HCT emc-1V User Manual

e-Fan Cooling System Controllers

with J1939 Interface

emc-1P & emc-1V

e-Fan Drive - System Controller

User Guide

High Country Tek, Inc. reserves 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.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 1

e-Fan Cooling System Controllers

with J1939 Interface

High Country Tek, Inc. (HCT) is North America’s foremost independent designer and

producer of modular, ruggedized digital and analog electronic controller products for the fluid power
industry.

From our factory in California, we build, test and produce ‘specialty’ controllers that provide solutions
for specific everyday functions as well as our ‘DVC family’ of fully adaptable user programmable units
that can be integrated together to enable large area networked system solutions.
The modules are typically used in mobile, industrial and marine applications, but are also applied
successfully in several other growing global market segments.

Because High Country Tek has an industry unique non-repairable product protection system, with
every module encapsulated in solid flame resistant material for maximum durability, electrical integrity
and complete environmental security, we have to deliberately select the highest quality components
from our suppliers at all times, ensuring our 100% operating shipped product.

HCT is also a market leader in many application arenas, including hydraulic generator, e-Fan and

hydraulic fan system controls where significant fuel, emission and operational savings can be realized
by using one of the aforementioned specialty units to optimize the applications operation.

HCT’s market neutrality and flexible product configuration approach offers dependable integration
with virtually any hydraulic OEM products for easy, simple and accurate control of valves, pumps,
sub-systems or systems.
Our best-in-class customer service and product reliability is well known and trusted throughout the
fluid power network and we look forward to working with you in the future.

www.Hctcontrols.com

The information in this publication is intended as a guide only, and High Country Tek, Inc. (HCT) takes
NO responsibility for usage and implementation in any user entered values into the provided GUI
structure.

HCT strongly suggests that the user attends one of the product training courses to ensure correct and full
understanding of this information and to learn further optimized methods of control techniques.

Please contact HCT customer service to book one of the scheduled training dates or to di scuss arranging
a course specific to your company needs.

Thank you for using High Country Tek Inc. Products.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 2

e-Fan Cooling System Controllers

with J1939 Interface



TableofContents

Welcome ....................................................................................................................... 4

Introduction .................................................................................................................. 4

Cautions ....................................................................................................................... 4

Warranty Information .................................................................................................. 4

Controller Updates: ..................................................................................................... 4

’emc-1P & emc-1V’ e-Fan System Controller ............................................................ 5

Product Overview ........................................................................................................ 6

Product Application Guidelines ................................................................................. 7

Software Safety ............................................................................................................ 7

emc-1P & emc-1v Electrical Specification Overview ................................................ 8

emc-1P Module Familiarity ......................................................................................... 9

emc-1P Connection Information ............................................................................... 10

emc-1V Module Familiarity ....................................................................................... 11

emc-1V Connection Information ............................................................................... 12

Error LED Code Descriptions for emc-1P & emc-1V .............................................. 13

Module Connection Descriptions ............................................................................. 14

Serial Communications ............................................................................................. 16

Loading the emc-1P or emc-1V GUI onto Host PC ................................................. 17

System Requirements ............................................................................................... 17

Controller adjustments and Monitor ........................................................................ 18

GUI Menu Options ................................................................................................................... 18

Password Protection ................................................................................................................ 19

Help ......................................................................................................................................... 20

GUI software – Main screen (Dashboard) ............................................................................... 21

Data Logging ........................................................................................................................... 22

General Settings ...................................................................................................................... 23

Unit Settings ............................................................................................................................ 23

Output Settings ........................................................................................................................ 24

Auto Reverse Settings ............................................................................................................. 24

Input Settings ........................................................................................................................... 25

Error Information Log ............................................................................................................... 27

Factory Information .................................................................................................................. 28

Temperature Sensor Information ............................................................................. 29

Main I/O connector & Accessories ........................................................................... 29

On Site Testing .......................................................................................................... 30

emc-1P & emc-1V Dimensional Information ............................................................ 32

RS232 Communication Cable ................................................................................... 33

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 3

e-Fan Cooling System Controllers

with J1939 Interface



Welcome

Welcome to the High Country Tek Inc. (HCT) e-Fan cooling systems controller user guide, and thank you

for selecting this HCT controller to use in your application

The following information is designed to allow you to connect, set-up and optimize the emc-1P and emc­1V modules.

If you have used HCT products before, you will recognize some of the instructions and settings. For those
of you that are new to HCT, please read the directions with care and be sure that if you have any
questions regarding this industry unique controller, then please contact us using one of the numbers
given on the back page of this manual.

We value our customers, their experience and abilities and ask that if you would like to see any additions,
subtractions or find any errors in this publication, that you contact HCT’s customer service so that we can
correct the information and make sure that our programming community is using the latest information.

If you require urgent support, more information or would like specific programming areas clarified, you can
contact us on the customer support number at 1 530 265 3236 or E-mail us through our website at

www.hctcontrols.com

, giving details of your issue and how we can contact you.

Introduction

This manual is designed to provide information needed for the installation and use of the emc-1P & emc­1V e-Fan Cooling System Controllers. Its intended user is qualified trained service personnel that
understand the hazards involved in an electromechanical environment. It is recommended that this
manual be read in its entirety before installation is begun with particular attention paid to caution and
safety information.

Cautions

Changing setup values and limits under computer control while the machine is operating may cause

sudden machine movement, which may lead to possible injury or death. It is strongly recommended that

any moving parts are disabled prior to any alignment procedure whenever possible. In any case, caution
should be exercised during any procedure and work should be completed only by qualified trained
personnel.

Warranty Information

High Country Tek Guarantees this product to be free of defects in materials and workmanship for a period
of one year extending from the date the unit was 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. If necessary, contact the factory for return authorization by phone (530)

265-3236, Fax [phone], E-Mail [e-mail]

High Country Tek, Service Dept., 208 Gold Flat Court, Nevada City, CA 95959. To help us serve you
better, please have the units full Model / Part Number and Serial Number available when contacting the
factory for any reason. Do not return products to the factory without prior authorization and a RMA
number attached.

or by writing our service department at,

Controller Updates:

HCT continuously improve the controllers and make additional information and/or features available.

Please check on-line at www.hctcontrols.com

controller information.

for the latest products, updated software and

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 4

e-Fan Cooling System Controllers

with J1939 Interface

’emc-1P & emc-1V’ e-Fan System Controller

The emc-1P and emc-1V are the latest additions to the High Country Tek (HCT) family of e-Fan control

modules. These highly cost effective controllers have all the features and input output functionality that

will support a wide range and configuration of e-Fan system applications. As with all of the HCT modules,

the controller is packaged in a small rugged enclosure and encapsulated in flame resistant resin to
withstand extreme conditions in the harsh mobile operating environment.

The modules are ideally suited for today’s OEM, distributor or system builder, with both mechanical and
electrical robustness paramount in the design priority, Windows™ compatible easy to use set-up software
and full CE compliance means this one product can be used across multiple platforms, markets and
applications. This unit’s cost effectiveness will become quickly apparent through the reduction in
inventory costs and stocking needs as well as in the engineering time taken usually associated with the
design to delivery cycle.

Programming of the controller parameters and all diagnostics is done through the RS232 connector
pendant. This is a separate connector from the main or SAE J1939 connector ( as fitted on the emc-1P )
so that optimization or operational observation can be carried out without disturbing the cooling system
operation. When programming, changes or observation of the module function is required, connection
can be made through a standard computer serial connection, either directly via a 9 way ‘D’ type connector
or through an HCT approved USB to serial converter. In all cases, the HCT programming interface cable
(Part No: 999 – 10075, RS232 programming cable) is required for communication from the controller to a
Windows™ based PC.

The controller is designed to make the fan system set-up easy to configure and control. The hardware
contains the framework software where the parameters can be changed depending on the user’s needs
via the PC graphical user interface (GUI).

The GUI has been organized into various user screens that are logical and simple to understand.
Terminology has been used that is commonplace through the mechanical, hydraulic, mobile and electric
fan drive industry to allow easy configuration, set-up and running and is intended to cater for a wide range
of users with varying levels of computer familiarity.

This controller is ideally suited to equipment upgrades as well as installation by OEM’s at machine build
time and offers all the necessary features required by today’s modern engines that use the J1939
communications standard.

The controller will take information directly from the J1939 bus for the common temperatures broadcast
such as Engine Coolant, Charge air and Transmission Oil Temperature making system integration very
quick and easy. Engine RPM is also monitored by the module giving the user an option to control the
engine load during the engine start cycle. (minimum RPM setting) Additional external inputs ( 1x emc-1P
& 2x emc-1V ) from Thermistors may be used to monitor non SAE J1939 temperatures and effect the fan
operation.

The emc-1P & emc-1V products are backed by High Country Tek’s industry leading product reliability,

easy to use software design and market leading customer service and technical support as well as on­time delivery while the well designed and intuitive graphical user Interface (GUI), allows you to program
multiple configurable modes of operation available within the one module.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 5

e-Fan Cooling System Controllers

with J1939 Interface

Product Overview

 NO software experience needed to apply this controller successfully.
 Pre-written ‘e-Fan Drive’ software for easy, fast system configuration, development and production.

 Intuitive Graphical User Interface (GUI) runs on any PC with Windows® XP or newer software (.net

compatible).

 9 – 32VDC operation with full reverse polarity and SAE J1455 protection.
 CE approved to latest international test standards.
 J1939 CAN Bus communications for engine and temperature zone data Inputs

**J1939 temperature data hard coded for:

 SPN 109, Engine Coolant Temperature; PGN 65262,
 SPN 177, Transmission Oil Temperature; PGN 65272
 SPN 105, Engine Intake Manifold 1 Temperature; PGN 65270

 Extended -40ºC (-40ºF) to +85ºC (+185ºF) controller operational temperature range.

 All inputs and outputs are protected from shorting to ground or the power supply.

 Diagnostic LEDs display I/O status and module operation at a glance.

 ‘Blinking’ error codes for fast on-site ‘health check’.

 System wiring and coil fault detection alarms.

 Configurable Alarm output for integration into host system.

 IP68 (NEMA 6P) rating on module for harsh environment reliability.

 Deutsch IP69K connectors for reliable and easy system wiring.

 Separate RS232 communications connector for programming, monitoring and diagnostics.

 Rugged encapsulated product withstands harsh environments found in mobile applications.

 Non Volatile Memory maintains ALL settings without power

 Completely user configurable and settings are password protected.

**J1939 PGN Address Note**

If the standard SAE J1939 PGN address for Temperatures or RPM is NOT compatible for a
particular application, HCT can change the PGN numbers as needed and re-issue personalized
program code to you. Please use the contact numbers on the back page of this manual to discuss
this with our customer support personnel.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 6

e-Fan Cooling System Controllers

with J1939 Interface

Product Application Guidelines

ALWAYS do the following

 Take a few minutes to FULLY read this manual and accompanying data sheets BEFORE starting.
 Keep High Voltage AC cables separate from Low Voltage DC signal and supply cables.
 Make sure the unit output voltage is compatible with the equipment being driven!
 Ensure that you are aware of the adjustments and consequences for the external equipment.
 Make sure you have the correct tools to do the intended job (i.e. P.C., software) etc.
 ‘Isolate’ this unit from all other equipment BEFORE any form of welding takes place.
 Check ALL wire connections to ensure there are no unintended SHORT or OPEN circuits.
 Check that the units supply voltage is CORRECT, ‘ELECTRICALLY CLEAN’ and STABLE.
 Operate the units within specified operating temperature for the best and most reliable performance.
 Ensure that any unused wires / terminals are terminated safely and not shorted together.
 Isolate the controller if ANY form of battery charging or battery boosting takes place on the vehicle.
 Ensure ALL connectors are wired correctly, secure, locked and connected.
 Observe all the set-up procedures in this manual for best operational results.
 Follow and abide by local and country health & safety standards – protect yourself and others!

NEVER do the following

 Arc Weld or Charge Batteries with this driver unit connected as damage can occur.
 Attempt to use this unit if you are unsure of electrical OR mechanical connections or expected operation.
 Use a power supply that is not rated for the correct required O/P current under full load.
 Allow wires TO or FROM the unit to short circuit (to each other or chassis/cabinet etc).
 Attempt to use this unit in areas of intense RF fields without adequate screening measures.
 Disconnect or connect wires to or from this unit unless it isolated from the power supply.
 Use this unit in temperatures that exceed those specified as operation may be effected.
 Start this unit without ensuring ALL work areas are clear of personnel!

Software Safety

 The software has been carefully written to give the user the maximum system configuration

flexibility while being transparent in operation and easy to use, even for novice system builders and
operators.

 To ensure safety when using the software and to prevent accidental connection to another module

that is not an emc-1P or emc-1V, rules have been written into the software to ensure correct

operation at all times. After program entries, cycle power, to ensure changes are accepted by

the unit.

 When the PC running the GUI is first connected to a powered controller, and before any data

exchange can be allowed, a ‘Handshake’ takes place that confirms the internal software (BIOS) is
compatible with the GUI software and only then allows the PC and the module to communicate and
share data.

 If at any point during the process above an error or miss-match is detected, or loss of

communication, the GUI software will indicate “OFF LINE” and NOT allow communications until the
problem is corrected.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 7

e-Fan Cooling System Controllers

with J1939 Interface

emc-1P & emc-1v Electrical Specification Overview

Board Style ...................................................... High Country Tek unique size and mounting

Connector Type (Main) ................................... 12 way male Deutsch IP69K rated

Connector SAE J1939 ..................................... 3 way male Deutsch IP69K rated

Communication I/O connector RS232 ............ 4 way Packard MALE (Tower) connector on 6 inch Cable

Communication Type ...................................... Serial data at 57.6K Baud through PC USB/Serial port

Input Supply Voltage ....................................... 9 – 32VDC (absolute maximums)

Input supply current ......................................... ~200mA quiescent + valve currents

Input supply protection SAE J 1455 & User supplied inline

fuse (AGC5 or compatible)

Command Input type Main .............................. SAE J1939 digital date OR

Command type additional - emc-1P ................ 1 x external discrete Thermistor

Command type additional - emc-1V ................ 2 x external discrete Thermistor

Thermistor types ............................................. 2 wire Resistance variety only (see page 29)

Proportional Output Type / Range

emc-1P .................................................... PWM / 33Hz to 500Hz, 0% – 100% Duty Cycle, 0 – 3000mA

emc-1V .................................................... Voltage, 0 – 5 VDC / 0 – 50mA ( short circuit protected )

Alarm Output Type / Range ............................ Discreet Active Low or High / 0 – 3000mA

Alarm Output Protection .................................. Short protection to power and ground

‘Reverse’ input signal range ............................ +5VDC to +V module supply momentary = ON

‘Reverse’ input signal impedance ................... 20K Ohm to ground

‘Fire Event’ input signal range ......................... +5V to +V module supply Fans turn OFF

(0V normal Fan operation)

‘Fire Event’ input signal impedance ................ 100K Ohm

‘Ignition’ input signal range .............................. +5VDC to +V module supply = ON

‘Ignition’ input signal impedance ..................... 20K Ohm to ground

Digital Input De-Bounce (Hold Time) .............. 150mS (triggered on rising edge)

Reverse Indicator output Type / Range .......... Discreet Active High / 0 – 3000mA

Reverse Output Protection .............................. Short protection to power and ground

Industry Compliant .......................................... CE certification to latest standards

SAE J1455 Load Dump

Environmental ................................................. Totally encapsulated unit for mechanical protection

IP rating ........................................................... IP 69K

NEMA rating .................................................... 6P

Humidity .......................................................... 95 – 100% Non-condensing

Storage Temp range ....................................... -60 to + 90°C

Operating temp range ..................................... -40 to + 85°C

Note:

ALL controller and system response adjustments are made through graphical user interface software.
See‘emc-1P & emc-1V Software’ section in this manual for full details.

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 8

emc-1P Module Familiarity

e-Fan Cooling System Controllers

with J1939 Interface

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 9

emc-1P Connection Information

NOTE:ControllerMUSThavein‐linefuse
fittedby
userinthe+VPowerInputforsystem
protection.

SAE J1939 Connections

Pin A CAN_Hi (SAE J1939)
Pin B CAN_Low (SAE J1939)
Pin C No connection

Pin 1 ................. Sensor #1 +signal input

Pin 2 ................. Fire detect input

Pin 3 ................. Fan #1 Diagnostic input

Pin 4 ................. Fan #2 Diagnostic input

Pin 5 ................. +Volts 9-32VDC input

Pin 6 ................. Reverse fan input (momentary)

Pin 7 ................. Ignition ON input

Pin 8 ................. Sensor #1 common

Pin 9 ................. Power supply return (GND)

Pin 10 ............... Alarm output (3A max sourcing)

Pin 11 ............... Reverse output (3A max sourcing)

Pin 12 ............... 0-100% PWM e-fan output

e-Fan Cooling System Controllers

with J1939 Interface

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 10

emc-1V Module Familiarity

e-Fan Cooling System Controllers

with J1939 Interface

Part No:- 021-00351 Rev 1.0 emc-1P & emc-1V e-Fan System Controller User Guide Page 11