HFS-2 User Manual - High Country Tek
Contents
1. p9 99104D WNC IILL HO 4 bucu ON ON HO p nous indino 5 b o o D mur D V C LL 2 oO m ON HO u zo Buyse HO HO u do 1ndino HAA p l oo 8 IILL HO O HO p Hou ndino M Ad abueyd ON HO p k Bulyse HO payoavog yne LL HO 19M0d p9 991109 NEJ IILL HO jefe 10113 SV WLS d l l O 1 AQ Indu 1015 Syulla XIS ON peHoys indjno wey syul g 3M4 Syulla 1104 u do ndul solsiu q L 10 11nE I 11 HO 10113 SV ewes 490 sulla p uous p9 991109 JJNE IIL HO 12M0d 404171 SV ewes d n HB 008 ueyL Wun 202 gt SV swe uun IILL HO 4 J sv S IV SUI OML 202 gt HUN IILL HO 4 MOd 40412 bucu ON sy Syulla OML 994 ueYyL lt Hun aunjies lli 2120 10 Yse 4 uinsyseyg Aiowsayy 10417 SV ewes IV yula vo Ag paea Spd 4o siuL u LL ndino wey qg 40114 Hc uolupuoo J8M0d 31 Hydraulic Fan System Controller HFS 2 Controller Mounting The electronic components used in this controller released by HCT conform to the Com2. The HFS 2Q option offers the user the choice of Weatherpack sealed connectors with a 6 way for thermistor inputs and 2 x 4 way for all other connections allowing the controller module to be mounted in an external environment The user can also specify any other connector required to match the intended application arena please contact the HCT factory for further details Startup Delay Feature This is a timed function and is intended to allow the vehicle to be started and running before applying the extra the load of the hydraulic fan and associated hydraulic pump demand The delay time can be adjusted in the set up software and is calibrated in seconds from zero O to a maximum of 60S This feature is initiated at every power ON OFF cycle 17 Hydraulic Fan System Controller HFS 2 Retry ALL Faults The user setting retry all faults determines if the unit will retry faults that are detected with the controller or peripheral devices after 4 seconds or if NOT selected the unit will stop operation until the power supply is turned OFF and back ON If after a power reset the fault is cleared the unit will return to normal operation If the fault persists the controller will once again stop and repeat the procedure above PC Hardware Requirements e Windows NT 2000 XP and Vista operating system e 2mB free hard disk e 68mB memory min e Unallocated 9 serial communication port OR e Unallocated USB port
3. We currently supply to virtually all areas of the fluid power industry increasing product integration and growing our customers business by allowing them to approach new profitable electro hydraulic markets successfully Please contact us to discuss your next project product training or system application we would be pleased to work with you and your team Need More Information For the latest company and product information visit us C at www highcountrytek com or for customer service Electro Hydraulic and application support contact us through E mail at Control Solutions info highcountrytek com 5 Tel 1 530 265 3236 Fax 1 530 265 3275 High Country Tek nc reserve the right to improve this product at any time and vvithout notice This manual may contain mistakes and printing errors The information in this publication is regularly checked and corrections made in the next issue Please check our vvebsite or contact our customer support for latest version HCT accepts NO liability for technical mistakes or printing errors or their consequences HFS 021 00152 Rev C Copyright High Country Tek Inc 2008
4. AutoZone AC Delco 13 928 aa GM 5326386 Was 12146312 Stanard GP Sorensen U81 Niehoff Wells MSD 3 190 Was 12110446 79 19001 3631 Was DR 136W Includes connector includes connector ol m y x Includes connector P r System Set Up Hints Setting the P term to 64 and the term to O calibrates the controllers output to start giving current at the Min setting at the set point temperature and to be at 100 output current max setting at the Overtemp temperature This relationship is linear and depending on whether positive or negative logic is applied at 100 controller output the fan will be going at the fastest speed possible P 64 1 0 Set point 20 C Overtemp 30 C Fan will go from zero to max over 10 C P 64 1 0 Set point 20 C Overtemp 50 C Fan will go from zero to max over 30 C 5 10 15 20 259 30 35 40 45 50 55 25 Hydraulic Fan System Controller HFS 2 High Country Tek Inc has been working with the fluid power industry for many years solving the tough problems and producing unique and mechanically robust products that continue to work reliably in the most extreme and hostile environments that we see hydraulics being applied in today Our controllers are ALL designed manufactured and tested in the U S A and can be sent anywhere in the world
5. is NOT selected otherwise it will resume normal operation when the fault is cleared A thermistor reaching Overtemp is an error that results in ramping to full fan speed The Overtemp error condition is automatically cleared if the thermistor drops below Overtemp ramping to the PWM value demanded by the PI loop Password Protection Password protection has been provided to ensure that damage cannot be caused once commissioning is completed There are three levels of security all of which may only be accessed via the Opto 2000 and PC software and with the proper password level of authorization Level 1 NO Password Monitor controller operation only no change in parameters allowed Level 2 OEM Password Authorized user has access to the functions that are needed for programming and set up Level 3 Factory Password HCT Engineering level which allows access to ALL base controller settings and some RESET functions Contact HCT on the e mail address info highcountrytek com for password 10 Hydraulic Fan System Controller HFS 2 Fan Noise Test Feature The controller allows the user to set a pre determined value of output current to the proportional valve that will equate to the required 70 forward fan speed required for the noise inspection Once set to the desired level this value is saved to the controller then allows the user to quickly demonstrate the noise level of a forw
6. mechanical connection between the Opto 2000 head not being attached to the controller securely or by the Opto 2000 battery level being to low or external power supply not being connected To remedy Check that the communications head is attached firmly that the two small holes are NOT filled with foreign matter and that the controller LED s are not damaged or dirty Replace the internal 9V battery or check the external power Supply for connection and operation The controller shows an error saying unit not communicating This error is reported usually if the PC is connected or the set up program is started after the controller is working Cycle the controller power ON OFF to reset the link or wait to see if the communications will synchronise after a few minutes If the problem still persists look at the Opto 2000 power supply and ensure this is correct The controller does NOT recognise open circuits on the valve coils The controller senses open circuits by passing a very small current all the time through the connected coils to ensure connectivity and winding integrity This non reporting error is caused by the valve coil plug having a light bulb fitted that appears to the controller to be an electrical load Remove the light bulb or use an LED variety that uses less current 33 Hydraulic Fan System Controller HFS 2 Temperature Sensor Information HFS Thermistor Compatibility Chart Des
7. HFS 2 Dimensional Information HFS 2Q E Inches Millimeters a an 0 las xx 3 Hcl Reverse O P ON H FS 2Q Reverse I P ON FAN SYSTEM CONTROLLER S No A00001 Reverse I P V Power I P 4 Prop O P Reverse Viv O P 4 Reverse O P Thermistor 2 GND i a Alarm O P ole Prop Viv O P NOT to scale contact HCT Thermistor 1 GND OV Power customer service for exact dimensions A c 3 x 8 screw Thermistor 3 SIG Thermistor 3 GND Thermistor 2 SIG www highcountrytek com Shown with the optional Q Weatherpack connectors G Wires and connectors removed for clarity SSS 4 way tower WPT 4 4 way shroud WPS 4 12015797 12010974 Mechanical Information Housing Type HCT unique encapsulated block Housing Material Polycarbonate Housing Color Black Surface Finish Semi Gloss Housing Thickness 16 5mm main module 25mm incl wire radius to connectors Unit size See above size detail drawings Unit Weight Approx 250 grams including Encapsulation material Wire entry Via Weatherpack connectors Tower and Shroud versions Encapsulation Flame Resistant Black Two Part Epoxy Resin Mounting Via through holed 3 suitable for No 10 4mm screw Temperature range 40 to 75 degrees Centigrade operational 28 Hydraulic Fan System Controller HFS 2 Electrical Co
8. Real time graphing window Drop down list of available parameters for display Digital representation of the parameter being displayed in O Selects Slow Medium or Fast graph time base setting Selects Graphic window scaling between FULL scale or AUTO Auto gives better resolution for lower values nik Setiinos Trolle Coces Permanent Log Help Quit D ashboard Her Unit Temp Power Supply 25 4 Fan Direction Fan Controlled by 82 F Forward Temp Fault Setpoint OverTemp 110 0 120 0 120 0 130 1 Thermistor 1 170 4 F Thermistor 2 125 0 F Off Off Alarm output Reversing Input Output Current 10 2 0 PUVM 96 I 1 j I j 00 25 0 50 0 75 0 100 0 Auto Purge Status Time Till Next Auto Purge Time remaining Purge phase Min 36 Sec 0 General display area for controller information and input output status o Analog needle display and digital readout of real time output current to proportional valve drive Analog bar graph and digital readout of real time output current as a of the maximum set 2 Status of the reverse Purge cycle auto or manual if reverse is enabled and or triggered 3 Clicking the HCT logo prompts the user for the password level required e When the HCT logo is clicked this window will open and reset the access level to NONE e You must enter a password to enter a new level Hydraulic Fan System Contr
9. comes ON Steady to indicate an error and if connected the PC program will show annunciators The proportional valve coil selected must be capable of withstanding the power supply s maximum voltage or the user must set the maximum output current Max to a safe value User adjustable minimum current I Min and selectable PWM frequency 31 to 250 Hz allows tuning for smoothly starting the fan from a stop The proportional output is rated for a 3 3A coil current maximum at the connected supply voltage The software allows user selection of driving normally open and normally closed proportional valves this sets the system default fan speed in the event of an electrical power loss to the controller module The proportional output is turned off if the units internal temperature sensor temperature exceeds 80 C 12 Hydraulic Fan System Controller HFS 2 Fan MAX speed setting This is called Max Vlv Current in the software and allows current to be adjusted from O 100 96 PWM output If Max Valve Current is set to zero all other settings will also go to zero Fan MIN speed setting This is called Min Viv Current in the software and allows current to be adjusted from O 100 PWM output set by Max Current above Ramp Settings The user programmable ramp Up and Down times are applied to limit the controllers rate of change in output current to a value that prevents
10. 24 Hydraulic Fan System Controller HFS 2 Thermistor Selection MEE Sawe Profile 3 ib l Thermister Setup Select Profile Name Borg Warmer o Temp Degl Res Ohms Thermistor 1 mi 4 gy Borg Warner u Enable pa 54 Delphi 2a Mig AE x 162 96 O Switch 287 gx za Ford IAT all B e 73 00 Sety x BO EE Thermistor 2 s Enable O Switch Setpoint 1279 400 1 The HFS software includes several pre characterized thermistor calibration profiles These are accessed by pressing lt Unit Settings gt lt Setup gt for the thermistor to be calibrated lt Select Profile gt This allows selecting one of these thermistors from a drop down list Thermistor 3 Enable This procedure is carried out for each channel which will allow different sensors to be used for different liquid medium measurement 3 Clicking the Save Profile button saves the thermistor points to a file called Name dtp in the same directory and will then appear in the Select profile list o The window showing Thermistor settings is only available with OEM and Factory password levels and when the menu bar Unit Settings tab is clicked This window displays the current profile selected for the relevant channel To change the profile follow step 2 and press accept The figure to the right shows the three thermistor inputs with Thermistor 1
11. NTC thermistors sensors with both wires brought back to the unit are required for each zone being monitored DO NOT use thermistors with one lead grounded as the sensor and the measuring accuracy will be severely degraded The controller is compatible with most automotive type thermistors with Borg Warner Delphi and Ford IAT sensors being pre configured and selectable on a drop down menu Other transducers not pre set may have their profiles added and stored under user selectable names for future use by HCT factory personnel If other thermistors are to be added the acceptable Ohmic range is 50ohms at the maximum temperature that can occur in the system to 2Mohm at the minimum temperature that can occur in the system Open gt 2 M ohm or shorted lt 50 ohms thermistor inputs will be detected and cause full fan speed output and indicate with the appropriate alarm response and error code to aide diagnosis of the problem Each thermistor input can also be configured and used as simple contact closure switch inputs The fan ON delay feature is intended to hold the fan at no rotation to avoid unnecessary windage forces and allow the hot engine to start with minimum loading possible This Start Up Delay is programmable by the user via the software set up program and can be set from zero 0 to sixty 60 seconds in one second increments This delay is activated every time the main power supply input is removed and r
12. an attempt to update FLASH or the user data file the corrupted unit should be returned without correcting the problem to HCT for failure analysis The other fault conditions stop flashing when the triggering error is cleared or if unit power is cycled depending on the Retry Fault user setting Error Indicator Blink Code No of blinks Fault Error THERM 3x PROP VLV PWM THERM2 ee ere 1 Memory checksum error TH Rza toh 2 Unit temperature greater than 75C REVERSE ON HFS 2 HeT 3 Selected thermistor input shorted REVERSE I P 2 1 775 7 4 Selected thermistor input open THERMISTOR 3 SIG PROP VEV O P THERMISTOR 3 GND REVERSE VLV O P Alarm output shorted THERMISTOR 2 545 REVERSE VLV 07 6 Over temp reached on one or more thermistor THERMISTOR 1 SIG PROP VLV O P THERMISTOR 1 GNOD OV POWER UP inputs 5 N www highcountrytek com 16 der Hydraulic Fan System Controller HFS 2 Alarm Output This lovv side on off output is able to output 3 3A current maximum and is capable of driving inductive or resistive loads and is Protected against shorted and misfired loads with shorted load detection only able to be detected when driven The output has two modes of operation Steady ON and Pulsing ON OFF The Steady ON mode is linked to NON critical errors or those that would allow the unit to keep functioning This type of error can be dealt w
13. the full menu bar Drop down list of available parameters for display options are displayed and available Alarm and Status text window Digital representation of the parameter being displayed in Error messages are in RED text The window stays as above while there are no errors or alarms reported by the system and or controller Q Selects Slow Medium or Fast graph time base setting Clicking this button starts the data logging process Selects Graphic window scaling between FULL scale or ALL of the parameters available in the item drop down AUTO Auto gives better resolution for lower values menu as well as other profile settings are logged for a period of 256 samples After the logging period a popup window asks for file name and storage location General parameter set up area for controller See following This file is saved with a csv extension which allows direct section in this manual for further details import reading and graphing in Microsoft Excel 4 Window where Real time graphing of selected parameter Qo Thermistor Enable and set up controls See following in is displayed section in this manual for further information 23 Hydraulic Fan System Controller HFS 2 Software Setup Guide Click the dovvn arrovv 2 and select the menu for Proportional or ON OFF type output current In ON OFF mode no Min Max Test or Rev Vliv current settings are avai
14. with user supplied USB to DB 9 hub powered and with USB driver software installed correctly Opto 2000 Communications This is the method by which the fan controller is set up and monitored and is explained more fully on page 26 of this manual The initial Opto 2000 unit must be ordered separately to the main controller but this is a universal communications adapter which will be used with other upcoming HCT controllers and products Set Up Software HA Find Opto Link High Country Tek Inc has realized that digital electronics comes with the need for the user to communicate with the controller and with this comes a new Set of practical problems associated with having to learn and become proficient with the set up software and hardware connections The software for this product is available from HCT and loads itself into a subdirectory the user is urged to allow the default directory paths This new generation of controller setup programs is specifically designed to be easy to use with a non threatening approach and with only the necessary items displayed determined by password levels to give a non cluttered display that is clear and understandable to both the professional and casual user The controller to PC communications is taken care of by the Opto 2000 unit which is plug and play in that all the user needs to do is physically connect the unit and run the provided software for the full automatic setup n The Opt
15. ERMISTOR 2 GN ALARM THERMISTOR 1 SIG PROF VWLV OP THERMISTOR 1 GND OV POWER PF CE PROP YLV PWM REVERSE O P ON ERROR REVERSE I F U S A www highcountrtek com connectors HCT Unique Size and Mounting Weidmuller two part polarised heavy duty screw type Weatherpack sealed connectors 10 32VDC Absolute Maximum Valve Current Setting 200mA Quiescent Max 2 wire Thermistor temperature switch software selectable Ohms only Max temp 50 QMin temp 2MQ All adjustments in software see attached literature Software adjustable 30 to 250Hz menu selectable Totally ENCAPSULATED Printed Circuit Board Designed to meet IP 68 MIN derate connector as required Designed to meet NEMA 6P derate connector as required 95 100 Non Condensing 40 to 85 Deg C Max 30 to 75 Deg C Max Inc Ambient e Module shown with 2 part Weidmuller Hydraulic Fan System Controller HFS 2 Thermistor Requirements Fan ON Delay The controller operation is based on input from up to three temperature measured zones One two or all three inputs can be used depending on the system requirements with all three thermistor inputs able to be enabled or disabled independently within the set up software The inputs can be from NTC Negative Temperature Coefficient Thermistors or Bi Metallic temperature switches and the choice can be made in the set up software Two wire
16. High Country Tek Inc Hydraulic Fan System Controller HFS 2 Hc Electro Hydraulic Control Solutions Electro Hydraulic Solutions for Mobile ndustrial amp Marine Applications Application Set up amp Information Manual THERM 3 PROP VLV PWM THERM2 z 3 REVERSE O P ON THERM12 ERROR REVERSE UP ON 2 4af Fan System Controller REVERSE I P S M A000 10 V POWER UP THERMISTOR 3 SIG PROP VEV QP THERMISTOR 3 GNO REVERSE VLV O P THERMISTOR 2 SIG REVERSE VLV OP THERMISTOR 2 GNOD ALARM O P THERMISTOR 1 SIG PROP VLV O P THERMISTOR 1 GND OV POWER iP MADE IN U S A www highcountrytek com Includes the HFS 2Q option information Part No 021 00152 Rev C August 2008 Hydraulic Fan System Controller HFS 2 Important Notes This product has been designed by High Country Tek Inc HCT to interface directly with any manufacturers range of proportional pressure and or flow control valves variable pumps motors and manifold blocks currently available for type of Please contact the factory by the e mail address given below or nearest High Country Tek Inc distributor for further technical information and availability Application Areas e ON and OFF road application suitability e Hydraulic system oil e OEM re power and retro fit markets e Automatic Transmission fluid e Mining equipment above and below ground e Engine sump oil e Drill exploration and blast hol
17. al staff before proceeding To maintain compliance with the tested EMC specifications listed above the HFS 2 controller must only be connected to the vehicle battery supply and must NOT be allowed to control or operate the fan system while the vehicle is connected to ANY external power supply l e battery Charger or engine warmer e t c and must be fully isolated from external supplies if this situation occurs This controller has been designed to operate with virtually any manufacturers range of valves pump strokers fan drive motors and fluid control manifold blocks as noted in this manual If you require advice or technical clarification please contact High Country Tek at info highcountrytek com Opto 2000 The Opto 2000 interface unit is intended for temporary use during static system set up commissioning and HFS 2 module programming only It is not designed for continuous connection and operation and should not be used or applied in areas where intense radio Frequency fields RF are present as unit resetting may occur system diagnostic information sent or received may be corrupted or the Opto 2000 unit damaged If any of the above problems are seen dis continue operation until the source of the RF has been identified and stopped Hydraulic Fan System Controller HFS 2 Important Notes ALWAYS Take a few minutes to FULLY read THESE information data sheets BEFORE starting ALWAYS Keep High Voltage AC cables
18. alve as shown in this manual is designed to default to full fan speed in the event of a power supply fuse or connection failure The user may also initiate full fan speed regardless of the controller settings by simply turning the unit OFF via a simple switch This option can be used on initial commissioning or during service to prove the hydraulic continuity circuit if required Once the unit is switched back ON the controller will re initialize and the real time temperature measurements in each zone used once again to dictate the ideal fan speed NOTE If the unit power Supply is turned OFF to force fan full speed the Purge function diagnostic indicators and alarm output will not operate until power is restored to the unit 29 Hydraulic Fan System Controller HFS 2 Normal Forward running fan speed determined by controller Manual or automatic Purge or reverse fan trigger detected here Fan speed decays to zero at Ramp Down rate set in software Dwell timer started to allow fan inertia to fully dissipate and fan stop Reverse output turned ON to energize directional valve Output signal to proportional valve started fixed mS after reverse valve signal to prevent hydraulic lock Fan rotation increased to Reverse running speed determined by user setting at Ramp Up rate set in software Fan speed Profile Contro
19. ard driven fan by following the sequence below 1 Turn controller power supply OFF 2 Depress and hold the Manual purge sequence button 3 Apply power to the controller 4 Continue to hold the manual purge button down for approx 5 seconds after power application then release to enter the Test mode 5 This Test mode will drive the fan in the forward direction for 3 minutes this time is fixed 6 When the time period has expired the fan will return to normal system operation and cannot be put back into test mode unless points 1 thro 4 are re applied Important Notes e This is an OPEN LOOP test feature which even after accurate factory setting can be marginally effected by external conditions such as ambient and oil temperature oil viscosity and system condition e The sequence can be stopped reset at any time during the 3 minute test period by removing the power supply e The Test mode period is pre set to 3 minutes by the manufacturer and is not changeable by the user The set up software allows the user to pre set the fan forward speed that is used during this Test mode lt Power Supply and Coil Voltage For most accurate smooth control with best resolution protection and product reliability the following combinations of power supply and valve coil voltage should be adhered to Proportional coils fan speed control NO PURGE OPTION FITTED 8 14VDC U
20. auto Purge or De ice feature NO external adjustments to maintain system integrity in the field Ruggedized design allowing use on Internal OR External applications Coded error indicator for real time diagnostics at the controller E Full remote PC and local smart visual diagnostics with optional Opto 2000 E Retarded and limit Charge Air cooling until engine warm feature E Fan ON Delay feature to reduce starting requirements on a hot system E Flame proof resin encapsulation E Mount anywhere encapsulated modular format The information in this guide is the intellectual property of High Country Tek Inc and should be considered at all times as strictly company confidential lt shall not be copied or transmitted by any format to any third parties without our knowledge and express written permission Hydraulic Fan System Controller HFS 2 CE and EMC Electro Magnetic Compatibility Notes The HFS 2 has been tested to comply with the current EN 50081 1 Emissions and EN 50082 2 Immunity The unit has been further tested to the new Euro Norms of EN 6 1000 6 4 2001 Emissions amp EN 61000 6 2 2001 Immunity The controller was also voluntarily tested to EN 12895 2000 which covers industrial Truck requirements Use of this controller under conditions not specified by EN 12895 2000 will require the user to clarify the application with HCT technic
21. ble Auto Purge Thermistor 2 i Enable 22 Switch P a 64 tal 0 Thermistor 3 14 Enable p 64 Swich 1 40 Warm Eng Temp F 51200 5 O 12 Startup Delay s 60 Temp Unit 11 der x I Time 5 Click this button to allovv inverted current output to control reverse acting proportional valves Set the Maximum valve current here from 0 100 Maximum current 10096 depends on coil Ohmic value and supply voltage and will determine the fans maximum speed This setting must be entered first and the software ensures that no other settings can be greater than this Set the Minimum valve current here from 0 100 of the maximum current in This current will determine the fans starting speed Software ensures that this setting cannot be greater than the maximum setting Set the Test valve current here from 0 100 of the maximum current in This setting determines the fan speed for the noise test mode Software ensures that this setting cannot be greater than the maximum setting Set the Reverse valve current here from 0 100 of the maximum current in This setting determines the fan speed for the Purge mode Software ensures that this setting cannot be greater than the maximum setting See the Thermistor Set up page 23 in this manual This resets the Auto Purge timer at any time This sets the Dwell time during the Purge sequence see page 30 for more details
22. cription Part number Comments Packard 15326386 3 8 18 NPTF thread 40C to 130C Connector Female GT 150 unshrouded Packard 15336024 Terminal Female 16AWG SXL Packard 15326267 Cable Seal 16AWG SXL Packard 12191229 Wire 16AWG SXL 2 Borg Warner Temp Sensor Borg Warner 5028 01666 02 Circular Push on Connector w 5 pigtails Kysor 1530 00027 Preassembled connector or Connector Assy TF Metri Pak 280 series Packard 15300027 TPA part of connector assy Packard 15300014 Terminal Female Sealed 16AWG SXL Packard 12077411 Cable Seal 16AWG SXL Packard 12015359 Wire 16AVVG SXL Description Part number Comments Packard 12110446 1 4 18 NPTF 40C to 130C Connector Female GT 150 unshrouded Packard 15336024 Terminal Female 16AWG SXL Packard 15326267 Cable Seal 16AWG SXL Packard 12191229 Wire 16AVVG SXL 2 Ford IAT Temp Sensor F6SZ 12A697 AA Also had 0A06A stamped on Part or F6SZ 12A697 AB Contact Ford dealer for part Plug Assembly Amp 184004 1 Receptacle Amp 184030 1 Cable Seal 18AWG SXL Amp 184141 1 Wire 18AVVG SXL Parts can be bought directly from Delphi by calling 1 800 packard 1 800 722 5273 Please e mail info highcountrytek com for additional information if required stating your question clearly and giving a valid return e mail address 34 Hydraulic Fan System Controller HFS 2 Temperature Sensor Information Cont Supplier Manufacturer NAPA Autoparts CHTSC200 ECHTSC300
23. d the cold engine The Cold Engine Fan Limit feature avoids these problems by not allow the Charge Air OR Reversing inputs to take control of the Fan speed while the Engine Coolant temperature is less than the Engine Warm Temp setpoint The Engine Coolant sensor MUST be connected to Thermistor 1 input and set to type Thermistor The Charge Air sensor MUST be connected to Thermistor 2 input and may be set to type Thermistor or Switch Fan control by the thermistor 1 and 3 inputs is not limited by the Engine Warm Temp setpoint While the unit is waiting for thermistor 1 to reach engine warm temperature clearing the Cold Engine Fan Limit will not exit the waiting mode Important Notes Charge Air temperature reaching the user entered Overtemp setpoint will override the Cold Engine Fan Limit and go to full fan forward rotation while the condition exists to ensure that damage does not occur and that the Overtemp condition is reduced The Charge Air limiting feature only functions when power is initially applied to the controller The Warm engine temp setting MUST NOT exceed the Coolant temperature setpoint Hydraulic Fan System Controller HFS 2 PI Proportional Integral Logic The controller uses PI to regulate the temperatures to be no more than the Setpoints entered by the user The P and I terms act on temperature error with the P term used to instanta
24. damaging the hydraulic system components and the fan blades The ramp rate is set in seconds s for a full scale current output change in the range of 1 to 10 seconds This ramp time should be set low enough not to interfere with the temperature control loop response but high enough to give smooth system operation Dither Frequency Settings The set up software allows the dither frequency PWM frequency to be set from 30Hz to 250Hz to cater for the known range of proportional valves that could be used for this application 13 Hydraulic Fan System Controller HFS 2 This feature is designed to de clog the fan protection guard and cooling elements and not as a permanent running option The output drive to the coil is rated to 3 3Amps maximum at controller supply voltage and is either ON or OFF with no proportionality or ramp functions associated The Purge sequence will cancel if at any time an overtemp alarm is detected The two individual Purge methods and the possible adjustments are noted below Reverse Sequence The Reverse sequence is specific to avoid damage to the fan blades and the motor hydraulic system and is a follows see page 30 of this manual for more details Reverse command detected manual or Auto reverse signal Fan proportional control valve ramped DOWN to give zero fan speed at ramp rate set in software Fan stopped Dwell time starts if seconds value set i
25. e above setpoint the thermistor that is controlling the PI process has a blinking LED and the others above setpoint are on steady Error Indicator The RED error led that flashes an Error code when fault conditions that have no other visual indicator have been detected The LED blinks error codes if faults have been detected with the thermistor inputs module temperature module memory and alarm output The blink code will occur at a rate of 0 5 seconds on and 0 5 seconds off with a two second pause before repeating Only the highest priority blink code will be displayed See table below for blink codes with the lower number of blinks having higher priority A controller unit temperature greater than SOC will be indicated by the error LED ON until retried if retry fault is selected or until power is cycled OFF then back ON The unit calculates the checksum of the internal FLASH program and the user settings data file at power up If the checksum is incorrect the unit is corrupt and will turn OFF all outputs except for alarm and flash ALL LEDs except for the Power LED which is required for OptoLink communication and the Reverse Input LED that is driven directly by the Reverse Input This condition is cleared by re loading the FLASH program and or the stored user characteristic data file This above situation should never occur unless power is lost during file storage or up or download If memory checksum failure occurs without
26. e applied to the controller In the case of a normally acting proportional valve the current is held at zero output for the delay time If a reverse acting valve is used the output current is held at the maximum set in the software to ensure the fan is fully OFF Hydraulic Fan System Controller HFS 2 Charge Air There can be a special case of cooling requirements when the engine is warming up from a cold start For this situation the controller has a Cold Engine Fan Limit option available to the user which if enabled will temporarily stop the fans rotation to prevent excessive cooling The Charge Air temperature can easily exceed its desired setpoint value while the Engine Coolant temperature is still too cold to let the standard mechanical thermostat open Normal operation would allow the Charge Air temperature to capture the fan control cooling any other above ambient liquids in the radiator This would typically cause a sudden introduction of cold water when the engine does eventually warm up enough to cause the thermostat to open resulting in the chance of engine block damage with thermal shock Charge Air controlled fan speed can also slow down engine warm up time generating unnecessary pollution inefficient running and excess fuel usage On a cold start reversing the fan during a purge cycle will have a similar effect as most radiators will then be cooled by the air sucked from aroun
27. e operator or observer to avoid confusion ALL inputs and outputs on the controller are fully protected continuously monitored and when connected displayed by the software in the Status window Readings are also taken and stored of highest temperatures seen in each active zone supply voltages and other parameters to allow event correlation and system diagnostics if required at a later date Hydraulic Fan System Controller HFS 2 a gt H Product Features EMC compliant product to EN50081 1 and EN50082 2 heavy industrial EMC compliant product to EN 12895 2000 Industrial Trucks Fail safe design gives full fan cooling even with NO electrical power Wide supply voltage range 10 32VDC Set up amp unit configuration up downloadable to any backup media via PC Quick select fan speed for in field noise inspection 75 of Fwd Fan speed Full remote PC and local smart visual diagnostics with optional Opto 2000 Product integrity maintained under extreme operational environments Fully isolated design for improved safety and ease of application in difficult areas Three independently selectable and configurable temperature sensing inputs Fully protected shorts opens and reverse connection Inputs and Outputs Unit status Diagnostic LED s user visible and functional at all times Industry standard sealed Weatherpack or two part polarized connectors Radiator pack Manual and
28. e rigs e Air conditioner refrigerant Chassis bus and RV builders Engine water jacket e Static applications standby generators e Engine charge air e Industrial cooling operations e External Attachment system fluids e Liquid nitrogen oxygen temperature conditioning e Diesel fuel conditioning System Part Numbers Controller Module with 2 part connectors P No HFS 2 Controller Module with VVeatherpack connectors z P No HFS 2Q e Controller Graphical User Interface GUI P No 023 00196 ODIO 2000 interface Unit anada daaa P No 999 10064 e HFS controller software CD R R YY RRRRRR Contact HCT customer service for info Controller info MANUAL ccccsssessescsssesecccsssseuscasesseuscuseseescasessecuseuseanaceussanauseass P No 021 00152 Rev B IMPORTANT NOTE High Country Tek Inc reserves the right to upgrade revise or better any controller as technology improves without notice being given Wherever possible full downwards compatibility for both hardware and software on replaced controllers will be maintained but it is the users responsibility to ensure that the latest technical details or literature is being used for application reference If you are unsure of the literature hardware or software revisions you have or suspect that it is an older revision please send an e mail request for t
29. ease contact the customer service personnel at HCT for advice on cooling and mounting Important Notes Enclosures should have an IN and an OUT vent for correct cooling air circulation Mount the controller so the operator can see it if required to do so Use fan blown air wherever possible to increase air exchange rate DO NOT mount controllers in direct sunlight Mount controllers with air gaps to allow correct ventilation Do not mount controllers in non ventilated sealed box s especially in high ambient areas DO NOT mount controllers face face or densely as this will cause over heating problems Read the literature and observe the max operating temp figures and work to them Remember High temp ambient air used for cooling is not a good solution 32 Hydraulic Fan System Controller HFS 2 Set up program does not reflect user changes made immediately If the controller is in any mid sequence l e reverse timer was set to a long period and now a new shorter period is entered the controller will normally only reflect the new settings once the currently running sequence has ended The only way to reset this type of occurrence is to physically power the controller down and then back up Once Opto 2000 communications have been re established the new settings will be valid and seen The Opto 2000 keeps losing communication or keeps resetting This is normally caused by a bad
30. ect e Auto Repetition rate set in minutes up to a maximum of 180 e Time to run in reverse Purge time direction set in seconds 60 max e Speed of fan in reverse as a of fan maximum forward speed The manual Purge feature can be actioned between automated operations as required 14 er Hydraulic Fan System Controller HFS 2 Diagnostic Indicators The unit is fitted with LED indicators to show real time diagnostic information and indicate by error codes in a visual manner the current operational status and if a fault develops with the system where the fault may be originating from Power ON Opto 2000 transmitter The red LED indicates power supply status with the LED OFF for less than 8 volts and flashes ON OFF for more than 40 volts This LED also acts as the communications transmitter when connected to the Opto 2000 unit Opto 2000 Receiver The clear LED is used only for Infra Red communications when connected to the Opto 2000 unit and never shows any visible light Proportional Valve Output The proportional coil PWM LED is fully RED for 0 PWM and fully GREEN for 100 PWM with shades of red orange yellow and green indicating intermediate values Manual Reverse Trigger The RED LED for the reversing coil trigger input comes ON only when the input is connected to the Supply voltage indicating that the manual reverse sequence has been initiated Once this Sequence has been start
31. ected system operation NEVER Attempt to use this unit in Areas where other AC or DC coils HAVE NOT been fully suppressed NEVER Use a power supply that is not rated for the correct required O P current under full load NEVER Allow wires TO or FROM the unit to short circuit to each other or chassis cabinet e t c NEVER Attempt to use this unit in areas of intense RF without adequate screening measures NEVER Disconnect or connect wires to or from this unit unless it isolated from the power supply NEVER Use this unit in temperatures that exceed those specified as operation may be effected NEVER Start this unit without ensuring ALL work areas are clear of personnel Electrical Specifications 1 Board Style 2 Connector Types 2a Connector types Q option 3 5 G 7 8 9 10 11 12 13 14 15 Input Supply Voltage Input Supply Current Max Command Input Type s Command Input Value s Available adjustments A V 7X A Dither Frequency Environmental IP Rating module only Humidity Storage temp eee ee ee ee ee i Working temp MADE IN NEMA Rating module only Hydraulic Fan System Controller HFS 2 THERM 3 2 THERM 2 z THERM 1 REVERSE UP ON 5 2 Fan System Controller S M A00110 V POWER THERMISTOR 3 SIG tPROP VLY OP THERMISTOR 3 GND REVERSE VLV O P THERMISTOR 2 5156 REVERSE VLV CP TH
32. ed and in the duration of the purge cycle new or multiple manual trigger inputs will be ignored as will any automatic purge sequence signals Reverse Valve Output The RED LED for the reversing coil output comes on with the output The LED blinks on for about 0 1 seconds and then off for about 0 1 seconds to indicate shorts and blinks on for about 0 5 seconds and then off for about 0 5 seconds to indicate opens n either cases the alarm output comes on Steady to indicate an error Power ON Opto 2000 Opto 2000 receiver Proportional Valve transmitter output ON Manual trigger Reverse THERM 3 X PROP VLV PWM Valve sequence Me ez REVERSE OP ox TE Activated ae THERM 1 gt ERROR le REVERSE vr ox FE See page 16 for Thermistor HFS 2 HeT details Input status Fan System Controller REVERSE S N A00010 V POWER UP Reverse Valve THERMISTOR 3 SIG PROP VLV O P THERMISTOR 3 GND REVERSE VLV O P Purge Output ON THERMISTOR 2 SIG REVERSE VLV THERMISTOR 2 GND ALARM O P Two part THERMISTOR 1 SIG ROP YLV OP polarised heavy TERMISTOR 1 GND OV POWER MADE IN duty connectors EA CE www highecoun tnytek com 15 Hydraulic Fan System Controller HFS 2 Thermistor Status The RED LED for the thermistor that is controlling the fan comes on steadily while the other thermistor LEDs are off if no more than one thermistor is above setpoint If multiple thermistors ar
33. enabled as a thermistor and with the Setup button depressed Clicking on the radio button marked Setup opens a box called The value in this window is the Set point that the controller Thermistor Setup shown to the right Thermistor 2 is shown enabled as a thermistor and with the setup button as normal Thermistor 3 is shown NOT enabled In this state the options associated with the thermistor are removed from the screen for clarity 2 Clicking this arrow will roll down a menu list Select Profile see 2a above of transducer profiles available Default profiles are supplied and all other user created files vvill be shovvn if stored in the default file locations NOTE will attempt to maintain be altering fan speed This value must be between 40 or 300 Degrees F The value in this window is the Overtemp alarm threshold that will cause the alarm output to activate if reached This value must be greater gt than the Set point value If the difference between Set point and Overtemp is to small the controller may keep going into alarm condition as the actual temperature is controlled around optimum Push this button to accept displayed data and return to the main program Push this button to disregard all displayed data and return to the main program The set up software has embedded default settings for Borg Warner Delphi and Ford AIT sensors available The
34. he CHARGE AIR SENSOR Sets the units of temperature displayed throughout the software from Degrees Centigrade C to Degrees Farenhieght F Sets the overall Integral constant of the controller This feature is intended to allow vehicle starting with minimum loading and holds OFF controller action until the time entered her in seconds 0 60S expires Click this button to enable retry all faults which will allow the controller to automatically try an error reset every 4 seconds to see if the fault has cleared If this feature is disabled any error will trigger the controller to shutdown and stop functioning until a Power On Reset is applied Click this button to enable or disable the entire controller This button on a new controller is defaulted to disabled The first time that a controller is enabled the date from the connected PC is Trapped and taken as activation date information cuit Settings aag Her j Prop Vly is Proportional w Rev Acting Prop Yi Dither Freq Hz Viv Current 96 ai 70 0 Ramp Up 5 4110 2 Min Viv Current al 35 0 sl 10 2 Test Vly Current 96 5 al 47 0 1 0053 Rev Viv Current 96 al 50 0 Time in Reverse Os 5 Auto Purge Delay Time m 180 180 Reset Auto Purge Mins Retry all faults Unit is Disabled 15 Cold Engine Fan Limit Ramp Dn 53 Dir Chg Dwell 5 Disable Reversing Ena
35. he latest releases to info highcountrytek com ALL information contained herein is copyrighted to High Country Tek Inc 2008 2 Hydraulic Fan System Controller HFS 2 System Overview This product has been designed specifically for Hydraulic Fan Drive control and gives the user new levels automation while integrating seamlessly into a typical discrete cooling system lt can control a hydraulically driven fan proportionally or in an ON OFF manner based on user settings system configuration and cooling needs with three independent inputs zones that will interface with industry standard NTC two wire thermistors Standard features include a robust vibration flame proof package 2 part or Q option connectors that provides either easy harness assembly or Waterproof heavy duty connections both polarized to avoid mis connections Alarm output interface intelligent diagnostics internal self protection that enables the controller to operate reliably under arduous environmental conditions and a real time graphing and data logging facility that offers the user option to observe and then record several operating parameters that are saved in a common file format for later examination in Microsoft Excel Local on board diagnostic LED indicators are available for power ON each individual thermistor input the proportional output reverse input and reverse valve output status and a specific error code LED which all show thr
36. ith in due time The Pulsed ON OFF state is intended to show that a critical error has been detected and that the controller system MUST be stopped and examined immediately or damage may result Data Logging Option The facility exists to allow the user to LOG data of the thermistors and several other controller functions for later or fault trend examination The files can be individually named to suit the application and is suffixed with a csv extension for direct and easy reading into Microsoft Excel for graphical plotting and mathematical calculations as required Internal Data Logging The unit records the controller serial number date first setup born date with a PC highest supply voltage the highest temperature of each thermistor input other than during calibration and the highest module temperature The user can not reset these values without a password Shorted or open thermistor faults will not be recorded as a high temperature Connectors HFS 2 and HFS 2Q The connectors used on the HFS 2 controller are Weidmuller two part polarised heavy duty screw variety to suit the intended in cab application environment while still allowing easy cable access installation pre harness assembly and normal maintenance The controller comes complete with all the connectors male on the unit amp female user wire connections necessary for immediate installation Connector Weidmuller style SLA and BLS
37. lable and the output will be dependent on the supply voltage to the controller In ON OFF mode the ramps are left active to aide the use of a soft shift valve if used Click the down arrow and select from the drop down menu the dither frequency between 31 5Hz and 250Hz that is nearest to the recommended value for the proportional valve product being driven Use the up down arrows on each box or directly enter a value in seconds in the range 0 60S for the ramp UP and DOWN Clicking this button will disable the reversing purge feature and remove from the display items s 8 Clicking this button will enable or disable the Auto purge feature but still allow the manual Purge feature to operate In Manual Purge items 3 need to be set Sets the time 1 60 seconds that the fan will spend in the reverse Purge direction Sets the time 1 180 Minutes between fan reverse Purge cycles when Auto Purge is enabled Clicking this button Enables the cold engine fan limit feature and will prevent the fan from operation until the temperature seen in is reached If this feature is Disabled item 10 is removed from the display If Thermistor 1 or 2 are disabled item is removed from the display Both Thermistors 1 amp 2 must be enabled for this feature to work with Thermistor 1 being allocated for the warm engine sensor and Thermistor 2 being allocated to t
38. ller Output profile to inverting type pressure control valve Reverse output to directional valve Fan at maximum speed for Reverse time period set in software This speed may be less than forward to protect fan Purge timing cycle expired ramp fan to zero at Ramp Down rate set in software Dwell timer started to allow fan inertia to fully dissipate and fan stop Reverse output turned OFF to de energize directional valve Output signal to proportional valve started fixed mS after reverse valve signal to prevent hydraulic lock Fan rotation increased to Forward running speed determined by user setting at Ramp Up rate set in software Normal Forward running fan speed determined by controller 30 SUOI IPUOD ULE V pue s po 10113 S nsouBbeip yun uiod s sindui ON ON bucu ON ON HO HO JoysjuueY E3 R Aoqy ndul ON ON bucu ON ON bune nS k HO HO nil 0 ir y loda s ON ON ON ON HO HO MO 9g S O SIUL UV L liv Buimojs uey y lodl s ON ON ON ON WUNWIUI HO HO Mmo j g S O SIUL UV L IV UIN ues ON pm ON b nc HO HO ss A H ul Buluunu SHOA Bup
39. mercial temperature range which is 40 to 75 Centigrade This rating means that the components will work reliably and give a good life span if the operating temperature is kept within these absolute maximum limits The controllers when in operation do generate and dissipate internal heat The amount of heat generated is dependent on the amount of work that the controller is being asked to do as well as other factors such as supply voltage type and voltage of coil being driven e t c with the worst case combination being a 24VDC supply with a 12V coil In order for the unit not to exceed the 75 C maximum operating temp and cause a self protection shut down situation the user must mount the controller in a position that is ergonomically preferred especially for visual inspection and system maintenance and also provide for adequate ventilation to ensure that the unit is cooled to maintain operation In addition to ventilation the system designer must also look at the mounting arrangement for the cards controllers and be aware that adequate space should be left around in front and behind to allow the above ventilation to take effect It should be noted that temperatures are Additive which means that with a high ambient temperature the units internal temperature rise need only be quite small to reach the maximum specified levels If controllers are going to be used in High ambient temperature or unusual application areas pl
40. n menu as well as other profile settings are logged for a period of 255 samples After the logging period a popup window asks for file name and storage location This file is saved vvith a csv extension vvhich allovvs direct import reading and graphing in Microsoft Excel 20 Hydraulic Fan System Controller HFS 2 Software Set Up Guide Menu Bar a Viydranlic Fan Controller Fili Dashbasrdi Una Getting Troubla Coda Parmanan Le Hip Gut Status About Controller HFS 2 Hydraulic Fan Controller No Errors File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit Status D E Gi Fart 0238200196 vii irimi Pian Controller EOS part Ho 023900074 y 2 0 Nin Frrars e At any password level Clicking the Help tab allows the user to see contact information web and e mail addresses as well as software and hardware revisions for the actual product currently n use e This information should be available if contacting HCT for advice or requesting product support El irs a Hydraulic Fan Controller Fle ashbnard Unt Settings Trouble Codes Permanent rg Hep Cut Status View Help HFS Hydraulic Fan Controller Errors File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit Mace hebi Files dela derbe y Status D 2 Pin Ferec e When Help is selected from the dropdown menu the user can click the View Help File button to see the text version of the man
41. n software Reverse valve O P switched ON change hydraulic state Proportional valve ramped UP to reverse current limit set in software Reverse command released manual or Auto reverse signal Fan proportional control valve ramped DOWN to give zero fan speed at ramp rate set in software Reverse valve O P switched change hydraulic state to original Pao OS 0 NE Proportional valve ramped UP to required Forward speed Manual Reverse Initiation For this feature to be activated the operator must initiate the sequence by sending a momentary or pulsed voltage signal vehicle supply level to the input marked REVERSE I P on the controller Upon receiving this signal the controller will follow the purge sequence to ensure correct and safe operation Re initiation of the manual Purge signal during a Purge sequence will be ignored by the controller Fan Reverse Notes The software controls the purge feature such that if the momentary manual input is continuously activated l e short circuited the sequence will complete once ensure the fan is re activated in the forward direction and wait until the input is cleared and then re initiated before another purge sequence is allowed Auto Fan Reverse This automated feature can be used to ensure free air flow through the radiator on a regular basis without operator intervention Adjustments are available in the set up software for e Auto Purge feature ON OFF sel
42. neously respond to temperature errors and should be adjusted to respond quickly to large temperature changes but have little impact otherwise The term is used to track the average fan current required to keep the hottest temperature measured closest to its setpoint and should be set up for slow and smooth response while giving accurate control round the setpoint General operation default values for the P amp terms are embedded in the software but may be altered by users with the proper password level of authorization to fine tune a system Temperature error is the difference between the actual measured temperature and the temperature setpoint scaled by the difference between the temperature setpoint and the Overtemp alarm setpoint The scaling is required to allow comparison of all the thermistor inputs on an equal basis The active thermistor input with the largest scaled error above its setpoint will be used by the PI process If all temperatures are below their user setpoints the thermistor closest to it s set point will be used to give control In a properly tuned system this process will result in the fan turning just fast enough to keep one temperature regulated to its setpoint and all other temperatures less than their Setpoints If a thermistor input is shorted or open the unit will ramp to full fan speed This error behavior will continue until power is turned off if the user programmable Retry All Faults
43. nnection Information V Power Input Alarm output shown driving a simple lamp to indicate fault error condition has occurred This same connection circuit can be used with a relay or solenoid Always use suitable Flyback or Suppression diode here to facilitate system integration as required such that V P Alarm Output 7 engine shutdovvn could be initiated if the fault continued un Alarm O P cleared Fan Reverse The maximum switching current of this output is 3 3amps at manual lnitiate supply voltage Reverse Zona Proportional Output Valve or Pump Control Prop Viv O P Prop O P HFS 2 External Temperature Thermistor 1 GND Sensor Channel 1 Hydraulic Fan e a External Temperature System Thermistor 2 GND Sensor Channel 2 Thermistor 3 i External Temperature Thermistor 3 GND Sensor Channel 3 Controller Fan Direction Reverse Valve Reverse Viv op XE Reverse Vlv O P OV Power I P e Always observe safety when adjusting this controller fan may start to rotate without warning e Always fit power supply fuse as shown externally to controller e Ensure two wires are used for every temperature sensor OV Power Input e Use software to make any changes to system configuration and or options Fan Max Speed Manual Override The system using the Reverse acting proportional pressure relief v
44. o 2000 should be connected to the host PC first and the HFS softvvare started The PC vill immediately check the available ports display a list shown right of available serial ports find the Opto 2000 and connect If the Opto 2000 is connected to an HFS that has power applied the program will take a few seconds to check module validity and then display the settings from that module At this point the user may enter a passvvord if changes to settings are required Hydraulic Fan System Controller HFS 2 Software Set Up Guide Menu Bar HFS 2 Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit 1 0 Display Unit Settings Trouble Codes Permanent Log H Temporary Memory gt Permanent Memory Temporary Memory gt Permanent Memory amp File Restore gt 170 Display Unit Settings Trouble Codes Permanent Le Permanent Memory gt Temporary Memory File gt Permanent and Temporary Memory HFS Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit 2 Status Pin Ferre Clicking the Dashboard tab brings up the real time controller information page which allows the user to observe the status alarms and access the diagnostic features e NO adjustments can be done from this page HFS Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quik Status Pin Fe
45. oller HFS 2 Software Setup Guide OEM amp Factory Password level HFS 2 Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Loq Help Quit Status Settings Unit is Disabled Prop Viv is Proportional 8 Rev Acting Prop Vly Dither Freq Hz 250 Vly Current 96 8 70 0 Ramp Up s 10 2 Min V v Current F 35 0 Ramp Dn s 10 2 Test Current 96 a 47 0 Dir Chg Dwell s 8 o Rev Vly Current 8 50 0 Disable Reversing Time in Reverse OF 5 Enable Auto Purge Auto Purge Delay Time m 180 Reset Auto Purge Mins Thermistor 1 6 Enable Switch Retry all faults Unit is Disabled Thermistor 2 Setup Cold Engine Fan Limit 6 Enable Switch mi Ji n U 2 AT HE 1 I 1 Ih VU yl q Warm Eng Temp 299 9 P HET ij VR Y mye Thermistor 3 setup I Time S 8 1 0 Enable Startup Delay s 8 60 Switch Full vv Graph Speed Fastest Temp Unit _degF v The major differences between the OEM level and the Factory level passwords is the ability at the Factory level to RESET data values in the Permanent Log that have been stored during the controllers operation Both levels allow the user full access to all controller parameters so password confidentiality should be of a high priority o At OEM and Factory passvvord levels
46. ough observation the current status of the controller and connected peripheral devices Easy to use set up and diagnostic software that is provided with the unit works in conjunction with the HCT Opto 2000 interface unit to provide high speed data communications between the controller and the host computer and runs on any PC with a Windows O S platform Once the profile for a particular cooling requirement has been established the software allows the developer to up dovvnload the complete personality into other blank controllers giving the user a high level of application specific security and keeping company confidential information in house The inputs if desired can also be configured to interface directly with pre set range ON OFF Bi metallic temperature switches without the proportional control offered by the thermistors but giving savings advantages where absolute accuracy is not required and system cost is at a premium There are no external or onboard potentiometers switches or adjustments for user settings to ensure controller integrity and operation under harsh environmental and operator conditions The set up software allows the controller to be very flexible regarding settings and system configuration with password levels invoked to ensure that characteristics cannot be changed without the proper authority Each password level entered affords the user more options and available settings that are kept transparent to th
47. q Hek Qut Status Permanent Log HFS 2 Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit Unit Serial Hurnber 8100667 Number Ford 1958 Date First Soup with 1519 pasat Termito 1 Highest Temperance 2424 F Reset Thenmistor 2 Gear Tomperatuns 2735 F Reset thormistor 3 Cras T nga Iiri 2065 F rik Highest Temperature ra F Foer Tappy Highest Vullaqa x v Status D 1 Pin Ferec At OEM passvvord level oniy Clicking the Permanent Log tab allovvs the user to observe list of Stored data that indicate the maximum levels that the controller has ever seen from initiation 1 The Unit Serial Number is unique to every controller Se 2 The Motor Serial Number is entered at commissioning if required 3 Date First Set Up with PC is the Born Date of the controller for warranty uses At OEM password level only items 2 3 4 Thermistor 1 3 Highest temperatures ever seen can be observed and reset 5 Unit Highest Temp is the actual controllers internal temperature max reading j e At Factory password level only items 2 3 6 Power Supply Highest Voltage is the maximum and 4 can be observed and reset supply applied to the controller Clicking this button starts the data logging process ALL of the parameters available in the item A drop dow
48. rec Depending on the passvvord level Clicking the Unit Settings tab brings up the available user adjustable windows for setting the controller profile shovvn here at Factory level vvith ALL options displayed The FILE tab brings the SAVE and RESTORE options to the user Temporary Memory gt Permanent Memory transfers all data from PC to the connected module for onward unattended operation at the current profile settings ONLY NO backup copy is made Temporary Memory gt Permanent Memory amp File transfers all data from PC to the connected module for onward unattended operation at the current profile settings ONLY Opens window to allow user to select stored file name and location for backup copy of profile Permanent Memory gt Temporary Memory transfers all data from the connected module to the PC for editing the current profile being used File gt Permanent and Temporary Memory transfers all data from a hard copy PC file to the connected module and onto the PC for editing HPS Hydraulic Fan Controller Fle Dashboard Unk Settings Trouble Codes Permanent bey Hep aut Dashboard Status 1 Errors Unit Temp Fan Direction Fan Coninolled by 1 mz F Forward Tomp Fault Sopot Ther miisior 1 1704 F Thearmigtor 2 10 0 F 119 139 0 sailfl fi Sealy Full F Graph Speed Fastest el Elurs Hydraulic Fan Controller File Dashboard Unt Settings Trouble Code
49. s Permanent log Hele Quk Settings Prog vh ig Proportional Dither Freq Hr 280 Ram ip 6 120 ET Rarnp Ory w C r b Ditke dik Cold Engine Fan Limit Warm Eng Temp F 13 0 ITimu ie Delay 2 T m Unit duq E 19 Hydraulic Fan System Controller HFS 2 ES urs Hydraulic Fan Controller File Dazhboard link Settings Trouble Codes Permanent Ley uk Status Trouble Codes io Errors HFS Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit pae Trobi wake Ogar vos Shot Ho Sta tu Cea woe Shore H Gulu Short 1 Gren Short Thermistor 2 Open shyt At OEM and Factory password levels only Clicking the Trouble Codes tab allows the user to observe a log of any OPEN or SHORT circuit error codes that have been triggered and stored 4426 F The matr 2 Cwer Tompooratune cra F Unit Highs T rmper ature Power Supply Higes Veihans The currently displayed event log can be reset from both of these levels vahit ff i Grae Full Graph Speed Fanen Event times and number of occurrences are NOT recorded rather that the error occurred at least once from the last log reset ES rs Hydraulic Fan Controller Fa Dachboand una iting Trouble Codes Permanent lo
50. s and current GUI versions for the controller and can be requested if required by e mail at info highcountrytek com or from our website at www highcountrytek com 26 Hydraulic Fan System Controller HFS 2 Dimensional Information HFS 2 I of Inches Millimeters e is so x o as 970 i r Ce sao R FAN SYSTEM CONTROLLER Reverse P S No A00001 eV Power P Thermistor 3 SIG Prop Viv O P Thermistor 3 GND Reverse Viv O P Thermistor 2 SIG Reverse O P Thermistor 2 GND Alarm O P Thermistor 1 SIG Prop O P Thermistor 1 GND OV Power I P NOT to scale contact HCT F customer service for exact J dimensions Shown with the standard H Weidmuller two part connectors Mechanical Information Housing Type HCT unique encapsulated block Housing Material Polycarbonate Housing Color Black Surface Finish Semi Gloss Housing Thickness 16 5mm main module 42mm incl 2 way Connectors Unit size See above size detail drawings Unit Weight Approx 250 grams including Encapsulation material Wire entry Via heavy duty polarized two part Deutsch connector Encapsulation Flame Resistant Black Two Part Epoxy Resin Mounting Via through holed 3 suitable for No 10 4mm screw Temperature range 40 to 75 degrees Centigrade operational 27 Hydraulic Fan System Controller
51. se 12V valve coil 20 36VDC Use 24V valve coil Directional coil Fan direction control NEEDED FOR PURGE OPTION 8 14VDC Use 12V valve coil 20 36VDC Use 24V valve coil 11 Hydraulic Fan System Controller HFS 2 A variable current output is used for driving a proportional valve to control the fan speed The value of the valve drive current is derived from a closed loop calculation relative to the temperature set points that the user has entered in the set up BOTH wires from the valve coil must be connected to the controller where indicated by Prop Viv O P and Prop Viv O P At NO time should any coil wires be connected to OV or application chassis e t c as this will effect the operation of the controller and could have damaging effects The output is internally fully protected against shorted or mis wired coils with errors being both indicated locally on the associated LED and annunciated on the controller software if the program is running on a PC connected to the unit ry 1 T as m A S 146 awe 2 z Shorted coils or connection wires are detected only when the controller tries to drive the coil and is indicated with a RED FLASHING output LED Open circuit coils or connection wires are detected only when the controller tries to drive the coil and is indicated with a GREEN FLASHING output LED In either of the above cases the Alarm output
52. se files are write protected to prevent accidental editing and should be left in this state for Reset to Datum Operation purposes 25 Hydraulic Fan System Controller HFS 2 Opto 2000 Interface Information HCT s Opto 2000 P No 999 10064 is required to interface between the fan controllers infrared communications LED port and the PC laptop RS 232 port This optically coupled interface is provided as an external item which must be ordered separately from the controller unit and allows setup monitoring and limited data logging from the fan controller unit on the bench or in the system via a laptop PC running standard Windows software The unit is fully compatible with Windows ME 2000 and NT versions Vista compatibility to be confirmed please contact HCT customer service for information If the user has only USB port styles available on the host PC Laptop the USB to DB 9 hub must be supplied by the user with the correct software installed onto the host PC Laptop This style of non contacting non electrical communications port has been chosen and developed because it is extremely rugged in physical nature the method is not prone to connector breakage or clogging with foreign matter from the working environment and is free from failure caused by electrolysis or common short circuits as seen with other communications alternatives used by others The optical communications also allows ver
53. separate from Low Voltage DC signal and supply cables ALWAYS Make sure the unit supply voltage is the same as the coils on the valve being driven ALWAYS Ensure that you are aware of the available adjustments and on the electronics and hydraulics ALWAYS Make sure you have the correct tools to do the intended job i e P C software e t c ALWAYS Isolate this unit from all other equipment BEFORE any form of welding takes place ALWAYS Check ALL connections to and from this unit to ensure NO short or OPEN circuits ALWAYS Check the units supply voltage is CORRECT ELECTRICALLY CLEAN and STABLE ALWAYS Operate the units within specified operating temperature for best amp reliable performance ALWAYS Ensure that any unused wires terminals are terminated safely and not shorted together ALWAYS Isolate the controller if ANY form of battery charging or boosting takes place on the vehicle ALWAYS Ensure ALL valve connectors are wired correctly secure locked and connected to correct coils ALWAYS Observe the set up procedures in this manual for best operational results ALWAYS Follow and abide by local and country health and safety standards protect yourself and others 1 NEVER Arc Weld or Charge Batteries with this driver unit connected as damage can occur NEVER Attempt to use this unit if you are unsure of electrical OR hydraulic connections NEVER Attempt to use this unit if you are unsure of the exp
54. ual or other file This can be very useful for other languages other than English HTFS 2 Hydraulic Fan Controller File Dashboard Unit Settings Trouble Codes Permanent Log Help Quit 7 Status Pan Peeare Wz iH NOTE At any passvvord level Clicking the Quit tab or EXIT button turns exits the program in the correct manner 21 Hydraulic Fan System Controller HFS 2 Software Setup Guide Dashboard level HFS 2 Hydraulic Fan Controller Fle Dashboard Status No Errors Logs Taken Log Sample 0 hermistor 1 Temperature w 300 0 250 0 200 0 150 0 100 0 50 0 MES 40 0 ale Full v Graph Speed Fastest w At the observer level Dashboard Help and Quit is the only options available on the menu bar Alarm and Status text window Error messages are in RED text The window stays as above while there are no errors or alarms reported by the system and or controller Clicking this button starts the data logging process ALL of the parameters available in the item drop down menu as well as other profile settings are logged for a period of 256 samples After the logging period a popup window asks for file name and storage location This file is saved with a csv extension which allows direct import reading and graphing in Microsoft Excel Window where Real time graphing of selected parameter in 5 is displayed 4
55. y high speed data transfer between the host PC and the controller for real time diagnostics and fast set up programming and allows all the available units inputs outputs and options to be displayed from within the user software which is supplied with the controller unit The Opto 2000 and controller requires that the correct interface software is loaded onto the host PC and run to establish communications with a compatible controller The program will automatically poll check all of the com ports available In Windows ME 2000 and NT versions the software will establish and display all free communications ports but the user will have to manually select one of these detect and check the Opto 2000 unit for operation allocate the respective port for communications while at the same time setting the fastest reliable baud rate and default port settings The Opto 2000 driver software monitors the battery voltage and indicates to the user on the PC Laptop screen that there is a problem If this warning is not seen or ignored and If the Opto 2000 battery voltage is becoming low the communications will be unstable with typically the port being re initialized on a regular basis If this situation occurs switch to the external power adapter provided or change the battery The Opto 2000 unit comes complete with DB 9 Male Female extension cable standard 9V battery and external power supply unit 110VAC 60 Hz only The latest software update
56. yullg ON ON ON ON op lt Aiddng s mod ON ON ON bucu ON HO HO HE HO HO HO SH0A 8 gt Ajddng Jamod AIMOIS Bulyse 4 HO bucu ON ON AMIIND GBuryse 4 HO abueyd ON abueyo ON ON ON ON ON ON ON ON ON ON ON ues ON ON ON ON BuryejnBay ON ON ON ON ues IIn I ON ON ON ON ues IIn I eBuey oN 1043 sy ewes HO 1042 UUM HO p H HO sy owes ON ON ON bucu ON bucu o 10113 SV owe 10419 10419 031 037 nd no indino AeA indino 4sH3AZH 393 3 qa nd no Wid leuonuodold HFS 2 UO S ulodi S AOQV 5 DulUSE1 I SI pajoajaS UO SI p l l Ss UO SI 3s sol HO IV bucu ON O A Ov PUY 8 bucu ON O usemjeg Ajddns Jamod 18S SHOA PUY 8 Ajddns s Mod bucu ON ON Ho o o D D lt o o o o Z 2 8 usemjeg Ajddns 18S HO p 19 4102 WNC ILL HO 4 ON ON HO u do indjno
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