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EMC-6 EMC-6L - High Country Tek

1. Fan ID numbers are assigned in the Bank Interlocks tab e State Indicators displays the state of the inputs RPM J1939 messages Supply voltage and Reference voltage Green the input is on or active Yellow the input is in an intermediate state e RPM low Red the input is off or timed out or in an error state like Ignition OFF e Log Data logs the operational data in Excel format The file size is only limited by the PC s hard drive Capacity Each log begins with a list of settings followed by operational information The sample rate depends on the workload of the PC and the controller at the recording A timestamp scales the logs appropriately Subsequent logs may be saved in a new file or appended to the original file by selecting the original file The log file is saved as a csv file Microsoft Excel can be used to open this file e Stimulus Bar Graphs displays the real time readings of the stimulus Select the stimulus from the pull down menu Scale the bar graphs The units are set in the Stimulus Settings for CAN values and in the Analog Settings for the Analog Inputs e Engine RPM displays the engine RPM from SPN 190 or the error value in Stimulus Settings when the engine RPM message times out 021 00360 Rev B 23 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions yas EMC 6 Control Messages The user may define up to 10 CAN
2. Figure 33 e Sample Time Seconds bigger number slows down the speed that the graphs move along X axis e Back ground Color click to change the background color e Graphing Title Uncheck to remove the graph Click or right click to format the graphing curves e Log Data logs the operational data in csv format GD hydraulics 021 00360 Rev B 40 Copyright High Country Tek Inc 2015 pas EMC 6 C EMC 6L Electro Hydraulic Control Solutions Appendix A Fan Status Messages The Fan Drive Message PGN 65213 FEBD Parameter Name Estimated Percent Fan Speed 0 100 Fan Drive State Parameter Name Bank Estimated Fan Speed 0 100 DG State Input 1 16 O Fan failure 1 Fan is Operational Estimated Fan RPM Parameter Name Bank Estimated Fan Speed 0 100 16 DG State Input 1 16 0 Fan failure 1 Fan is Operational 1639 Estimated Fan RPM The Bank 3 Status Message PGN 45824 B300 SEN Startbit bits 0 oO ParameterName 95 1 8 Bank Estimated Fan Speed 0 100 La 16 DG State Input 1 16 0 Fan failure 1 Fan is Operational Estimated Fan RPM The Module Status Message PGN 46068 B400 Note 1 SPN Startbit bits Parameter Name Li 8 ignition Input Volts 7 6 Reverse Input Volts ii Im 7117 021 00360 Rev B 41 Copyright High Country Tek Inc 2015 pas EMC 6 C EMC 6L Electro Hydraulic Control Solu
3. GA Diag In C2 Iren ja 3 1 Jan Hi Ee Diag In 8 Figure 3 EMC 6 EMC 6L Connector Designation Table Bank 3 PWM Bank 4 3A Bank 4 PWM Diag In 9 Bank 6 PWM Deg In 10 Bank 1 PWM Bank 3 An Out Bank 2 PWM Diag_In 11 Bank 5 PWM Deg In 12 Figure 4 NOTE Thermistors 1 4 pins C1 C2 D2 E2 can be utilized as Fan Diagnostic inputs and configured within the GUI on the Analog Settings tab A Sun Hydraulics Company 021 00360 Rev B 11 Copyright High Country Tek Inc 2015 Mer EMCS Electro Hydraulic Control Solutions LEDs Diagnostic Codes The module has 4 LEDs GUI LED blinks GREEN Normal communication GUI LED steady GREEN No communication CAN LED steady RED and Error Status blinks GREEN CAN message timeout CAN LED blinks RED Intermittent CAN message timeout CAN LED blinks green fast Normal operation Error Status LED steady GREEN Normal operation Error Status LED blinks RED 1 6 times Bank 1 6 diagnostic error Error Status LED blinks GREEN 1 time CAN message timeout Error Status LED blinks GREEN 2 times Analog value o
4. A Sun Hydraulics Company 021 00360 Rev B 999 10107 18 pin Harness 3M length 108 00134 999 10075 USB Mini B 4 way weatherpak 2M length to RS232 D 999 10213 Mating connector For both liquid and dry thermistors EMC 6 EMC 6L Tess AMAR 999 10077 48 pin Mating Connector Kit e 108 00119 RS232 to PC USB 206 00084 3 8 18NPT Dry Thermistor 40 C to 150 C Copyright High Country Tek Inc 2015 EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions Example Applications MP 12 MI 12 f i r lt C2 Ano_in 1 K1 Power_in Ca aen D2 Ana_in 2 o1 rower_ Get a2 Not used cali F2 Reverse_in Ci Ana_in 4 GAIB Di Ana in 5 62 Fire_In GE E1 Ana_in 6 JA cap H2 Ignition_in 03 cND 3 GND d2 Alorm_Out I T 2 d3 Reverse_Out a f1 GND RS232 C mp aa SENEN A3 Not used a3 Ref_Out omg 0 5A PWM duty cycle Pin b1 we BI CMH EMC 6 Bonk 14 0 51 5mA CAN Le use EMC 6L Bonk 2 0 54 Set output Pin H3 F1 Diog_in 1 VS Bonk 3 0 51 5mA J1 Diog_in 4 T J2 Diag_In 5 l LI J3 Diog_In 6 E fons Bonk 4 za K2 Diog_In 7 K3 Diog_In 8 i e2 Diog_In 9 e3 Diog_In 10 f2 Diog_In 11 in i f3 Diog_In 12 Mini USB a i Datar AAN Spade ie tei apd eit em le ei a elle cece ee J Figure
5. Diag_In 5 J3 Diag_In 6 K2 Diag_In 7 K3 Diag_In 8 e2 Diag_In 9 e3 Diag_In 10 f2 Diag_In 11 f3 Diag_In 12 K1 Power_In al Power ln a2 Not used H cr F2 Reverse_In G2 Fire_In H2 Ignition_In d2 Alarm_Out d3 Reverse_Out EMC 6 EMC 6 f1 GND a3 Ref Out Bank 1 L X momentary gt latched_ e latched SO 0 5A On Off sourcing 3A On Off sourcing gt 5V 5 200mA 0 5V 5mA Pin G3 0 5A PWM Pin b1 BB 0 5A PWM Pin b2 Bank 2 0 5V 5mA Output Pin H3 SES lt gt 0 5A PWM Pin c1 0 5V 5mA Output Pin d1 0 5A PWM Pin c2 Bank 4 3A Prop PWM sourcing Pin e1 Bank 5 Bank 6 gt 0 5A PWM Pin b3 gt D PA PWM Pin c3 e lt Mini USB Port Figure 2 PWM outputs are sourcing for EMC 6 PWM outputs are sinking for EMC 6L 021 00360 Rev B Copyright High Country Tek Inc 2015 C Electro Hydraulic Control Solutions Her os PINOUT The module has a 30 Pin Cinch connector and an 18 Pin Cinch connector Either the RS232 port from the 30 pin Cinch connector or the mini USB port at the top of the controller can be used for serial communication EMC 6 EMC 6L Connector Designation Table RXD RS232 Diag_In1 TXD RS232 Diag In 2 Diag_In 3 Diag_In 4 ad ke LA Diag_In5 LA Diag_In 6 Ke 1 Power_In Therm_In 4 Reverse_In ad
6. TMP Documents and SetkingsahinziLocal System variables Variable Value A Comzper CUWINDOW S systemazicmd exe DevMgr_ Show Mon 1 Ds ROOT C entortrapbiceg DFPADSASOD Hor we ELDO FLOW sim k 4 MM gt Figure 35 New System Variable DeyvMor_ Show MonPresent_Devices Figure 36 Variable name Variable value 44 Copyright High Country Tek Inc 2015 EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions Open the Device Manager gt View gt Show Hidden Devices Device Manager will show all hidden and phantom devices gt Uninstall the phantom devices by right clicking on them and delete gt Reboot the PC P Device Manager Device Manager e Bu x File Action View Help File Action Help Ices Wise 8 Microchip Tools Devices by connection Za Modems Resources by type Monitors Resources by connection gt E Network adapters amp Non Plug and Play Drivers Show hidden devices ro Other devices Penn Wi Portable Devices l USTOMIZE 4 Ports COM amp LPT Figure 37 Ja Communications Port COM1 7 DR Controller COM 1O ECP Printer Port Update Driver Software YI Intel R Active Ma Uninstall Intel R Active Ma USB Serial Port Q USB Serial Pont d Properties USB Serial Port COM6 7 USB Serial Port COM7 USB Serial Port COM8 Figure 38 Scan for hardware changes Option 2 Open the Control Panel Add or
7. 5 A Sun Hydraulics Company 021 00360 Rev B 14 Copyright High Country Tek Inc 2015 Mer EME SL Electro Hydraulic Control Solutions GUI Installation Use the default file locations for easy future update when installing the Graphical User Interface GUI The user has the option to choose file location Do NOT run the GUI from a network drive as it needs to access certain files only in the local Windows directories System Requirements e Windows XP Vista Windows 7 or 8 100MB or greater free disk space Installation Steps e Insert the CD and follow the on screen instructions This will install the GUI manual and help files e Go to Help menu install the CommFront driver or Mini USB driver e To insure a complete install for Comm Front install it twice e Install all software and drivers before plugging in the USB dongle or USB cable Launch the GUI Click Start gt HCT Products gt Fan Drives gt EMC 6 L HCT Products h Daily password A Digital Controllers epc amp evc 2 h Fan Drives EMC 6 foe EMC 6 D Single Fan Bank Controller Figure 6 021 00360 Rev B 15 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 GUI Overview At start up the GUI searches all the PC communication ports and identifies the controller The GUI appears once the module is identified File Controller Password Help EXIT Access Level Basic Check Device ID
8. 6L Electro Hydraulic Control Solutions fa EMC 6 Interlock Selection e Fire Input check to enable the input The fire input will override all controlling inputs When the Fire Input switch is activated this fan bank stops Manual mode overrides the fire input e Ignition Input check to enable the input When the Ignition switch is de activated this fan bank stops e Minimum RPM check to enable the input When enabled the fan bank will not run until the Engine RPM meets or exceeds the Minimum Engine RPM set point on Global Settings e Display Interlock Truth Table opens a window that displays a table of the interlock logic Fire input takes precendence when enabled and turns off All Fans Selection Selection Condition Condition Condition Condition Result Figure 29 Manual Reverse Configuration Manual Reverse Operation is allowed only when the fire input is off and the ignition is on unless the inputs are disabled in the Interlock Selection Box e Manual Reverse check to enable the input When disabled this fan bank has no Manual Reverse e Engine RPM is Off low if checked this fan bank has Manual Reverse when the Engine RPM is lower than the Minimum Engine RPM setting on Global Settings or Orpm Engine J1939 message timeout does not qualify as Orpm e Engine RPM is ignored when checked the user can operate a reverse cycle by enabling the Reverse Switch while the engine is running
9. HCT products are encapsulated in solid flame resistant material for maximum durability electrical integrity and complete environmental security HCT is a market leader in many application arenas including hydraulic generator e Fan and hydraulic fan system controls These controllers facilitate significant fuel emission and operational savings HCT s market neutrality offers integration with any hydraulic OEM valves pumps sub systems or systems For more information please visit us at www hctcontrols com EMC 6 Product Overview The industry s first hybrid fan controller designed with diverse flexibility enabling the precise control of variable speed hydraulic fan systems and brushless e fans in addition to engine accessories The controller provides low current varying PWM signals to six independent e fan banks based upon the command inputs with each bank capable of driving up to 20 e fans per bank The EMC 6 is targeted for more complex Tier IV and Tier V cooling systems due to the thermistor and diagnostic inputs SAE J1939 communication and precise temperature control The CE and E Mark certified controller is designed with a unique hardened package making it a durable and rugged option for the Mobile and Mass Transit industries It is ideal for dynamic systems that require a single hydraulic fan with additional precise e fan bank control for isolated cooling needs like charge air engine bay ventilation transmission or hydraulic oil
10. Inc 2015 C EMC 6L Electro Hydraulic Control Solutions fa EMC 6 Dashboard The Dashboard monitors the fan system in real time Configure all tabs from left to right so that the subsequent tabs have the correct background settings vi EMC 6 v2 4 Beta 3 File Controller Password Help EXIT _D1 D2 03 04 05 be o7 os os po 011 012 a1 a2 As As sm wi Figure 16 e Gauges PWM RPM displays either the real time PWM or the Calculated Fan RPM There are six operational states for the fan bank gauges Normal All the fans in this bank are operating normally Diag Error At least one fan in this bank is reporting an error Manual All the fans in this bank are in manual mode Reset At least one Locked Rotor error was detected The module is resetting all the fans in this bank Dwell The fans in this bank are freewheeling before entering into reverse direction Reverse The fans in this bank are in Reverse A Sun Hydraulics Company 021 00360 Rev B 22 Copyright High Country Tek Inc 2015 EMC 6L Fa EMC 6 Electro Hydraulic Control Solutions e Fan Operating Status and Fan Error Status indicates the fan status Green indicates that fans are running Gray indicates that fans are OFF Red indicates one or more fans have errors It happens when the respective diagnostic pin does not have voltage when the fan is running or has voltage when the fan is not running
11. Remove Programs Remove old versions of FTDI drivers Windows Driver Package FTDI CDM Driver Package Reinstall the FTDI Drivers as explained in Software Installation above The current driver package for your operating system may be obtained directly from the vendor at http www ftdichip com F T Drivers htm 021 00360 Rev B 45 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 Appendix C PID Tuning for Setpoint Control Overview The process of setting the optimal gains for P and D to get an ideal response from a closed loop control system is called tuning Tuning Procedure This is a trial and error method 1 Set the and D terms are set to zero first 2 Increase the proportional term P until the output oscillates after a step change to the set point 3 As the proportional gain is increased the system response becomes faster don t increase P too much otherwise the system could become unstable 4 Increase the integral term to reduce the steady state error difference between the set point and the actual feedback value at steady state The integral term reduces the steady state error but increases overshoot Some amount of overshoot is always necessary for a fast system so that it can respond to changes quickly 5 If needed increase the derivative term D until the system response is acceptably quick to a step change with minimal overshoot Increasing the
12. a saa gagana aa pa san apanga a ee er ee 15 EU Ree 16 Wl 16 Beja ge 17 PS SW OG aaa min ala apa aana aa en na BN a Ka ee BA DE Ra EN AKE E a Ran ner re 20 aE WE 21 Ee EN DAN ee ee ee E een 22 Seite 24 GEIER 26 e E e IND sasi ba aaa kak aan aan ca nes E ee een EE 28 BKC ONTO E 29 Set E LOCK Se ee E E E T A EE E A a NA a 35 ENEE 36 VEN ET D IS aana paga WE Dai aia NGGAE ee Nee 40 Appendix A Fan Status Messages nennen ee 41 Appendix B Troubleshooting Communication Port Adapters cccccssecccessecceeseceeeecesaeseeeseaeceseeecesseeeeees 44 EES 44 Appendix C PID Tuning for Setpoint Control 46 BEE 46 PONNE POC COU sete en ee Kawah oe en ee De error ie 46 021 00360 Rev B 3 Copyright High Country Tek Inc 2015 021 00360 Rev B EMC 6 EMC 6L This page is intentionally left blank 4 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 HCT Introduction Welcome to High Country Tek Inc HCT is North America s foremost independent designer and producer of modular ruggedized digital and analog electronic controllers for the fluid power industry From our factory in California we manufacture specialty controllers for specific functions and the user programmable DVC family to enable large area networked system solutions The modules are used in mobile industrial and marine applications They are also applied successfully in other industry segments
13. cooling in order to achieve enhanced engine performance and reduced emissions The EMC 6 s unique PID Set Point feature automatically adjusts the fan speed based upon the user set temperature while prioritizing multiple thermistor inputs and J1939 messages For greater performance requirements the OEM can adjust the cooling response by adjusting the PID closed loop settings The EMC 6 is also unique such that it can be configured through the Graphical User Interface GUI to invert the waveform for Active High and Active Low e Fans making this a single solution for multiple fan types The simple and easy to use GUI enables the user to perform simple or complex actions based upon configurable inputs The GUI is password protected for OEM manufacturers in order to prevent tampering of the pre tested and qualified OEM configurations The GUI is designed to have a standard diagnostic dashboard for service technicians that enable access to non critical functions while obtaining necessary functional information and recording data for troubleshooting or performance monitoring The EMC 6 provides a great deal of functionality making this an effective solution for the most stringent and complex demands for today s Tier IM and V requirements 021 00360 Rev B 5 Copyright High Country Tek Inc 2015 Fa EMC 6 EMC 6L Electro Hydraulic Control Solutions Warranty Information High Country Tek guarantees this product to be free of defects in m
14. from the pull down menu defined in Control Messages Tab e Select SPN Selection text file A new window will open e Select the stimulus from the pull down menu Stimulus SPN the respective values appear automatically Select the desired SPN for your Stimulus Values may be changed on the Stimulus page Startbit Readbits Offset Gain Error Value Units Figure 20 A Sun Hydraulics Company 021 00360 Rev B 26 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 The stimulus has to match the control message E g SPN177 Transmission Oil Temperature matches J1939 TF e lf the Stimulus does not match the Control Message this window will appear This SPN will not work with the selected Stimulus Control Message Select another SPN or change your Control Message Figure 21 e Match the Stimulus to the Control Message e Accept or Cancel the selection e Enter the Error Value on Stimulus Settings tab This will be the stimulus value when this message times out e The user can also modify the values on Stimulus Settings tab Configure Stimulus Settings Manually e Select Stimulus from the list defined in Control Messages Tab e Enter a name in the Stimulus Name SPN Use the SPN number and or a short description e Enter values for the following e Start Bit The bit number where the data begins Bit numbering starts at 0 e Read Bits The number of bits in t
15. has 12 discrete Fan Diagnostic inputs DG with four additional configurable Fan Diagnostic inputs providing the potential for 16 total DG inputs Analog inputs 1 through 4 can be configured as diagnostic inputs and are displayed as A1 A2 A3 and A4 on the Dashboard and Bank Interlock tabs Turn the buttons to ON if DG inputs are connected to this fan bank Ensure all the others are OFF Select Digital Inputs For Fan Status Loi o2 os o4 fos Poe o7 oe f os logo Io at a2 az 44 ResetLocken Fan Eror Enabled Figure 31 e Reset locked fan error when selected the controller will set the fan bank PWM to 0 to restart the failed fans after the fans give up restarting by themselves The period for resetting the fans is set on Global Settings 021 00360 Rev B 37 Copyright High Country Tek Inc 2015 Fa EMC 6 EMC 6L Electro Hydraulic Control Solutions Global Settings The parameters on this page apply to all of the fan banks File Controller Password Help Factory Calibration EXIT Dashboard Control Messages Stimulus Settings Analog Settings Bank Control Bank Interlocks Global Settings View Graphs Enable Controller Type EMC 6 Access Level Factory Status Msg PGN SA Name Msg 1 4 FEBD AE Fan Drive Send New Settings Change ID or Data Rate Msg 2 X B100 AE Bank Status PW
16. which affects the operational status of the fan bank outputs Direction Change Dwell Seconds see the EMC 6 reverse cycle definition see Figure 25 For hydraulic fan dwell time equals the ramp down and ramp up time fan changes from max rpm to O or vice versa For E fan dwell time is the coast down time plus Orpm time before entering reverse cycle and getting out of reverse cycle Locked Rotor Timeout Seconds sets the period that the EMC 6 will reset the failed fans after fans give up restarting by themselves This only works if Reset locked fan error is enabled on the Bank Interlocks section Coil current displays the valve current to the hydraulic fan in real time Coil Current Maximum is the maximum current for the proportional hydraulic valve up to SA Coil Current Minimum is the minimum current for the proportional hydraulic valve Coil PWM Freq Hz is the PWM frequency dither for the hydraulic valve Enable Coil check to enable 3A output 021 00360 Rev B 38 Copyright High Country Tek Inc 2015 pas EMC 6 C EMC 6L e Current Feedback check to have constant current control Uncheck to have PWM duty cycle control for the hydraulic valve e Reverse Acting Valve check for a reverse acting hydraulic valve uncheck for normal acting hydraulic valve e Ignore Open Circuit when checked the controller will not detect an open circuit When coil max current is set high and PWM output is 10
17. 0 controller will not declare coil open as long as some current is flowing It does not matter whether Ignore open circuit is checked or not Fan Fault Conditions This sets how the module interprets the DG inputs for all fans e Fan Inputs Pull Low High Pull High is used when the fan provides a DG signal that drives the voltage low when active Pull low is used when the fan provides a DG signal that drives the voltage high when active e Fan Is ls Not Operating if High Determines the polarity state of the DG input refer to the fan datasheet for more information Detection Switches e Ignition Detection Fire Detection Reverse Detection when set high the inputs are ON when the input voltage is higher than 8V When set low the inputs are OFF when the input voltage is higher than 8V The inputs are pulled low OV if left unconnected Device Settings e Device ID Determines the module s PGN addresses on the SAE J1939 bus The user may install multiple EMC 6 modules on a single SAE J1939 bus The default Device ID is 1 e Message Data Rate is the CAN data rate EMC 6 supports 250K 500K or 1000Kbps It must match the J1939 bus to ensure the communication e Communication Baud Rate displays the baud rate for the serial port e GUI Version displays the version of the GUI e Serial Number displays the serial number of the specific unit referenced to the factory record e Activation Date is the d
18. 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 Controller e Write all settings to controller executes all send new settings on every Tab and saves settings to Volatile Memory RAM It does not save settings permanently a Power Cycle will restore permanently saved settings Password Help EAT Write all settings to controller Reset to last saved settings Reconnect to Controller Permanently Save settings Open Error Logging Window Figure 9 Settings not permanently saved will be lost after a power cycle e Reset to last saved settings like a Power Cycle the module reloads the settings permanently saved in Non Volatile Memory e Reconnect to Controller the GUI resets communication with the module re reads and updates all variables e Permanently Save settings saves the settings to its Non Volatile Memory permanent memory e Open Error Logging Window opens the internal data logging windows that display the error situations such as the count of timeouts coil open shorts fire input ON the high and low error when bank stimulus and diagnostics occur Error Logging Window Control Messages and Unit Errors This tab displays the received messages and the number of times the message timed out counting from 1 to 255 The messages displayed are defined in the Control Messages tab of the EMC 6 GUI Ivdraulics Company 021 00360 Rev B 17 Copyright High Country Tek Inc 2015
19. EMC 6L ha EMC 6 Electro Hydraulic Control Solutions be Logged Error Counts Read Data Errors Clear All Errors Export Data PGW in HEX or Decimal Hex Decimal Message Time Out and System Condition Control Msg Name ema mz nss En get emm mm 31939 CM1 Engine 9 o J1939 CM1 Transmission nsa FE mem Ras nse mn mem mn Supply Low JL Referencetow mt Genen TT Figure 10 e Control Msg Name the CAN message defined on the Control Messages tab Each message shows the PGN in Hex or Decimal and Source Address SA as per defined in the Control Messages tab NOTE The Source Address SA in this case is the address of the device on the J1939 Bus that the EMC 6 is receiving messages from e Counts ranging from 1 to 255 this represents the number of times the message timed out per the defined Time Out value in the Control Messages tab e Supply Low supply voltage drops below 8 volts for more than 2 seconds e Reference Low reference voltage output pin a3 drops below 4 00 volts for more than 2 seconds indicating the output is sourcing more than 250mA e Unit Overtemp the controller hardware rises above 85 C for more than 2 seconds e Fire Input On Fire Input is switched high greater than 8 volts for more than 2 seconds Fire and Reverse are normally low unless inverted on the Global Settings page Error Logging Window Bank Stimulus and Diagnostics This t
20. M Frequency Hz Y 100 Device ID E Fj o fae Minimum Engine RPM 21750 ENEE KE Pa S y Message Data Rate 250K w ra Direction Change Dwell sec 15 Sas Msg 4 7 B300 AE Bank3 Status y Comunication Baud Rate 19200 Oo B red as Locked Rotor Timeout sec F 20 39 5 V B400 s ZE SS Coil Current 0 751 Amps ace V2 6 8500 AE Module Status I c Msg 6 Coil Current Maximum GER Amps GUI Version v2 1Beta 17 7 V D nn AE Bankt Status ini 0 000 EE ege Msg 7 L i Coil Current Minimum 0 000 Amps Serial r YA00000254 Msg 8 Z B700 AE Bank6 Status Coil Ramps sec 15 I er CH FEN ss c Activation Date 06 05 2014 Msg 9 B800 AE Analog Input Values Coil PWM Freg Hz a0 nn Communication Port COMS Hex Decimal High Low Enable Coil ae ae 3 LO Ign Detection Current Feedback x Fan fault condition for all fan status inputs HH Fire Detection KEE N Show Password Fan inputs pull low i Rev Detection Ignore Open Circuit deg C Convert from deg F Fan is operating if high Application EMC 6 Standard Application V11 Jo degCtodegF 32 00 Figure 32 The EMC 6 can transmit the module status messages via SAE J1939 Check to enable the messages The Source Address SA for the EMC 6 module is 78 0x4E See the Appendix A for more details PWM Frequency Hz is the PWM frequency for all E fan banks Minimum Engine RPM is the minimum engine RPM defined by the user
21. Mer EME SL Electro Hydraulic Control Solutions EMC 6 EMC 6L Hybrid Fan Controller User Manual www hctcontrols com EMC 6L Fa EMC 6 Electro Hydraulic Control Solutions Revision Record Rev C Mi Date Released zen RevA Initial Revision 9 May 14 Rev A 1 E fan and hydrualic fan auto reverse curves updated 2 Jun 14 WB controller weight is added format updated 27 Jun 14 WB Rev A 2 Updated product photo on cover page 4 Oct 14 BC Rev A 3 Updated error logging information and Appendix B 2 Jul 15 BC Diagnostic inputs increased from 12 to 16 Added RevB inverted waveform functionality Added Setpoint 10 Jul 15 BC Control Increased operating fan duty cycle to 1 000 Hz 1 Hydraulic npany 021 00360 Rev B 2 Copyright High Country Tek Inc 2015 Fa EMC 6 Electro Hydraulic Control Solutions Contents REVISION C OFC ee 2 w l CCGA reece san Darana a Bana Aa ANA ee ae oe sua cave aa a gaga aa haa ee 5 EMCO Produc e 5 Warani HOF IU O ME 6 Produc WSC Ron EC e E 6 CH den CG 6 Produc siele ge fake GE UE 7 Controller Specii CaO saananira agan ei Bag NA ee 8 Controller Dimensions Mounting Information 9 lge TOV ST cas aa aan E A ne dam a E NGA NGA SE Te rer 10 PINOUT ee een 11 LEDS AC OSES Codes ee ee ee re ee 12 A C OT er een 13 EHNEN 14 GALI ASA A DOA kra anana E aia na aa aa a ED an EE SN EN KG E A E AN BAGE NIN Ta a NE GN DE a ANG a E E Ena gka NB 15 Syst m Be Te nn E EC 15 Ia AI SEI Om SEO aia
22. When ignition input is disabled make sure nobody is working on the fans when switching on manual reverse with ignition OFF A Sun Hydraulics Company 021 00360 Rev B 36 Copyright High Country Tek Inc 2015 Mer EMCS Electro Hydraulic Control Solutions Manual Control The user may manually verify that the E fans are working properly and determine the maximum minimum and reverse PWM duty cycles e Enable Disable Manual Control turns On Off manual control e PWM Output displays the PWM duty cycle output for this fan bank e Manual PWM Output displays the command input for this fan bank To change the input the user can drag the bar or type the value or increase decrease arrow e Manual Mode Status The indicators are dark when the banks are in normal mode and Red when the banks are in manual mode Send New Settings PWM Output Enable Manual 0 2 40 60 80 100 d Manual PWM Output SE a Control 0 2 40 60 80 100 a Manual Mode status JE Decrease PWM 4 Increase PWM Figure 30 Caution e Only allowed with the OEM password e All settings on this tab will immediately affect the output e All limits and controls are bypassed e The controller goes back to normal operation when disabling the manual mode e Cycling power on the unit will exit the manual model e Disconnecting the communication cable will exit manual mode Select Digital Inputs for Fan Status The EMC 6
23. ab displays the number of faults for each stimulus within each fan bank defined in the Bank Control tab of the EMC 6 GUI A Sun Hydraulics Company 021 00360 Rev B 18 Copyright High Country Tek Inc 2015 EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions e Logged Error Counts anganan A TT Gi TI TT Read Data Errors Clear All Errors Export D Control Messages and Unit Errors Bank stimulus and Diagnostics ae Radiator LowError High Error al SPN 190 Engine Speed Oo H Fan bank description Stimulus description LSPN 177 Trans Oil Temp 0 7 0 LH 0 E AE Diagnostics Error Di ll 8 ChargeAirCooler LowError High Error SPN 110 Coolant Temp 0 0 SPN 177 Trans OilTemp 0 o0 Diagnostics Error H II ii O O y y f Oil Cooler L LowError High Error SPN 105 Intake Manifold Temp 0 0 SPN 986 Enaine 0 0 Figure 11 e Low Error ranging from 1 to 255 this represents the number of times the stimulus temperature dropped below the Alarm Low temperature defined in the Bank Control tab e High Error ranging from 1 to 255 this represents the number of times the stimulus temperature exceeded the Alarm High temperature defined in the Bank Control tab 021 00360 Rev B 19 Copyright High Country Tek Inc 2015 EMC 6 Hc EMC 6L Electro Hydraulic Control Solutions Password e OEM Password allows full ac
24. achine movement It could lead to possible injury or death Any moving parts should be disabled prior to changing setup values or operating modes In every case exercise caution and work should be completed only by qualified personnel 021 00360 Rev B 6 Copyright High Country Tek Inc 2015 KM EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions Product Application Guidelines ALWAYS do the following FULLY read this manual and accompanying data sheets BEFORE starting Isolate this unit from all other equipment BEFORE any form of welding Isolate the controller from ANY form of battery charging or battery boosting Be aware of the electrical amp mechanical connections and the expected reactions of the equipment Operate the units within the temperature range Use the correct tools to do the job i e P C software etc Separate High Voltage AC cables from Low Voltage DC signal and supply cables Make sure power supply is CORRECT ELECTRICALLY CLEAN STABLE and rated for the full load Make sure the controller output voltage amp current is compatible with the equipment All unused wires terminals should be terminated safely Ensure ALL connectors have no unintended SHORT or OPEN circuits Ensure ALL connectors are wired correctly secure locked in place and fully connected Disconnect or connect wires to or from this unit only when the power supply is disconnected Use adequate screening in areas of intense Radio Fr
25. ate when the module is configured first time at the factory e OEM Password the OEM Password is included in the GUI CD Users may reset the OEM password Just don t forget it e Communication Port displays the PC Communication Port that the GUI is connected to e Temperature Conversion Tool converts temperature from Celsius to Fahrenheit or vice versa e Change ID or Data Rate loads the new settings into the units RAM memory and activates these values 021 00360 Rev B 39 Copyright High Country Tek Inc 2015 Fa EMC 6 EMC 6L Electro Hydraulic Control Solutions View Graphs Any input and or output can be graphed in the two windows Each window displays up to two parameters simultaneously selected from the pull down menus Each graph can be scaled individually The graph will display the Calculated Fan RPM if the Gauges are toggled to RPM on Dashboard File Controller Password Help Factory Calibration EXIT lashboar ontrol Messages Stimulus ings nalog St ings ank Control Bank Interlocks Global tings apns Dashboard Control Messag Stimulu Setti Analog Setti Bank Control Bank Interlocks Global Setti View Graphs Bank 4 SPN 110 Coolant Temp F 87 00 7 Bank 4 SPN 110 Coolant Temp AN Log Data Coil Current T 1 SPN177 Transmission Ol x 0 75 93 00 7 Coil Current 7 SPN177 Transmission Oil Temp BEA Sample Time Seconds A 1 sadi Background Color B
26. aterials and workmanship for one year from the date shipped from the factory Within this time frame High Country Tek will provide evaluation of warranted items free of charge Warranty repair or replacement will be at the factory s discretion Please have the units full Model Part Number and Serial Number available when contacting the factory Do not return products to the factory without a RMA Return Material Authorization number Product Use Limitations HCT products may not be suited for any of the following applications e Any product which comes under the Federal Highway Safety Act namely steering or braking systems for passenger carrying vehicles or on highway trucks e Aircraft or space vehicles e Ordinance or military equipment e Life support equipment e Any end product which when sold comes under U S Nuclear Regulatory Commission rules and regulations HCT does not have any performance assurance programs for testing their products for the above applications HCT s products are not designed for these applications and HCT does not warrant recommend or specifically approve its products for these applications The user shall be solely responsible for any loss or damages occasioned by breach of the provisions of this paragraph and shall carry product liability and liability insurance to insure against such loss or damages Cautions Changing setup values or operating modes while a machine Is running may cause unintended m
27. cess to view settings setup data files apply changes or upload data files to controllers and manual control NOTE Passwords are CASE SeNsitivE File Controller WESS 01 D2 03 04 os oe 07 os os p10 D11 012 a1 a2 As SPN 110 Coolant Temp SPN 105 Intake Manifold SPN 177 Trans Oil T Figure 12 A Sun Hydraulics Company 021 00360 Rev B 20 Copyright High Country Tek Inc 2015 er Electro Hydraulic Control Solutions Help EMC 6 EMC 6L e About Controller displays the controller type BIOS Serial No Activation Date the GUI revision and Part Number contact information etc Controller type EMC 6 BIOS information Serial No Activation date GUI version v1 20 Beta 1 5 OUI Part No 0235 00533 High Country Tek Inc 208 Gold Flat court levada City CA 95959 U S A www hetconirols com Figure 13 28 her About Contr coll e Help Files opens the folder C HCT products Fan Drives EMC 6 where the manual and other related information are located e USB drivers opens the folder where USB driver installation instruction is located Hen Exit About Controller Help Files USB to EMC 6 drivers Figure 14 e Exit Program exits the GUI and frees up the communication port and memory used by the application A Sun Hydraulics Company 021 00360 Rev B EXIT Program Figure 15 21 Copyright High Country Tek
28. derivative term decreases overshoot and yields higher gain with stability in Hydraulics Company 021 00360 Rev B 46 Copyright High Country Tek Inc 2015 lt Mining amp Exploration lt Agriculture Cranes amp lifts Refuse amp Re cycling ZG Construction d Off Road vehicles d Forestry Wood amp Pulp d Reclamation amp Salvage ZG Oil Field amp Sands Demolition Equipment d Cooling Solutions Military Apparatus ZG Specialty Use lt Remote Control d Power Generation Emission Controls d Integrated Drivers HCT Product Sales and Support Fora full list of authonzed distributors worldwide please visit Valve amp Pump Controls www hctcontrols com distributors index htm Need More Information For customer service pricing order placement and application support contact us through E mail at info hctcontrols com www hctcontrols com A SUN Hydraulics Company 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
29. ep EMC 6 v2 4 Beta 3 File Controller Password Help EXIT Fan Bank 2 Charge Air Cooler Figure 26 e PID Control enables the Setpoint Control feature When this is selected Stimuli 2 through 4 become nonfunctional and the PID terms become available e Invert Duty Cycle enables the negative logic duty cycle when the checkbox is selected The EMC 6 default unchecked is positive logic duty cycle Reference the e fan spec sheet in order to determine which definition the fan uses Example This is an example of positive logic duty cycle see Figure 27 Continuous low voltage is 0 duty cycle Continuous high voltage is 100 duty cycle A Sun Hydraulics Company 021 00360 Rev B 33 Copyright High Country Tek Inc 2015 EMC 6L Fa EMC 6 Electro Hydraulic Control Solutions T D T T 100 26 T Tyt I Figure 27 TL Using the same waveform diagram Figure 27 negative logic duty cycle would be D T 100 Disable Auto Reverse When checked the automatic fan reverse cycle occurring after a time interval period is disabled Fans will reverse only if the reverse input is toggled with the Reverse Switch NOTE The Module Status LED blinks alternately RED and GREEN when any fan bank is in reverse including E Fans and or Hydraulic in Hydraulics Company 021 00360 Rev B 34 Copyright High Country Tek Inc 2015 Electro Hydraulic Control Solutions EMC 6 Hel EMC 6L Ban
30. equency fields Ensure ALL work areas are clear of personnel before operating the controller Follow and abide by local and country health amp safety standards 021 00360 Rev B Fi Copyright High Country Tek Inc 2015 EMC 6 EMC 6L Mer Electro Hydraulic Control Solutions Controller Specification Housing Type HCT encapsulated block flameproof Power Supply Voltage 9 to 32VDC Absolute Maximum Current Consumption Load current 200mA Quiescent Max Command Inputs Outputs PWM Freq Module Connector Communication Housing Material Encapsulation Mounting Temperature Range NEMA IP Rating CAN Data Rate 021 00360 Rev B Programmable SAE J1939 CAN messages 3x option selection switches ON Off Up to 16x inputs for fan diagnostics ON Off Up to 6x inputs for sensors or Potentiometers Max temp 50Q min temp 2MQ Up to 3x 0 5Vdc 10mA analog outputs Up to 6x 0 100 PWM Sourcing for EMC 6 Sinking for EMC 6L max 500mA short circuit protection 1x 3A Proportional PWM current output 1x 3A on off output for reverse coil 1x 0 5A on off output for alarm indicator 1x 5V 5 regulated reference voltage Software adjustable 33 to 1000Hz 48 way Cinch 1 5mm SHS Header Cinch PN 581 01 48 011 Mini USB or 4 way Weatherpak for RS232 Black Polycarbonate Flameproof epoxy resin 2x Va x20 SAE Grade 2 screws 40 to 85 C Operational 60 to 90 C Storage NEMA 6P IP68 250Kbps 500Kbp
31. ess is ignored The module can receive messages from any source address for the specified PGN number Send New Settings loads the new settings into the units RAM memory and activates these messages Control messages are now available on the Stimulus Settings Tab Message Indicators Msg State indicates if the command message is being received on the J1939 Bus Green the message is Active Red the message is Timed Out Grey the message is Inactive Hex Decimal Switch switches PGN numbers between Hexadecimal or Decimal format 021 00360 Rev B 25 Copyright High Country Tek Inc 2015 ho EMC 6 C EMC 6L Electro Hydraulic Control Solutions Stimulus Settings The user may define up to 10 CAN messages as the inputs NOTE The first message is always EEC1 Engine RPM Only the error value can be changed for this SPN File Controller Password Help Factory Calibration EXIT DJ SPN 110 Coolant Temp tt ei J1939CM1 Engine ww El SPN 986 Engine Req Fan speed asam El sem Transmission Oit Temp Jg CWM Transmission E sPNo86Trans OOOO 31939 CM1 Engine EI sm 986 Engine Req Fan speed frans oilalternate ei DJ transmission oilaitemate transoilatternate e El transmission oit atternate b i E Figure 19 Configure Stimulus Settings Configure Stimulus Settings from a default file included in the GUI installation e Select specific Control Message
32. he data package e Offset The offset is applied after the Gain Calculation e Gain The Scale Factor for the Gain Calculation e Error Value the value used for the stimulus when the message times out e Units the unit of the stimulus value e Send New Settings loads the new settings into the units RAM memory and activates these stimuli e Stimulus Settings are now available on the Bank Control Tab 021 00360 Rev B 2 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions ho EMC 6 Analog Inputs The user may define up to 6 analog inputs voltage thermistor or diagnostic inputs NOTE Additional diagnostic inputs are reserved for analog inputs 1 through 4 feo EMC 6 v2 4 Beta 3 File Controller Password Help EXIT ngine Coolant Potentiometer Figure 22 Configure Analog Inputs e Pull Up 5V Select On for thermistors When on the module sources current for use with resistive thermal devices Select Off for potentiometer or analog inputs e Enable check to enable the input e Input Type Select Thermistor or Voltage type e Analog Name name the input e Low Value amp High Value the minimum and maximum values the sensor can report e Send New Settings loads the new settings into the units RAM memory and activates these stimuli e Permanently save settings e Analog Settings are now available on the Bank Control Tab A Sun Hydraulics Compa
33. ine RPM in Global Settings tab if Engine RPM interlock is used NOTE The Dashboard will display Analog Error or Msg Data Limit when the value meets or exceeds the Alarm High or Alarm Low setting Fan Bank Profile This defines the operational properties of the e fan used for the specific bank Maximum RPM the rated fan Maximum RPM Minimum RPM the rated fan Minimum RPM Zero Fan Speed PWM the PWM that causes the fan s to stop see Figure 24 Maximum PWM the PWM that causes the fan s to run at maximum RPM see Figure 24 Minimum PWM the PWM that causes the fan s to run at minimum RPM see Figure 24 021 00360 Rev B 30 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 e Reverse PWM the PWM that causes the fan s to run in Reverse see Figure 24 e Auto Reverse Enable Disable enables or disables the Auto Reverse feature e Auto Reverse Interval minutes see the EMC 6 reverse cycle definition see Figure 25 It is the time between the 1 reverse signal and the 2 auto reverse signal e Reverse Period seconds see the EMC 6 reverse cycle definition see Figure 25 It is the total time of ramp up in reverse direction full fan reverse time and ramp down time in reverse direction Ramp up and down time equal to the dwell time set on the Global Settings e Minimum Run Time Seconds the minimum run time It prevents the fans from re
34. ing Communication Port Adapters Overview Windows does not like Com ports with the same name and some devices might hang onto a com port when not in use Here is how to clean and remove problem ports Option 1 Devices that have been installed but are not currently available are phantom devices These devices are not usually displayed in the device manager but can be made to be displayed This allows device properties to be changed or devices to be uninstalled even though the device is not physically connected to the PC Control Panel gt System Properties Advanced option and click Environment Variables In the System Variables sections click New gt DevMgr_Show_NonPresent_Devices and set the value to 1 gt OK gt Close the System Properties panel System Properties System Restore Automatic Updates Remote Advanced G eneral Computer Mame Hardware You must be logged on as an Administrator to make most of these changes Performance Visual effects processor scheduling memory usage and virtual memory Settings User Profiles Desktop settings related to your logon Settings Startup and Recovery System startup system failure and debugging information Settings Environment Warables Error Reporting Figure 34 A Sun Hydraulics Company 021 00360 Rev B Environment Variables User variables for ahinz Variable Value TEMP C Documents and SetkingstahinziLocal
35. is 0 250 each bit 0 4 Example 0x00 0 OxFA 100 OxA7 66 8 e DG State Input 1 16 assigns a 0 or 1 for up to 16 fan diagnostic inputs for selected fan bank 0 Fan failure 1 Fan is operating or not selected for this bank NOTE This is true for all cases regardless if the fan is configured with an inverted waveform e Estimated Fan RPM calculates the fan speed based upon user configurations in the Bank Control tab of the GUI multiply by 0 125 RPM bit for RPM value Example Byte3 Fan RPM Low Side Byte Byte A Fan RPM High Side Byte Byte 3 4A Byte 4 39 0 x 394A 14666 decimal 14666 x 0 125 1833 25 RPM NOTES 1 The scale factor for Voltage Inputs Supply Fire Ignition and Reverse is 0 01 V bit with an offset of 0 Example 0x04B0 1200 decimal 1200 x 0 01 12 Volts 2 The scale factor for Analog Inputs depends on how the input is set up a If setup asa voltage input i Scale Factor 0 02 V bit with an offset of 0 range is 0 5 Volts b If setup as a thermistor input i Scale Factor 1 C bit with an offset of 40 range is 40 215 C Voltage Example 0x7D 125 decimal 125 x 0 02 2 5 Volts Thermistor Example 0x7D 125 decimal 125 40 85 C 3 For more information on Suspect Parameter Numbers SPN refer to SAE J1939 71 021 00360 Rev B 43 Copyright High Country Tek Inc 2015 Hel Electro Hydraulic Control Solutions EMC 6 EMC 6L Appendix B Troubleshoot
36. k Interlocks The user may define interlock logic for each bank File Controller Password Help EXIT Dashboard Control Messages Stimulus Settings Analog Settings Bank Control Bank Interlocks Global Settings View Graphs Access Level OEM Send New Settings Fan Bank1 Radiator Enabled PWM Output Enable Manual Interlock Selection Manual Reverse Operation is allowed 3 J Control when all conditions exist Al ea Pa a ea je ja aa aa ja a pa a ja a a Game 3 0 20 40 60 30 100 Fire input Enabled Manual reverse Enabled Manual PWM Control ignition input 7 Enabled Fire Input is off A ar amig S Pr A I 1 JE l E l tani 1 I 1 1 1 l Be 1 l Minimum RPM 7 Enabled nE 0 20 40 60 80 100 Engine RPM is low or off _ 2 ah ob WO bh Manual Mode status Display Interlock Truth Table Engine RPM is ignored Il Decrease PWM Increase PWM Ja V Crease WV a Demand Demand Stimulus 1 SPN 110 Coolant Temp 0 0 No Message Stimulus3 Stimulus 0 0 Stimulus 2 RAD Thermistor 0 0 Stimulus 4 Stimulus 0 0 Select Status Inputs For Fan Monitoring 4 2 A 5 6 T S 5 10 11 12 Reset Locked Fan Error Enabled Figure 28 e Fan Bank n selects the fan bank to be configured e Fan Bank n Text Box displays the fan bank name defined in the Bank Control tab e Enabled check to enable the fan bank A Sun Hydraulics Company 021 00360 Rev B 35 Copyright High Country Tek Inc 2015 C EMC
37. messages as the controlling inputs Currently the EMC 6 supports the SAE J1939 protocol NOTE The first message is always EEC1 Engine RPM hard coded File Controller Password Help Factory Calibration EXIT K lt 8 TEE EJ y K kl Ki u J1939 CM1 Engine RER E kl Ki kl Li kl Ki E E 7 7 Figure 17 Configure Control Messages Configure Control Messages from a default file included in the GUI installation e Select Msg From a File opens the control message file and displays the Message Window These defaults settings will be available for adjustment in the Control Message and CAN Values tabs 0 vi Msg Name v Figure 18 e Select PGN or Select Message Name the GUI will match PGN and Message Name e Accept or Cancel the message A Sun Hydraulics Company 021 00360 Rev B 24 Copyright High Country Tek Inc 2015 Fa EMC 6 EMC 6L Electro Hydraulic Control Solutions Check to enable the message Select SAE J1939 as the CAN Msg Format Mask SA if checked the source address is ignored The module can receive messages from any source address for the specified PGN number Configure Control Messages Manually Select SAE J1939 as the CAN Msg Format Enter the PGN number Source Address Message Name and the message time out in milliseconds Check Box enables the message Mask SA if checked the source addr
38. ny 021 00360 Rev B 28 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions pas EMC 6 Bank Control Controller Password Help Factory Calibration EXIT Dashboard Control Messages Stimulus Settings Analog Settings Bank Control Bank Interlocks Global Settings View Graphs Access Level Factory Send New Settings Fan Bank2 w Charge Air Cooler Maximum Minimum Alarm Alarm Alarm Demand Sa Message Set Point Set Point High Ind Low State Stimulus1 SPN 110 Coolant Temp Group ei 93 e WA 120 O An 3 Ba Stimulus 2 coolant alternate Group2 ei 93 e 120 KI A oo U Stimulus 3 Oil Cooler Thermister w Groupo ei 150 9 20 BI o za Stimulus 4 transmission oil alternate T Group No T 99 g3 gg 2 0 P 66 7 Conditions for Fan Speed Limit Message Timeout Engine I PID Control Diagnostic Error Low RPM of Fan Speed Eet S Duty Cycle C Low Engine RPM 900 J5 EES Fan Bank Profile Auto Reverse Maximum Minimum ZeroFan Speed Maximum Minimum Reverse Auto Reverse Reverse Minimum Minimum RPM RPM PYM PWM PWM PWM Interval Min Period Sec Run Time Sec Demand s4000 3200 cb 100 Sun azo 0 size San a Figure 23 Setup Fan Bank Parameters The user may define independently up to 6 banks of electric fans and up to 1 bank of hydraulic fan Fo
39. or use Find Module Enter Device ID i teaata Menge Fma modue Figure 7 e Device ID When using more than one EMC 6 with the same computer each EMC 6 will need to have a unique device ID The default Device ID is 1 e Log Data logs the operational data in Excel format see Page 23 for details e Work Off Line allows the user to work with GUI offline without the module connected The user can load any existing data files modify them or create new data files and save them to the PC without an OEM password e Find Module the GUI tries to find the controller and reconnect it File e Save settings to a file txt saves the settings to a data file that may be loaded into any EMC 6 controller e Read settings from a file txt loads the data file from the PC to the EMC 6 GUI At this point the data is not written to the controller yet UES Controller Password Help EXI Save settings to a file txt Read settings from a file txt Read data file and Save to unit Read Thermistor data from a file dat Figure 8 e Read data file and Save to unit loads the data file from the PC writes to the controller and permanently saves the settings e Read Thermistor data from a file dat loads the thermistor data file from the PC to the GUI to match the thermistor in the system The data are not written to the controller yet iydraulics Compan 021 00360 Rev B 16 Copyright High Country Tek Inc
40. peatedly starting and stopping when there is low demand and helps reduce thermal cycling in the equipment e Minimum Demand determines the fan minimum speed until the controlling input demands a higher speed This eliminates the fans start up delay and quickly responds to fast changing heat loads such as Charge Air Coolers etc e Send New Settings loads the new settings into the units RAM memory and activates these stimuli Minimum Maximum PAM M J 10 max speed recovery speed Speed set min speed Zero Fan Speed PWM Reverse PWM max speed negative Duty cycle Figure 24 Hydraulics Company 021 00360 Rev B 31 Copyright High Country Tek Inc 2015 EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions EMC 6 Reverse Cycle Definition Current for hydraulic fon LED coll for reverse ON LED coll for reverse OFF E fan PWM tener starts ot Figure 25 021 00360 Rev B 32 Copyright High Country Tek Inc 2015 C EMC 6L Electro Hydraulic Control Solutions ho EMC 6 Setpoint Control PID This is a precise closed loop control feature that automatically compensates to changing Stimulus inputs The PID gains can be adjusted to increase or reduce the response characteristics due to changing Stimulus inputs This feature uses a single Stimulus input instead of 4 For an overview of PID control and simplified tuning procedure refer to Appendix C
41. r each bank the user may define up to four stimulus inputs e Fan Bank n selects the fan bank to be configured e Name the Fan Bank n names the bank to identify it on the GUI e Stimulus selects stimuli for this bank All previously configured stimuli are in the pull down menu Multiple fan banks may use the same stimull e Stimulus Grouping in each fan bank the inputs can be grouped Group No When a stimulus reaches a value that is out of range as defined by the Alarm High and Alarm Low settings and is not grouped left as Group No then the fan bank will default to the of Fan Speed condition Group 1 The fan bank does not default to the of Fan Speed condition if a stimulus value becomes out of range while grouped with more than one stimulus and the additional stimulus is the operational set points Example Stimulus 1 and 2 are both grouped as Group 1 Stimulus 1 reaches an alarm set point but Stimulus 2 is still within the operation limits the fan bank ignores Stimulus 1 and continues to operate with Stimulus 2 as priority in Hydraulics Company 021 00360 Rev B 29 Copyright High Country Tek Inc 2015 Fa EMC 6 EMC 6L Electro Hydraulic Control Solutions Group 2 Like Group 1 the fan bank does not default to the of Fan Speed condition if a stimulus reaches an Alarm High set point while grouped with more than one stimulus and the additional stimulus is within an operational set points E
42. s and 1000Kbps 8 Copyright High Country Tek Inc 2015 EMC 6 Hcl EMC 6L Electro Hydraulic Control Solutions Controller Dimensions Mounting Information Controller weight is approximately 1 26Lbs e Mount controller in an easily accessible location e Mount controller to a flat surface e f mounting to a hydraulic product allow at least a 2mm air gap underneath the unit e Use BOTH mounting holes with correct hardware e DO NOT mount controller with connector facing UP if possible e Recommended 4 20 SAE Grade 2 screws Dry Torque 4 Ft Ibs Lubricated 3 Ft Ibs 4 63 in 4 00 in 3 60 in High Country Tek Inc Hcl Electronic Controls for the Global Fluid Power Industry C EMC 6 SAE J1939 Compatible 6 Channel Controller 20 29 in FR fo e smes amponi eme 10113 OO NWO Woo INS 9 60 in www hetcontrols com SERIAL NO Made In USA 2 57 in 1 71 in 9 00 in Figure 1 A Sun Hydraulics Company 021 00360 Rev B 9 Copyright High Country Tek Inc 2015 Hel Electro Hydraulic Control Solutions Wiring Diagram 9 32VDC Power Input EMC 6 EMC 6L FUSE C2 Ana_In 1 D2 Ana_In 2 E2 Ana lng C1 Ana_In4 D1 Ana_In5 EI Ana In 6 C3 GND D3 GND E3 GND A1 RXD F3 GND A2 TXD A3 Not used Bi CAN H B2 CAN Lo B3 GND F1 Diag_In 1 G1 Diag_In2 H1 Diag_In3 J1 Diag_In 4 J2
43. tions The Bank 4 Status Message PGN 46336 B500 SPN Startbit bits ParameterName 975 1 8 Bank Estimated Fan Speed 0 100 BEE DG State Inout 1 16 0 Fan failure 1 Fan is Operational Estimated Fan RPM The Bank 5 Status Message PGN 46592 B600 SEN Startbit bits ParameterName 975 1 8 Bank Estimated Fan Speed 0 100 Ia l 6 DG State Input 1 16 0 Fan failure 1 Fan is Operational Estimated Fan RPM The Bank 6 Status Message PGN 46848 B700 SPN Startbit bits Parameter Name 975 1 8 Bank Estimated Fan Speed 0 100 a 16 DG State Input 1 16 0 Fan failure 1 Fan is Operational Estimated Fan RPM Analog Inputs PGN 47104 B800 Note 2 SPN Start bit bits _ Parameter Name Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Analog Input 5 Analog Input 6 e Estimated Percent Fan Speed an average percent fan speed 0 100 of all active fan banks NOTE Range is 0 250 each bit 0 4 Example 0x00 0 OxFA 100 OxA7 66 8 e Fan Drive State assigns a 0 or E 0 Error if any DG bit within any active bank shows a fan failure E Normal fan operation GD hydraulics 021 00360 Rev B 42 Copyright High Country Tek Inc 2015 pas EMC 6 C EMC 6L Electro Hydraulic Control Solutions e Bank Estimated Fan Speed calculated percent fan speed 0 100 of selected bank NOTE Range
44. ut of range Error Status LED blinks GREEN 3 times CAN value out of range Error Status LED blinks GREEN 4 times Reference Voltage low When multiple errors occur the LED sequences through the error codes Module status LED steady GREEN Normal operation Module status LED blinks RED GREEN Reverse cycle Module status LED steady RED Fire Module status LED blinks GREEN Low voltage Alarm indicator blinks RED 1 6 times at 0 5 seconds intervals Bank 1 6 diagnostic error Alarm indicator sequences through the error codes _ Diagnostic errors on more banks Alarm indicator steady red J1939 times out Alarm indicator blinks red 1 time at 1 0 seconds intervals Any fan bank in reverse 021 00360 Rev B 12 Copyright High Country Tek Inc 2015 Mer Electro Hydraulic Control Solutions Accessories 999 10104 30 pin Harness 3M length E N Ke d E DE GR e e 3 e te Em e kn kama en SEIFE msm gj tome gi e _ CD EMC 6 PC set up software System diagnostics Data logging feature 206 00083 3 8 18NPT 206 00083M M12x1 5 Liquid thermistor 40 C to 150 C sonronar om
45. xample Stimulus 3 and 4 are both grouped as Group 2 Stimulus 3 reaches an alarm set point but Stimulus 4 is still within the operation limits the fan bank ignores Stimulus 3 and continues to operate with Stimulus 4 as priority Maximum Set Point the stimulus value that makes the fan bank run at full speed Minimum Set Point the stimulus value that makes the fan bank run at minimum speed Alarm High the stimulus value that trips the High Alarm condition Alarm Low the stimulus value that trips the Low Alarm condition Demand displays the normalized percentage of demand Message State displays green when normal red when timed out A timeout occurs when the message has not been received for a period greater than the Time Out setting in the Control Messages tab Conditions for Fan Speed Limit Message Timeout when checked the fan speed defaults to the Yo of Fan Speed specified by the user if there is a message timeout If stimulus is grouped and there is a message timeout indicated on the Message State the fan bank does not default to the Yo of Fan Speed as long as there is an additional valid stimulus within the same Group 1 or 2 Diagnostic Error when checked the fan bank speed defaults to the of Fan Speed if there is diagnostic error Low Engine RPM when checked the fan bank speed defaults to the of Fan Speed if the engine RPM is lower than the RPM defined but it must also be higher than the Minimum Eng

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