HCT HFS User Manual
High Country Tek, Inc.
Hydraulic Fan System Controller: HFS
Electro-Hydraulic Solutions for Mobile, Industrial & Marine Applications.
Application, Set-up
&
Information Manual.
Part No. 021-00135 Rev. C September - 2009
Hydraulic Fan System Controller: HFS
Important Notes:
This product has been designed by High Country Tek, Inc ( HCT ) to interface directly with any manufacturers range of
proportional pressure and/or flow control valves, variable pumps, motors and manifold blocks currently available for
type of
Please contact the factory by the e-mail address given below or nearest High Country Tek, Inc. distributor for further
technical information and availability.
Application Areas:
• ON and OFF road applications
• OEM, re-power and retro-fit markets
• Mining equipment
• Drill, exploration and blast hole rigs
• Chassis, bus and RV builders
• Static applications – standby generators
• Industrial cooling operations
• Fluid temperature conditioning
• Hydraulic system oil.
• Automatic Transmission fluid.
• Engine sump oil.
• Air conditioner refrigerant.
• Engine water jacket.
• Engine charge air
• „External Attachment‟ system fluids.
• Diesel fuel.
System Part Numbers:
• Controller Module:-……………………………………………... HFS
• Female 12 way Deutsch connector:-………………….……… 999-10088
• Opto 3000 interface Unit:-………………………………………… Opto3000
• HFS controller software CD:-………………….………………. TBA – Contact HCT customer service for info
• Controller info manual:-………………………………………… 021-00135 Rev B
IMPORTANT NOTE:-
High Country Tek, Inc. reserves the right to upgrade, revise or better any controller as technology improves without
notice being given.
Wherever possible, full downwards compatibility for both hardware and software on replaced controllers will be
maintained but it is the users responsibility to ensure that the latest technical details or literature is being used for
application reference.
If you are unsure of the literature, hardware or software revisions you have, or suspect that it is an older revision,
please send an e-mail request for the latest releases to info@highcountrytek.com
The information contained in this literature is the sole intellectual property of High Country Tek, Inc It shall not be copied or transmitted by any
format to any third parties without our knowledge and express written permission.
ALL information contained herein is copyrighted to High Country Tek, Inc - © 2008.
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Hydraulic Fan System Controller: HFS
System Overview:
This product has been designed specifically for Hydraulic Fan Drive control and gives the user new levels automation
while integrating seamlessly into a typical discrete cooling system.
It can control a hydraulically driven fan proportionally or in an ON/OFF manner based on user settings, system
configuration and cooling needs with three independent inputs ( zones ) that will interface with industry standard NTC,
two wire thermistors. Two (2) switch inputs, suitable for over temperature switches, retarder switches and air
conditioning clutch switches are also provided for added system flexibility
Standard features include a robust vibration, flame proof package, Waterproof single heavy duty connector ( DT15-
12PA Deutsch 12 pin header ), Alarms interface, intelligent diagnostics, self protection that enable the controller to
operate reliably under arduous environmental conditions and a „real-time‟ graphing and data logging facility that allows
the user to observe and then record several operating parameters that are saved in a common file format for later
examination in Microsoft Excel®.
Local on-board diagnostic LED indicators are available for power ON, each thermistor input, Two on/off override inputs,
proportional output and a specific error code LED which all show through observation, the current status of the
controller and connected peripheral devices.
Easy to use „set-up‟ and diagnostic software that is provided with the unit, works in conjunction with the HCT „Opto
3000‟ interface unit to provide high speed data communications between the controller and the host computer and
runs on any PC with a Windows®O/S platform.
Once the profile for a particular cooling requirement has been established, the software allows the developer to
up/download the complete personality into other blank controllers giving the user a high level of application specific
security and keeping company confidential information in-house.
The inputs can be configured to interface directly with pre-set range ON/OFF Bi-metallic temperature switches without
the proportional control offered by the thermistors but giving savings advantages where absolute accuracy is not
required and system cost is at a premium.
There are no external or onboard potentiometers, switches or adjustments for user settings to ensure controller
integrity and operation under harsh environmental and operator conditions.
The set-up software allows the controller to be very flexible regarding settings and system configuration with password
levels invoked to ensure that characteristics cannot be changed without the proper authority.
Each password level entered, affords the user more options and available settings that are kept transparent to the
operator or observer to avoid confusion.
ALL inputs and outputs on the controller are fully protected, continuously monitored and when connected, displayed by
the software in the „Status‟ window.
Readings are also taken and stored of highest temperatures seen in each active zone, supply voltages and other
parameters to allow event correlation and system diagnostics if required at a later date.
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Hydraulic Fan System Controller: HFS
Product Features:
Fail safe design gives full fan cooling even with NO electrical power
Wide supply voltage range ( 10 – 32VDC )
Industry standard Deutsch 12 pin connector DT15-12PA.
User settings inputted via provided software package – NO software to be written.
Set-up & unit configuration up/downloadable to any backup media via PC.
NO external adjustments to maintain system integrity in the field.
Three independently selectable and configurable temperature sensing inputs
Two on/off „override‟ switch inputs for full cooling if required.
ALL Inputs and Outputs fully protected ( shorts, opens and reverse connection ).
Unit status „Diagnostic‟ LED‟s user visible and functional at all times.
Coded error indicator for real time diagnostics at the controller.
Full remote (PC) and local „smart‟ visual diagnostics ( with optional Opto 3000 ).
Product integrity maintained under extreme operational environments.
Fully „isolated‟ design for improved safety and ease of application in difficult areas.
Very cost effective compared to other available modules with comparative functions.
Ruggedized‟ design allowing use on either in-cab or external applications.
Flame retardant resin encapsulation.
Mount „anywhere‟ mechanically hardened modular format.
The information in this guide is the intellectual property of High Country Tek, Inc. and should be
considered at all times as strictly company confidential.
It shall not be copied or transmitted by any format to any third parties without our knowledge and
express written permission.
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Hydraulic Fan System Controller: HFS
Important Notes:
ALWAYS - Take a few minutes to FULLY read THESE information / data sheets BEFORE starting.
ALWAYS - Keep High Voltage AC cables separate from Low Voltage DC signal and supply cables.
ALWAYS - Make sure the unit supply voltage is the same as the coils on the valve being driven !
ALWAYS - Ensure that you are aware of the available adjustments and on the electronics and hydraulics.
ALWAYS - Make sure you have the correct tools to do the intended job ( i.e. P.C., software ) e.t.c.
ALWAYS – „Isolate‟ this unit from all other equipment BEFORE any form of welding takes place.
ALWAYS - Check ALL connections to and from this unit to ensure NO short or OPEN circuits.
ALWAYS - Check the units supply voltage is CORRECT, „ ELECTRICALLY CLEAN ‟ and STABLE.
ALWAYS - Operate the units within specified operating temperature for best & reliable performance.
ALWAYS - Ensure that any unused wires / terminals are terminated safely and not shorted together.
ALWAYS - Isolate the controller if ANY form of battery charging or boosting takes place on the vehicle.
ALWAYS - Ensure ALL valve connectors are wired correctly, secure, locked and connected to correct coils.
ALWAYS - Observe the set-up procedures in this manual for best operational results.
ALWAYS - Follow and abide by local and country health and safety standards – protect yourself and others !
NEVER - Arc Weld or Charge Batteries with this driver unit connected as damage can occur.
NEVER - Attempt to use this unit if you are unsure of electrical OR hydraulic connections.
NEVER - Attempt to use this unit if you are unsure of the expected system operation.
NEVER - Attempt to use this unit in Areas where other AC or DC coils HAVE NOT been fully suppressed.
NEVER - Use a power supply that is not rated for the correct required O/P current under full load.
NEVER - Allow wires TO or FROM the unit to short circuit ( to each other or chassis/cabinet e.t.c. ).
NEVER - Attempt to use this unit in areas of intense RF without adequate screening measures.
NEVER - Disconnect or connect wires to or from this unit unless it isolated from the power supply.
NEVER - Use this unit in temperatures that exceed those specified as operation may be effected.
NEVER - Start this unit without ensuring ALL work areas are clear of personnel !
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Hydraulic Fan System Controller: HFS
Electrical Specifications
1) Board Style: HCT Unique Size and Mounting.
2) Connector Types: DT15-12PA Deutsch 12 pin
3) Input Supply Voltage: 10 – 32VDC ( Absolute Maximum )
5) Input Supply Current ( Max ): Valve Current Setting + 200mA Quiescent (Max)
6) Command Input Type(s): 2 wire Thermistor, temperature switch ( software selectable )
2 x on/off inputs for fan speed override ( software selectable ).
7) Command Input Value(s): Ohms only ( Max temp = 50 ΩMin temp = 2MΩ)
2 x Contact closure.
8) Available adjustments: All adjustments in software, see attached literature.
9) Dither Frequency : Software adjustable, ~30 to 250Hz ( menu selectable )
10) Environmental: Totally „ENCAPSULATED‟ Printed Circuit Board.
11) IP Rating ( module only ): Designed to meet IP 68 ( MIN ) derate connector as required.
12) NEMA Rating ( module only ): Designed to meet NEMA 6P derate connector as required.
13) Humidity: 95 - 100% Non Condensing.
14) Storage temp.: -40 to +85 Deg C ( Max )
15) Working temp.: -30 to +75 Deg C ( Max ) Inc Ambient.
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Thermistor Requirements:
Hydraulic Fan System Controller: HFS
The controller operation is based on input from up to three temperature measured
zones.
One, two or all three inputs can be used depending on the system requirements with
all three thermistor inputs able to be enabled or disabled independently within the
set-up software.
The inputs can be from NTC ( Negative Temperature Coefficient ) Thermistors or BiMetallic temperature switches and the choice can be made in the set-up software.
Two wire NTC thermistors sensors with both wires brought back to the unit are
required for each zone being monitored.
DO NOT use thermistors with one lead grounded as the sensor and the measuring
accuracy will be severely degraded !
The controller is compatible with most automotive type thermistors with Borg
Warner, Delphi and Ford IAT sensors being pre-configured and selectable on a drop
down menu.
Other transducers not pre-set may have their profiles added and stored under user
selectable names for future use by HCT factory personnel.
If other thermistors are to be added, the acceptable Ohmic range is 50ohms at the
maximum temperature that can occur in the system to 2Mohm at the minimum
temperature that can occur in the system.
Open (> 2 M ohm) or shorted (< 50 ohms) thermistor inputs will be detected and
cause full fan speed output and indicate with the appropriate alarm response and
error code to aide diagnosis of the problem.
Each thermistor input can also be configured and used as simple contact closure
switch inputs.
Temperature ‘Switched’ Inputs
Switch inputs to the controller MUST indicate HIGH temperature by disconnecting (
open circuit ) or tying the input(s) to the units power supply voltage and indicate LOW
temperature by grounding the input.
This switching convention is required to provide „Fail-safe‟ operation as the input(s) is
normally internally pulled to +5VDC with a current limiting resistor.
When a input(s) reads a HIGH temperature ( NOT grounded ), it produces a fixed error
value that is acted upon by the controller to determine the fan speed ( on or off ).
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Hydraulic Fan System Controller: HFS
Switched Inputs ( Fan Speed Override ):
These inputs are ON/OFF in nature and are additional to the proportional thermistor inputs. They allow the application
to have two „Emergency‟ maximum fan speed selector channels. These inputs can be connected to simple
temperature switches and used to give full fan speed if the actuation point of the temperature switch is reached.
Alternative operation could be manually triggered from in-cab or when a particular vehicle operation is activated, the
fan goes to full speed for the duration of the cycle.
Power Supply & Valve Coil Voltage
For most accurate smooth control with best resolution, protection and product reliability, the following combinations of
power supply and valve coil voltage should be adhered to:-
Proportional coils ( fan speed control ):-
8 – 14VDC:- Use 12V valve coil.
20 – 36VDC:- Use 24V valve coil.
CE and EMC Notes:
This unit has been electrically designed to pass the latest CE tests but has not yet been certified for stand-alone
usage.
This unit can however, confidently be used as part of a larger system which will then be tested to the relevant CE
standards.
Opto 3000 Notes
The Opto 3000 interface unit is the equipment by which the fan controller is set-up and monitored, and is intended for
temporary use during static system set-up, commissioning and HFS module programming only.
It is not designed for continuous connection and operation, and should not be used or applied in areas where harsh
environmental or intense radio Frequency fields ( RF ) are present as unit resetting may occur, system diagnostic
information sent or received may be corrupted or the Opto 3000 unit damaged.
If any of the above problems are seen, dis-continue operation until the source of the RF has been identified and
stopped.
The Opto 3000 unit must be ordered separately to the main controller but this is a universal communications adapter
which will be used with other HCT controllers and products.
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Hydraulic Fan System Controller: HFS
Fan Control Logic:
The controller uses "PI" to regulate the temperatures to be no more than the Set points entered by the user.
The „P‟ and I terms act on temperature difference between set point and actual temperatures, with the P term used to
change the amount of response at the control valve and should be adjusted to respond smoothly to smaller
temperature changes. The larger the number set, the more aggressive the change will be for a small difference.
The „I‟ term tracks the temperature difference and automatically adjusts the control valve to increase or de-crease fan
speed while attempting to get as close as possible to the set point. The larger the number set, the bigger corrective
step to the control valve will be seen.
General operation default values for the P & I terms are embedded in the software but may be altered by users with
the proper password level of authorization to fine tune a system.
Temperature error is the difference between the actual measured temperature and the „temperature set point‟,
scaled by the difference between the „temperature set point‟ and the „'Overtemp' alarm set point.
The scaling is required to allow comparison of all the thermistor inputs on an equal basis.
The active thermistor input with the largest scaled error above its set point will be used by the PI process.
If all temperatures are below their user set points, the thermistor closest to it‟s set point will be used to give control.
In a properly tuned system, this process will result in the fan turning just fast enough to keep one temperature
regulated to its set point and all other temperatures less than their Set points.
If a thermistor input is shorted or open, the unit will ramp to full fan speed. This error behavior will continue until
power is turned off if the user programmable „Retry All Faults‟ is NOT selected, otherwise, it will resume normal
operation when the fault is cleared.
A thermistor reaching „Overtemp‟ is an error that results in ramping to full fan speed. The „Overtemp‟ error condition is
automatically cleared if the thermistor drops below „Overtemp‟, ramping to the PWM% value demanded by the PI loop.
Password Protection:
Password protection has been provided to ensure that damage cannot be caused once commissioning is completed.
There are three levels of security, all of which may only be accessed via the Opto 3000 and PC software and with the
proper password level of authorization:
Level 1:- ( NO Password ) Monitor controller operation only, no change in parameters allowed, can data
log for system diagnosis if required.
Level 2:- ( OEM Password ) Authorized user has access to the functions that are needed for programming and
set-up.
Level 3:- ( Professional Password ) HCT Engineering level which allows access to ALL base controller settings
and some RESET functions.
Contact High Country Tek , Inc. on the e-mail address ( info@highcountrytek.com ) for password .
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Hydraulic Fan System Controller: HFS
Proportional Output:
A variable current output is used for driving a proportional valve to control the fan speed.
BOTH wires from the valve coil must be connected to the controller where indicated by „+Prop Valve O/P‟ and „-Prop
Valve O/P‟.
The output is fully protected against shorted or mis-wired coils with errors being both indicated locally on the
associated LED and annunciated on the controller software if the program is running on a PC connected to the unit.
Shorted coils or connection wires are detected only when the controller tries to drive the coil and is indicated with a
RED FLASHING output LED.
Open circuit coils or connection wires are detected only when the controller tries to drive the coil and is indicated with
a GREEN FLASHING output LED.
The proportional valve coil selected must be capable of withstanding the power supply's maximum voltage or the user
must set the maximum output current ( I Max ) to a safe value.
User adjustable minimum current ( I Min ) and selectable PWM frequency ( 31 to 250 Hz ) allows tuning for smoothly
starting the fan from a stop.
The proportional output is rated for approx. 3A coil current maximum at the connected supply voltage.
The software allows user selection of driving normally open and normally closed proportional valves.
For data and integrity protection, the controller and proportional output is turned off if the units internal temperature
sensor temperature exceeds 80 C ( 176 F ).
Fan MAX Speed Setting:
This is called „ Max Vlv Current %‟ in the software and allows current to be adjusted from 0 – 100 % PWM output.
If Max Valve Current is set to zero (0) all other settings will also go to zero.
Fan MIN speed Setting:
This is called „ Min Vlv Current %‟ in the software and allows current to be adjusted from 0 – 100 % PWM output set by
„Max Vlv Current‟ above.
Ramp Settings :
The user programmable ramp Up and Down times are applied to limit the controllers rate of change in output current
to a value that prevents damaging the hydraulic system components and the fan blades.
The ramp rate is set in seconds (s) for a full scale current output change in the range of 1 to 10 seconds.
This ramp time should be set low enough not to interfere with the temperature control loop response but high enough
to give smooth system operation.
Dither Frequency Setting ( Valve Coil ):
The set-up software allows the dither frequency ( PWM frequency ) to be set from 31.5 to 250Hz to cater for the
known range of proportional valves that could be used for this application.
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