HFS-3-12V User Manual
Contents
1. View showing connector configuration Mechanical specifications Housing Type Self contained DIN 43650 Plug Top Housing Material High Impact Resistant Molded ABS Housing Colour Black dark Grey Surface Finish Matt Housing Thickness 2mm Mounting Flange and Face 1 7mm All Internal Dividers Lid material High Impact Resistant Molded ABS Lid Colour Opaque clear Lid finish Matt Unit size See above size detail drawings Unit Weight Approx 400 grams including Encapsulation material amp Cable Wire entry Via PG11 gland to fixed cable Encapsulation Flame Resistant Black Two Part Epoxy Resin Wire length Approx 3 Meters 10Ft colour coded cable Wire specification 4 core 16 02 with PVC outer protection to Def Standard 16 12 Part 5 Screened 2 5 Amps core 70 C Max Operating Temp Hydraulic Fan System Controller HFS 3 12v Assembly Information Rubber gasket seal in lid M3 x 40mm mounting screw recess Liquid tight cable outlet If required Apply lithium grease under lid fill and between driver plug base gasket and valve coil connector Driver plug base to ls valve coil rubber gasket supplied loose Harsh Environment Information e Use care when re assembling unit after adjustment and ensure that lid gasket is in place e DO NOT over tighten the central M3 x 40mm mounting screw e Ensure that flat rubber gasket2. approx 100Hz e Fully Clockwise Approx 250Hz e Set command to Zero Volts e Isolate plug from 12VDC supply e HFS 3 12v Plug top controller is now set e Replace opaque lid carefully ensuring that seal is maintained e Replace securing screw and tighten e Do not over tighten or lid damage is seen e Unit is now ready for continuous application use Hydraulic Fan System Controller HFS 3 12v Adjustment Guide INVERTED valve control operation Relief Pressure vs Current DC Characteristic Relieving Pressure to __ 250 3500 _ S q 3000 2 Typical characteristic of an inverted 2 200 7 pressure control valve This option 4650 2500 ow will allow fail to full speed safety R 2000 D operation He 1500 Et II NN ok gt 50 N tt SMe 0 ee O 10 20 30 40 50 60 70 80 90 100 of Maximum Control Current Output Characteristics INVERTED Valve operation I Max 100 1200mA Max Max 75 I Max 50 0 10 90 100 PWM PWM PWM PWM 110 lt 100 5 80 SO 60 2 5 40 O 20 0 0 10 20 30 40 50 60 70 80 90 100 PWM input Typical input output current linearity graph of this controller Hydraulic Fan System Controller HFS 3 12v Adjustment Guide NON INVERTED valve control operation NON INVERTED operation means that the output current follows the input command signal i e 10 PWM Min O P 90 PWM Max O P This option is intended for use
3. supplied is fitted between valve coil and driver plug e For high moisture applications apply lithium grease between valve coil and driver plug base before final assembly and mounting screw tightening process e For total immersion applications follow above step and additionally fill driver plug lid with lithium grease after adjustment and before final assembly to form liquid proof seal around all potentiometers and units plug base valve coil joint 16 Hydraulic Fan System Controller HFS 3 12v Page left intentionally blank Hydraulic Fan System Controller HFS 3 12v Page left intentionally blank Hydraulic Fan System Controller HFS 3 12v Page left intentionally blank Hydraulic Fan System Controller HFS 3 12v 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 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 trai
4. Fan System Controller HFS 3 12v Important Notes ALWAYS Take a few minutes to FULLY read THESE information data sheets BEFORE starting ALWAYS Keep High Voltage AC cables 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 consequences 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 battery 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 NEVER Arc Weld or Charge Batte
5. High Country Tek Inc Hydraulic Fan System Controller HFS 3 12v Electro Hydraulic Solutions for Mobile Industrial amp Marine Applications Hydraulic Fan System Controller 12V 1200mA Application Set up amp information Manual CE Part No HFS 3 12v RevC November 2009 Hydraulic Fan System Controller HFS 3 12v 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 this type of system 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 OEM re power and retro fit markets e Mining equipment above and below ground e Drill exploration and blast hole rigs e Chassis bus and RV builders e Static applications standby generators e Industrial cooling operations e Liquid nitrogen oxygen temperature conditioning System Part Numbers e Controller Module with DIN 43650 connector 0 e Controller info MANUAL t ccececececececececccececececececececaceceaeaeas IMPORTANT NOTE e Hydraulic system oil e Automatic Transmission fluid e Engine sump oil e Air conditioner refrigerant e Engine wate
6. e with a reverse acting proportional control valve In this configuration if the power supply fails the fan unit will default to the FULL ON speed This option is the default for the plug top controller and link A MUST be intact and not removed the location of link A is shown in the picture at the bottom of this page CAUTION Link A once removed CANNOT be replaced e Plug driver unit onto valve coil to be driven e Remove HFS 3 12v securing screw e Remove HFS 3 12v opaque lid to reveal internal adjustments e Ensure command PWM signal is set to zero e Ensure that all wire connections are correct and secure e Turn Min potentiometer 1 turn Anti Clockwise Minimum e Turn Max potentiometer 20 turns Clockwise Maximum e Apply 12VDC 10 to 14VDC absolute Maximum to the driver plug e Slowly increase command to approx 90 of maximum PWM e Use the Min adjustment to give minimum motor speed required e Slowly Increase command signal to 10 of maximum setting e Adjust Max until desired motor maximum speed is achieved e Check that Output ON led is functioning proportionally by varying the command signal e Ensure link is intact and NOT removed Link A Hydraulic Fan System Controller HFS 3 12v Adjustment Guide INVERTED valve control operation Default setting e Adjust Dither frequency to suit valve product being driven e Fully Anti clockwise
7. er 12 Hydraulic Fan System Controller HFS 3 12v Block Diagram Min adjust Max 20 Turn potentiometer V Supply Internal PWM f PSU enerator GND Ov 9 Dither PWM frequency adjust Ramp Generator 7 Output invert link PWM from ECU PWM to Voltage Current Output to PWM Feedback valve coil from ECU interface Wiring Information C wec rmon meo ravo 70101406 suppu _ GREEN Pum Signal rom ECU 13 Hydraulic Fan System Controller HFS 3 12v Connection Options m m 12VDC 10 to 14V max RED BLUE Rubber gasket M J ovDC YELLOW GREEN PWM 0V PWM output output Engine Control Unit ECU Proportional Valve Coil 12VDC 10 to 14V max Rubber gasket N j YELLOW y Emergency Fan NC i STOP relay nan configuration output Engine Control Unit ECU Proportional Valve Coil NOTE The Emergency Fan STOP configuration shown above assumes that the controller is being used in Inverted mode i e 10 PWM fan full on 90 PWM fan full off Closing the relay will force the input to 12V supply voltage and the fan will be controlled to fully OFF and will remain in this state until the relay is released If the NON Inverted mode is selected the relay should be connected to OV to achieve fan OFF when relay energized 14 Hydraulic Fan System Controller HFS 3 12v Mechanical Information 34mm 68mm
8. ning or system application we would be pleased to work with you and your team Need More Information For customer service orders and application C support contact us through E mail at Electro Hydraulic Control Solutions info highcountrytek com www highcountrytek com High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 Fax 1 530 265 3275 High Country Tek Inc reserve the right to improve this product at any time and without 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 website or contact our customer support for latest version HCT accepts NO liability for technical mistakes or printing errors or their consequences 20 HFS 3 12v C Copyright High Country Tek Inc 2009
9. ositive logic circuits To maintain operational integrity and prevent unauthorized adjustments once set the assembly of the driver is such that the enclosure containing the electronics electronic printed circuit board and components are fully isolated from the casing must be assembled as described in this manual and mounted to the valve coil with the correct length screw The controller electronics are fully encapsulated in black flame proof resin to allow continuous operation in adverse conditions while protecting them from vibration and external environmental influences This unit has been designed to meet all the current EMC requirements and is a well proven control circuit with many years of field and time proven operation Important Note Please be aware that fan blades can start rotating without warning and may cause personal injury if precautions are not taken and safe working practices observed ALL information contained herein is copyrighted to High Country Tek Inc 2009 5 Hydraulic Fan System Controller HFS 3 12v TOP VIEW OF PLUG DRIVER WITH LID REMOVED Output ON led The output ramp UP and DOWN rate is decided by the engine ECU rate of change Dither Frequency Adjustment to the PWM signal The HFS3 controller is designed to track and follow this command as closely as possible to give optimized fan speed operation Fully Anti Clockwise 100Hz Fully Clockwise 250Hz Outp
10. r jacket e Engine charge air e External Attachment system fluids e Diesel fuel conditioning E T EEEE E P No HFS 3 12v EE E P No HFS 3 12v RevC 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 the latest releases to info highcountrytek com ALL information contained herein is copyrighted to High Country Tek Inc 2009 2 Hydraulic Fan System Controller HFS 3 12v Product Overview This driver unit has been designed to interface and operate with e Wide supply range 10VDC to 14VDC 12V nominal e Engine Control Unit ECU 5 to 95 PWM output with 0 5 to 4 5V based on 5V maximum and e PWM frequency input from 20 125Hz e Fan system control manifold blocks e Vane and Gear motors with internal or external pressure control valves e Piston pump with remote compensator using proportional pilot pressure valves e Systems with 12VDC cartridge valves as fluid controlling elements Positive or Negative logic Produc
11. red by HCT will save fuel reduce emissions particle and noise and increase application productivity by only operating the fan when required and matching the fan speed to the heat load that requires dissipation For fail safe operation HCT strongly recommends that the hydraulic valves used are of the Negative logic variety This means that the valve gives less pressure for an increasing drive current This choice results in full pressure and therefore defaults to full fan speed in the event of the electronic controller or the fan speed requirement signal being dis connected or disabled There are situations where full fan speed with no drive current may not be optimal so the controller in this manual allows the user the choice of either negative logic or positive logic Increasing pressure with increasing current valves by a simple link setting found under the units lid Because the controller is designed to connect directly to the engine ECU all the decisions on ramp rates proportionality slope angle e t c are already calculated to suit the application This means that adjustment of the controller is simple with only five potentiometers a Dither frequency which is needed to ensure correct repeatable and smooth valve operation a Min which sets the Max fan speed on Negative logic valves or Min fan speed in positive logic circuits a Max which sets the Min fan speed on Negative logic valves or Max fan speed in p
12. ries with this driver unit connected as damage can occur NEVER Attempt to use this unit if you are unsure of electrical OR hydraulic connections or expected 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 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 It 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 3 12v Important Notes High Country Tek Inc HCT recognizes that fan drive systems are an important part of the protection needed for the engine and associated peripheral components to ensure maximum reliability productivity and long term operation The fan drive system controller HFS 3 12v offe
13. se Approx 250Hz e Set command to Zero Volts e Isolate plug from 12VDC supply e HFS 3 12v Plug top controller is now set e Replace opaque lid carefully ensuring that seal is maintained e Replace securing screw and tighten e Do not over tighten or lid damage is seen e Unit is now ready for continuous application use 11 Hydraulic Fan System Controller HFS 3 12v Adjustment Guide NON Inverting valve control operation 250 i 3500 Typical characteristic of a normal A TERETNE 3000 A pressure or flow control valve or 2 200 A a variable piston pump Electro 450 et ttt tt lade mee hydraulic stroker This option will P LLT AA yO 2000 z NOT allow fail to full speed safety i 100 A 1500 if operation oO so Le me Gk It is strongly recommended that the 900 INVERTED option is used in A ot ttt ERTED o 0 Frrr 0 conjunction with a reverse operating O 10 20 30 40 50 60 70 80 90 100 pressure control valve to allow of Maximum Control Current fail to full speed operation Output Characteristics NON Inverted Valve operation This graph shows the typical iMai a 43 gt Se eee 1200mA Max adjustments for the PWM input signal IMax75 PP I Max 50 a 0 10 90 100 PWM PWM PWM PWM 80 60 40 Output Current mA 20 0 0 10 20 30 40 50 60 70 80 90 100 PWM input Typical input output current linearity graph of this controll
14. t Features a Self contained controller plug for Mobile Industrial or Marine Hydraulic fan cooling systems a Interfaces directly with engine PWM fan speed signal m Space saving ON Valve mounting using standard DIN 43650 connector EMC compliant product to EN50081 1 and EN50082 2 heavy industrial 1 x proportional MosFet driver output PWM at upto 1200mA 12VDC Sealed and environmentally protected to IP68 or NEMA 6P Flame proof resin Encapsulated version to suit application environment No extra DIN housing or Card Holder to buy Pre wired with 3 meters 10 ft of colour coded cable for fast reliable connection Fully isolated design for improved safety and ease of application difficult areas Unit status Diagnostic LED visible through opaque plug cover Low cost compared to other available modules with comparative functions Easy to use top entry adjustments for all major parameters Single turn potentiometer 1 turns I Min adjustment for driven solenoid Multiturn potentiometer 20 turns Max adjustment for driven solenoid m Dither frequency Variable single turn from 100Hz to 250Hz 20 m Heavy duty approved cable for all application environments Protected inputs and user outputs for maximum reliability and product life ALL information contained herein is copyrighted to High Country Tek Inc 2009 3 Hydraulic
15. ut Current Adjustment I Max Clockwise adjustment Increase Output Current Min adjustment Output invert Select link lout Default Inverted valve drive O P drive link intact Clockwise adjustment on m 7 Higher Min Non inverted valve O P drive link cut Cmd Product Specifications 1 Board Style HCT Unique Size and Mounting 2 Connector Type DIN 43650 3 Cable Type Pre connected 3M 10ft colour coded cable fitted 4 Input Supply Voltage s 12V D C 10 14VDC absolute maximum 5 Input Supply Current Max Maximum Valve Current Setting 50mA Quiescent Max 6 Command Input Type PWM From ECU 7 Command Input Value 5V 10 to 90 PWM typical range 8 Command Input Frequency 20 to 125Hz 9 Available adjustments Max Min Dither Frequency adjust 11 Dither Frequency Variable from 100Hz to 250Hz 20 12 Environmental Totally ENCAPSULATED Printed Circuit Board 13 IP Rating IP68 Min When assembled correctly 14 NEMA Rating NEMA 6P 15 Humidity 95 Non Condensing 16 Storage temp 120 Deg C Max 17 Working temp 20 Deg C max to 70 Deg C Max Inc Ambient Hydraulic Fan System Controller HFS 3 12v Adjustment Guide INVERTED valve control operation Default setting INVERTED operation means that the output current is inverse to the input command signal i e 10 PWM Max O P 90 PWM Min O P This option is intended for us
16. with a proportional flow control or variable pump electro hydraulic stroker In this configuration if the power supply fails the fan unit will default to the OFF speed For this option to be activated the user must remove by cutting link A the location of which is shown at the bottom of this page CAUTION Link A once removed CANNOT be replaced e Plug driver unit onto valve coil to be driven e Remove HFS 3 12v securing screw e Remove HFS 3 12v opaque lid to reveal internal adjustments e Ensure command PWM signal is set to zero e Ensure that all wire connections are correct and secure e Turn Min potentiometer 1 turn Anti Clockwise Minimum e Turn Max potentiometer 20 turns Clockwise Maximum e Apply 12VDC 10 to 14VDC absolute Maximum to the driver plug e Slowly increase command to approx 90 of maximum PWM e Use the Min adjustment to give minimum motor speed required e Slowly Increase command signal to 10 of maximum setting e Adjust Max until desired motor maximum speed is achieved e Check that Output ON led is functioning proportionally by varying the command signal Ensure link A is cut and REMOVED Link A 10 Hydraulic Fan System Controller HFS 3 12v Adjustment Guide NON INVERTED valve control operation e Adjust Dither frequency to suit valve product being driven e Fully Anti clockwise approx 100Hz e Fully Clockwi
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