Hydraulic Generator Controllers

Our new TekBook-110 will now allow mobile users and field operatives to have access to HCT’s full featured standard graphical user interfaces ( GUI’s ) for specialty and DVC product ranges, making programming, set-up, data-logging and modifications easier, simpler and clearer than ever before.

About the HGC-2 Controller:

The highly cost effective HGC-2 is designed to control a generator driven by a hydraulic motor where speed is controlled by a proportional solenoid valve, either directly at the motor or as part of the pump compensator.

The HGC-2 is a closed loop controller that monitors the AC line voltage from the generator output for outer loop closure and provides the necessary current to a valve coil in order to maintain the desired generator frequency.  The HGC-2 has a single LED indicator on the top of the unit to provide an overview of the operating status

The unit has enough processing power and functionality when operating as a single control module to support a wide range of hydraulic generator applications. As with all of the HCT modules, the HGC-2 is packaged in a small rugged enclosure. All connectors are sealed and the module is encapsulated to withstand extreme conditions in the harsh mobile operating environment.

The HGC-2 is housed in a small, rugged housing and is fully encapsulated for maximum reliability. All I/O connections are made through a heavy duty industry standard 8-pin Deutsch connector.

PC Graphical User Interface (GUI):

HGC-2 set-up, monitoring, health checks and diagnostics can be accessed through the supplied GUI.  This program will operate on PC using a based Windows® operating system and is password protected to maintain module parameter integrity by only allowing authorized users to access different levels of the controller settings.

For ease of setting up the unit, all parameters and response are on one easy to use screen. Terminology has been used that is commonplace through the industry to allow easy configuration, set-up and running.  The GUI is intended to cater for a wide range of users with varying levels of computer familiarity.  Once configured, all the settings are stored in permanent memory within the unit, even when no power is applied.

After communications have been established, the user will be presented with the initial information screen that will give all the basic information needed to assess the health of the system. Real time graphing is available here to monitor a wide range of items (selectable from a drop down list) and for diagnostics a ‘Data Log’ button will start a Windows Excel file that can be used as diagnostics, Log a monitor for comparison to other logged charts during the system’s life or can be E-mailed to an engineering source if there is a problem for diagnosis.

HGC-2 Specifications:

 Housing Type:                  HCT unique ‘encapsulated’ block.

 Input Supply Voltage:     9 to 28VDC (Absolute Maximum)

 Input Supply Current:     Valve Current Setting + 50mA Quiescent (Max)

 Feedback Voltage:          100 to 250VRMS

 O/P Current Ranges:      600mA, 1.2A and 2.5A

 Solenoid Min Ohms:       2Ω minimum resistance

 Dither Frequency:           Software adjustable, ~50Hz to ~1KHz

 Housing Material:            ABS, black

 Encapsulation:                 Flameproof epoxy resin

 I/O Connections:              8 pin Deutsch - DTS06 - Male

 Mounting:                          2 x No. 6 (4mm) screws

 Working Temp.:               -20 to +80 ºC (operational)

 Storage Temp.:                -40 to +85 ºC

 Humidity:                           95 to 100% non condensing

 NEMA/IP Rating:               NEMA 6 / 67 (module only)

 Operating System:          Windows® XP Professional / Vista Business and Ultimate

 Unit Settings:                    All by PC user interface

HCT part number: 999-10166.

About the HGC Controller:

The HGC Hydraulic Generator Controller is used to regulate the frequency output of an AC generator.  By monitoring the output signal of a generator, the controller will drive a proportional valve’s solenoid to reach and maintain the set-point frequency.  User settings and adjustments to the regulation process are made via a computer through the Opto3000 and with the closed loop Controller software.

Application Information:

Controls generator speed to maintain 50 or 60Hz frequency

Mobile equipment power source

Can control multiple sizes of Genset up to 35KW

OEM and Retro-fit opportunities

On-road and Off-Road suitable mechanical package

Controller compliments existing system functionality

Product Feature Overview:

Pre-written Windows™ software application, ready for user values

Can operate with single or three phase generators

Separate Enable / Disable input connection

WeatherPak sealed system connectors

1 x PWM output for any make of proportional valve or pump control

Data logging features (requires connection to PC)

Direct 110VAC, 175VAC (RMS) feedback from generator output

Unit uses HCT Opto 2000 system for set-up and PC communications

Controller Specifications:

Housing Type:                      HCT unique ‘encapsulated’ block

Input Supply Voltage:         10 to 30VDC (Absolute Maximum)

Input Supply Current:         Valve Current Setting + 200mA Quiescent (Max)

Command Input Type(s):  Target frequency (50/60Hz) set in PC software

                                                Enable Input (+5 to 30VDC)

Feedback Input Value(s): 100 - 175VAC (RMS)

Feedback frequency:         50 or 60 Hz (40 - 200HZ)

Dither Frequency:               Software adjustable, ~30 to 250Hz

Housing Material:               Black, Polycarbonate

Wire Connections:             2 x AC feedback

                                                2 x Module DC power supply

                                                2 x Proportional valve output

                                                1 x Module Enable / Disable input

Connector type(s):             WeatherPak

Encapsulation:                    Flameproof epoxy resin

Mounting:                              3 x No. 8 (5mm) screws

Temperature range:          -40 to +75 ºC (operational)

NEMA/IP Rating:                  Designed to meet NEMA 6P/68 derate for connector as required

PC Graphical User Interface (GUI):

A PC running Windows XP Professional, Windows Vista Business or Ultimate with a Minimum of 16 MB ram, 32 MB or more recommended and a USB Port.  System set-up and adjustment can be made through the Opto3000 and with the Closed Loop Controller software, P/N: 023-00198.

When enabled, the unit will start a PWM ramp control starting at Start PWM%. The controller continues ramping until the Target Frequency is reached.  The controller then continues varying its output current to maintain the Target Frequency set point.

User selectable software preferences include the following 4 features: 

1. Use of the Enable In input feature. 

2. The controller will go to Loss of Signal (LOS) PWM% when the feedback signal is lost or the target frequency has not been acquired for a period greater than the LOS Timeout setting. 

3. The controller will automatically shutdown if overload shutdown is enabled and PWM% has reached 100% without the feedback signal reaching the frequency set point for a period greater than the Overload Timeout setting. 

4. The controller will automatically shutdown if the Over speed set point is reached for a period greater than the Over speed Timeout.

Data Logging

This feature is used to log real time data to an output file.  This is useful for troubleshooting, maintenance records etc.  The output file is stored as a Comma Separated Value (CSV) file and may be viewed or edited with Microsoft Excel™ or other applications that will read a CSV file.

The data log will contain the unit settings and real time “snapshots” of:

*    PWM%

*    Supply Volts

*    Generator Frequency

*    Elapsed Time during the logging operation

Passwords - There are two levels of user passwords available to customers.

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