High Country Tek, Inc. Hydraulic Fan System Controller : HFS - 2 Electro-Hydraulic Solutions for Mobile, Industrial & Marine Applications. Application, Set-up & Information Manual. Includes the HFS-2Q HFS 2Q option information. Part No.
Hydraulic Fan System Controller : HFS - 2 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.
Hydraulic Fan System Controller : HFS - 2 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.
Hydraulic Fan System Controller : HFS - 2 Product Features: EMC compliant product to EN50081-1 and EN50082-2 ( heavy industrial ) EMC compliant product to EN-12895:2000 ( Industrial Trucks ) Fail safe design gives full fan cooling even with NO electrical power. Wide supply voltage range ( 10 – 32VDC ) Set-up & unit configuration up/downloadable to any backup media via PC. Quick select, fan speed for in-field noise inspection ( 75% of Fwd Fan speed ).
Hydraulic Fan System Controller : HFS - 2 CE and EMC ( Electro Magnetic Compatibility ) Notes: The HFS-2 has been tested to comply with the current EN-50081-1 ( Emissions ) and EN-50082-2 ( Immunity ). The unit has been further tested to the new Euro-Norms of:-EN-61000-6-4:2001 ( Emissions ) & EN-61000-62:2001 ( Immunity) The controller was also voluntarily tested to EN-12895:2000 which covers industrial Truck requirements.
Hydraulic Fan System Controller : HFS - 2 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.
Hydraulic Fan System Controller : HFS - 2 • Module shown with 2 part Weidmuller connectors Electrical Specifications 1) Board Style: HCT Unique Size and Mounting.
Hydraulic Fan System Controller : HFS - 2 Thermistor Requirements: 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.
Hydraulic Fan System Controller : HFS - 2 Charge Air: There can be a special case of cooling requirements when the engine is warming up from a cold start. For this situation, the controller has a ‘Cold Engine Fan Limit’ option available to the user which if enabled, will temporarily stop the fans rotation to prevent excessive cooling.
Hydraulic Fan System Controller : HFS - 2 PI ( Proportional/Integral) Logic: The controller uses "PI" to regulate the temperatures to be no more than the Setpoints entered by the user. The P and I terms act on temperature error, with the P term used to instantaneously respond to temperature errors and should be adjusted to respond quickly to large temperature changes, but have little impact otherwise.
Hydraulic Fan System Controller : HFS - 2 Fan ‘Noise Test’ Feature: The controller allows the user to set a pre-determined value of output current to the proportional valve that will equate to the required 70% forward fan speed required for the noise inspection. Once set to the desired level, this value is saved to the controller then allows the user to quickly demonstrate the noise level of a forward driven fan by following the sequence below:1) Turn controller power supply OFF.
Hydraulic Fan System Controller : HFS - 2 Proportional Output: A variable current output is used for driving a proportional valve to control the fan speed. The value of the valve drive current is derived from a closed loop calculation relative to the temperature set-points that the user has entered in the set-up. BOTH wires from the valve coil must be connected to the controller where indicated by ‘+Prop Vlv O/P’ and ‘-Prop Vlv O/P’.
Hydraulic Fan System Controller : HFS - 2 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.
Hydraulic Fan System Controller : HFS - 2 Fan Reverse Output: This feature is designed to ‘de-clog’ the fan protection guard and cooling elements and not as a permanent running option. The output drive to the coil is rated to 3.3Amps maximum ( at controller supply voltage ) and is either ON or OFF with no proportionality or ramp functions associated. The ‘Purge’ sequence will cancel if at any time, an overtemp alarm is detected.
Hydraulic Fan System Controller : HFS - 2 Diagnostic Indicators: The unit is fitted with LED indicators to show real time diagnostic information and indicate by error codes in a visual manner the current operational status and if a fault develops with the system, where the fault may be originating from. Power ON / Opto 2000 transmitter: The red LED indicates power supply status with the LED ‘OFF’ for less than 8 volts and flashes ‘ON/OFF’ for more than 40 volts volts.
Hydraulic Fan System Controller : HFS - 2 Thermistor Status : The RED LED for the thermistor that is controlling the fan comes on steadily while the other thermistor LEDs are off, if no more than one thermistor is above setpoint. If multiple thermistors are above setpoint, the thermistor that is controlling the PI process has a blinking LED and the others above setpoint are on steady.
Hydraulic Fan System Controller : HFS - 2 Alarm Output: This low side on / off output is able to output 3.3A current maximum, and is capable of driving inductive or resistive loads and is Protected against shorted and misfired loads with shorted load detection only able to be detected when driven. The output has two modes of operation, ‘Steady ON ‘ and ‘Pulsing ON/OFF’. The ‘Steady ON’ mode is linked to NON critical errors or those that would allow the unit to keep functioning.
Hydraulic Fan System Controller : HFS - 2 Retry ALL Faults: The user setting “retry all faults” determines if the unit will retry faults that are detected with the controller or peripheral devices after 4 seconds or if NOT selected, the unit will stop operation until the power supply is turned OFF and back ON. If after a power reset, the fault is cleared, the unit will return to normal operation. If the fault persists, the controller will once again stop and repeat the procedure above.
Hydraulic Fan System Controller : HFS - 2 Software Set-Up Guide ( Menu Bar ): The ‘FILE’ tab brings the ‘SAVE’ and ‘RESTORE’ options to the user. Temporary Memory -> Permanent Memory:- transfers all data from PC to the connected module for onward unattended operation at the current profile settings ONLY. NO backup copy is made ! Temporary Memory -> Permanent Memory & File:- transfers all data from PC to the connected module for onward unattended operation at the current profile settings ONLY.
Hydraulic Fan System Controller : HFS - 2 Software Set-Up Guide ( Menu Bar ): At ‘OEM’ and ‘Factory’ password levels only, Clicking the Trouble Codes tab allows the user to observe a log of any OPEN or SHORT circuit error codes that have been triggered and stored. The currently displayed event log can be reset from both of these levels. Event times and number of occurrences are NOT recorded, rather at e tthat at tthe ee error o occu occurred ed at least east o once ce from o tthe e last ast log og reset.
Hydraulic Fan System Controller : HFS - 2 Software Set-Up Guide ( Menu Bar ): • At any password level, Clicking the Help tab allows the user to see contact information, web and e-mail addresses as well as software and hardware revisions for the actual product currently in use use. • This information should be available if contacting HCT for advice or requesting product support.
Hydraulic Fan System Controller : HFS - 2 Software Setup Guide – Dashboard level: 1 13 2 9 3 6 5 11 10 12 4 8 1 2 7 At the observer level, Dashboard, ‘Help’ and ‘Quit’ is the only options available on the menu bar bar. The window stays as above while there are no errors or alarms reported by the system and/or controller. 10 Analog needle display and digital readout of ‘real-time’ output current to proportional valve drive.
Hydraulic Fan System Controller : HFS - 2 Software Setup Guide – ( OEM & Factory Password level ): 1 2 3 6 5 9 10 4 8 7 The major differences between the OEM level and the Factory level passwords is the ability at the Factory level to ‘ RESET’ data values in the ‘Permanent Log’ that have been stored during the controllers operation. Both levels allow the user full access to all controller parameters so password confidentiality should be of a high priority.
Hydraulic Fan System Controller : HFS - 2 Software Setup Guide: 1 2 3 4 Click the ‘down arrow ‘ and select from the menu for ‘Proportional or ON/OFF’ type output current. In ON/OFF mode, no Min, Max, Test or Rev Vlv current settings are available and the output will be dependent on the supply voltage to the controller. 16 In ON/OFF mode the ramps are left active to aide the use of a ‘softshift’ valve if used.
Hydraulic Fan System Controller : HFS - 2 Thermistor Selection: 2 3 4 2a 10 11 12 13 1 The HFS software includes several pre-characterized thermistor calibration profiles. These are accessed by pressing , (for the thermistor to be calibrated),
Hydraulic Fan System Controller : HFS - 2 Opto 2000 Interface Information HCT’s Opto 2000 ( P/No. 999-10064 ) is required to interface between the fan controllers infrared communications LED port and the PC / laptop RS-232 port.
Hydraulic Fan System Controller : HFS - 2 Dimensional Information: HFS-2 A C L Label Inches Millimeters A 3.77 96.0 B 1.89 48.0 C Ø 0.186 5.0 THERM 3 D 3.82 97.0 THERM 1 E 3.10 78.8 HFS-2 F 0.46 12.0 G 3 25 3.25 82 6 82.6 H 1.6 41.5 I 0.64 16.5 J 0.26 6.
Hydraulic Fan System Controller : HFS - 2 Dimensional Information: HFS-2Q Label Inches Millimeters A 3.77 96.0 B 1.89 48.0 C Ø 0 186 0.186 5.0 D 3.82 97.0 E 3.10 78.8 THERM 1 F 0.46 12.0 HFS-2Q G 3.25 82.6 H 0 64 0.64 16 5 16.5 I 0.26 6.5 A E D THERM 2 PWR COM IN THERM 3 Reverse O/P ON Error Reverse I/P ON FAN SYSTEM CONTROLLER S/No:- A00001 MADE IN U.S.A.
Hydraulic Fan System Controller : HFS - 2 Electrical Connection Information: Alarm output shown driving a simple lamp to indicate fault / error condition has occurred. This same connection circuit can be used with a relay or solenoid ( Always use suitable’ Flyback’ or suppression diode here ) to facilitate system integration as required such that engine shutdown could be initiated if the fault continued un cleared. The maximum switching current of this output is 3.3amps at supply voltage.
Hydraulic Fan System Controller : HFS - 2 Fan ‘Reverse’ profile ( reverse acting control valve ): Fan speed Profile. 4 10 7 9 3 13 8 6 2 1 5 12 11 14 Controller Output profile to inverting type pressure control valve. Reverse output to directional valve. 1 Normal ‘Forward’ running fan speed determined by controller. 2 3 4 5 6 7 8 Manual or automatic ‘Purge’ or reverse fan trigger detected here. Fan at maximum speed for Reverse time period set in software.
On On On On On Off Six Blinks Off Off Off Off Off No Change No Change Off Thermisto or Input Over Temp PWM Outtput Shorted PWM Outtput Open Reverse O Output Shorted Reverse Output Open Power Su upply < 8 Volts Power Su upply Between 8 And 40 Volts Power Su upply > 40 Volts Running In Reverse Off Several T Thermistor Inputs Ab bove Setpoint Off Off Off Off Off Off No Change N Off Off Only One e Thermistor Input Abo ove Setpoint Fan Min, All Thermisto ors Below Setpoint Fan
Hydraulic Fan System Controller : HFS - 2 Controller Mounting: The electronic components used in this controller released by HCT, conform to the Commercial temperature range which is -40° to +75 ° Centigrade. This rating means that the components will work reliably and give a good life span if the operating temperature is kept within these ( absolute maximum ) limits. The controllers when in operation do generate and dissipate internal heat.
Hydraulic Fan System Controller : HFS - 2 FAQ’s: Set-up program does not reflect user changes made immediately:If the controller is in any mid sequence ( I.e. reverse timer was set to a long period and now a new shorter period is entered ), the controller will normally only reflect the new settings once the currently running sequence has ended. The only way to ‘reset’ this type of occurrence is to physically power the controller t ll down d and d then th back b k up.
Hydraulic Fan System Controller : HFS - 2 Temperature Sensor Information: HFS - Thermistor Compatibility Chart Coolant/Oil Sensors Description 1 Delphi Packard Temp Sensor Connector, Female GT-150 (unshrouded) Terminal, Female 16AWG SXL Cable Seal, 16AWG SXL Wire, 16AWG SXL Part number Packard #15326386 Packard #15336024 Packard #15326267 Packard #12191229 2 Borg-Warner Temp Sensor Circular Push on Connector w/ 5" pigtails or Connector Assy TF Metri-Pak 280 series TPA (part of connector assy) Terminal, Fe
Hydraulic Fan System Controller : HFS - 2 Temperature Sensor Information - Cont: S t System Set-Up S t U Hints: Hi t Setting the P term to 64 and the I term to 0, calibrates the controllers output to start giving current ( at the I Min setting % ) at the ‘set point’ temperature and to be at 100% output current ( I max setting % ) at the ‘Overtemp’ temperature.
Hydraulic Fan System Controller : HFS - 2 High Country Tek, Inc has been working with the fluid power industry for many years, solving the tough problems and producing unique and mechanically robust products that continue to work reliably in the most extreme and hostile environments that we see hydraulics being applied in today. Our controllers are ALL designed, manufactured and tested in the U.S.A. and can be sent anywhere in the world.
