manual

I've decided to abandon the pdf manual, because it's too tedious to maintain. Please print this web page as pdf, if you need it.

You can use the link in the footer "print page", and then select the printer "print to pdf".

For some browsers, there are "export to pdf" addons available. On mobile devices, there are "web to pdf" apps available. Or use the "read offline" function.

The current pdf manual is still available at https://www.sites.google.com/site/hydrocontrol1/downloads

Protection features

One thought in advance: ANY DEVICE CAN FAIL.

In other words: do not rely on one device only for safety-critical functions. See also this forum post on worst-case scenario and fail-safe design

If the microcontroller itself (not the 5V power supply) fails, all dumploads might go off, depending on how the MCU fails.

In an earlier version of the hydrocontrol, I had an external circuit which would monitor the health of the MCU, and switch all dump loads on in case of MCU failure. This circuit is not a bad thing, but it does rely on a functioning 5V power supply. Now the hydrocontrol has the option of a second 5V power supply with automatic switchover. But what if overvoltage destroys both 5V power supplies?

From a safe design point of view, it would be better to have a completely separate safety device. E.g. a frequency relay or an overvoltage protection relay, which can either switch on all DLs at once. (to do - wiring scheme for parallel switing of DLs) and/or disconnect the generator from all parts of the system, which would not survive maximum voltage.

My recommendation:

If you already have an ELC, the hydrocontrol could be your backup safety device.

If you have only a hydrocontrol, you would need another backup safety device.

During regular maintenance, the function of the backup safety device needs to be tested.

SD card

if you have an SD card inserted, you also have to enable it in the settings. If you don't enable it, then the SD card will not be properly initialized, and will occassionally crash the display. The SD sits on the same SPI bus as the LCD dipslay, and if not properly initialized, it will disturb the SPI communication.

Processor load

normal load is 94% or 8000 loops per second.

Temperature settings

recommended:

air in 40 deg C

ari out 50 deg C

heat sink SSR 60 deg C

heat sink triac: 55 deg C

triac direct: 60 deg C

casing inside: 45 deg C