Dual CANbus monitor and instrumentation cluster. Presently tuned for the Nissan Leaf EV.

Dependencies:   SPI_TFTx2_ILI9341 TFT_fonts TOUCH_TFTx2_ILI9341 mbed

Fork of CANary_corrupt by Tick Tock

After adding the LPC1768 platform, import as a program and do not select the "update to latest revision" box

User Guide

Eagle Schematic and Board design

/media/uploads/TickTock/canaryr6.zip

/media/uploads/TickTock/canary_sch.jpg

/media/uploads/TickTock/canaryr6brd.jpg

For LCD Rev 1.01:

/media/uploads/TickTock/lcdsch.jpg

For VCD Rev 2.00:

/media/uploads/TickTock/lcdr2.jpg

Parts List

qtyinstancepart #packagesupplierDescription
1BAT3Vhttp://www.ebay.com/itm/10x-CR2032-SMD-Battery-Holder-for-CR2032-Battery-/180938057979?pt=LH_DefaultDomain_0&hash=item2a20bfa8fbLithium 2032 coin battery holder
4C1-C4ECST1DC106R6032Tantalium capacitor 10uF
3FC1-FC3ZF1-20-01-T-WThttp://www.samtec.com/cable-systems/idc-ffc/ffc/zero-insertion.aspx20 conductor 1mm pitch flex cable connector (optional)
1FJ-20-R-08.00-4http://www.samtec.com/cable-systems/idc-ffc/ffc/zero-insertion.aspx8\" 20 conductor 1mm pitch flex connector, end reversed (optional)
2H1-H4(DON'T populate H1-H4 headers - solder mbed directly)
1H5http://www.ebay.com/itm/221186042943?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l26491x12 .1\" pitch header (optional)
1H62x6 .1\" pitch header (optional)
2IC1,IC2VP230LMDSOP8http://www.ebay.com/itm/130488665247?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649canbus transciever
1IC3LM1117-5VSOT2235V regulator
5JP*2 pin .1\" jumper header
1mbedLPC1768http://www.ebay.com/itm/200830573509?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649mbed uC
2Q1,Q22N2222SOT23General purpose NPN transistor
1R1R393M120639K resistor
1R2R103M120610K resistor
4R4-R6R102M12061K resistor
1R3R500M120650 Ohm resistor
2TR1-TR5ZJYS81R5-2PL51TG01http://www.digikey.com/product-detail/en/ZJYS81R5-2PL51T-G01/445-2223-1-ND/765232CM Choke
1Z11N5340BGC1702-15http://www.ebay.com/itm/150878122425?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l26496V, 5W Zener Diode
1Z1DC-DC conveterhttp://www.ebay.com/itm/251142727849?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l264912V-7V, 3W DC-DC converter
1X1USBhttp://www.ebay.com/itm/New-Vertical-USB-2-0-A-pcb-connector-socket-USB-A-Type-/300553895292?pt=LH_DefaultDomain_0&hash=item45fa687d7cvertical USB connector
2LCD0,LCD1TFThttp://www.mikroe.com/add-on-boards/display/tft-proto/320x240 LCD with touch screen
1E0Enclosurehttp://www.shapeways.com/model/1077799/canary.html?li=user-profile&materialId=63d printed enclosure

Assembly

1) LCD Displays

I found ribbon cable is a nice way to organize the wires to the displays. There are two versions of the display and each must be wired differently. The original project used HW REV. 1.01. For that version, you'll need 12 conductors and I connected them in the following order:

1LED+
2LED-
3RST
4SDI
5WR/SCLK
6CS
7X+
8X-
9Y+
10Y-
11VDD
12GND

If, instead, you have HW REV 2.0, you will need 13 conductors with the following order:

1LED+
2LED-
3RST
4SDI
5RS (SCLK)
6WR (DC)
7CS
8X+
9X-
10Y+
11Y-
12VDD
13GND

First I connected all the GND connections (2 GND & IM0, IM1, IM3 for REV1.01 or 2 GND, RD, & IM0 for REV2.00). Do not connect the bottom GND until you have the ribbon cable connected. After making all the ribbon cable connections (connecting the GND of the ribbon cable to the bottom GND pad), solder the GND bar from the previous step to the back of the bottom GND connection. Finally, make a connection from the back side 3.3V pin to IM2 for REV1.01 or to IM1,IM2,&IM3 for REV2.00. Take a break and repeat for the second display.

Examples of REV1.01 boards:

/media/uploads/TickTock/lcdtop.jpg /media/uploads/TickTock/lcdbot.jpg

Examples of REV2.00:

/media/uploads/TickTock/rev2front.jpg /media/uploads/TickTock/rev2back.jpg

Once the two displays are complete combine all wires except CS0, CS1, X+, X-, Y+, and Y-. Connect X- of the left display to X+ of the right. Similarly connect Y- of the left display to Y+ of the right. Insulate any exposed wires.

2) PCB

Refer to the schematics to place all the components on the board. If you plan to install into the CANary 3D enclosure, DO NOT install the battery holder or the socket for the mbed and, instead, connect two wires to the VB and GND pads nearby. You will have to install the battery holder against the back wall to avoid interfering with the right-hand display and the mbed will have to be directly soldered. I have not found a socket with a low enough profile to fit in the space provided (depth of enclosure is limited by the space behind the center console). Also, I recommend keeping as much lead as possible on the Zener diode (bending it as shown to clear the back wall). Although it is operating well within parameters, the Zener gets quite hot during extended operation and the leads help dissipate the heat and keep it away from the PCB and other components.Update: Several Zeners have failed resulting in damage to some users boards so I recommend using a DC-DC converter instead to bring the 12V down to 7V.

/media/uploads/TickTock/pcbtop.jpg /media/uploads/TickTock/pcbbot.jpg

Once the PCB is populated, solder the LCDs to the PCB. CS0 connects to the right display and CS1 connects to the left. /media/uploads/TickTock/brddis.jpg

Update: The Zener diodes tended to fail after a few months so I am recommending removing them and replacing with a DC-DC converter. This will run cooler and waste less energy, too. To install, remove the left display panel to gain access to the Zener. From there, the Zener can be removed and it's pads used to connect to the DC-DC converter. I recommend setting the output voltage on the bench before installing since the trim pot is tricky to reach once installed. Set it to 7V. The input can be connected to the left pad previously occupied by the zener and the output can connect to the right. GND(-) can be connected to the bottom right pad on the 2x6 header below the flex cable connector. Make sure the GND wire lies flat so it doesn't interfere with the connection of the flex cable. /media/uploads/TickTock/dcdcinst2.jpg

Once soldered in place, the DC-DC converter can easily be mounted to the back wall with double sided tape above the battery holder. /media/uploads/TickTock/dcdcinst3.jpg

3) Testing

1)First step is to buzz out all connections from the LCDs to the pins in the main board
2)Next check the touch screen connections. On the main board, place an Ohm meter across X+ and X-. You should read 700 Ohms. Repeat for Y+ and Y-. Then test the resistance from X+ to Y+. With nothing touching the screens, it should read >100K Ohms and <1K when touching either screen.
3)When all connections are checked, solder in the mbed. Download and install the touch2 program http://mbed.org/users/TickTock/code/touch2/ to test the basic operation of the mbed and touch screens.
tips:
Touch screen is sensitive - excess flux on X+,X-,Y+,Y- connection on mbed can result in flakey operation
If touch is not working, double-check the LCD0_CS and LCD1_CS are not swapped. LCD0_CS must connect to the CS of the LCD that has X- & Y- connected to the mbed. LCD1_CS must connect to the CS of the LCD that has X+ & Y+ connected to the mbed.
4)Once touch2 works, it is time to connect to the OBD connector. I highly recommend double checking all connections from the OBD to the PCB with the cable in place before connecting to the Leaf. Buzz out all the pins in the OBS to make sure none are shorting to each other, Check that the 12V goes to the Zener (and nothing else) and the switched 12V to the resistor divider (and nothing else). Test the ground connection properly connects to ground and nothing else.
5)Once you are confident there are no shorts or wrong connections from the OBD connector, take a deep breath and plug it into your leaf. Touch2 program should come up and function. Unplug and install the latest CANary firmware. If you have the REV2.00 LCD boards, you will need to edit the precompile.h file in the TOUCH_TFTx2_w9341 library and set USE_ILI9341 to 1. Test all features before installing into the enclosure (gids, cellpair, menu system, logging) since installing and removing from the enclosure is a PITA.

/media/uploads/TickTock/pcbdone.jpg /media/uploads/TickTock/functioning.jpg

4) Enclosure

The 3D printer leaves a lot of powder behind - I used a strong spray of water to get it out of all the cracks. The enclosure comes with a rather rough finish. I recommend convincing yourself you like it, then simply lightly sand then paint before assembly. Sanding is very difficult - the nylon is very nicely fused and doesn't want to sand. I tried sandblasting and that didn't work either. I had some limited success with filler and then sanding, but only on the outside - it is too difficult to sand the face. /media/uploads/TickTock/enclosure.jpg

5) Final Assembly

Make sure you are well rested with lots of patience before attempting assembly. It is a puzzle figuring out how to get both displays and the PCB in place. Enclosure was too expensive for me to keep iterating to optimize for assembly. I ended up snipping the thin display posts shorter and using various tools to push the displays into place. Also, some USB connectors are taller than others. If you have one of the taller ones, you will have to deflect the back wall a bit while inserting the PCB (being careful not to bend the housing) to get it to it's opening in the back wall. Do use a screw in the provided post to secure the PCB as USB insertion will otherwise dislodge it.

I added an additional safety line which wraps around the center post to prevent the enclosure from becoming a projectile in the event of an accident. /media/uploads/TickTock/safety.jpg Installed: /media/uploads/TickTock/installed.jpg

Revision:
129:8991d0de01ab
Parent:
64:a2b3c7201faa
Parent:
128:25314f339565
Child:
130:1a9d2a6d99ce
--- a/main.cpp	Wed Apr 10 13:31:35 2013 +0000
+++ b/main.cpp	Sun Jul 21 23:59:00 2013 +0000
@@ -1,33 +1,39 @@
 // main.cpp
-
+//
 //To Do:
-// * USB device detect
-// * Ability to update binary from the thumb-drive (requires file timestamp)
 // * Audible friction brake feedback
 // * User-configurable watchpoint
-// * Better graphical DTE display with historic efficiency information considered and displayed
 // * Add 50% charge option
-// * Tire Pressure Sensor display
+// * Add coasting regen to regen/braking display
+// * Change semilog efficiency graph to linear with 10 minute values
+// * Add additional 79b bank readouts
+// * Add ability to transfer settings config file to/from USB
+// * Subtract accessory power from efficiency history (add back in when displaying)
 
 #include "mbed.h"
 #include "CAN.h"
 #include "beep.h"
-#include "MSCFileSystem.h"
+#include "ff.h"
 #include "PowerControl.h"
 #include "EthernetPowerControl.h"
 #include "utility.h"
 #include "displayModes.h"
 #include "TOUCH_TFTx2.h"
 
+char revStr[7] = "128b"; // gg - revision string, max 6 characters
+
+FATFS USBdrive;
 LocalFileSystem local("local");
-
+bool waitasec = true;
+unsigned char wait5secs = 5;
 // to write to USB Flash Drives, or equivalent (SD card in Reader/Writer)
-MSCFileSystem fs("usb"); // to write to a USB Flash Drive
-
+// class10 SDcard in Reader/Writer recommended
+FRESULT mfr = f_mount(0,&USBdrive);
 time_t seconds ;
 
 Ticker autoPoll;
 Ticker playback;
+Ticker msgReq;
 Timer timer;
 
 DigitalOut led1(LED1);
@@ -45,22 +51,30 @@
 PwmOut dled(p23);
 Beep spkr(p21);
 
-bool logEn = false, logOpen = false; 
-bool yesBattLog = false ; // gg - Batt Log
-unsigned char tNavRow = 3 ; // gg - 4x4 touch
+bool debugMode = false;
+bool usbEn = false;
+bool logEn = false;
+bool logOpen = false; 
+bool yesBattLog = true; // gg - Batt Log
+unsigned char tNavRow = 3; // gg - 4x4 touch
 
-FILE *cfile;
-FILE *file;
-char fileName[35] = "" ;
-char writeBuffer[maxBufLen][13]; // buffer for USB write
+FILE *hfile; // history file
+FIL efile; // external usb file
+FRESULT efr; // external file access flags
+unsigned int bytesRW;
+char fileName[35] = "";
+char writeBuffer[maxBufLen][13] __attribute__ ((section("AHBSRAM1"))); // buffer for USB write
 char indexLastMsg[0x800]={0}; // index table for last message
 CANMessage lastMsg[100]; // table to store last message of eachtype
-unsigned char battData[256]={0};
+
+unsigned char battData[BatDataBufMax]={0}; // 7 * 0x3D = BatDataBufMax
+
 unsigned char msgChanged[100]; // inidcates which bytes changed
 char c;
 volatile int writePointer = 0;
-volatile int secsNoMsg = 0;
-volatile int secsNoTouch = 0;
+int readPointer=0;
+volatile unsigned short secsNoMsg = 0;
+volatile unsigned short secsNoTouch = 0;
 volatile bool canIdle;
 volatile bool userIdle;
 bool touched=false; //flag to read touchscreen
@@ -69,16 +83,18 @@
 unsigned char dMode[2] = {mainScreen,brakeScreen}; //display mode
 unsigned char sMode = 0; // setup mode
 unsigned char lastDMode[2] = {0,0}; //last screen mode
-unsigned char dtMode = 6;
+unsigned char dtMode = 0;
 char displayLog[20][40];
 unsigned char displayLoc = 0;
+unsigned int fwCount=1;
 unsigned char indexOffset = 1;
 bool showCP = false;
-bool pollCP = false;
 bool logCP = false; //Turbo3
-bool repeatPoll = false;
+bool logOnce = false;
+bool repeatPoll = true;
 bool headlights = false;
 bool tick = false;
+bool ZeroSecTick = false;
 float ledHi = 0.8; // Bright LED value (until config file read)
 float ledLo = 0.1; // Dim LED value (until config file read)
 unsigned short pollInt = 300; // polling interval=5 minutes (until config file read)
@@ -92,41 +108,48 @@
 bool playbackEn = false;
 bool playbackOpen = false;
 //float playbackInt = 0.05; //read messages every 50 ms
-float playbackInt = 0.005; //read messages every 50 ms
+float playbackInt = 0.005; //read messages every 5 ms
 bool step = false;
 char header[5];
 char data[8];
 signed long motorRPM;
-unsigned char skin = 0;
+unsigned char skin = ttSkin ;
 unsigned char dtePeriod = 14; //ten minute averaging interval
+float kWh_trip[3]={0};
+float miles_trip[3]={0};
 float mph[39]={0};
 float kW[39]={0};
 float mpkWh[39]={0};
+float unloadedV_x2,Resr,curRmax,curRmin,redRmax,redRmin,incRmax,incRmin;
+signed short Imax, Imin;
 // Logarithmic division scale (roughly - snapped to common units of time)
 float timeConstant[39] = {1, 1.58, 2.51, 3.98, 6.31, 10, 15.8, 25.1, 39.8, 60, // 1 minute
                      60*1.58, 60*2.51, 60*3.98, 60*6.31, 60*10, 60*15.8, 60*25.1, 60*39.8, 60*60, // 1 hour
                      60*60*1.58, 60*60*2.51, 60*60*3.98, 60*60*6.31, 60*60*10, 60*60*15.8, 60*60*24, // 1 day
                      60*60*24*1.58, 60*60*24*2.51, 60*60*24*3.98, 60*60*24*6.31, 60*60*24*10, 60*60*24*15.8, 60*60*24*30, // 1 month
                      60*60*24*39.8, 60*60*24*63.1, 60*60*24*100, 60*60*24*158, 60*60*24*251, 60*60*24*365}; // 1 year
-bool updateDTE = false;
+bool tock = false;
+unsigned short pointerSep;
+unsigned char reqMsgCnt = 99;
+unsigned long Ah_x10000 = 0;
+unsigned long SOC_x10000 = 0;
+unsigned short SOH_x100 = 0;
+float maxTemp = 0;
+bool metric = false;
+bool shunt[96]={0};
+bool charging=false;
+bool showHealth=false;
+unsigned char saveDmode=99;
+bool moving=false;
 
 int main() {
-    int readPointer=0;
+    //can1SleepMode.mode(OpenDrain);
+    //can2SleepMode.mode(OpenDrain);
     char sTemp[40];
     unsigned long secs;
     unsigned char i,j,display=0,lwt=0;
     point lastTouch;
     float average;
-
-    can1.monitor(true); // set to snoop mode
-    can2.monitor(true); // set to snoop mode
-    can1.frequency(500000);
-    can2.frequency(500000);
-    can1SleepMode = 1;         // Turn on Monitor_only Mode
-    can2SleepMode = 1;         // Turn on Monitor_only Mode
-    can1.attach(&recieve1);
-    can2.attach(&recieve2);
-    
     tt.set_orientation(1);
     tt.background(Black);
     tt.set_display(2);       // select both displays
@@ -135,12 +158,12 @@
     touchpad.rise(&touch_ISR);
     tt.wfi();               // enable interrupt on touch
     dled = 0.8; // turn on display LED 80%
-
+    Resr = 0.075; // initial guess of Resr
     timer.start() ;
     RTC_Init(); // start the RTC Interrupts that sync the timer
     struct tm t; // pointer to a static tm structure
-    NVIC_SetPriority(TIMER3_IRQn, 1); //set ticker priority
-    NVIC_SetPriority(CAN_IRQn, 2); //higher than can (so RTC sync works)
+    NVIC_SetPriority(CAN_IRQn, 2); //set can priority just below RTC
+    NVIC_SetPriority(TIMER3_IRQn, 3); //set ticker priority just below can
 
     seconds = time(NULL);
     t = *localtime(&seconds) ;
@@ -154,64 +177,27 @@
     }
     t = *localtime(&seconds) ;
     strftime(sTemp, 32, "%a %m/%d/%Y %X\n", &t);
-    logMsg(sTemp);
+    printMsg(sTemp); // record RTC
     
     // revision
-    sprintf(sTemp,"CANary firmware rev64\n");
-    logMsg(sTemp);
-
-    // Look for new binary on thumbdrive
-    // Can't make this work right now since USB doesn't attach the right timestamp (so new binary isn't loaded)
-    /*cfile = fopen("/usb/CANary.bin", "rb");
-    lastDMode[whichTouched]=99;//force refresh
-    if (cfile!=NULL){ //found a new binary on the thumbdrive so copy it over
-        sprintf(sTemp,"New binary found.\n");
-        logMsg(sTemp);
-        file = fopen("/local/CANary.bin", "wb");
-        if (file==NULL){ //failed to open destination
-            sprintf(sTemp,"Unable to open destination file.\n");
-            logMsg(sTemp);
-        } else {
-            tt.set_display(2);
-            tt.foreground(White);
-            tt.background(Black);
-            tt.cls();
-            tt.locate(1,40);
-            printf("%s\n","Copying binary - Do no remove power.");
-            tt.locate(1,80);
-            printf("CANary will reset when complete.\n");
-            wait(1); //Wait 1 sec for display DMA to finish before writing file
-            while ( int size = fread( writeBuffer, sizeof(char), maxBufLen*13, cfile )){
-                fwrite( writeBuffer, sizeof(char), size, file );
-                led4=led3;
-                led3=led2;
-                led2=led1;
-                led1=!led4;
-            }
-        fclose(cfile);
-        fclose(file);
-        remove("/usb/CANary.bin"); // delete original
-        mbed_reset(); //restart
-        }
-    }*/
+    sprintf(sTemp,"CANary firmware rev%s\n", revStr); // gg - for Logging the revision
+    printMsg(sTemp); // revision
 
     secsNoMsg = 0;
 
     //read efficiency history data
-    cfile = fopen("/local/ehist.cny", "r");
-    if (cfile!=NULL){ // found a efficiency history file
+    hfile = fopen("/local/ehist.cny", "r");
+    if (hfile!=NULL){ // found a efficiency history file
         for(i=0;i<39;i++){
-            if(!feof(cfile)){
-                fscanf(cfile,"%f %f\r\n",&mph[i],&kW[i]);
+            if(!feof(hfile)){
+                fscanf(hfile,"%f %f\r\n",&mph[i],&kW[i]);
                 mpkWh[i]=mph[i]/kW[i];
             }
         }
-        fclose(cfile);
-        sprintf(sTemp,"History Loaded.\n");
-        logMsg(sTemp);
+        fclose(hfile);
+        printMsg("History Loaded.\n"); // History loaded
     } else { // create initial file
-        sprintf(sTemp,"History not found.  Created.\n");
-        logMsg(sTemp);
+        printMsg("History not found.  Created.\n"); // history not found, created
         for(i=0;i<39;i++){
             // Pre-load with 4 mpkWh @ 40 mph
             mph[i]=40*timeConstant[i];
@@ -222,71 +208,94 @@
 
     // Read config file
     readConfig();
+    if (repeatPoll) { // enable autopolling if enabled
+        autoPoll.attach(&autoPollISR,pollInt);
+    }
+    
+    // Start monitors
+    can1.monitor(true); // set to snoop mode
+    can2.monitor(true); // set to snoop mode
+    can1.frequency(500000);
+    can2.frequency(500000);
+    can1SleepMode = VP230Sleep;         // Turn on Monitor_only Mode
+    can2SleepMode = VP230Sleep;         // Turn on Monitor_only Mode
+    can1.attach(&recieve1);
+    can2.attach(&recieve2);
 
     touched=false;
     secsNoTouch=2;
     while (true) {
         if (!logOpen) { // Open new file if one is not already open
-            if(logEn){ //logging enable
+            if(logEn&&usbEn){ //logging enabled and USB device detected
+                strftime(fileName, 32, "%m%d%H%M.alc", &t); //mmddhhmm.alc
+                efr = f_open(&efile,fileName,FA_WRITE|FA_OPEN_ALWAYS);
                 seconds = time(NULL);
                 t = *localtime(&seconds) ;
-                strftime(fileName, 32, "/usb/%m%d%H%M.alc", &t); //mmddhhmm.alc
-                //sprintf(sTemp,"Using file %s\n",fileName);
-                //logMsg(sTemp);
-                file = fopen(fileName, "ab");
-                lastDMode[whichTouched]=99;//force refresh
-                if(file==NULL){
-                    sprintf(sTemp,"\nUnable to open %s\n\n\n\n",fileName);
-                    logMsg(sTemp);
+                lastDMode[0]=99;//force refresh
+                lastDMode[1]=99;//force refresh
+                if(efr != FR_OK){
+                    sprintf(sTemp,"\nERR:%d Unable to open %s\n\n\n\n",efr,fileName);
+                    printMsg(sTemp); // cannot open alc file
                     logEn=false;
                     spkr.beep(1000,0.25);
+                    wait_ms(500);
+                    spkr.beep(1000,0.25);
                 } else {
                     logOpen = true;
                     readPointer=writePointer;
                     sprintf(sTemp,"Starting Can Log %s\n",fileName);
-                    logMsg(sTemp);
-                    logTS();
+                    printMsg(sTemp); // starting alc log file 
+                    
+                    logTS(); // Date Time at start
+                    logEvent("Starting"); // Log startup msg for testing
+                    sprintf(sTemp,"Cr%s",revStr);
+                    logEvent(sTemp); // gg - log firmware version   
                     spkr.beep(2000,0.25);
                 }
-            }//logging enabled
+            }//logging enabled and USB detected
         } else { // if (logOpen)
-            if (((writePointer+maxBufLen-readPointer)%maxBufLen)>(maxBufLen/16)||canIdle||!logEn) {
+            pointerSep=(writePointer+maxBufLen-readPointer)%maxBufLen;
+            if (pointerSep>(maxBufLen/16)||canIdle||!logEn) {
                 // Dump buffer if > 1/16 full or canbus has stopped
-                if (file == NULL) {
+                //if (&efile == NULL) {
+                if (efr != FR_OK) {
                     logOpen = false;
-                    sprintf(sTemp,"Failed to append log file.\n");
-                    logMsg(sTemp);
-                    spkr.beep(1000,0.25);
+                    printMsg("Failed to append log file.\n"); // failed to append 
+                    spkr.beep(3000,0.25);
+                    spkr.beep(1500,0.25);
+                    spkr.beep(750,0.25);
+                    spkr.beep(375,0.25);
                     logEn=false;
                 } else {
-                    if (((writePointer+maxBufLen-readPointer)%maxBufLen)>(maxBufLen*7/8)) { // Hi-water mark
-                        sprintf(sTemp,"Write buffer overrun.\n");
-                        logMsg(sTemp);
-                        spkr.beep(1000,0.25);
+                    while (readPointer != writePointer) {
+                        efr=f_write(&efile,&writeBuffer[readPointer][0],13,&bytesRW);
+                        if(++readPointer >= maxBufLen){
+                            readPointer=0;
+                            led4 = !led4;
+                        }
                     }
-                    while (readPointer != writePointer) {
-                        for (j = 0; j<13; j++){
-                            fprintf(file,"%c",writeBuffer[readPointer][j]);
-                        }
-                        if(++readPointer >= maxBufLen)
-                            readPointer=0;
-                    }
-                    led4 = !led4;
                 }
             } // if > 1/16 full, canbus has stopped, or logging stopped
             if (!logEn) {
-                fclose(file);
+                sprintf(sTemp,"Stopping Can Log %s\n",fileName);
+                printMsg(sTemp); // stopping alc log file 
+                f_close(&efile);
                 logOpen=false;
+                pointerSep=0;
+                led4=false;
             }
         } // if logOpen
         if (canIdle&&userIdle&&!playbackEn) { // canbus idle --> sleep to save power
-            if (logOpen){
-                fclose(file);
-            } // if (logOpen)*/
+            if (repeatPoll) { // stop autopolling if enabled
+                autoPoll.detach();
+            }
+            if (logOpen){ //close file to dump buffer
+                f_close(&efile);
+            } // if (logOpen)
             seconds = time(NULL);
             t = *localtime(&seconds) ;
             strftime(sTemp, 40, "Sleeping: %a %m/%d/%Y %X\n", &t);
-            logMsg(sTemp);
+            printMsg(sTemp); // sleeping date time
             updateDisplay(0); //Added for turbo3 who has a display override and wants to see the sleep message before going to sleep
             updateDisplay(1);
             //LPC_RTC->CIIR=0x00; // block RTC interrupts
@@ -302,20 +311,29 @@
                 //__wfi(); // freeze CPU and wait for interrupt (from canbus or touch)
                 Sleep();
             }
+            lastDMode[0]=99;
+            lastDMode[1]=99;
             secsNoTouch=2;
             canIdle=secsNoMsg>canTimeout;
-            //userIdle=!touched;
             dled=0.8; // turn on display LED
             seconds = time(NULL);
             t = *localtime(&seconds) ;
             strftime(sTemp, 40, "Waking: %a %m/%d/%Y %X\n", &t);
-            logMsg(sTemp);
+            printMsg(sTemp); // wakeup date time
             if (time(NULL)>(secs+1800)) {
-                logOpen = false; // Start new file if asleep for more than 30 minutes
+                if (logOpen){
+                    f_close(&efile);
+                    logOpen = false; // Start new file if asleep for more than 30 minutes
+                } // if (logOpen)
                 if (secsNoTouch>100) secsNoTouch = 100; // also mostly reset user Idle counter
             } else if (logOpen){ // insert timestamp on each wake if logging enabled (disabled for now)
-                file = fopen(fileName, "ab");
-                logTS();
+                efr = f_open(&efile,fileName,FA_WRITE|FA_OPEN_ALWAYS);
+                f_lseek(&efile,0xffffffff); // goto end of file (append existing)
+                logEvent("WakingUp"); // gg - use messeges
+                logTS(); // Date-Time at wakeup
+            }
+            if (repeatPoll) { // re-enable autopolling if enabled
+                autoPoll.attach(&autoPollISR,pollInt);
             }
         } // if idle
         
@@ -341,7 +359,7 @@
                 sMode = 1;
             }
             //sprintf(sTemp,"%d,%d ",lastTouch.x,lastTouch.y);
-            //logMsg(sTemp);
+            //printMsg(sTemp); // touch x,y - for debug
             touched = false; // clear interrupt flag
         }
         //---------------
@@ -355,7 +373,7 @@
                 secsNoTouch +=2; // increment to prevent double touch
                 sMode = 1;
                 //sprintf(sTemp,"button %d %d,%d %d\n",i,buttonX(lastTouch.x,3),buttonY(lastTouch.y,3),lastTouch.x);
-                //logMsg(sTemp);
+                //printMsg(sTemp); // button parms - for debug
                 switch (sMode) {
                     case 0: // no select
                         break;
@@ -372,10 +390,13 @@
                         if( tRow == tNavRow ) tRow = 7 ; // gg                   
                         switch ( (tCol*10) + tRow ) {
                             //---------------------------------
-                            case 00: // 00 on screen 0 or 1
+                            case 00: // top row, left button on screen 0 or 1
                                 if (dMode[whichTouched]==monitorScreen||dMode[whichTouched]==changedScreen) {
-                                indexOffset=indexOffset>4?indexOffset-4:1;
-                                } else if (dMode[whichTouched]==config1Screen) {
+                                    indexOffset=indexOffset>4?indexOffset-4:1;
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = mainScreen ; // GoTo Main Screen
+                                    sMode=0;
+                                } else if (dMode[whichTouched]==configScreen) {
                                     wait_ms(500);
                                     tt.background(Black);
                                     tt.calibrate();
@@ -390,17 +411,23 @@
                                 }
                                 break;
                             //-----------------------------------------------
-                            case 10: // 1,0 (col,row) on screen 0 or 1
+                            case 10: // 1,0 (col left of center,top row) on screen 0 or 1
                                 if (dMode[whichTouched]==changedScreen) {
                                     for(j=0;j<100;j++) msgChanged[j]=0; // clear changed data
                                     lastDMode[whichTouched]=99;//force refresh
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    sMode=0;
+                                    dMode[whichTouched] = brakeScreen ; // GoTo Brake Screen
                                 } else if (dMode[whichTouched]==cpScreen) {
-                                    pollCP=true;
+                                    reqMsgCnt=0;
+                                    msgReq.attach(&sendReq,0.015);
                                 } else if (dMode[whichTouched]==cpHistScreen) { // gg - hist
-                                    pollCP=true;
+                                    reqMsgCnt=0;
+                                    msgReq.attach(&sendReq,0.015);
                                 } else if (dMode[whichTouched]==cpBarScreen) { // gg - cpbars
-                                    pollCP=true;
-                                } else if (dMode[whichTouched]==config1Screen) {
+                                    reqMsgCnt=0;
+                                    msgReq.attach(&sendReq,0.015);
+                                } else if (dMode[whichTouched]==configScreen) {
                                     mbed_reset();
                                 } else if (dMode[whichTouched]==playbackScreen) { // pause/unpause
                                     playbackEn=!playbackEn;
@@ -418,9 +445,11 @@
                             case 20: // col 2 and row 0 on either screen 0 or 1
                                 if (dMode[whichTouched]==monitorScreen||dMode[whichTouched]==changedScreen) {
                                     indexOffset=indexOffset<77?indexOffset+4:80;
-                                } else if (dMode[whichTouched]==config1Screen) {
-                                    sprintf(sTemp,"Saving config file.\n");
-                                    logMsg(sTemp);
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = effScreen ; // GoTo EFF Screen
+                                    sMode=0;
+                                } else if (dMode[whichTouched]==configScreen) {
+                                    printMsg("Saving config file.\n"); // saving config
                                     saveConfig();
                                     spkr.beep(2000,0.25);
                                 } else if (dMode[whichTouched]==playbackScreen) { // faster
@@ -431,19 +460,41 @@
                                             playback.attach(&playbackISR,playbackInt);
                                         }
                                     }
-                                }else{
+                                } else {
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                }
+
+                                break;
+                                
+                            case 30: // right-most on top row
+                                
+                                if (dMode[whichTouched]==configScreen) {
+                                    // step through skins
+                                    if( skin < maxSkin ) skin += 1 ;
+                                    else skin = 0 ;
+                                    
+                                    // repaint both screens, I think
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                    // and re-paint the other screen too, to see new skin there
+                                    lastDMode[whichTouched ^ 1]=99; // repaint other screen (^ = XOR)
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = healthScreen ; // Goto health screen
+                                    sMode=0;
+                                } else {
                                     lastDMode[whichTouched]=99;//repaint to clear highlight
                                 }
 
                                 break;
                             //----------------------------------
                             //----------------------------------
-                            case 01: // col 0 row 1
-                                if (dMode[whichTouched]==config1Screen) {
+                            case 01: // left col middle row
+                                if (dMode[whichTouched]==configScreen) {
                                     logEn = !logEn;
-                                    if (!logEn) repeatPoll=false; // disable auto polling, too
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = cpScreen ; // GoTo CP Data Screen                                
+                                    sMode=0;
                                 } else if (dMode[whichTouched]==dateScreen){
-                                    dtMode=(dtMode<6)?dtMode+1:0;
+                                    dtMode=(dtMode<5)?dtMode+1:0;
                                     lastDMode[whichTouched]=99;
                                 } else {
                                     lastDMode[whichTouched]=99;//repaint to clear highlight
@@ -452,40 +503,42 @@
                                 break;
                             //------------------------------
                             case 11:
-                                if (dMode[whichTouched]==config1Screen){
-                                    repeatPoll = !repeatPoll&&logEn;
+                                if (dMode[whichTouched]==configScreen){
+                                    repeatPoll = !repeatPoll;
                                     if (repeatPoll) {
                                         autoPoll.attach(&autoPollISR,pollInt);
                                     } else {
                                         autoPoll.detach();
                                     }
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = cpHistScreen ; // GoTo CP Hist Screen
+                                    sMode=0;
                                 } else if (dMode[whichTouched]==playbackScreen) {
                                     // Start/stop playback
                                     if(!playbackOpen){
-                                        if(!logOpen){
-                                            file = fopen("/usb/playback.alc", "rb");                                          
+                                        if(!canIdle){
+                                            printMsg("Cannot playback while connected to canbus\n");
+                                        }else if(!logOpen){
+                                            efr = f_open(&efile,"playback.alc",FA_READ|FA_OPEN_EXISTING);
                                             lastDMode[whichTouched]=99;//force refresh
-                                            if(file==NULL){
-                                                sprintf(sTemp,"Unable to open /usb/playback.alc\n");
-                                                logMsg(sTemp);
+                                            if(efr != FR_OK){
+                                                printMsg("Unable to open /usb/playback.alc\n"); // no playback.alc
                                                 spkr.beep(1000,0.25);
                                             } else {
                                                 playbackOpen = true;
                                                 playbackEn=true;
                                                 playback.attach(&playbackISR,playbackInt);
-                                                sprintf(sTemp,"Starting playback\n");
-                                                logMsg(sTemp);
+                                                printMsg("Starting playback\n"); // start playback
                                                 spkr.beep(2000,0.25);
                                                 can1.attach(&doNothing);// Stop recieving CAN data
                                                 can2.attach(&doNothing);
                                             }
                                         } else {
-                                            sprintf(sTemp,"Must stop logging first\n");
-                                            logMsg(sTemp);
+                                            printMsg("Must stop logging first\n");
                                         }
                                     } else {
                                         playback.detach();
-                                        fclose(file);
+                                        f_close(&efile);
                                         playbackOpen=false;
                                         playbackEn=false;
                                         can1.attach(&recieve1);// Restore CAN data recieve
@@ -502,9 +555,11 @@
                                 break;
                             //---------------------------------
                             case 21: // col 2 row 1
-                                if (dMode[whichTouched]==config1Screen) { // gg - Batt Log Enable Button
+                                if (dMode[whichTouched]==configScreen) { // gg - Batt Log Enable Button
                                     yesBattLog = !yesBattLog;
-                                    
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = cpBarScreen ; // GoTo CP Bars Screen  
+                                    sMode=0;
                                 } else if (dMode[whichTouched]==dateScreen){
                                     upDate(dtMode,false);
                                     lastDMode[whichTouched]=99;
@@ -514,6 +569,66 @@
 
                                 break;
                                 
+                            case 31: // col 3 row 1
+                                if (dMode[whichTouched]==configScreen) { // gg - Batt Log Enable Button
+                                    debugMode = !debugMode;                                
+                                } else if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = configScreen ; // GoTo Config Screen                                   
+                                } else if (dMode[whichTouched] == tripScreen) {
+                                    miles_trip[1]=0;
+                                    kWh_trip[1]=0;
+                                    sMode=0;
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                } else {
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                }                            
+                                break;
+                                
+                            //-----------------------------------
+                            case 02: // left col, bottom row (not nav)
+                                if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = playbackScreen ; // GoTo Playback Screen                                    
+                                } else if (dMode[whichTouched]==configScreen) {
+                                    metric = !metric; // toggle metric/imperial display
+                                } else {
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                }            
+                                break;
+                                
+                             case 12: // left-middle col, bottom row (not nav)
+                                if (dMode[whichTouched] == configScreen) { // gg - index
+                                    dMode[whichTouched] = dateScreen ; // GoTo Set Date/Time Screen  
+                                } else {
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                } 
+                                break;
+                             
+                             case 22: // right-middle col, bottom row (not nav)
+                                if (dMode[whichTouched] == indexScreen) { // gg - index
+                                    dMode[whichTouched] = logScreen ;    
+                                } else if (dMode[whichTouched]==configScreen) {
+                                    showHealth = !showHealth;
+                                } else {
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                } 
+                                break;
+
+                             case 32: // right col, bottom row (not nav)  
+                                if (dMode[whichTouched] == configScreen) {
+                                    logEn=false;
+                                    updateFirmware();
+                                } else if (dMode[whichTouched] == tripScreen) {
+                                    miles_trip[2]=0;
+                                    kWh_trip[2]=0;
+                                    sMode=0;
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                } else if (dMode[whichTouched] == indexScreen) {
+                                    dMode[whichTouched] = tripScreen ;    
+                                } else {                             
+                                    lastDMode[whichTouched]=99;//repaint to clear highlight
+                                }
+                                break;
+
                             //-----------------------------------
                             //-----------------------------------
                             // Prev Navigation
@@ -530,7 +645,7 @@
                             //-----------------------------------
                             // Index Navigation
                             case 27: // col 2 row tNavRow
-                                dMode[whichTouched]= mainScreen; // indexScreen ; // gg - index
+                                dMode[whichTouched]= indexScreen ; // gg - index
                                 break;
                             //------------------------------------
                             // Next Navigation
@@ -560,63 +675,123 @@
         }
 
         if(tick){ // Executes once a second
+            tick=false;
+            headlights = (lastMsg[indexLastMsg[0x358]].data[1]&0x80)?true:false;  // headlight/turn signal indicator
             accV=floor(mon12V*scale12V*10+0.5)/10; //Round to nearest 10th
             accOn=(accV>5)?true:false;
+            moving=(mph[0]>0.1);
+            charging=!moving&&(kW[0]<-1); // not moving and generating energy so must be charging
             if(laccOn&&!accOn){ // Car turned off
+                if (repeatPoll) { // Log on shutdown if autopoll enabled
+                    tripLog(); // Write trip log on powerdown
+                }
                 //write efficiency history data
-                cfile = fopen("/local/ehist.cny", "w");
-                if (cfile!=NULL){ // found a efficiency history file
+                hfile = fopen("/local/ehist.cny", "w");
+                if (hfile!=NULL){ // found a efficiency history file
                     for(i=0;i<39;i++){
-                        fprintf(cfile,"%f %f\r\n",mph[i],kW[i]);
+                        fprintf(hfile,"%f %f\r\n",mph[i],kW[i]);
                     }
-                    fclose(cfile);
+                    fclose(hfile);
+                }
+            }
+            if(!laccOn&&accOn){ // Car turned on
+                miles_trip[0]=0;
+                kWh_trip[0]=0;
+                wait5secs=5;
+                if(showHealth){
+                    saveDmode=dMode[0];
+                    dMode[0]=healthScreen;
                 }
             }
             laccOn=accOn;
-            if(!accOn&&!logEn&&userIdle&&!playbackEn){
-                //sprintf(sTemp,"Display Off %4.2f\n",accV);
-                //logMsg(sTemp);
-                dled = 0; // turn off display if car off and logging disabled and no user activity
+            if(!accOn&&!logEn&&userIdle&&!playbackEn){ // Car off and logging disabled and no user activity
+                dled = 0; 
             }else if(!headlights){
                 dled = ledHi;
-            }else{
+            } else {
                 dled = ledLo;
             }
-            
+            if(wait5secs>0){ // Wait a few seconds after poweron to give BMS time to measure CP's
+                wait5secs-=1;
+                if (repeatPoll&&(wait5secs==0)) { // Poll on startup if autopoll enabled
+                    logOnce=true;
+                    reqMsgCnt=0;
+                    msgReq.attach(&sendReq,0.015);
+                }
+            }
+            if(moving&&(saveDmode<99)&&(wait5secs==0)){
+                dMode[0]=saveDmode;
+                saveDmode=99;
+            }
+
             //compute historic efficiency
             if(numSsamples>0){ // Avoid div0
-                mph[0]=((float) motorRPM)/numSsamples/215; // Empirically derived - may change car to car
-            }else{
+                mph[0]=((float) motorRPM)/numSsamples/220; // Empirically derived with MXV4s - may change with different wheels&tires
+            } else {
                 mph[0]=0;
             }
             if(mph[0]>99){
                 mph[0]=0;
             }
-            mpkWh[0]=mph[0];
+            numSsamples=0;
+
             if(numWsamples>0){ // Avoid div0
+                mpkWh[0]=mph[0];
                 kW[0]=((float) mWs_x4)/numWsamples/4e3;     
                 mpkWh[0]/=kW[0];
                 if (mpkWh[0]<0) {
                     mpkWh[0]=99;// negative means inf.
                 }
-            }else{
+            } else {
                 kW[0]=0;
                 mpkWh[0]=0;
             }
-            //mpkWh[0]=floor(mpkWh[0]*10+0.5)/10; // Round to nearest 10th
+            numWsamples=0;
+
+            if (!charging){
+                miles_trip[0]+=mph[0]/3600;
+                miles_trip[1]+=mph[0]/3600;
+                miles_trip[2]+=mph[0]/3600;
+                kWh_trip[0]+=kW[0]/3600;
+                kWh_trip[1]+=kW[0]/3600;
+                kWh_trip[2]+=kW[0]/3600;
+            }
+            
             motorRPM=0;
-            numSsamples=0;
             mWs_x4=0;
-            numWsamples=0;
-            if(accOn||playbackEn){
+            
+            // Compute ESR
+            if((Imax-Imin)<40){ // do nothing - insufficient delta_I to measure
+                unloadedV_x2 = (curRmax+curRmin)/2;
+            }else if ((redRmax-redRmin)<(curRmax-curRmin)) {
+                Resr-=0.001;
+                unloadedV_x2 = (redRmax+redRmin)/2;
+            } else if ((incRmax-incRmin)<(curRmax-curRmin)) {
+                Resr+=0.001;
+                unloadedV_x2 = (incRmax+incRmin)/2;
+            } else {
+                unloadedV_x2 = (curRmax+curRmin)/2;
+            }
+            curRmin=1000;
+            curRmax=0;
+            incRmin=1000;
+            incRmax=0;
+            redRmin=1000;
+            redRmax=0;
+            Imax=-1000;
+            Imin=1000;
+
+            if((accOn||playbackEn)&&!charging){
                 for(i=1;i<39;i++){
                     average=mph[i]/timeConstant[i];
                     mph[i]-=average;
                     mph[i]+=mph[0];
                     mpkWh[i]=average;
                     average=kW[i]/timeConstant[i];
-                    kW[i]-=average;
-                    kW[i]+=kW[0];
+                    if(!charging){ //Not charging - so include in efficiency data
+                        kW[i]-=average;
+                        kW[i]+=kW[0];
+                    }
                     mpkWh[i]/=average;
                     if (mpkWh[i]<0) {
                         mpkWh[i]=99;// negative means inf.
@@ -624,31 +799,33 @@
                     //mpkWh[i]=floor(mpkWh[i]*10+0.5)/10; // Round to nearest 10th
                }
             }
-            updateDTE=true;
-            if(logCP)
-                logPackVoltages(); // Turbo3
-            tick=false;
-        }
+            if(logCP&&usbEn){
+                if(logOnce){
+                    tripLog();
+                    logOnce=false;
+                }
+                logPackVoltages(); // Turbo3, only call
+            }
+            if(!usbEn&&!waitasec){
+                usbEn=detectUSB(); // Keep looking if none found
+            }
+            waitasec=false; // work around to avoid hang when USB tries to init immediately
+            tock=true;
+        } // tick
 
         display=display<1?display+1:0; // toggle display
         updateDisplay(display);
-
-        if(pollCP){ // We do this inside main loop instead of ticker so CAN RX will not be blocked
-            sendCPreq(); // send cellpair data request.
-            wait_ms(16);
-            sendTreq(); //send temperature request
-            pollCP=false;
-        }
         
         if(step){ // playback
             if(playbackOpen&&playbackEn){
                 for(i=0;i<120;i++){
-                    if(!feof(file)){
-                        fscanf(file,"%5c%8c",&header,&data);
-                        logCan(header[0],CANMessage(0x7ff&((header[4]<<8)+header[3]), data, 8));
-                    }else{
-                        fclose(file); // restart
-                        file = fopen("/usb/playback.alc", "rb");                                          
+                    if(!f_eof(&efile)){
+                        efr=f_read(&efile,&header,5,&bytesRW);
+                        efr=f_read(&efile,&data,8,&bytesRW);
+                        logCan(header[0],CANMessage(0x7ff&((header[4]<<8)+header[3]), data, 8)); // Playback
+                    } else {
+                        f_close(&efile); // restart                                       
+                        efr = f_open(&efile,"playback.alc",FA_READ|FA_OPEN_EXISTING);
                         lastDMode[whichTouched]=99;//force refresh
                         spkr.beep(2000,0.25);
                     }