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EATON

HFX Product Family Installation and Operation Manual E-ELCL-II002-E2 July 2019

The System Configuration I/O mapping contains the following:

A set of Global fault status variables to aid in managing faults. This consists of active and historic faults, a fault count,

as well as a means to clear the faults. There is also a Fault Monitor where specific faults can be monitored. See below:

Figure 13:

Note: the location of Global Fault Status and Fault Monitor shown above.

The following are the predefined faults:

List of Codesys Faults

VE5_max and VE5b_max – indicates the sensor_

supply_1/2 are shorted to something above 5V (i.e.

12V power).

VE5_min and VE5b_min – indicates the sensor_

supply_1/2 is shorted to ground.

VE5ab_OOR – Both sensor supplies are "out-of-

range". So if you short both high or short both low it

will occur. It is functionally (VE5_max OR VE5_min)

AND (VE5b_max OR VE5b_min).

COPfail is active – This is the system/firmware COP

(computer operating properly) fault, AKA watchdog.

This will only occur if there is a bug that causes

the firmware to lock up or not trigger the COP

approximately every 100ms.

RTI is active – This indicates that one of the internal

firmware loops is not executing (1ms/5ms/50ms).

Basically, this is similar to a COP for each of our

internal loops.

RTI2 is active – This indicates that one of the internal

firmware loops is not executing (1ms/5ms/50ms).

Basically, this is similar to a COP for each of our

internal loops.

RTI3 is active – This indicates that one of the internal

firmware loops is not executing (1ms/5ms/50ms).

Basically, this is similar to a COP for each of our

internal loops.

Adloss is active – This occurs if the ADC routine

is not running for some reason (similar to a COP

overseeing the ADC operation).

Interrupt is active – This is caused if an invalid/

unhandled interrupt is ever executed.

flash_fail is active – CPU hardware error.

RAM_fail is active – CPU hardware error.

HWID_fail is active – 2 specific resistors are present

on the PCB. Their value is used to identify the PCB

hardware version. If these are at an unknown value,

this fault will trigger.

J1939_Tx(x)Fail is active – Currently unsupported in

CODESYS.

J1939_Rx(x)Fail is active – Currently unsupported in

CODESYS.

DevDesc_error is active – This indicates there is a

mismatch between the firmware and CODESYS

device description.xml.

HFX Product Family

Summary of Contents for HFX Series

Page 1: ...Eaton HFX Product Family Installation and Operation Manual HFX Product Line ...

Page 2: ...S FOR A PARTICULAR PURPOSE OR MERCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES In no event will Eaton be responsible to the purchaser or user in contract in tort including negligence strict liabil...

Page 3: ...Indicates a potentially hazardous situation which if not avoided can result in serious injury or death CAUTION Indicates a potentially hazardous situation which if not avoided can result in minor to moderate injury or serious damage to the product The situation described in the CAUTION may if not avoided lead to serious results Important safety measures are described in CAUTION as well as WARNING ...

Page 4: ...ecision However since the potential for error exists we can provide no assurance of the absolute accuracy of its contents Warranty In order to consistently bring you the highest quality full featured products we reserve the right to change our specifications and designs at any time A limited warranty is given with these Eaton products Please see our website for details http www eaton com Eaton Pro...

Page 5: ...r HFX 16 10 4 Install The HFX Target Definitions 16 11 0 GETTING STARTED 16 11 1 Create Your First Project 16 11 2 Connect And Program Your Controller 16 12 0 FUNCTIONALITY BASIC OPERATION 17 12 1 Reset Procedure 17 12 2 Sleep Mode Time Delay Operation 17 12 3 Task Configuration 17 12 4 Watchdog Operation 18 12 5 Controller Memory 19 12 6 Calibration parameter memory 19 12 7 LED Operation 19 13 0 ...

Page 6: ... 35 19 0 PWM 35 19 1 What Is PWM 35 20 0 CAN SAE J1939 37 21 0 INPUT STATUS FEEDBACK AND DIAGNOSIS 37 21 1 Block Diagram 39 22 0 TESTING VALIDATION 43 23 0 SERVICE TOOL 44 24 0 FAULT CONDITIONS 49 25 0 APPENDIX 56 25 1 Supported Unsupported CODESYS Features 56 25 2 Supported 56 25 3 Not Supported 56 26 0 DEVICE COMMUNICATION TROUBLESHOOTING 57 27 0 DEVICE RECOVERY 57 Table of Contents ...

Page 7: ...EATON HFX Product Family Installation and Operation Manual E ELCL II002 E2 July 2019 7 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 8: ...fore using this hardware The HFX product family is optimized for reliable operation in severe environments possessing IP and temperature ratings that exceed existing solutions from competitors HFX controllers employ several advanced technologies e g I O with variable configuration architecture enabling simple management and enhancing both ease of use and functionality These controllers are intende...

Page 9: ...ddress 0 CAN Default Baud Rate 250kb s USB Specification USB 2 0 Note 3 0 devices are compatible USB Baud Rates See below USB Default Node Address N A USB Default Baud Rate 1 5 Mb s Number of Sensor Supplies 2 Sensor Supply Output Voltage 5 VDC or 10 VDC configurable Sensor Supply Maximum Current 200 mA 5VDC 100 mA 10V per supply Analog Input Resolution 12 bits 10 bits Accuracy 1 FS Measuring Rang...

Page 10: ...ack Protection Integrated Duty Cycle Resolution 01 250 Hz Output Type PWMi High Side Software configurable Max Amperage 4A Diagnostics Open Short circuit protection PWM Frequency 50 2 kHz Dither Frequency Configurable 1 500 Hz Dither Amplitude Configurable 1 100 Control Range 0 05 4 A Control Resolution 1 5 mA Fly Back Protection Integrated Duty Cycle Resolution 01 250H Connector Manufacturer Deut...

Page 11: ...ld form a basis for the simple configuration of the controller and the creation of programs specific to your application needs Proper operation of the controller is dependent on the program that is created and ultimately downloaded to the hardware therefore extensive testing is required Customers programming the controller possess the responsibility of ensuring that both the hardware and software ...

Page 12: ... supporting function PWM 8 6 4 2 PWMi 8 6 4 2 High Side output 8 6 4 2 Low Side output 8 6 4 2 H Bridge pair 4 3 2 1 HFX48m HFX32m HFX20m HFX12m Controller Model 24 I O 16 I O 10 I O 6 I O Total Inputs 24 16 10 6 Total frequency channels 8 6 4 2 Number of channels supporting function High frequency 8 6 4 2 Variable reluctance 2 2 2 2 High Side input 8 6 4 2 Low Side input 8 6 4 2 Total analog chan...

Page 13: ...n be configured to add either an internal pull up or pull down resistor The HFX20m incorporates 10 total outputs comprised of 4 x 4 A channels 6 x 2 A channels Each channel is capable of High Side output Open loop PWM Closed loop PWM with current control The 4 x 4 A channels are also capable of Low Side output and can be configured in pairs for H Bridge operation The HFX20m also incorporates 10 to...

Page 14: ... cfg defines how Pro FX Control connects to the HFX device HFX USB Driver Pro FX Control connects to the HFX using USB This is the driver to support that connection ECOM USB Driver The Pro FX Configure HFX Service Tool connects to the HFX over CAN Port 1 at 250k using the ECOM device This is the driver for that device When updating an existing HFX Support Package it is necessary to update each of ...

Page 15: ...s Start Menu shortcuts 9 0 FIRMWARE 9 1 Install the Firmware 9 1 1 Launch Pro FX Configure for HFX SFX select the appropriate adapter and click Next 9 1 2 Once the Pro FX Configure UI is displayed select the Application Firmware Update tab From this tab you can browse for a firmware file and click Update During an update the rest of Pro FX Configure will not be usable Once the update is complete t...

Page 16: ...troller you will be using for your project Click OK 11 2 Connect and Program your Controller 11 2 1 Connect the HFX controller to the USB port of your computer via the 6 pin Deutsch connector 11 2 2 Ensure that the unit is powered up properly by verifying that LED A is green 11 2 3 In the Pro FX Control Devices tree view double click on the Device 11 2 4 Click on the Communication Settings tab 11 ...

Page 17: ...vides a mechanism to remove a frozen application 1 Load a new application or 2 Reset origin will clear entire application memory Boot Process Continue Booting Load IEC from flash Yes No No PWM 1 2 11 VDC IEC or HFX service tool is detected within delay period Yes Abort and don t load IEC app from flash 12 2 Sleep Mode Time Delay Operation Sleep Mode provides a mechanism to have a controlled shutdo...

Page 18: ...serviceable and is not visible to the user It will trigger in the event of a task timeout and can only be reset through a hard reset of the controller which means that the user must connect the service tool or IEC programming tool to the controller tie PWM 1 2 to supply voltage and then power up the unit This will prevent the IEC application code from loading Each controller also features a second...

Page 19: ...st Green power LED Off Not powered up Solid on Powered up and Pro FX Control application not running Fast flash 100ms on 100ms off Pro FX Control application running LED B middle Red MIL Malfunction Indicator Lamp Pro FX Control application running Flashing 200ms on 200ms off critical fault is active Solid on standard fault is active Off no fault Pro FX Control application not running Fast Flashin...

Page 20: ...sure manufacturer for appropriate guidelines concerning the necessary enclosure volume to adequately limit thermal rise below the maximum operating temperature of 105 C 13 3 Recommended Wiring Practices This section contains information about the controller connectors and pin outs Please use the following recommended wiring practices when installing and using the controller Ensure correct and adeq...

Page 21: ...supply voltage return point On a HFX32m or HFX48m all HFX Load PWR pins 9A 10A 19A 1B 2B and 3B must be connected to the same supply voltage source On a HFX32m or HFX48m all HFX LOAD_PWR pins 18A 28A 29A 12B 13B and 22B must be connected to the same supply voltage return point Failure to connect all the pins to their respective sources or returns or to use them to power or ground other devices may...

Page 22: ...PWR Note All 4 of the HFX units share a common pin out The HFX12 does not utilize the following pins 8 15 17 25 27 31 32 and 40 1 21 11 31 2 22 12 32 3 23 13 33 4 24 14 34 5 25 15 35 6 26 16 36 7 27 17 37 8 28 18 38 9 29 19 39 10 30 20 40 KEY B Similiar to DRC23 40PB Mating Connector DRC26 40SB J1B E2486100 FREQ5 FREQ6 FREQ7 FREQ8 INPUT_7 INPUT_8 INPUT_9 INPUT_10 INPUT_11 INPUT_12 INPUT_13 INPUT_1...

Page 23: ...d Operation Manual E ELCL II002 E2 July 2019 23 HFX Product Family 7 7 1 7 1 7 1 7 6 5 4 1 2 3 J1P E2486101 DT04 6P USB_D CAN1 USB_D CAN1 USB_ 5V The above connector is used for programming and is common to all 4 models of the HFX controller ...

Page 24: ...or Voltage Ignition Pin Voltage Sleep Pin Voltage User LED State USB Connected etc The other folders consist of System Information e g Firmware Rev Serial Number Hour Meter etc Internal Relay status Global Fault Status for both active and historic faults and a Fault Monitor for managing faults see below image The above variables can be monitored in the application program to alter controller respo...

Page 25: ...gurations are possible through selection of the appropriate mode in the PLC configuration tab in the IDE see screens below 15 3 Analog Configuration Figure 1 Analog Digital Inputs I O Mapping tab This is the area where analog or digit input values are mapped to addresses These variables are all accessible in the application program Variables AnalogInValue Analog value with units dependent upon con...

Page 26: ... This is used in manual mode to activate the Current shunt resistor Filter time constant This is a Digital low pass filter time constant that the input passes through this is useful if you wish to filter out some random variation on the input or if you wish to reduce how quickly the input changes value DIN debounce This is a time value used to debounce mechanical switches that would otherwise trig...

Page 27: ...orced off The status of the Pull up Pull down and Shunt are displayed for convenience In Manual Config the programmer has complete control to alter these values Each of the analog modes offers a user adjustable filter The purpose of this is to smooth an input signal and or limit how quickly it is changing The filter is a digital approximation of a first order series RC network low pass filter The ...

Page 28: ...EATON HFX Product Family Installation and Operation Manual E ELCL II002 E2 July 2019 28 HFX Product Family Note Thermistor 1 2 modes display value based on two user configurable lookup tables see below ...

Page 29: ...066 0 20309 7 52336 0 11 0 98 6 993 2 10006 0 20188 3 51969 0 12 0 102 5 999 1 10054 5 20289 4 52220 0 13 5 8 108 5 1005 0 10054 5 20289 4 52283 0 14 5 4 105 8 1005 0 10066 0 20309 7 52283 0 15 6 8 108 5 1005 0 10077 6 20330 0 52400 0 16 6 4 108 5 1005 0 10077 8 20331 0 52408 0 16 2 Frequency Configuration Figure 3 Frequency Digital Input I O Mapping Tab The tab displays the following Selected Inp...

Page 30: ...his selects channel pair used for phase comparison 1 is 1st pair 2nd is 2nd pair etc When configured in Encoder Mode Filter time constant This is a low pass filter time constant that is used on the following values frequency duty cycle and voltage measurements Over voltage limit This is the upper limit used for the over voltage fault Lower voltage limit This is the lower voltage limit used for the...

Page 31: ...tial frequency inputs duty cycle calculation is not supported on these two channels Additionally note that the accuracy of phase measurement is more limited than with the other 6 channels Also when measuring frequency phase pulse width or count the measurement limit is the shortest detectable pulse i e 20 μS When using inputs configured as Frequency voltage indication is not supported Also note th...

Page 32: ...red output current for the channel Note That this is only active in Current Control mode measuredCurrent _ A This is the average current measured over a single dither period desiredDuty _ A This is the desired PWM duty cycle Note That this is only active in PWM mode actualDuty _ A This is the PWM duty cycle commanded by the hardware binaryOutput _ A This is the commanded output state of the high o...

Page 33: ... PWM Frequency Dither Amplitude This is the amount of peak to peak variation in of PWM duty cycle used for dithering Drive Mode This selects between closed loop current control mode or open loop PWM duty cycle mode High or Low Side Selects between a high or low side driver for the channel note that this only applies to 4 A channels Enable Channel Faults Select to enable automatic system fault proc...

Page 34: ...e configured with the same frequency All remaining synchronization is handled automatically in the firmware including a 50µs dead time Each leg of an H Bridge is individually given a command between 100 and 100 A positive command closes the Low Side driver and switches the High Side PWM corresponding to the command value The inverse occurs for a negative command A command of 0 switches off both si...

Page 35: ...nd saturation and is behaving like a variable resistor constantly having to dissipate the power not used by the load as heat PWM uses the output device digitally and therefore the device is either on or off Using this technique the output device supplies a series of pulses of the same voltage level to the load Since transistors are very efficient when either on or off much less heat is dissipated ...

Page 36: ...e upper waveform is current through a typical inductance 19 1 3 2PWM with Dither Single cycle of 2 kHz PWM with 100 Hz 40 dither Note PWM voltage duty cycle is changing value 20 from commanded value at a rate of 100 Hz 19 1 3 3PWM with Dither PWM with dither illustrating duty cycle 62 42 20 19 1 3 4PWM with Dither PWM with dither illustrating duty cycle 22 42 20 HFX Product Family ...

Page 37: ...g The I O mapping tab represents all the variables available in the device These can be used in code for either inputs or outputs depending on whether it is a transmitted or received packet You can automatically convert and scale variables by clicking on the SPN in the Tx Signals page and then enabling the Conversion option This lets you deal in engineering units i e rpm mph etc as opposed to the ...

Page 38: ... 38 Figure 7 Fault Table I O Mapping This is convenient location where all active and historic faults can be viewed Additionally user defined faults from the IEC application can be set here for monitoring There are numerous faults and further details in the appendix HFX Product Family ...

Page 39: ...A Current Feedback Digital High Side PWM Digital Outputs 4A Current Feedback Digital High Low Side Sensor Power Supply 1 Note Only FREQ1 FREQ2 support variable reluctance type sensors inputs SENS_PWR 30A SENS_PWR 20A 22A CAN1_H 12A CAN1_L 4P CAN1_H 5P CAN1_L 13A CAN2_H 23A CAN2_L 14A CAN3_H 24A CAN3_L 1P USB_GND 2P USB_D 3P USB_D 6P USB_ 5V 21A INPUT_1 11A INPUT_2 33A INPUT_3 34A INPUT_4 36A FREQ1...

Page 40: ...ts 4A Current Feedback Digital High Low Side Sensor Power Supply 1 Note Only FREQ1 FREQ2 support variable reluctance type sensors inputs SENS_PWR 30A SENS_PWR 20A 22A CAN1_H 12A CAN1_L 4P CAN1_H 5P CAN1_L 13A CAN2_H 23A CAN2_L 14A CAN3_H 24A CAN3_L 1P USB_GND 2P USB_D 3P USB_D 6P USB_ 5V 26A Sleep 16A IGN 6A VBATT PWM1_4A 1A PWM2_4A 35A PWM3_4A 31A PWM4_4A 8A 10A Load_PWR 19A Load_PWR 9A Load_PWR ...

Page 41: ... CAN1_H 12A CAN1_L 4P CAN1_H 5P CAN1_L 13A CAN2_H 23A CAN2_L 14A CAN3_H 24A CAN3_L 1P USB_GND 2P USB_D 3P USB_D 6P USB_ 5V 26A Sleep 16A IGN 6A VBATT PWM1_4A 1A PWM2_4A 35A PWM3_4A 31A PWM4_4A 8A PWM5_4A 38B PWM6_4A 32B VBATT 7A 9A Load_PWR 10A Load_PWR 19A Load_PWR 1B Load_PWR 2B Load_PWR 3B Load_PWR Load_PWR 18A Load_PWR 28A Load_PWR 29A Load_PWR 12B Load_PWR 13B Load_PWR 22B SENS_PWR1 30A SENS_...

Page 42: ...SB_D 3P USB_D 6P USB_ 5V 26A Sleep 16A IGN 6A VBATT PWM1_4A 1A PWM2_4A 35A PWM3_4A 31A PWM4_4A 8A PWM5_4A 38B PWM6_4A 32B PWM7_4A 6B PWM8_4A 4B VBATT 7A 9A Load_PWR 10A Load_PWR 19A Load_PWR 1B Load_PWR 2B Load_PWR 3B Load_PWR Load_PWR 18A Load_PWR 28A Load_PWR 29A Load_PWR 12B Load_PWR 13B Load_PWR 22B SENS_PWR1 30A SENS_PWR1 21B SENS_PWR1 20A SENS_PWR1 11B SENS_PWR2 15B SENS_PWR2 16B SENS_PWR2 2...

Page 43: ...mited to 85 C Initial Conditioning 40 C for 24 hours 105 C for 24 hours High Temperature endurance 125 C for 200 hours unpowered After test unit must be functional Voltage Range 6 V 32 V Ignition Cycling 10 000 cycles of I minute max supply voltage alternating with 1 minute no voltage at power supply connection Thermal Shock J1455 Section 4 1 3 2 2 hour 40 C two hour soak 5 four hour cycles two ho...

Page 44: ...ere are five pages that display and or allow configuration of various I O types Figure 8 Service Tool Main Page This page allows the user to check the status of the MIL supply voltage ignition pin voltage solid state relay hours of use and application It also provides the total output current and several additional details about the software and hardware setup Additionally the output voltage on th...

Page 45: ...2019 45 Figure 9 Service Tool Analog Input Page This page enables the user to view input values associated with the analog channels and configure each channel for a specific type of input It also offers the ability to individually select filters for each channel HFX Product Family ...

Page 46: ...ation Manual E ELCL II002 E2 July 2019 46 Figure 10 Service Tool Frequency Input Page This page enables the user to view input values associated with the frequency channels and configure each channel for a specific type of input HFX Product Family ...

Page 47: ...page enables the user to view controller temperature individual channel feedback current voltage dither duty cycle frequency and current control gain specific to each output channel Each channel can also be configured as current control or PWM Additionally the 4 A channels can be configured as Low Side outputs HFX Product Family ...

Page 48: ...roduct Family Installation and Operation Manual E ELCL II002 E2 July 2019 48 Figure 12 The Service Tool Fault Page The faults page displays warnings system status and any faults that are active HFX Product Family ...

Page 49: ...f the faults are mapped to addresses that are directly accessible in the application control program There is also a reserved area for user defined IEC faults in this section This is very flexible as all faults can be easily scanned through in one area of the environment Both the predefined System Faults and the User Faults feature active and historic fault indication Please see below Fault table ...

Page 50: ...cle is commanded above DUTY_LS 50 and Voltage on output Input Load Power VLOAD_RATIO 90 then trigger the Short to Power fault OPEN_DUTY and OPEN_CURRENT If the duty cycle is commanded above OPEN_DUTY 10 and the measured current is less than OPEN_CURRENT 50mA trigger the PWM output Open is Active fault GND_SHRT_DUTY and GND_SHRT_VRATIO In Low Side output configuration if duty cycle is commanded bel...

Page 51: ... trigger the COP approximately every 100ms RTI is active This indicates that one of the internal firmware loops is not executing 1ms 5ms 50ms Basically this is similar to a COP for each of our internal loops RTI2 is active This indicates that one of the internal firmware loops is not executing 1ms 5ms 50ms Basically this is similar to a COP for each of our internal loops RTI3 is active This indica...

Page 52: ...YS This is used for all of their code There is information about this on the EDIS Debug Sys page CODESYS out of dn mem is active similar to low memory fault above but this is when the operating system is out of dynamic memory CODESYS bad pointer is active CODESYS internal code calls a function that checks if memory is good CODESYS target mismatch The CODESYS target description does not match the f...

Page 53: ... circuit on output channel 1 2A The controller is comparing the commanded current value to the measured value or checking for a ground short on the output The default values can be overwritten in the configuration of the unit List of PWM Faults for PWM1_4A to PWM8_4A Fault Description PWM _4A Loss of Control This fault indicates that current or reverse current exceeding a default 75 mA is flowing ...

Page 54: ... signal on the analog input X is too high AINX value under range The value of the signal on the analog input X is too low Frequency Fault List For FREQ1 to FREQ8 Fault Description FREQX Input over voltage The max voltage for input X in frequency mode has been exceeded 34 Volts FREQX max frequency limit exceeded The max frequency for input X in frequency mode has been exceeded 50 kHz Max Total inpu...

Page 55: ...EATON HFX Product Family Installation and Operation Manual E ELCL II002 E2 July 2019 55 HFX Product Family ...

Page 56: ...te boot application downloaded with service tool 12 Debug visualization debugging in IDE 13 Task monitor no jitter measurements though 14 Retain cycle by cycle 4K 15 Task timing cyclic freewheeling event 16 Dynamic IO configuration 17 Fault monitoring and acknowledgement 18 Debug Display mode 19 Simulation 20 IEC Task watchdog 21 IEC 61131 3 Programming languages 22 Microsecond time resolution 23 ...

Page 57: ...FX Control 7 Restart your PC 8 In some cases Windows will automatically assign a high COM port number to the USB device If the device manager shows something higher than COM20 then you should reassign it to something lower Then restart the gateway and unplug and plug the USB port 9 Each time a unique mobile controller is connected to your PC Windows will provide 2 new COM port numbers In some case...

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