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High Country Tek, Inc.

HGC-2 Initial Installation Guide

Electronic Control Solutions for the Global Fluid Power Industry

www.hctcontrols.com

Beware of HIGH VOLTAGE when operating any

generator system – high voltage can be LETHAL –

observe ALL laws, by-laws and health & Safety

recommendations for your immediate location,

state and/or country.

HGC-2 Product Features:

 Full PID closed loop speed controller for use with AC generator systems

 Customer selectable voltages and frequencies for global applications

 Operates with all major OEM electro-hydraulic valve and pump equipment

 Industry standard Deutsch 12 way connector protected to >IP69K ( NEMA 6P )

 Environmentally hardened by ’Solid’ potting with flame retardant materials

 Full CE compliance for confident global application on all mobile equipment

 Comprehensive on-line literature, manuals, user guides and application information

 Fully configurable by PC based user interface for set-up and diagnostics

 Fast, easy and reliable development-to-production timeline across multiple platforms

 U.S.A. designed, built and supplied

Summary of content (8 pages)

PAGE 1
High Country Tek, Inc. HGC-2 Initial Installation Guide Electronic Control Solutions for the Global Fluid Power Industry Beware of HIGH VOLTAGE when operating any generator system – high voltage can be LETHAL – observe ALL laws, by-laws and health & Safety recommendations for your immediate location, state and/or country.
PAGE 2
Electronic Controller Solutions for the Global Fluid Power Industry Application Hints & Tips: ALWAYS do the following:                  Take a few minutes to FULLY read THESE information / data sheets BEFORE starting. Isolate this unit from all other equipment BEFORE any form of welding takes place. Isolate this unit if ANY form of battery charging or boosting takes place on the vehicle. Isolate this unit if ANY form of alternator ‘load dump’ testing takes place.
PAGE 3
Electronic Controller Solutions for the Global Fluid Power Industry HGC-2 Connection Information: Housing Type:- HCT unique ‘encapsulated’ block. Input Supply Voltage: 9 – 28VDC ( Absolute Maximum ) Input Supply Current: Valve Current Setting + 50mA Quiescent (Max) Feedback Voltage:- 100 to 250VRMS Feedback Frequency:- 50 or 60Hz with +/-3Hz adjustment O/P Current Ranges:- 600mA, 1.2A or 2.
PAGE 4
Electronic Controller Solutions for the Global Fluid Power Industry Graphical User Interface: A Typical Initial Test Configuration: C Set to measure AC volts Throttle Setting Engine Hydraulic Pump Hydraulic Motor Valve B Set to measure current - mA Supply 4 AC Generator Fixed Electrical Load
PAGE 5
Electronic Controller Solutions for the Global Fluid Power Industry Controller Set-up: PID Tuning System Repeatability & Stability: Run Open loop using CC ( Constant Current ) mode A 1) Set fixed current value for CC mode test using GUI and entering mA level at 2) Connect meter as shown in B – measuring DC valve current in mA. 3) Connect fixed load to generator – non voltage/frequency dependent ( i.e.
PAGE 6
Electronic Controller Solutions for the Global Fluid Power Industry Controller Set-up: PID Tuning Initial explanation of operation: 1. 2. 3. 4. See red outlined box above for location of setting described above: The PID loop time sets the number of cycle periods averaged between PID samples. The adjustment range is from 1 to 30 cycles - default setting is 8 ‘Cycle Period’ is the reciprocal of the frequency x 2 ( internal multiplication for accuracy ) which is 120 for a generator O/P frequency of 60Hz 5.
PAGE 7
Electronic Controller Solutions for the Global Fluid Power Industry Controller Set-up: PID Tuning Tuning the PID loop on the HGC-2-XX: The HGC-2-XX has a true Proportional (P), Integral (I) and Derivative (D) closed loop correction system built into it for maximum accuracy speed control and load correction. The ‘P’, ‘I’ and ‘D’ values (coefficients) can be adjusted from 0 to 100% in each case . 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PAGE 8
Electronic Controller Solutions for the Global Fluid Power Industry Controller Set-up: Modes & Adjustments CC – Constant Current Mode: This mode is used to verify the system is stable under a constant command signal. The current mode would be set to any level in the control range of the valve or pump. By commanding the system with a constant signal, there should be no oscillation and the system should remain stable. If not, there may be a problem with the hydraulics or a mechanical problem.