L = heaterL / 3.6e6;

 //checks to see if can run at full power
      if (ch1.realPower > (ch2.realPower +1090)) {
      digitalWrite(HRelayOn,HIGH); //turn the half power output off
      delay (200);
      digitalWrite(RelayOn,LOW); //turn the full output on
       }
  else{
      digitalWrite(RelayOn,HIGH); //turn the output off
       //checks to see if can run at half power
       if (ch1.realPower > (ch2.realPower +545)) {
        delay (200);
        digitalWrite(HRelayOn,LOW); }//turn the output on
          else  {
           digitalWrite(HRelayOn,HIGH); //turn the output off
     }
   }

 //LED control
   if (digitalRead(RelayOn) == LOW) {
     analogWrite(led_on, 200);  }
   else if (digitalRead(HRelayOn) == LOW) {
     analogWrite(led_on, 20);   } //low brightness
   else {
         digitalWrite (led_on,HIGH);
         delay (100);
         digitalWrite (led_on,LOW);
        }

  //Calculate number of kwh generated.
  Solarkwh += ((ch1.realPower/1000.0) * 1.0/3600.0 * (t_diff/1000.0));
  Mainskwh += ((ch2.realPower/1000.0) * 1.0/3600.0 * (t_diff/1000.0));

    //------------Data Output-------------

    //Read menupin to see what menu to display
    menuState = digitalRead(menupin);
    if ( menuState == LOW) {
    menu = menu+1;
    menuintro = 0;  } //because the button has been pressed, sets menuintro to 0, so intro screen is displayed
    if (menu > 4){
    menu = 0;
    }

    //MENU 0
    if (menu == 0) {
    // clear the lcd screen
    lcd.clear();
    //if-else statement to alter LCD print format depending upon power reading
    lcd.setCursor(0, 0);
        if (ch1.realPower >= 1000)  {
      lcd.print("Solar "); lcd.print(ch1.realPower / 1000.0, 3); lcd.print(" kW");  }
    else  {
      lcd.print("Solar "); lcd.print(ch1.realPower, 0); lcd.print(" Watts");  }

    lcd.setCursor(0, 1);
        if (ch2.realPower >= 5000)  {
      lcd.print("M/Power over 5kW"); }
    else
      if (ch2.realPower >= 1000)  {
      lcd.print("Mains "); lcd.print(ch2.realPower / 1000.0, 3); lcd.print(" kW");  }
    else  {
      lcd.print("Mains "); lcd.print(ch2.realPower, 0); lcd.print(" Watts");  }
    }

    //MENU 1 - Displays kWh's per 24hrs
    if (menu == 1) {
      if (menuintro == 0) {  //if menu button has been pressed, displays intro screen
      lcd.clear();
      lcd.setCursor(0, 0);
      lcd.print ("Power Stats for");
      lcd.setCursor(0, 1);
      lcd.print("today");
      delay (2500); }
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("Solar "); lcd.print(Solarkwh); lcd.print(" kWh");
    lcd.setCursor(0, 1);
    lcd.print("Mains "); lcd.print(Mainskwh); lcd.print(" kWh");
    menuintro = 1;  }  //sets menu intro to 1 so that intro screen is not repeated

    //MENU 2 - Displays kWh's diverted to heater per 24hrs
    if (menu == 2) {
    if (menuintro == 0) {
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print ("kWh diverted to");
    lcd.setCursor(0, 1);
    lcd.print("imm heater today");
    delay (2500);  }
      lcd.clear();
      lcd.setCursor(0, 0);
      lcd.print(KWH_H); lcd.print("H + "); lcd.print(KWH_L); lcd.print("L");
      lcd.setCursor(0, 1);
      lcd.print("Total= "); lcd.print(KWH_H + KWH_L); lcd.print(" kWh");
      menuintro = 1; }

    //MENU 3 - Displays Voltage & Power Factor calibration
    if (menu == 3) {
      if (menuintro == 0) {
      lcd.clear();
      lcd.setCursor(0, 0);
      lcd.print ("Voltage and");
      lcd.setCursor(0, 1);
      lcd.print("power factor");
      delay (2500);  }
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("PowerF "); lcd.print(ch1.powerFactor, 2);
    lcd.setCursor(0, 1);
    lcd.print("Voltage "); lcd.print(ch1.Vrms, 0); lcd.print(" V");
    menuintro = 1;  }

    //MENU 4 - DEMO MODE
    if (menu == 4) {
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print ("Press button for");
    lcd.setCursor(0, 1);
    lcd.print("2 secs for demo");
    delay (2000);
    if (digitalRead(menupin)== LOW) {  //check to see if button is still pressed
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print ("DEMO MODE");
    delay (2000);
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("Solar 1.326 kW");
    lcd.setCursor(0, 1);
    lcd.print("Mains 298 Watts");
    digitalWrite (led_on,HIGH);
    delay (4000);
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("Solar 18.36 kWh");
    lcd.setCursor(0, 1);
    lcd.print("Mains 4.29 kWh");
    digitalWrite (led_on,HIGH);
    delay (4000);
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("2.44H + 1.80L");
    lcd.setCursor(0, 1);
    lcd.print("Total= 4.24 kWh");
    delay (4000);
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("PowerF 0.98");
    lcd.setCursor(0, 1);
    lcd.print("Voltage 247 V");
    digitalWrite (led_on,HIGH);
    delay (4000);
    menu = 0; }
    else {
      menu = 0; }
    }

    //----------------Serial Data to Ethernet unit------------------//

    if (digitalRead(RelayOn) == LOW) {
      sd6 = 1090 ;  }
       else if (digitalRead(HRelayOn) == LOW) {
         sd6 = 545 ;  }
          else {
            sd6 = 0  ;}

    //timer to control ethernet send rate
    if (t_culm > (ethsend + 30000)) {  //will execute a serial UART send 'after' 30 seconds
      ethsend = t_culm;
      //ethernet  send code goes here
        mydata.sd1f = (ch1.realPower, 0);
        mydata.sd2f = (ch2.realPower, 0);
        mydata.sd3f = (Solarkwh);
        mydata.sd4f = (Mainskwh);
        mydata.sd5f = (KWH_H + KWH_L);
        mydata.sd6f = sd6;
        mydata.sd7f = (ch1.Vrms, 0);
     //send the data
        ET.sendData();
    }
 }