HCT Plug Top Driver User Manual

High Country Tek, Inc.

Plug Top Drivers

Electronic Controller Solutions for the
Mobile, Industrial & Marine Fluid Power Industry

High Country Tek, Inc. ( HCT )

Introduces the latest in a range of cost effective
proportional driver products.

These Plug Top Drivers (PTD) are designed to control
single valve coils, and come in 12 or 24V versions that
can interface with 4-20mA or 0-10V command signals.

Simple analog technology, full CE compliance and HCT’s

signature potting process makes these very physically robust and
ideal for use in valve stack or manifold applications.

Each controller comes pre-wired with 3m/10 feet of 4 core color coded
cable as well as a complete mounting kit allowing secure connection to any
valve with a DIN 43650 interface.

Application Examples:

Single coil proportional pressure , flow or screw-in cartridge control valves.
System load / Unload valves - ‘bumpless’ decompression.
Pump stroker ( single side operation )

Mobile applications where ‘CHASSIS’ or ‘EXTERNALLY’ mounted.
High Vibration and /or ‘G’ force applications.

High Humidity applications and/or marine usage.
Cost conscious applications.

www.highcountrytek.com

Copyright © High Country Tek, Inc. - 2009

Electronic Controller Solutions for the Fluid Power Industry

Application Guidelines:

ALWAYS - Take a few minutes to FULLY read THESE information / data sheets BEFORE starting.

ALWAYS - Keep High Voltage AC cables separate from Low Voltage DC signal and supply cables.

ALWAYS - Make sure the unit supply voltage is the same as the coils on the valve being driven !
ALWAYS - Ensure that you are aware of the available adjustments and consequences on the electronics and hydraulics.
ALWAYS - Make sure you have the correct tools to do the intended job ( i.e. P.C., software ) e.t.c.
ALWAYS – ‘Isolate’ this unit from all other equipment BEFORE any form of welding takes place.
ALWAYS - Check ALL connections to and from this unit to ensure NO short or OPEN circuits.
ALWAYS - Check the units supply voltage is CORRECT, ‘ ELECTRICALLY CLEAN ’ and STABLE.
ALWAYS - Operate the units 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 battery boosting takes place on the vehicle.
ALWAYS - Ensure ALL valve connectors are wired correctly, secure, locked and connected to correct coils.

ALWAYS - Use screened / shielded wires wherever possible to avoid electrical noise that may be present.
ALWAYS - Make sure the cable screen IS connected to GND at one end only - typically the user power supply terminal.
ALWAYS - Use a wire gage that is rated for the voltage and current associated with this units operations

ALWAYS - Observe the set-up procedures in this manual for best operational results.
ALWAYS - Follow and abide by local and country health and safety standards – protect yourself and others !

NEVER - Arc Weld or Charge Batteries with this driver unit connected as damage can occur.

NEVER - Attempt to use this unit if you are unsure of electrical OR hydraulic connections or expected operation.
NEVER - Attempt to use this unit in Areas where other AC or DC coils HAVE NOT been fully suppressed.
NEVER - Use a power supply that is not rated for the correct required O/P current under full load.
NEVER - Allow wires TO or FROM the unit to short circuit ( to each other or chassis/cabinet e.t.c. ).
NEVER - Attempt to use this unit in areas of intense RF without adequate screening measures.
NEVER - Disconnect or connect wires to or from this unit unless it isolated from the power supply.
NEVER - Use this unit in temperatures that exceed those specified as operation may be effected.
NEVER - Start this unit without ensuring ALL work areas are clear of personnel !

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.

HCT reserves the right to improve this product at any time without notice.
Please check our website www.highcountrytek.com for latest versions of this manual.

Electronic Controller Solutions for the Fluid Power Industry

Plug Top Driver Overview:

The High Country Tek, range of PTD’s is available in four (4) versions to suit virtually any

application need.
The Voltage command versions can accept 0-10VDC while the Current Command versions

can use the industry standard 4-20mA.
Choose from one of the part numbers below for the correct unit that matches your

requirement:

Part Number -

PTD-12-V - 12V supply, Voltage command, 3000mA O/P current
PTD-24-V - 24V supply, Voltage Command, 1500mA O/P current
PTD-12-C - 12V supply, Current command, 3000mA O/P current
PTD-24-C - 24V supply, Current Command, 1500mA O/P current

12V and 24V PTD Technical Specifications::

Housing Type:- Plug top style using HCT unique ‘encapsulated’ process.
Input Supply Voltage: 12VDC or 24VDC nominal, both ±20% ( Absolute Maximum )
Input Supply Current: Valve Current Setting + ~200mA Quiescent (Max)
Command Input Type(s): Voltage OR Current depending on model used
Command Input Value(s): 0 to +Vref or external 0 - 10VDC max OR 4-20mA depending on model used.

User reference: +12V supply Vref = +8VDC ( ±5%) @ 5mA max

+24V supply Vref = 15VDC ( ±5%) @ 5mA max

Ramp Times (all models) : 300mS to ~8 Secs ( with I max at 100% ) with separate UP and Down settings
Dither Frequency (all models) : Adjustable, ~100 to ~250Hz ( ± 20%)
Housing Material:- High Impact resistance ABS.
Wire Connections:- 3Meters / 10feet pre-connected 4 core, color coded cable to DEF. standard.
Encapsulation:- Flameproof. Black epoxy resin filled
Mounting:- DIN 43650 connector footprint
Temperature range:- -20 to +70 ºC ( operational )

NEMA/IP Rating: NEMA 6P/67 when assembled and mounted to coil correctly

Electronic Controller Solutions for the Fluid Power Industry

+V Supply

0VDC

10K
Potentiometer

BLUE

GREEN

YELLOW

RED

+VRef

+V Supply

0VDC

+I-I

BLUE

GREEN

YELLOW

RED

External Signal

4-20mA

0VDC

0V

BLUE

GREENYELLOW

RED

+V

External Signal

0 to +10VDC

+VRef. NOT USED

Terminate Safely.

+V Supply

Voltage Command Connection Details:

PTD voltage input (GREEN wire ) is internally pulled to
0V to prevent spurious operation with no command
signal connected.

Ramps DO NOT work if power is dis-connected.
Use internal reference voltage +Vref for local control with

potentiometer or joystick e.t.c.
HCT recommends 10KΩ potentiometers / joysticks.
+Vref is protected and current limited to ~5mA.

12VDC PTD’s have +8VRef output.
24VDC PTD’s have +15VRef output.

Always use screened wires wherever possible.

PTD voltage input (GREEN wire ) is internally pulled to
0V to prevent spurious operation with no command
signal connected.

Ramps DO NOT work if power is dis-connected.
Use 0-10V maximum command signal input.
Ensure external command signal source is connected to

same GND (0V) as the PTD power supply for correct
operation.

Ensure +VRef is terminated safely to avoid shorts.
Always use screened wires wherever possible.

Current Command Connection Details:

PTD current input uses a 250Ω shunt resistor connected

to GND (0V) internally
Yellow wire (-ImA) is internally connected to GND (0v)

supply
4-20mA command is connected between +I and –I
Ramps DO NOT work if power is dis-connected.

Use 4-20mA maximum command signal input.
Always use screened wires wherever possible.

FUSES:

For clarity, no fuses are shown here.
HCT strongly recommends that the user installs a fuse
holder that if fit for purpose in the application and uses a
correctly rated fuse for each plug top driver to ensure
that damage does not occur under short circuit or wiring
circumstances.