Replace hv_mode gate with CS60 hv_limit logic for unrestricted HV setpoints (v1.0.25).

Co-authored-by: Cursor <cursoragent@cursor.com>

Core/Inc/charger_config.h

@@ -9,6 +9,14 @@
 
 #define PSU_NUM 1
 
+/* Dynamic LV clamp (CS60 hv_limit): active only on overload at low bus voltage. */
+#define PSU_LV_CLAMP_V              499u
+#define PSU_HV_LIMIT_ON_THRESHOLD   480u
+#define PSU_HV_LIMIT_OFF_THRESHOLD  495u
+#define PSU_HV_SWITCH_DELAY_MS      1000u
+#define PSU_HV_LOAD_CURRENT         300u   /* 30.0 A, MeasuredCurrent is 0.1 A/bit */
+#define PSU_HV_LIMIT_MAX_COUNT      3u
+
 /* Fast discharge: PSU off/on cycle on step-down setpoint (unloaded bus). */
 #define PSD_ENABLE                    1u
 #define PSD_MAX_CMD_CURRENT_0P1A      20u   /* 2.0 A */

Core/Inc/charger_control.h

@@ -68,6 +68,9 @@ typedef struct{
 	uint16_t WantedCurrent; //0.1A/bit
 	CONN_Error_t chargingError; // 0 if okay
 	uint8_t EvConnected;
+	uint8_t hv_limit;        // Limits PSU voltage to LV range when set
+	uint32_t hv_tick;        // Timer for delayed HV limit switching
+	uint8_t hv_limit_count;  // Anti-chatter counter for LV limit switching
 
 } ChargingConnector_t;
 

Core/Inc/main.h

@@ -27,7 +27,7 @@ extern "C" {
 /* USER CODE BEGIN EC */
 #define FW_VERSION_MAJOR 1
 #define FW_VERSION_MINOR 0
-#define FW_VERSION_PATCH 24
+#define FW_VERSION_PATCH 25
 /* USER CODE END EC */
 
 /* Exported macro ------------------------------------------------------------*/

Core/Inc/psu_control.h

@@ -84,8 +84,6 @@ typedef struct {
 
 	// Дополнительные параметры для одного модуля DC30
 	uint32_t power_limit;    // лимит мощности [кВт]
-	uint8_t  hv_mode;        // HV-режим (ограничение напряжения)
-	uint32_t hv_tick;        // таймер для задержки входа в HV-режим
 
 	uint32_t tempAmbient;    // температура окружающего воздуха (из PSU_04)
 	union { uint8_t raw; PSU_Status0_t bits; } status0;  // modularForm0

Core/Src/charger_control.c

@@ -13,6 +13,9 @@ void CONN_Init(){
 	CONN.connControl = CMD_NONE;
 	CONN.connState   = Unknown;
 	CONN.RequestedVoltage = PSU_MIN_VOLTAGE;
+	CONN.hv_limit = 0u;
+	CONN.hv_tick = 0u;
+	CONN.hv_limit_count = 0u;
 
 }
 

Core/Src/psu_control.c

@@ -33,6 +33,69 @@ extern CAN_HandleTypeDef hcan2;
 
 static void PSU_SendCmd(uint8_t source, uint8_t destination, uint8_t cmd, void *data);
 
+static void PSU_HvControl(void)
+{
+	if (CONN.EnableOutput == 0u) {
+		if ((CONN.hv_limit != 0u) || (CONN.hv_limit_count != 0u)) {
+			log_printf(LOG_INFO, "HV limit reset output off\n");
+		}
+		CONN.hv_limit = 0u;
+		CONN.hv_tick = 0u;
+		CONN.hv_limit_count = 0u;
+		return;
+	}
+
+	if (!PSU0.online) {
+		if ((CONN.hv_limit != 0u) || (CONN.hv_limit_count != 0u)) {
+			log_printf(LOG_INFO, "HV limit reset no PSU\n");
+		}
+		CONN.hv_limit = 0u;
+		CONN.hv_tick = 0u;
+		CONN.hv_limit_count = 0u;
+		return;
+	}
+
+	if (CONN.hv_limit == 0u) {
+		if ((CONN.hv_limit_count < PSU_HV_LIMIT_MAX_COUNT) &&
+		    (CONN.MeasuredVoltage < PSU_HV_LIMIT_ON_THRESHOLD) &&
+		    (CONN.MeasuredCurrent > PSU_HV_LOAD_CURRENT)) {
+			if (CONN.hv_tick == 0u) {
+				CONN.hv_tick = HAL_GetTick();
+			} else if ((HAL_GetTick() - CONN.hv_tick) >= PSU_HV_SWITCH_DELAY_MS) {
+				CONN.hv_limit = 1u;
+				CONN.hv_limit_count++;
+				CONN.hv_tick = 0u;
+				log_printf(LOG_WARN, "HV limit ON V=%d I=%d cnt=%d\n",
+				           (int)CONN.MeasuredVoltage,
+				           (int)CONN.MeasuredCurrent,
+				           (int)CONN.hv_limit_count);
+				if (CONN.hv_limit_count >= PSU_HV_LIMIT_MAX_COUNT) {
+					log_printf(LOG_WARN, "HV limit locked cnt=%d\n",
+					           (int)CONN.hv_limit_count);
+				}
+			}
+		} else {
+			CONN.hv_tick = 0u;
+		}
+	} else {
+		if ((CONN.MeasuredVoltage > PSU_HV_LIMIT_OFF_THRESHOLD) ||
+		    (CONN.MeasuredCurrent <= PSU_HV_LOAD_CURRENT)) {
+			if (CONN.hv_tick == 0u) {
+				CONN.hv_tick = HAL_GetTick();
+			} else if ((HAL_GetTick() - CONN.hv_tick) >= PSU_HV_SWITCH_DELAY_MS) {
+				CONN.hv_limit = 0u;
+				CONN.hv_tick = 0u;
+				log_printf(LOG_INFO, "HV limit OFF V=%d I=%d cnt=%d\n",
+				           (int)CONN.MeasuredVoltage,
+				           (int)CONN.MeasuredCurrent,
+				           (int)CONN.hv_limit_count);
+			}
+		} else {
+			CONN.hv_tick = 0u;
+		}
+	}
+}
+
 static void PSU_SwitchState(PSU_State_t state){
 	PSU0.state = state;
 	PSU0.statetick = HAL_GetTick();
@@ -169,8 +232,6 @@ void PSU_Init(){
 	PSU0.statetick = HAL_GetTick();
 
 	PSU0.power_limit = PSU_MAX_POWER; // kW
-	PSU0.hv_mode     = 0;
-	PSU0.hv_tick     = 0;
 
 	PSU_Enable(0, 0);
 	PowerSetpoint_Init();
@@ -203,7 +264,9 @@ void PSU_SetVoltageCurrent(uint8_t addr, uint16_t voltage, uint16_t current){
 
 	if(voltage<PSU_MIN_VOLTAGE) voltage = PSU_MIN_VOLTAGE;
 
-	if((PSU0.hv_mode==0) && voltage>499) voltage = 499;
+	if((CONN.hv_limit != 0u) && (voltage > PSU_LV_CLAMP_V)){
+		voltage = PSU_LV_CLAMP_V;
+	}
 
 	uint32_t current_ma = current * 100;
 	uint32_t voltage_mv = voltage * 1000;
@@ -295,19 +358,8 @@ void PSU_ReadWrite(){
 #endif
 
 	if (PSU0.ready) {
-		if (CONN.MeasuredVoltage > 490) {
+		PSU_HvControl();
-			if (PSU0.hv_tick == 0) {
-				PSU0.hv_tick = HAL_GetTick();
-			} else if ((HAL_GetTick() - PSU0.hv_tick) >= 10000) {
-				PSU0.hv_mode = 1;
 	}
-		} else {
-			PSU0.hv_tick = 0;
-		}
-	}
-
-	// PSU_SetHVMode(0, PSU0.hv_mode); // auto set, no need
-	// ED_Delay(CAN_DELAY);
 
 }
 
@@ -387,8 +439,9 @@ void PSU_Task(void){
 
 	case PSU_READY:
 		// модуль готов, но выключен
-		PSU0.hv_mode = 0;
+		CONN.hv_limit = 0u;
-		PSU0.hv_tick = 0;
+		CONN.hv_tick = 0u;
+		CONN.hv_limit_count = 0u;
 
 		RELAY_Write(RELAY_DC, 0);
 		if(!PSU0.ready){