HGC-2 User Manual - High Country Tek
Contents
1. transitions If this fault is triggered the HGC 2 PWM output will be set to zero output i e minimum generator speed until the HGC 2 is first disabled and re enabled or the supply power to the unit is cycled To correct this issue the operator should first isolate and fully stop B uccz 25 HGC 2 v1 0 Fe Unit Hep Quit gt p A Valve Type Value Normal Reverse Target Frequency Proportional Gain Sz or 60Hz D to 100 3 MET ES Ey Intergral Gain Derivative Gain PID Leap Tine Dither Frequency Max Current in Frequency Oboe 10056 D be 10056 1t0 30 copdes 02 to 2 50A 35 0 to 53 5 Hz Below Min Freq Acton Max Frequency Above Max Freg Acton Fault Time CC Mode Current Cut Off Frequency Hp Fault Timed Fault 50 4 to B0 i Hz Mo Fault Timed Fault 0 0 tn 25 0 ser JA fs to 7 5AJs D3 js to 7 8A JS Selectable the generator and check the high voltage feedback connections to and the HGC 2 controller for correct and firm connection If these are secure the settings for the HGC 2 may need to be adjusted please contact HCT for assistance GROUND FAULT DETECTED This fault is displayed when the controller detects the there is a physical or short circuit connection between the solenoid output and any GROUND point on the generator set This could be caused by a frayed wire touching the inside of the enclosure as an example2. High Country Tek Inc Cl Hydraulic Generator Controller HGC 2 Electro Hydraulic Control Solutions Electronic Controller Solutions for Mobile Industrial amp Marine Applications Application Guide Set up amp information Manual FB ucc212 aE V QE HGC 2 da aWwgc 2 ESL HcT Supply Fault Status Voltage ES voc alve Type al Reverse Target Frequenc 50Hz or 60Hz H7 r ar o Hz oportional Ga 0 to 100 b 7 5 A E ergral Ga 0 to 100 wl 96 Valve Current ITE Amps m OP IL f ar f ve auve oa o 100 wil 2 5 L BH ed EN ELE i EL j E j EE l nem Nx ae ra c 0 0 2 20 4 06 0 8 1 1 2 1 to 3U cycles xj les Dither Frequenc Selectable Hz Valve Curren Freq Error 500 500 Ww ar n Curren J 20A y EH A wi P 4 stie at Le at race _ So e Manual Part No 021 00160 May 2009 Hydraulic Generator Controller HGC 2 Important Notes This product has been designed to interface directly with any manufacturers range of proportional pressure and or flow control valves variable pumps motors and manifold blocks currently available 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 Limitations High Country Tek Inc HCT designs and supplies products specifically for use in commercial industrial and mobile contro
3. dual capacitor passive Electrical specification Regulated power supply 13 VDC from integrated PSU on test application HV electrical loading by combined resistive and inductive loads Test Specifications Stability With Load Changes No load Full load No load test Z9 70 This result shows what can be achieved with the N 65 correct settings on the controller The graph left T demonstrates the recovery time of the output ea 60 frequency when the generators load is fully E applied then fully removed then fully applied 2 DD once more D This sequence of instantaneous events is u 50 probably the worst that the generator will see yet 4 undershoot overshoot and steady state are well 5 controlled and acceptable for the majority of 40 eene a ea ee a eee today s applications 1 16 31 46 61 76 91 106 121 136 151 166 181 Time base Milliseconds 18 Hydraulic Generator Controller HGC 2 Operational Guide DC Supply Voltage Fluctuation DC Supply Voltage Fluctuation 13V 10V 13V within 1 second 80 19 The HGC 2 has been designed to work under 70 extreme conditions seen in mobile equipment T One variable that can effect operation is the 65 vehicle battery voltage but as can be seen in the e 60 graph right the fluctuations that can occur have ad 5 very little effect on the controlled frequency of the D 55 generator outp
4. The CC Mode Current parameter is variable AC FREQUENCY AC Frequency displays the nominal frequency of the Feedback Input The Feedback parameter is a monitor type OUTPUT CURRENT Output Current displays the nominal current being supplied to the output The Output Current parameter is a monitor type SUPPLY VOLTAGE The Supply Voltage parameter displays the module s power supply voltage This value is included as an aid to troubleshooting The Supply Voltage parameter is a monitor type 16 Hydraulic Generator Controller HGC 2 Initial Set up Procedure The following steps are recommended when commissioning a HGC 2 controller 1 Select the desired operating frequency 2 Set the Minimum and Maximum Outputs according to the valve data sheet 3 Set the Dither Frequency as recommended by the valve manufacturer NOTE Higher dither frequencies can sometimes be used in closed loop systems to improve frequency response 4 Set the Ramp Up Rate and Ramp Down Rate as desired 5 Adjust the PID parameters as needed to optimize the system response Start with Proportional P setting and increase to achieve a stable system Once stability is achieved gradually increase the add Integral I setting and finally Increase the Derivative D setting as needed to improve system response and or stability Troubleshooting Constant Current Mode The Constant Current Mode or CC Mode is useful for setup and troubleshooti
5. a hydraulic motor where speed is controlled by a proportional solenoid valve either directly at the motor or as part of the pump compensator The HGC 2 is a closed loop controller that monitors the AC line voltage from the generator output for outer loop closure and provides the necessary current to a valve coil in order to maintain the desired generator frequency A single LED indicator on the top of the unit to provide an overview of the operating status The unit has enough processing power and functionality when operating as a single control module to support a wide range of hydraulic generator applications As with all of the HCT modules the HGC 2 is packaged in a small rugged enclosure All connectors are sealed and the module is encapsulated to withstand extreme conditions in the harsh mobile operating environment The HGC 2 is designed to make the generator unit easy to configure and control The hardware contains the framework software where the parameters can be changed depending on the users needs via the PC Graphical User Interface GUI The GUI has been organized into various user screens that are logical and easy to understand Terminology has been used that is commonplace through the industry to allow easy configuration and is intended to cater for a wide range of users with varying levels of computer familiarity Once configured all the settings are stored in permanent memory within the unit even when no power is applied The
6. graphing is available here to monitor a wide range of items selectable from a drop down and select list and for remote diagnostics a Data Log button will start a Windows Excel file that can be used as a monitor for comparison to other logged charts during the system s life or can be E mailed to an engineering source if there is a problem for diagnosis 6 Hydraulic Generator Controller HGC 2 Loading the HGC 2 GUI onto your PC Go to www highcountrytek com or contact HCT to ensure you have the latest revision of the HGC 2 GUI The PC Graphical User Interface GUI is a self extracting and installing program that will reside on the chosen host PC hard drive It is recommended that the user allow the defaults to be used for easy future update installation but the option is given to allow the user to choose where the program should be located It is NOT recommended that this program be run from a network as it needs access to certain files available only in the Windows directories To start the installation process insert the CD ROM or if this does not work search for the contact Factory for latest exe program file on the cd and run Graphical User Interface GUI Overview HGC 2 Dashboard view E HGC2 25 HGC 2 v1 0 File Unit Help Quit Once the PC is connected to the HGC 2 module and the Graphical Parameter Limits User Interface GUI started VaveType Nor
7. support for the user About Controller when clicked will open another window that will show the user relative information on the controller model Firmware GUI and communications versions as well as contact information and web address for support Click OK to exit the window QUIT Menu Options The Quit menus has two drop down options 1 Quit Quit when clicked close the Graphical User Interface GUI correctly and release any USB communications ports that may have been used for set up allowing other programs to use these resources NOTE It is important to note that if the quit is clicked before the Send Changes button the GUI will close and the controller will default to the settings stored in the internal memory with no user changes taking place Hydraulic Generator Controller HGC 2 HGc2 25 Her a Help Quit Print Parameters ucc2 25 Her Normal Reverse SOHz or 60Hz 0 to 100 0 to 100 Vende HGC2 25 Firmware Version V 1 00 Comunication Mode C2 1 Nevada City CA 95959 USA www highcountr ytek com 0 to 100 Copyright 2006 National Instruments Corporatiog All rights reserved Parameter Valve Type Target Frequency Limits Normal Reverse Proportional Gain Intergral Gain Derivative Gain PID Loop Time Dither Frequency Min Current 02 to 2
8. will actively search communications ports for a genuine HGC controller and then refresh the parameter screen with the settings in that found module 60 or 50Hz Screen Differences The HGC 2 controller is designed to cater for global markets and as such can manage both 110VAC and 240VAC generator outputs at either 50 or 60Hz The line high voltage feedback is taken directly from the generator secondary with NO other external equipment or components needed The easy to use Graphical User Interface GUI allows the user to select feedback voltage as well as frequency with the GUI meters and displays changing to ensure that the user is always presented with the best resolution graphics that will allow HGC 2 v 1 0 File Unit Help Quit h Her Fault Status ll Voltage EEEN voc litt O 0 6 7 aso D sS 1 15 2 25 X ValveCurrent Freq Error 500 500 vw 3 500 BEEN ucc v 1 0 File Unit Help Quit X ValveCurrent Freq Error 50 50 w ee XN 4n 11 Hydraulic Generator Controller HGC 2 Data Logging Options The HGC 2 controller can log operational data as long as it is connected to the host PC The data is directly saved onto the PC hard drive as a CSV format file into a location that can be selected by the user Logging is started by the user clicking the Log Data button The controller logs the following data 1 Valve coil Current 2 PSU voltage 3 Freque
9. will meet this specification 19 Hydraulic Generator Controller HGC 2 a gt H HGC 2 Electrical Specification 1 Housing Type HCT unique encapsulated block 2 Input Supply Voltage 9 to 28VDC Absolute Maximum 3 Input Supply Current Valve Current Setting 50mA Quiescent Max 4 Feedback Voltage 100 to 250VRMS See note below in yellow box 5 O P Current Ranges 600mA 1 2A or 2 5A specified at time of order 6 Solenoid Min Ohms 20 minimum resistance 7 Dither Frequency Software adjustable 50Hz to 1KHz 8 Housing Material ABS black 9 Encapsulation Flameproof epoxy resin 10 I O Connections 8 pin Deutsch DTSO6 Male 11 Mounting 2 X No 6 4mm screws 12 Working Temp 20 C 4 F to 80 C 176 F operational 13 Storage Temp 40 40 F to 85 C 185 F 14 Humidity 95 to 100 NON condensing 15 NEMA IP Rating NEMA 6 67 module only 16 Operating System Windows XP Professional Vista Business and Ultimate Compatible 17 Unit Settings All by PC user interface 18 User PC interface P No 023 00228 19 USB Communications Optical link Infra red 20 Interface Cable P No 999 10166 HGC 2 Module overview 1 Main Input Output connector for HGC 2 2 STATUS led with blink code for local diagnostics 3 Infra red transmitter lens flush with module 4 Infra red receiver lens flush with module 20 Hydraulic Generator Control
10. 50A Max Current 02 to 2 50A Min Frequency Below Min Freq Action 35 0 to 59 5 Hz No Fault Timed Fault Max Frequency 50 4 to 80 1 Hz Above Max Freq Action No Fault Timed Fault Fault Time 0 0 to 25 0 sec Ramp Up Ramp Down 03A s to 7 5A s 03A s to 7 5A s CC Mode Current 02 to 2 50A Cut Off Frequency Selectable Hydraulic Generator Controller HGC 2 Controller Setting Security Passwords B ucc2 25 HGC 2 v1 0 l Bi He Quit Password Protection DOr COM 17 The password is entered after first Fault Status i Voltage REON voc clicking the HCT logo in the top left of the dashboard screen This opens another window where the password is Parameter Valve Type Target Frequency Proportional Gain Derivative Gain Limits 50Hz or 60Hz 0 to 100 0 to 100 entered PID Loop Time 1 to 30 cydes Dither Frequency Selectable Min Current NO Password User Level This level allows the user to only observe operation but not make any changes to the parameter settings or operation of the controller 02 to 2 50A OEM level This level allows the equipment OEM access to all settings and controller functions NOTE Passwords may be obtained by contacting High Country Tek Inc sales and support department File Menu Options GB ucc2 25 HGC 2 v1 0 The File me
11. HGC 2 is housed in a small rugged housing and is fully encapsulated for maximum reliability All I O connections are made through a heavy duty industry standard 8 pin male Deutsch connector PC Graphical User Interface GUI HGC 2 set up monitoring health checks and diagnostics can be accessed through the supplied GUI This program will operate on PC using a based Windows XP Professional or Vista Business and Ultimate operating system and is password protected to maintain module parameter integrity by only allowing authorized users to access different levels of the controller settings Passwords protect the settings of the module at all times and are needed to make any changes to the operational parameters The interface is designed to be simple to use and follows the familiar Windows amp menu format with drop down option screens to select the various options available at the user level allowed Explanation of the screens are covered in detail later in this guide Once the PC has been connected to a live HGC 2 and the GUI program started a free communications port will be either automatically allocated Windows XP Professional or Vista Business and Ultimate or will have to be manually chosen from a menu that will be displayed After communications have been established the user will be presented with the initial information screen that will give all the basic information needed to assess the health of the system Real time
12. Physical Memory 2 5MB Screen Resolution 1024X768 Hydraulic Circuit Guidelines Hydraulic Configurations Used in Hydraulic Generator Applications There are three commonly known approaches to hydraulic generator circuits 1 Load sense 2 Bypass flow control 3 Pressure control Field experience shows the most common circuit design is load sense with proportional two way acting as the LS orifice This design has difficulty with piston motors and the spikes induced by the low number of power elements Both the load sense and the bypass flow control approach require a fixed displacement motor of some technology gear vane bent axis piston e t c Motors with integrated cartridge valves make for a cleaner installation and reduce the need for leak paths manifolds hoses and fittings e t c in confined spaces normally seen in generator sets Orifice added Proportional 2 way 2 Fixed here is pozn as load HGC 2 Controller displacement dependent on EX pump a E compensator I AAA TA requirements I1 1 7 and system m design di Load Sense variable displacement pump Hydraulic Generator Controller HGC 2 About the HGC 2 Controller The HGC 2 Hydraulic Generator Controller is the latest addition to the HCT family of rugged controller modules designed for reliability under extreme conditions The highly cost effective HGC 2 is designed to control a generator driven by
13. To correct this issue the operator should first isolate and fully stop the generator and check the connections to from the HGC 2 controller to the solenoid for correct and firm connection If these are secure the user should inspect all the cables connected to the HGC 2 for wear and possible touching to a ground point H HGc2 25 HGC 2 v1 0 Fe Unit Hep Quit vake Type Normal Fue verse T Valve Current 3 257 3 Target Frequency Proportional Gain Sz or Dh Dto 100 Intergral Gain Derivative Gain PID Loop Tine Dither Frequency Max Current Min Frequency Obe 10056 02 tm 2 504 35 0 to 53 5 Hz Below Min Freq Acton Max Frequency Abowe Max Freg Action Ho Fault Timed Fault 50 4 to B0 i Hz hoa Faut Timed Fault 0 0 to 25 0 sec JD3A fs ta 7 5A s D3Ajs to 7 54 5 Selectable Once this fault is triggered the HGC 2 PWM output will be set to zero output i e minimum generator speed until the HGC 2 is first disabled and re enabled or the supply power to the unit is cycled 13 Hydraulic Generator Controller HGC 2 Connecting the HGC 2 to the Programming Cable In order for the HGC 2 to communicate with the PC User Interface a programming cable 999 10166 must be temporarily connected to the PC USB port and also to the HGC 2 controller The controller and programming cable use Infra red transmission technology
14. U S A and can be sent anywhere in the world Please contact us to discuss your next project product training or system application we would be pleased to work with you and your team C Electro Hydraulic Control Solutions High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 Fax 1 530 265 3275 24 Copyright High Country Tek Inc 2009
15. 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 Generator Controller HGC 2 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 wit
16. aulic Generator Controller HGC 2 Mining amp Exploration s Agriculture Cranes amp lifts Refuse amp Re cycling Construction Off Road vehicles Forestry Wood amp Pulp lt Reclamation amp Salvage Oil Field amp Sands Demolition Equipment Cooling Solutions Military Apparatus Specialty Use 4 Remote Control Power Generation Emission Controls Integrated Drivers Valve amp Pump Controls Contact Us For product orders delivery pricing training or any other customer service related item please contact us through E mail at info highcountrytek com www highcountrytek com 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 Manual Part No 021 00160 HGC2 Man D ppt 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 manufactured and tested in the
17. e Disconnect Power before servicing 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 3 Hydraulic Generator Controller HGC 2 Product Features Digital controller for repeatability reliability and accuracy in your application Accuracy is dependent on HGC 2 module Tuning and the type of hydraulic circuit used 100 to 250VRMS generator output compatible 50 or 60 Hz settable for global sales opportunities User configurable Under and Over frequency handling Wide supply voltage 9 to 28VDC and full reverse polarity protection 20 C 4 F to 80 C 176 F controller operational temperature range Valve dither selectable in steps up to 1000Hz Fully adjustable PID closed loop control for smooth speed control with fast correction and accuracy Designed to meet CE criteria to latest standards Diagnostic Status LED shows I O status and module operation at a glance Blinking error code LED for fast on site system wiring coil fault detection Solenoid PWM current output is short circuit protected 4 IP67 NEMA 6 rating on module for harsh environment reliability connector IP rating may differ Single Deutsch 8 way male connector for eas
18. erator speed until the HGC 2 is first disabled and re enabled or the supply power to the unit is cycled and no further open circuit is detected Valve Type Send Changes Hormal Fg verse Target Frequency Propor tonal Gain Sz or amp Dz D ta 10055 Intergral Gain Dertveattve ain Dither Frequency Max Current in Frequency D ia 10055 Oto 10056 1 to 30 copdes 02 tm 2 504 35 0 to 53 5 Hz To correct this issue the operator should first isolate and fully stop the generator and check all connections Bekyw Min Freq Acton Max Frequency Above Max Freq Action Fault Time LC Mone Current Cut Off Frequency Np Fauit Timed Fault 50 4 to B0 1 Hz Exi ha Fault Tmed Fault 0 0 to 25 0 sec 03A s to 7 5AJs D3A s to 7 SAJs 02 te 2 504 Selectable to and from the HGC 2 controller for correct and firm connection If the faulty still exists check the solenoid coil for continuity and correct Ohmic value see manufacturer details or change the solenoid coil 12 Hydraulic Generator Controller HGC 2 Faul Screens FREQ FAULT DETECTED This fault is displayed when the controller detects the high voltage feedback frequency is either below or above the Min and Max frequency settings selected The fault indicator only appears after a time period to allow for minor fluctuations in frequency that may occur during load no load load
19. for fast data transfer and the user must ensure that the programming head is correctly aligned and fitted to the controller for successful communications Philips Pan head screw Philips Pan head screw Connector profile HighCountryTek com Grip top and bottom here to slide programming head into position Ensure this profile meets connector profile 1 Install the HGC 2 Graphical user Interface onto the PC that will be used for set up and configuration of the HGC 2 2 Ensure you have if necessary installed the USB drivers needed for the programming cable onto your PC that will be used for setting up the HGC 2 found ob software CD or at www highcountrytek com 3 Wipe clean both the surface of the HGC 2 module directly under the connector and also the underside of the Programming head making sure there is no debris or material that could cause an issue 4 Hold the Programming head such that the label is facing upwards as shown in the picture to the right 5 Holding the Programming head firmly top and bottom between thumb and forefinger slide it UNDER the two Philips Pan head screws see bubbles above until the profile in the Programming head meets and matches the connector profile Only now is the head aligned correctly with the optical coupling 14 Hydraulic Generator Controller HGC 2 HGC 2 Controller Settings and Descriptions TARGET FREQUENCY The Tar
20. get Frequency parameter sets the desired output frequency of the generator to 50Hz or 60Hz The Proportional parameter is a variable type PROPORTIONAL GAIN The Proportional parameter sets the proportional gain in the control loop The proportional gain represents the P term in a PID control loop The proportional term is simply a multiplication of the error which is added to the output The Proportional parameter is a variable type INTEGRAL GAIN Integral Gain is used to determine the integral or term in the PID control loop The integral term is a accumulation of error over a period of time The integral term is generally used to overcome an offset in the output or to correct for very small deviations over time at a fixed command The Integral Gain parameter is a variable type DERIVATIVE The Derivative parameter sets the derivative gain in the control loop The derivative gain represents the D term in a PID control loop The derivative term is the rate of change of the error The derivative term is generally used to increase the responsiveness of a system The Derivative parameter is a variable type PID LOOP TIME PID Loop Time represents the PID loop closure time in number of dither cycles Therefore the lower the number the more quickly the system will respond to error The PID Loop Time parameter is a variable type RAMP UP RATE The Ramp Up Rate sets the rate at which the controller will increase current to the solenoid once enab
21. hin 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 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 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 Hazardous voltag
22. in the system for full protection and warranty Use separate cables for each connection as shown above Connect proportional valve coil cables and run separate from all any high voltage wires Ensure that high voltage feedback cable is protected to prevent insulation wear during usage through vibration 22 Hydraulic Generator Controller HGC 2 HGC 2 Ordering Information jajcj2 1 2 Output Current Range 06 600mA current range 12 1200mA current range 25 2500mA current range Notes The current range chosen represents the maximum current available at the controller output See rear of controller for part number and model number HGC 2 Connector Kit 8 way Metri Pack 150 series MALE connector Note Mating connector gender 8 way Female Socket kit complete with pins and separator Correct crimp tool must be used contact HCT sales and service for more information Order P No 999 10073 HGC 2 Programming Cable The programming cable is USB compatible and requires 5VDC power from the USB port to operate The programming method is infra red and will only work when the head is securely mounted to the HGC 2 controller The head is a tight push fit using the two screw heads either side of the Deutsch connector for location The head should be mounted with the BLACK side downwards facing the controller ensuring that it is fully pushed home Order P No 999 10166 23 Hydr
23. l applications with products only warranted for this type of use HCT distributors are not authorized to approve the use of any HCT product in any of the following applications e Any product that comes under the Federal Highway Safety Act i e steering braking systems for passenger carrying vehicles or on highway e Aircraft private military commercial or other or space vehicles e Ordnance equipment fixed or mobile e Any end product that when sold comes under the U S Nuclear Regulatory Commission rules and regulations Specific written approval for any application of HCT products in any of the above named applications should be obtained from High Country Tek Inc and consultation with our factory engineers is advised in unusual situations where applicability is questionable System Part Numbers e Controller Module sess mme oee rear of manual for ordering info e Controller Graphical User Interface GUI sssee P No 023 00228 e HGC2 controller software CD seseseseessseeeeses Contact HCT customer service for info e Controller info manual osseessessessesee me P No 021 00160 Programming Cable 0 ccc cece cece cence eee e ana EAN n P No 999 10166 e HGC 2 8 pin Connector Kit ccc cc cccee eee e eee eeeeeeeeeaeeeaeenaes P No 999 10073 IMPORTANT NOTE High Country Tek Inc reserves the right to upgrade revise or better
24. led Once the AC frequency is within approximately 1096 of the target frequency the closed loop control algorithm will take over The Ramp Up Rate parameter is a variable type RAMP DOWN RATE The Ramp Down Rate sets the rate at which the controller will decrease current to the solenoid after the enable signal is removed Once the AC frequency is within approximately 1096 of the target frequency the closed loop control algorithm will take over The Ramp Up Rate parameter is a variable type DITHER FREQ The Dither Frequency parameter has 11 options for dither control The choices are 50 75 100 125 150 175 200 225 250 275 300 350 400 500 and 1000 Hz Dither control provides low frequency modulation which is required in many proportional valve applications The Dither Frequency parameter is variable MINIMUM OUTPUT The Minimum Output parameter represents the minimum current of the output This is often referred to as the dead band The value displayed represents the current in milliamps amps for 12A 25A The Minimum Output parameter is variable 15 Hydraulic Generator Controller HGC 2 HGC 2 Controller Settings and Descriptions MAXIMUM OUTPUT The Maximum Output parameter represents the maximum current of the output This is often referred to as the gain The value displayed represents the current in milliamps amps for 12A 25A The Maximum Output parameter is variable MINIMUM FREQ The Minimum Frequency para
25. ler HGC 2 Frequency Fault output frequency has been below min or above max for greater than fault time Note The STATUS led is a monitor is used to indicate locally the controller operation only NO external output is provided to mimic the STATUS led HGC 2 Hardware Description Inches Millimeters cr E STATUS di 7 Hydraulic Generator Controller D HGC 2 www highcountrytek com IMPORTANT NOTES e ALWAYS Mount HGC 2 controller with I O connector facing downwards to avoid debris collection Recommended tightening torques for securing bolts on the HGC 2 module are as follows For 2 x 6 4mm bolts Dry Torque 6 Ft Lbs Lubricated Torque 4 Ft Lbs 21 Hydraulic Generator Controller HGC 2 Electrical System Connections V Power Input FS 1 Power u r TV Wet HCl Normal Enable HI ENABLE IN 8 49 to 28VDC CC Enable HI CC Mode ENABLE 7 9 to 28vDC VDC Input Supply H G C 2 VDC Input Supply ardie Coil 9 ren Solenoid Connection O P loa a Vc Pump Solenoid Connection O P AC feedback Neutral I P ACUTE ER 6 c TN AC feedback Line I P ooma Y j Constant Current Mode enable I P AC Neutral Input CE P Controller ENABLE I P 50 60 HZ Power Com s OV Power Input Hazardous voltage Disconnect Power before servicing HGC 2 Module Connection notes Ensure that the recommended fuses FS1 amp FS2 is installed
26. malfReverse communications will be established and this Dashboard screen will appear From here the user can observe all e R ane PID LoopTime 1 to 30 cydes operations of the controller as well i i Min Current 02 to 2 50A o4 as see the settings for individual E TTE characteristics that have been Min Frequency 350tos9 5Hz m asi programmed Max Frequency 50 4to 80 1Hz If the user is authorized and has the A PUES PEN correct password s the unit settings FautTme 0 0t025 0sec SERRE sec and other information can also be RampUp 03A s to 7 5A s amp sec Ramp Down 03A s to 7 5A s 5 5 31 1 amp sec configured from here CC Mode Current 02 to 2 50A F iE PNE amps Cut Off Frequency Selectable 100 Hz OFF LINE 4 E HGC 2 Beta v L 2 data HGC225 dat The Graphical User Interface GUI screens are designed to help the user understand the operation of the HGC 2 as well as allow set up and diagnostics when needed Wi i iso atm atm oe 24 rz Gel 5 I ie o lels DA L w 3 z R a me tue alli iie s ps z When the PC is connected to the controller and the GUI is started there may be several seconds while the PC establishes communications with the module During this time the OFF LINE indicator will be present This indicator also displays if communications are lost or dropped during connection between the PC and the module Under
27. meter is used to establish the minimum frequency for the desired range of operation A frequency below this value will be handled according to the Below Min Freq parameter The Minimum Frequency parameter is a combination variable monitor type BELOW MIN FREQ Below Minimum Frequency selects which function to use when the frequency falls below the Minimum Frequency NO FAULT will ignore the condition and TIMED FAULT will trigger the corresponding fault causing the controller to shut down after the set time The Below Minimum Frequency parameter is variable MAXIMUM FREQ The Maximum Frequency parameter is used to establish the maximum frequency for the desired range of operation A frequency above this value will be handled according to the Above Max Freq parameter The Maximum Frequency parameter is a combination variable monitor type ABOVE MAX FREQ Above Maximum Frequency selects which function to use when the frequency rises above the Maximum Frequency NO FAULT will ignore the condition and TIMED FAULT will trigger the corresponding fault causing the controller to shut down after the set time The Above Maximum Frequency parameter is variable FAULT TIME Fault Time sets the amount of time that a frequency fault condition exists before the controller shuts down and indicates the fault The Fault Time parameter is variable CC MODE CURRENT The CC Mode Current sets the desired output current used when the constant current mode is enabled
28. ncy feedback Information transfer rate from the controller to the CSV file is governed by the host PC performance Fault Screens OPEN CIRCUIT FAULT DETECTED LUTEX IET This fault is displayed when the controller detects that the proportional coil being driven by the PWM output has become dis connected or has B ucc2 25 HGC 2 v1 0 File Unit Help Quit Her Parameter Valve Type Jp 3L Normal Reverse Target Frequency i 50Hz or 60Hz Proportional Gain 0 to 100 Intergral Gain 0 to 100 Derivative Gan 0 to 100 m iz PID Loop Time st oe coe oco noe AP RJ Ar 1 to 30 cydes Dither Frequency i Selectable Mn Current 02 to 2 50A o Max Current 02 to 2 50A Min Frequency tuom o e Lo UR ry like JS 35 0 to 59 5 Hz Below Min Freq Action d i No Fault Timed Fault Max Frequency IE i 50 4 to 80 1 Hz Above Max Freq Action No Fault Timed Fault d w o Fault Time 0 0 to 25 0 sec Ramp Up 03A s to 7 5A s CC Mode Current Ramp Down 03A s to 7 5A s puto coe ice t le YI hag Cut Off Frequency failed internally to an open circuit condition Other causes of this fault detection may be broken wires within the generator set enclosure po If this fault is triggered the HGC 2 PWM output will be set to zero output i e minimum gen
29. ng It can also be used in electrically noisy environments where the AC feedback might become overly distorted In this mode the controller will maintain a constant output current to the valve coil without regard to the AC line feedback To initiate CC Mode apply a signal to both the CC Mode Enable and the main Enable simultaneously Once started the CC Mode Enable signal can be removed and the controller will continue in this mode until the main Enable is removed CC Mode cannot be initiated after the controller is started in normal mode 17 Hydraulic Generator Controller HGC 2 Operational Guide The following section gives the user a generic overview of expected control results once the controllers PID settings have been optimized for the individual generator set up being produced These results are for reference only and may vary depending on individual circumstances product technologies Hydraulic Circuit configuration Prime Mover 50KW 1800 RPM on Variable Frequency Drive e Pump 45 cc rev load sense pump Valve 2 position 2 way non compensated proportional size 12 cartridge with 12 VDC coil Oil temperature forced air cooled with ambient air Oil type Standard Hydraulic Mineral oil Generator Configuration e Armature Mec Alte 2 pole S16F 180 B rated at 8KW 3600 RPM de rated to 6KW for severe duty service e Hydraulic Motor Sauer Danfoss SNM2 FL 08 SSCO06 RZZ1 Voltage regulator
30. normal circumstances re connection of communication will be automatic If the module fails to re connect the user may have to cycle power to the HGC 2 to perform a hard reset it alle RIR E x te 9 ERES den e 5 d 85 0 oo oce oe Hydraulic Generator Controller HGC 2 Explanation of major windows HGC2 25 HGC 2 v1 0 Cex 1 The header of the GUI window tells the user the version of the software and which controller should be connected to the host PC 2 This main indicator should be bright GREEN to show a correct operational function of the controller with the light showing real time status of the units Selectable operation If there is an error of any RD ae type this indicator will be bright RED cae with the fault description shown under me ere the light until the fault is cleared ee 3 This digital display shows in real time the DC supply voltage to the HGC 2 controller 4 This meter shows the user the actual feedback frequency that is being measured from the generator under control The needle should be in the GREEN band for correct operation 5 This bar graph and digital meter shows the user the PWM DC current trend and value that is being supplied to the control valve used to regulate the generator rotational speed This valve may be direct on the motor
31. nus has two drop omm Head File 2 Save File Valve Type Target Frequency 50Hz or 60Hz Proportional Gain 0 to 100 Intergral Gain 0 to 100 Derivative Gain Read File when clicked will allow the user 0 to 100 PID Loop Time 1 to 30 cydes Dither Frequency to look for previously saved HGC 2 setting Selectable Mn Current profiles and up load these into the PC and 02 to 2 50A 02 to 2 50A 35 0 to 59 5 Hz then into any HGC 2 controller Max Frequency No Fault Timed Fault 50 4 to 80 1 Hz Above Max Freq Action No Fault Timed Fault IMPORTANT NOTE Fault Time 0 0 to 25 0 sec O3A s to 7 5A s When editing the default data file that comes with the controller ensure that you choose the correct file name for the model of HGC 2 ordered and used For example Use data file name HGC 2 12 dat for the HGC 2 12 s HGC206 dat 2 HGC225 dat My Documents gs My Computer Save File when clicked Allow the user to save to PC hard drive the setting file for an HGC 2 controller This feature is used to store 03A s to 7 5A s File name HGC212 dat Y different generator model profiles that can be retrieved quickly at any time as required J My Network Files of type Custom Pattem dat v Hydraulic Generator C
32. ontroller HGC 2 Unit Menu Options E ucc2 25 HGC 2 v1 0 The Unit menus has three drop down options Fe ust Hdp QA Read Parameters Send Parameters Find Controler Read Parameters 2 Send parameters 3 Find Controller Read Parameters Selecting this option allows the GUI to read the parameter setting file from a connected controller to allow backup editing or copying to other controllers Valve Type Normal Reverse E 3 Target Frequency SOHz or 60Hz Proportional Gain 0 to 100 Intergral Gan 0 to 100 Derivative Gan 0 to 100 Isto coe coe o oe Q RIE z PID Loop Time 1 to 30 cydes Dither Frequency Selectable i Mn Current 02 to 2 50A i e Sis Max Current 02 to 2 50A iso incom Un Min Frequency 35 0 to 59 5 Hz Below Min Freq Action No Fault Timed Fault gt j ptos ico oce oco en por m t fios fles Ho 10 rns Max Frequency 50 4 to 80 1 Hz Ir Above Max Freq Action No Fault Timed Fault Fault Time 0 0 to 25 0 sec Ramp Up 03A s to 7 5A s Ramp Down 03A s to 7 5A s CC Mode Current 02 to 2 50A Send Parameters This option sends all i ae Cut Off Frequency Selectable the parameters currently shown on the screen down to the controllers permanent memory to become the settings used from this point forward Find Controller This option
33. or as part of a compensator assembly on a variable displacement pump 6 This graph area allows the user to watch operation of various signals to observe stability and speed of correction e t c as required 7 This table shows at a glance all of the settable parameters that may be adjusted to suit the individual generator set needs If the table window has a blue background with yellow text he user may enter a value directly and use the up down arrows to adjust the value as required 8 The changes made to the parameters in the table mentioned in 7 only take effect within the controller when this Send Changes button is clicked 9 This button allows the user to LOG controller functionality directly to the connected PC hard drive The data is saved in CSV format Excel compatible for easy and quick graphing of operation NOTE With NO password entered the options bar will only show Help and Quit highlighted as these are the only choices available to the un authorized user Help Menu Options The Help menus has two drop down options Print Parameters 2 View Help About Controller a Print Parameters when clicked this option will allow the user to get a hard copy of the controller settings via the default printer connected to the PC View Help when clicked will open a PDF format file that is the complete manual for the HGC 2 controller allowing local on site information
34. ut with good control being shown a 50 at all times 45 40 I I 1 3 5 7 9 11 13 15 17 19 21 23 25 27 Time base Milliseconds Test Specifications Prime Mover Speed Change Prime Mover Speed changes 80 15 In the event that the prime mover has variations 70 in speed i e engine momentary loading the N controller must be able to react quickly and 65 smoothly avoiding major over and undershoots 5 60 and recovering to steady state as soon as S possible Q 99 This test demonstrates the generator output with iL 50 prime mover speed changes from mid range normal 3600RPM to minimum 3400 RPM 45 and then to maximum 3800 RPM 40 PUTT TTT ATT TTT FEE T ETE EHE EETEEERETEEE EFE ETE TEE TEE HE EFE HE ET EE EHE EETEEERE EET HE EET TEE TET HE EFE ETE T TT ETT HET I 1 16 31 46 61 76 91 106 121 136 151 166 181 Time base Milliseconds Test Specifications General There are few hydraulic generator specifications existence The most common is the NFPA specification for generators applied to fire protection equipment It is based on a non electronically controlled hydraulic generator load sense pump with fixed orifice and thus addresses dynamics specific to that design such as frequency droop over time under full load to assess volumetric efficiency losses This specification is attached A generator using either test specimen
35. y system wiring Separate Infra red communications connector for programming monitoring and diagnostics 4 Rugged encapsulated enclosure withstands harsh environments found in mobile applications Field programmable and upgradeable for future complex fan system applications Intuitive Graphical User Interface GUI easy and fast to use for set up and diagnostics Runs on any PC with Windows XP Professional or Vista Business and Ultimate software Completely user configurable for setting confidentiality lt Compatible with ALL major hydraulic manufacturers suitable hydraulic products Manual Variations Note PC Screen shots shown in this manual may have small differences to the picture being displayed on the Graphical User Interface you are using This is normal and is due to the PC software being updated as we add more functionality 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 Hydraulic Generator Controller HGC 2 Software and PC requirements Min Requirements Disk space 165MB Software GUI and National Instruments embedded drivers required
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