User Manual - High Country Tek
Contents
1. NoLetter Emin Hak sahd NolLetier Sandhdgtimannveterpod pot qim adk bvil be poviced Leavethis Q Wate Rk Cnr Qio potas it i V Skate Tisi He eae n vapaf pt qtim Tisqgtim had sxinhkakwilte K 10A 016A G_LRADATA MAMADA Figure 4 Additional information may be obtained by visiting our website at http hctcontrols com High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 8 82. undesired system response i Note that the dither may cause both coils to be energized at the midpoint of the control input The higher the System Wiring Best Practices All sophisticated electronic systems require attention as to how various components are wired together to insure reliable operation without interference to or from other components What follows is a brief explanation of issues associated with PWM Valve Drivers and some tips to help you avoid difficulties arising from noise generated by inductive switching The industry technique most commonly used to control proportional hydraulic valves is called Pulse Width Modulation PWM PWM varies the effective voltage across and inductor by applying the full supply voltage to the coil then quickly switching it off Regulating the ratio of on time verses off time of the pulse at a fast enough frequency an average voltage is seen across the coil and this can be controlled to position a hydraulic valve with a high degree of High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 4 8 Hel HAD Product Manual resolution PWM control of inductive devices causes voltage spikes on the power supply or battery positive wires These voltage spikes are a product of Flyback Current which is result of the decaying magnetic field of an inductor valve coil when voltage is removed during the PWM switching These spikes of vol
3. Het C HAD Product Manual Instruction Installation and Operation Guide for HAD Series Controllers S o a G D 3 N e e Analog Valve Driver POWER HADETFO75 con i au ay Say Document Number 021 00141 Document Revision B2 1 Document Issue Date Document Creator J Clark Document Creation Date 9 10 2009 High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 1 8 Wet C HAD Product Manual Description The HAD provides precise control of a dual coil proportional valve The HAD will accept a control input of 5V to 5V OV to 5V OV to 10V or 4 to 20 mA from an external source or a potentiometer driven by the onboard reference output It will accept power supply voltages from 11 to 30 volts DC and is able to drive coils with requirements from 31mA to 5 0 A Options include ramping dither waterproof potentiometers and WeatherPak connectors Indicator B Light Lights when the B coil is selected because the command input is in the B coil range Wiring Connect the unit as shown in Figure 3 using only one of the three command input configurations Use 16 AWG wire for power and coil wiring Use shrouded coil connectors Locate the fuse as close to the power supply as possible to protect the wiring and the valve controller Fusing Use an AGC 5 fuse for systems up to 3 3 amps
4. and an AGC 10 for systems from 3 4 to 5 0 amps Place fuse as close to the battery as possible A Failure to properly fuse the unit invalidates the warranty Set up procedure Compare the part number on your unit to the Part Number Index in Figure 4 for an explanation of options specific to your unit This controller is best adjusted by observing system response Coil current can be used but coil voltage is not accurate Coil current may be measured by installing a 0 1 or 1 0 ohm resistor in series with the coil and measuring the voltage drop across the resistor using a volt meter Current may be calculated by I Eres R or current equals the voltage across the resistor divided by the resistance in ohms INITIAL SETUP Turn the MAX pot 10 turns CCW then 5 turns CW set to center of pot Turn the MINA amp MINB pots 10 turns CCW off Turn all RAMP pots 10 turns CCW off Turn the DITHER AMP pot 10 turns CCW off ASUNG High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 2 8 Het C HAD Product Manual Alignment Turn on the power supply Crossover Point Crossover Adjustment Comer Pot 100 Drive Coil B Drive Coil A Min B Coil Min A Coil lt Center Pot gt Center Pot Coil Current Drive Coil B Drive Coil A MAX B Coil MAX A Coil Min Pot Max Pot 0 Min Control Input Max Figure CROSSOVER is the po
5. int at which the valve driver output changes between A and B coils Only one coil will be active at a time The CROSSOVER pot is used to tell the valve driver what input value will cause this change For control inputs just above the crossover point the output will be MIN A and will increase to MAX for the A coil as the control input increases For control inputs just below the crossover point the output will increase to MAX for the B coil as the control input decreases When the B LIGHT is off the A coil will be energized and the MIN A control is active When the B LIGHT is on the B coil will be energized and the MIN B control is active Typically the crossover point is the midpoint of the control input range See Figure 1 above 1 Set the control input to the desired crossover point 2 With the command input at the CROSSOVER point i e 5 volts on a 0 10 volt input if the B LIGHT is on turn the CROSSOVER pot CW until the B LIGHT goes off Ifthe B LIGHT is off turn the CROSSOVER pot CCW until the B LIGHT goes on Very slowly adjust the CROSSOVER pot back and forth observing the midpoint of where the B LIGHT goes off and on and set the CROSSOVER pot to this midpoint 3 Adjust the command input for the desired minimum response point for coil A Observing system response adjust the MIN A pot for the desired minimum current spool shift on COIL A Turn the MIN A pot CW for more current The MIN controls are provided to allow the use
6. l 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 5 8 Hel HAD Product Manual Check the card at full on and full off Do not try the full on test if the power supply is 50 higher than the coil s rated voltage Temporarily disconnect all wires from the VOLT and CUR inputs To test the card at full on turn the MAX and MIN pots 10 turns CW and temporarily short the VOLT and REF terminals together Measure the voltage from COIL to COIL and from POWER to PWR COM The voltage difference should be no more than one volt if the card is operating correctly To check the card at full off disconnect the VOLT and REF terminals and turn the MAX pot 10 turns CW and the MIN pot 10 turns CCW The COIL to COIL voltage should be zero If the valve won t fully shift If the card passes the full on test above the problem is in the system Measure the power supply voltage at the power supply or battery and the voltage across the coil s terminals Compare these readings to the values taken at the card If there is excessive voltage drop in any of those wires they should be shortened or replaced with smaller gauge wires larger conductor Bad frame ground connections can cause large voltage drops When the coil heats up in use it increases its resistance Most coils will be able to draw sufficient current to fully shift the valve if their rated voltage is supplied to the card and the card causes less than one volt drop When this is not the case y
7. ou must use a coil rated for less voltage or increase the power supply voltage By using current regulation the card will have no trouble safely driving a 12 V coil from a 24 V supply or a 10 V coil from a 12 V supply for example You will need a different card if the new coil draws more current than the card is rated for If the valve shift is erratic See the set up procedure section for Dither or visit our website for more help with troubleshooting including an explanation of hysteresis and stiction 3 77 1 89 www highcountrytek com 3 82 3 10 Model HAD Serial No DO000x 3 25 Mounting Holes 0 186in Figure 2 High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 6 8 Voltage amp Call Connections FUSE POWER COILA COIL B High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com A COIL B COIL 4 1 2 Jal Battery HAD Product Manual Input Gonnectlans Voltage Sensor CUR SIG COM 4 20 mA Sensor SIG COM Figure 3 021 00141 Rev B2 1 7 8 Hel HAD Product Manual HAD Part Number Index aoc ProrcrerioNsL VALVE Drevin Sens AT E acc Consult factory for customoptions COWNCIR Skectttenathod RE Sect thetypecfetemal poertioater
8. output to reach its desired setting in relation to a given change in input The following illustration explains the adjustment procedure for a unit with RAMP adjustments in both directions for each coil Only adjust what is supplied on your specific model and needed for your own application See the RAMP section in Figure 4 for an explanation of different ramp options 1 Set the RAMP UP pot s to the desired value by quickly switching the command for that coil from minimum to maximum while observing the speed of response Note that the minimum control input is just above or below the crossover point Turning the ramp pot adjustment CW increases the ramp time 2 Set the RAMP DOWN pot s the same way but going from maximum command to minimum command for each coil Dither Optional The DITHER AMP pot if equipped is set fully CCW no dither at the factory Dither is used to keep the valve moving back and forth a small amount at all times to avoid hysteresis and stiction You can visit our website for further explanation of hysteresis and stiction If the valve shift is erratic or if the valve sticks adjust the DITHER AMP pot for the desired amplitude dither amplitude the larger the control input region is where both coils can be energized simultaneously Dither acts as if the control input were changing and it may crossover the point between the COIL A and B If necessary the user may adjust the Min pots to add a larger Deadband to reduce any
9. r to add or eliminate the valve s Deadband 4 Adjust the command input for the desired minimum response point for coil B Observing system response adjust the MIN B pot for the desired minimum current spool shift on COIL B Turn the MIN B knob CW for more current 5 The MAX pot controls the maximum current spool shift for both the A and B coils Set the control input to its maximum 20 mA 10 V or 5 V or the high end of an external 10K pot for example and observing system response adjust the MAX pot for the desired maximum COIL A current spool shift Turn the MAX pot CW for more current High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Tel 1 530 265 3236 www hctcontrols com 021 00141 Rev B2 1 3 8 Hel HAD Product Manual A Do not adjust the unit to supply more current than is required to fully shift the valve additional current may exceed the coil s rating will reduce the useful range of the control input and may damage the valves coil 6 Adjust the control input to fully shift the B coil and check system response If the coil has not fully shifted adjust the MAX pot as necessary 7 The MIN MAX and CROSSOVER pots interact and the hydraulic system response may change as it warms up Warm up the system and repeat steps through 6 until the system reacts as desired Ramp Optional Depending on the model number your unit may have one or more RAMP pots Ramp time is the time it takes for an
10. screwdriver are required Check the power input The card will not function correctly unless the POWER to PWR COM voltage is at least 11 V If this voltage is more than 30 V the card may be damaged Check the control input you are using Pot input Measure the wiper voltage between the VOLT and SIG COM terminals With a 10 K ohm pot the wiper will go from 0 to 9 V The difference in voltage should be more than 5 V from minimum to maximum The voltage must not be less than 0 V or more than 10 V Current loop input Measure the current into the CUR terminal The difference in current should be at least 10 mA from minimum to maximum The current must not be negative or more than 20 mA If a current meter is not available measure the voltage from the CUR terminal to the SIG COM terminal and divide by 150 for an approximate reading Voltage input The difference in voltage between the VOLT and SIG COM terminals should be greater than 5 V from minimum to maximum The voltage must not be less than 5 V or more than 10 V NOTE Only one type control input at a time may be connected Verify the coil is not shorted If the COIL to COIL is shorted the valve driver will shut down its output until the short is removed Disconnect the wires going to the COIL and COIL terminals and measure the resistance between the wires Verify it is correct for the coil being driven High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 Te
11. tage can generate electromagnetic noise that may affect the operation of other components or sensors within the system The best solution to avoid problems stemming from these current spikes is to first dedicate an isolated regulated power supply for powering sensitive sensors Not all sensor manufacturers filter their inputs or outputs Secondly it is recommended that all power input and output cables used on the PWM module and its valve control wires be twisted pair and or shielded and grounded at one end Routing of the cables to and from the valves should be in separate cable bundles and routed separately from cables that go to delicate instruments Greater physical separation between the positive battery wires and the wires to and from sensitive sensors helps minimize the noise coupling If it is necessary to cross cables that connect to sensitive instruments cross the cables at a 90 angle in order to reduce noise coupling Power cables for PWM modules should come directly from the battery or main system power supply and run separately from those going to other equipment Finally if necessary we recommend installing a commonly available engine noise filter on the battery line they are available at most auto parts stores Trouble shooting If the set up procedure does not achieve the desired results double check the wiring perform the following tests and record the test results Tools required A battery operated multi meter and a small
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