emc-3 Controller Module User Guide – Rev A emc-3 3 array e-Fan Electronic 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.
emc-3 Controller Module User Guide – Rev A 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.
emc-3 Controller Module User Guide – Rev A Introduction The emc-3 application allows for independent control of up to three fan banks. Each bank is controlled by any three of the seven Command Inputs. The emc-3 is designed to drive PWM controlled fans with up to 3 Amps/Channel by providing a High Side sourcing 100Hz PWM signal. A normally low Alarm output notifies the user to check the fan system. A normally low Reverse output notifies the user that the fans are in reverse.
emc-3 Controller Module User Guide – Rev A Table of Contents Introduction ......................................................................................................................... 3 Controller Mechanical information..................................................................................... 6 Theory of Operation ............................................................................................................ 7 Normal Operation ...........................................
emc-3 Controller Module User Guide – Rev A 3) Starting the Program Loader Monitor: ................................................................ 33 4) Main Program Loader Monitor Screen: .............................................................. 33 6) Program Loader ..................................................................................................... 34 Frequently Asked Questions: ............................................................................................
emc-3 Controller Module User Guide – Rev A Controller Mechanical information IMPORTANT NOTE: Recommended tightening torques for the securing bolts are as follows: For a 1/4-20 bolt, SAE Grade 5 DRY Torque: 8 Ft-Lbs Lubricated Torque: 6.3 Ft-Lbs Use 0.5” or 12-15mm spaces if mounted to hot surface 9 i.e.
emc-3 Controller Module User Guide – Rev A Theory of Operation Normal Operation At Power On, the module will not run the fans until the Startup Delay has expired. The Startup Delay is set by entering a value into the EE-Memory location “Startup_Delay_Seconds” using the PLM or SAE J1939 configuration messages. After the delay the controller will check 2 inputs before enabling the outputs: The Minimum Engine RPM ( must exceed entered value ).
emc-3 Controller Module User Guide – Rev A Wiring Page 8 of 39
emc-3 Controller Module User Guide – Rev A emc‐3 Connector Designation Tables 30 Pin Metri‐Pak Connector ( Male, Plug ) PIN A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 Name RXD TXD RTS CAN‐H CAN‐L COM CAN‐H Uni‐1 GND CAN‐L Function Receive RS232 Data ‐ Pin 'A' Transmit RS232 Data ‐ Pin 'C' Request To Send ‐ RS232 Pin 'D' CAN #1 High CAN #1 Low 0V/COM RS232 Data ‐ Pin 'B' CAN #2 High Universal Input #1 Ground / 0V / Signal Common CAN #2 Low PIN D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 Name Uni‐2 GND Vref Uni‐3 GND DIG‐1 ANA‐1 G
emc-3 Controller Module User Guide – Rev A Reverse Mode Operation A Reverse Cycle may be initialized either Manually or Automatically. initiation of a Manual Reverse Cycle is done by momentarily toggling the Reverse Input at any time that the Ignition Switch is “On”. A Manual Reverse Cycle Request is considered valid if the Reverse Input pulse is between 500mS and 3.0S in duration. Pulses of less than 500mS will be ignored.
emc-3 Controller Module User Guide – Rev A Manual Control To manually control the Fan Banks, set “Manual Control Enable” to a number greater than 0. Then do any one of the following; 1. Cycle power, 2. Cycle the Ignition Switch or 3. Reduce the engine RPM to less than the “Minimum Engine RPM” set point in the EE-Memory. Once the emc-3 has entered Manual Mode, each Banks fan speed is determined by the “Bank n Manual DYCY” set points in the EE-Memory.
emc-3 Controller Module User Guide – Rev A Inputs Command Inputs With only one exception, all command inputs have common settings: 1. Start Temp – The set point at which positive demand is calculated. 2. Max Temp – The set point for 100% demand. 3. Over Temp – The set point at which an error is reported due to over temperature. An Input demand is calculated as a percentage of error between the Start and Max Temp set points.
emc-3 Controller Module User Guide – Rev A Diagnostic ( digital ) Inputs ( ALL via 30 way ) There are eight digital inputs available on the emc-3, used to monitor fan health; they may be configured either as Active Low or Active High by setting the EEMemory variable “Fan DG Input Enable” as follows; 0 – DG Inputs are disabled. 1 – DG Inputs Enabled active low. 2 – DG Inputs Enabled active high.
emc-3 Controller Module User Guide – Rev A Outputs ( all via 18 way ) Output Bank Settings Each Bank has the following configuration settings; 1. Off DYCY – The duty cycle used to turn the fan off 2. Start DYCY – The duty cycle used to run the fan at minimum speed 3. Max DYCY – The duty cycle used to run the fan at maximum speed 4. Rev DYCY – The duty cycle used to run the fan in reverse. 5. Number of Fans – The Number of fans assigned to the bank 6.
emc-3 Controller Module User Guide – Rev A Indicators Status LED The Status LED will Flash Red to indicate trouble codes. Module behavior varies according to the error detected. The following table lists the trouble codes for the emc-3 and their associated behavior; 1. DG Input Active Indication Only (Load absorbed by the system) 2. Over Temp Active Indication Only (Fans at Max Already) 3. CAN Bus Error Affected Fan Bank(s) Max Speed until clear 4. Fire Input Active All Fans Hard Stop (Bank_n_Off_DYCY) 5.
emc-3 Controller Module User Guide – Rev A % Current O/P LED STATE MEANING Off (Outputs Disabled) GRN (0-33%) YEL (34-66%) RED (66-100%) Flashing RED PWM or High Side output Short circuit detected Error Status LED STATE Off Flashing YELLOW Multi Digit Blink Code RED MEANING No errors Output Short Detected Application defined blink codes listed above. Module Configuration The EMC-3 may be configured by using either the DVC PLM or from the J1939 CAN Bus using any configurable CAN application.
emc-3 Controller Module User Guide – Rev A SAE J1939 CAN Messages All J1939 CAN messages for the EMC-3 can be either enabled or disabled except the FD (fan drive) State message. The FD State is always transmitted when the system is enabled. The HCT Status message will be transmitted when it is enabled in the EE-Memory and the system is enabled. Setting the Engine Minimum RPM to a value that is greater than 0 will enable the EEC1 message.
emc-3 Controller Module User Guide – Rev A HCT Status Message – enable/disable through the EE-Memory.
emc-3 Controller Module User Guide – Rev A Data Set 1 Byte 5 Byte 6 Byte 7 Byte 8 Bank 1 output % Bank 2 Output % Bank 3 Output % Bits 1 – 4 Offset = 0 Factor = 0.4 Offset = 0 Factor = 0.4 Offset = 0 Factor = 0.
emc-3 Controller Module User Guide – Rev A Current Configuration Message Format Transmission Cycle Time: Data Length: Data Page: PDU Format: PDU Specific: Priority: Parameter Group Number: Start Position Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Length 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte Change Settings Message Format Transmission Cycle Time: Data Length: Data Page: PDU Format: PDU Specific: Priority: Parameter Group Number: Start Position Byte 1 Byte 2 Byte 3 Byte 4 Byte
emc-3 Controller Module User Guide – Rev A emc-3 Configuration Message Multiplex Data Set Table 1st Data Set Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Mux Control Coolant Start Temp Coolant Max Temp Coolant Over Temp Manifold Start Temp Manifold Max Temp Manifold Over Temp Write Enable (FF01 Only) 2nd Data Set Byte 1 Mux Control Byte 2 Trans Oil Start Temp Byte 3 Trans Oil Max Temp Byte 4 Trans Oil Over Temp Byte 5 Thermistor 1 Start Temp Byte 6 Thermistor 1 Max Temp Byte 7 Thermistor 1 Over
emc-3 Controller Module User Guide – Rev A Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Bank 2 Off DYCY Bank 2 Start DYCY Bank 2 Max DYCY Bank 2 Rev DYCY Bank 2 Number of Fans Bank 2 Fans Idle Enable Write Enable (FF01 Only) 6th Data Set Byte 1 Mux Control Byte 2 Bank 3 Off DYCY Byte 3 Bank 3 Start DYCY Byte 4 Bank 3 Max DYCY Byte 5 Bank 3 Rev DYCY Byte 6 Bank 3 Number of Fans Byte 7 Bank 3 Fans Idle Enable Byte 8 Write Enable (FF01 Only) 7th Data Set Byte 1 Mux Control Byte 2 Bank 1 Control 1 Byte 3
emc-3 Controller Module User Guide – Rev A 9th Data Set Byte 1 Mux Control Byte 2 Manual Control Enable Byte 3 Bank 1 Manual DYCY Byte 4 Bank 2 Manual DYCY Byte 5 Bank 3 Manual DYCY Byte 6 Startup Delay Seconds L Byte 7 Startup Delay Seconds H Byte 8 Write Enable (FF01 Only) 10th Data Set Byte 1 Mux Control Byte 2 Reverse Interval Minutes L Byte 3 Reverse Interval Minutes H Byte 4 Reverse Cycle Seconds Byte 5 Reverse Dwell Seconds Byte 6 Reserved Byte 7 Reserved Byte 8 Write Enable (FF01 Only) 11th Data Set
emc-3 Controller Module User Guide – Rev A Appendix A, EE-Memory Configuration Codes Fire Input Enable Settings Code Description Disabled 0 Normally High, Trouble Low 1 Normally Low, Trouble High 2 DG Input Settings Code Description 0 Disabled Normal, High - Trouble, Low 1 Normal, Low - Trouble, High 2 Bank Demand Input Assignment Codes Code Description % Fan Request, SPN 986 1 Engine Temp, SPN 110 2 Manifold Temp, SPN 105 3 Transmission Oil Temp, SPN 177 4 Thermistor 1 5 Thermistor 2 6 Thermistor 3 7 Pag
emc-3 Controller Module User Guide – Rev A Appendix B, Status LED Alarm Codes Code 1 2 3 4 5 6 7 8 9 Description DG Input Active Over Temp Active CAN Bus Error Fire Input Active Reverse Mode Active Ignition Input Error Auto dB Test Active Manual Mode Active Thermistor Input Error Controller Action Indication Only (Load absorbed by the system) Indication Only (Has Fans at Max Already) All Fans Max Speed until clear All Fans Hard Stop (Bank_n_Off_DYCY) Indication only Indication only Indication only Indica
emc-3 Controller Module User Guide – Rev A Appendix C, Settings and Limits EE-Memory Variable Coolant_Start_Temp Min 0 Max Max - 1 Description Start Temp for J1939 Coolant Temperature Coolant_Max_Temp Start + 1 150 100% Demand for J1939 Coolant Temperature Coolant_OverTemp Max + 1 Max + 30 Over Temp Trip Point for J1939 Coolant Temp Manifold_Start_Temp 0 Max - 1 Start Temp for J1939 Manifold Temperature Manifold_Max_Temp Start + 1 150 100% Demand for J1939 Manifold Temperature Manifold_
emc-3 Controller Module User Guide – Rev A Bank_2_Rev_DYCY 0 100 DYCY for Reverse Fan Operation Bank_3_Off_DYCY Bank_3_Start_DYCY Bank_3_Max_DYCY Bank_3_Rev_DYCY 0 0 Start + 1 0 Start - 1 Max - 1 100 100 DYCY to ensure fan is Off DYCY for Minimum Fan Speed DYCY for Maximum Fan Speed DYCY for Reverse Fan Operation Startup_Delay_Seconds 0 300 Minimum_Fan_Cycle_Seconds 0 300 Delay from Power on until the unit will operate fans Minimum time fans can run on each bank Bank_1_Fans_Idle_Enable 0 65
emc-3 Controller Module User Guide – Rev A Bank_3_Control_1 0 7 Assignment for control input Bank_3_Control_2 0 7 Assignment for control input Bank_3_Control_3 0 7 Assignment for control input Manual_Control_Enable 0 65535 (False = 0, 1 - 65535 = True) Turns on Manual Control Bank_1_Manual_DYCY 0 100 Bank_2_Manual_DYCY 0 100 Bank_3_Manual_DYCY 0 100 Auto_Db_Test_Enable 0 65535 Auto_Db_Test_Percent 0 100 Auto_Db_Test_Time 0 300 DYCY output during Manual Control DYCY output d
emc-3 Controller Module User Guide – Rev A Appendix D, Electrical Characteristics Absolute Maximum Ratings Absolute Maximum Ratings indicate limits beyond which damage to the device may occur.
emc-3 Controller Module User Guide – Rev A Appendix E, the Program Loader Monitor (PLM) 1) Introduction: The Program Loader Monitor (PLM) is used to download programs to the DVC family of controllers and to display information from the unit. It runs on your Windows PC / Laptop / TekBook and uses a RS232 cable (HCT P/No. 999-10075) to communicate with the emc-3 module. NOTE: To use the 999-10075, you MUST have an installed a 4 way serial port adaptor when installing the controller.
emc-3 Controller Module User Guide – Rev A Note: *.IMF files contain all of the DVC configuration information (i.e. Input or Fx Curve settings etc.). If changes are made to the DVC configuration using the Program Loader Monitor, you can update the DVC program with the new configuration data by doing the following:1) Using the Program Loader Monitor, save a new *.IMF file by clicking on "Export to File".
emc-3 Controller Module User Guide – Rev A 2) Connecting the PC to the DVC Family: The DVC controller uses the RS232 standard to communicate between itself and the PC. If a traditional ‘DB 9’ sub-miniature serial COMM port is available, please use this port or, use one of the HCT recommended USB to serial converters to ensure correct connection. Full details can be found on our website, and make sure that the converter software drivers are fully installed as recommended.
emc-3 Controller Module User Guide – Rev A 3) Starting the Program Loader Monitor: From Windows press the “Start” button and then from the menu select HCT Products\Intella 700\PLM v5xx OR Using Windows file explorer, locate the file here: C:\Program Files (x86)\HCT Products\Intella v5xx.
emc-3 Controller Module User Guide – Rev A 5) DVC Family Master Display: The Program Loader Monitor is used to observe the actual input and show specific information as your application executes. The names assigned to them in the Programming Tool appear on the main screen shown below. The runtime graph is used to plot any two variables as fast as the computer can collect data from the DVC.
emc-3 Controller Module User Guide – Rev A When you Click in the Path Window, the window shown to the right will open and allow the user to browse and navigate to the file for the project with the .pgm file extension. The browser window will filter all other file types so only valid files will be seen. Once the correct application file has been found, the user should click one to highlight the choice in the list, then click the ‘OK’ button.
emc-3 Controller Module User Guide – Rev A Frequently Asked Questions: Description: DVC controller goes into programming mode when powered on. Models Affected: All DVC based Master Controllers including the emc-3 Background: The DVC controller is in programming mode when ALL the LED’s are OFF – even the power LED will extinguish in this mode.
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