LIMITED W ARRANTY ST ATEMENT INST ALL ATION INSTRUCTIONS · INST ALL ATION INSTRUCTIONS SP AL USA ¥ 1731 SE Oralabor Road ¥ Ankeny , IA 50021 Email: [email protected] ¥ W eb: www

FAN-PWMINSTALLATION INSTRUCTIONS

SPAL USA • 1731 SE Oralabor Road • Ankeny, IA 50021 Email: [email protected] • Web: www.spalusa.comMain/Sales: 800-345-0327 • Technical: 800-454-7725www.spalusa.com

SPAL USA LIMITED WARRANTY STATEMENT

SPAL USA warrants this product to be free from defects in material and workmanship for a period of eighteen (18) months from the date of sale to the original purchaser. SPAL USA will repair thisproduct free of charge if, in the judgment of SPAL USA, it has been proven defective within the warranty period. The product should be returned, at the customer expense, to the location of original purchase. This warranty does not cover any expenses incurred in the removal and/or reinstallation of the product.

This warranty does not apply to any product damaged by improper installation, misuse, abuse,improper line voltage, fire, flood, lightning, or other acts of God, or a product altered or repaired by anyone other than SPAL USA.

This warranty is in lieu of other warranties, expressed or implied, including any implied warranty of merchantability. No person is authorized to assume for SPAL USA any other liability concerningthe sale of this product.

IMPORTANT-KEEP YOUR INVOICE WITH THIS WARRANTY STATEMENT!

16 03/06

Parts Included In Kit

Optional Items

PWM (1)

OEM Temperature Sensor Harness (1)

SPAL Temperature Sensor Harness (1)

Secondary Fan - AC Harness (1)

PowerHarness (1)

Instructions

Zip Ties (12)

FRH FAN-PWM-TS

2 19

Troubleshooting

The PWM controller will provide a direct connection for a single fan. If you should needto connect an additional fan an external relay is required (SPAL part # FRH). The graywire from the PWM connects to the relay coil and outputs a low power ground to activatethe 2nd fan when HIGH speed is reached.

Many older european cars have a voltage stabilizer. It drops the power for the gaugecluster to a regulated constant 10-12V depending on model. If this part has failed it willcause the voltage to fluctuate rapidly. Quickly test for this by probing the sensor wirewith your multi meter (digital preferred) and while the engine is running observe the volt-age. As the engine heats up you should see a constant voltage that slowly decrease. Ifthe voltage stabilizer is bad the voltage will rapidly swing up and down. Removal orreplacement of this piece will be required to use the PWM with this sensor.

The white wire from the PWM may be connected to nearly any sensing circuit operatingat 12 volts or less. The unit recognizes both NTC and PTC type curves

ProblemProblem

Possible Solution

I have a dual fan setup how do I connect it..

Problem

I have connected the PWM to my older cars original temp gauge and programmed it successfully, but the unit operates very erratically.

Possible Solution

Problem

Possible Solution

I want to use my PWM to control the speed of a fan through a sensor other than the water temperature sensor. Example 0-5V computer controlled output.

Hardware Baggy

How To Measure Fan

Suggested Fuse ValuesAIRFLOW (CFM)

147124.6

312312

295

330330

440440

740740590590

10701070650650

278013901390970970810810

3170136013601630163012301230870870

1710171012501250920920

172017201720172012801280960960

3000236023602070192024701610161013001300

ITEM#

3010301830103009

3010301130103013

30100291

3010040230100403

3010035830100393

30102061301020533010039230100381

30102057301020583010036030100374

30102052301020543010204030101500301015023010036430100365

301020303010202930102030301020383010202530101504301015053010037530100384

301020443010204530101507301015083010039830100399

3010204130102055301020423010205630101509301015103010038530100382

3010211330102036301020473010204930102048301020823010151630101517301004003010040130130074

C

4.294.29

5.515.51

5.91

7.037.03

7.957.95

9.379.379.729.72

10.610.6

10.5910.59

23.4611.9311.9311.5711.5711.5711.57

25.8312.6412.6413.0313.0312.6412.6412.6412.64

13.6213.6213.6213.6213.6213.62

14.4514.4514.4514.4514.4814.4814.4814.48

15.7515.7515.7515.7515.7515.7115.7515.7515.7515.75

DESCRIPTION

4'' Fan-Pull4'' Fan-Push

5.2'' Fan-Pull5.2'' Fan-Push

5.6”Fan-Pull

6.5”Fan-Pull6.5”Fan-Push

7.5”Fan-Pull7.5”Fan-Push

9”High Performance Fan-Pull9”High Performance Fan-Push

9”Fan-Pull9”Fan-Push

10”High Performance Fan-Pull10”High Performance Fan-Push


11”Dual High Performance Fan-Pull11”High Performance Fan-Pull

11”High Performance Fan-Push11”Medium Profile Fan-Pull

11”Medium Profile Fan-Push11”Fan-Pull

11”Fan-Push

12'' High Performance Dual Fan-Curved Paddle 12”High Performance Fan-Pull Curved Blade

12”High Performance Fan-Push Curved Blade12”High Performance Fan-Pull

12”High Performance Fan-Push12”Medium Profile Fan-Pull


12”Fan-Push

13”High Performance Fan-Pull Curved Blade13”High Performance Fan-Push Curved Blade

13”Medium Profile Fan-Pull13”Medium Profile Fan-Push


14”High Performance Fan-Pull Straight Blade14”High Performance Fan-Push Straight Blade14”High Performance Fan-Pull Curved Blade

14”High Performance Fan-Push Curved Blade14”Medium Profile Fan-Pull


14”Fan-Push

16”Extreme Performance Pull Fan16”High Performance Fan-Pull Straight Blade

16”High Performance Fan-Push Straight Blade16”High Performance Fan-Pull Curved Blade

16”High Performance Fan-Push Curved Blade16'' High Performance Fan-Pull Curved Paddle

16”Medium Profile Fan-Pull16”Medium Profile Fan-Push


16'' Fan Shroud Gasket

A

4.294.29

5.515.51

5.91

7.247.24

8.278.27

9.729.729.729.72

10.910.911.211.2

16.2612.3612.3612.212.212.212.2

17.3213.2313.2313.0313.0313.2313.2313.2313.23

14.1714.1714.1714.1714.1714.17

15.0415.0415.0415.0415.0415.0415.0415.04

16.316.316.316.316.3

15.7116.316.316.316.3

B

2.382.38

2.362.36

3.86

2.052.05

2.052.05

3.73.7

2.052.05

3.73.7

2.052.05

4.253.73.7

2.482.482.052.05

4.023.393.393.73.7

2.482.482.052.05

3.393.392.482.482.052.05

3.393.393.393.392.482.482.052.05

3.653.393.393.393.393.742.482.482.052.05

RECOMMENDED FUSE VALUE AT 13 VOLTS

44

55

5

1515

1515

25251515

20201010

30 / Per Motor303015151010

30 / Per Motor3030303020201010

303020201010

3030303020201010

30303030303020201010

4”

5.2”

5.6”

6.5”

7.5”

9”

10”

11”

12”

13”

14”

16”

18 3

Troubleshooting

The yellow, red, and green LEDs are flashing and my fan does not operate

With FAN-PWM-TS Sensor

1. Your LOW and HIGH settings are too close in temperature, either move your LOW lower or your HIGH higher. A MINIMUM of 20-25 degrees AT THE SENSOR between the two points is required

2. Possible bad wire connection during last point programmed. Double check all connections and repeat the last programming sequence

Using Factory Coolant Temp Sensor (OEM) Or Electric Water Temp Gauge

1. Sensors profile not compatible with current LOW / HIGH set values. Depending upon application a minimum spread of 20-25 degrees may not be sufficient. This is more prevalent with older factory water temperature gauges.

2. White wire not connected to proper wire on the vehicle. Typically on a 2 wire coolant temp sensor 1 of the wires will be a chassis ground while the other will vary in voltage with temperature. The white wire must be connected to the wire on which the voltage varies.

3. Connection was made to a temperature SWITCH not a sensor. The PWM will not function connected to a switch (such as our 195-TS) that is used to turn on a relay or warning light. The sensor type must be a for a gauge, or a coolant temp sensor for a fuel injection computer.

4. Wiring from the sensor to the gauge or computer is faulty. The white wire is a passive input, it must be connected in parallel with the original circuitry designed for that specific sensor.

Problem

Possible Solutions

The current LOW and HIGH settings are too close to calculate the fan speed correctly fromthe sensor input. Until the program is changed the unit will remain in a standby statewith the fan off.

The SPAL Electric Fan Controller (FAN-PWM) will vary the speed of the primary fan based onengine temperature by using Pulse Width Modulation technology. A second fan can be addedbut requires the use of an additional fan wiring kit to control the secondary fan (SPAL partnumber FRH). The secondary fan will not be PWM controlled; it will be ON/OFF only.

The concept behind the FAN-PWM was simple; make a modern electric fan replicate anengine driven-clutch style fan. The old clutch style fans were spinning all the time, but theyweren’t fully engaged until a specified temperature was reached. This removed the strainon the engine, while allowing adequate cooling when required.By allowing the fan speed to change based on engine temperature, you allow the coolingsystem to determine how much airflow is required to keep the engine within normal operat-ing temperatures. In most applications this means the cooling system can be kept at a sta-ble operating temperature with the fan running at only 80% of full capacity. If the enginetemperature increases, most likely due to towing or low speed cruising, the fan will increasein speed to maintain a normal operating temperature.

Because the FAN-PWM was designed to alter the speed of the fan, SPAL USA suggests set-ting the High above the thermostat rating, and setting the low at least 20 degrees below theHigh. (SPAL USA suggests setting the high 10° to 15° above your thermostat rating). Thisallows a broad range for the fan to vary in speed, while providing some insurance shouldthe cooling system temperature rise above the thermostat rating.

By programming your controller in this way, you not only have the advantage of automatedfan control, but the fan will also be turned off, or spinning very slowly, when the vehicle istraveling at speed on the highway. Though the fan may be running at 50%, this does notoverly restrict the air moving through the radiator core.

When the Low setting is reached the yellow LED will light and the fan will run at 100% for1/2 second to get the fan rotating. After the initial kick-start, the fan will run at 50%, or 1/2speed. The fan will increase in speed as the engine temperature increases.

When the High setting is reached the red LED will light and the fan will run at 100%, or fullspeed. When the red LED lights, a negative output will also be sent on the grey wire. This isused to trigger the secondary fan relay, turning on the secondary fan full speed.If the cooling system is able to lower the coolant temperature approximately 10° below theHigh setting, the red LED will turn off, the yellow LED will light, and the fan will slow inspeed.If the cooling system is able to lower the coolant temperature approximately 10° below theLow setting, the yellow LED will turn off, and the fan will stop.

The SPAL Electric Fan Controller is waterproof and can be mounted inside the vehicle or theengine compartment.

Mount the Fan Controller away from high heat sources such as engine exhaust. A wheelwell, the radiator support, or the firewall are good mounting locations.

Operation

Introduction / Overview

Mounting

4 17

Fan Override Options (For Use With Electric Water Pump)

Trinary Switch

AIR CONDITIONING COMPRESSOR

Blue from FAN-PWM

A/CThermostat

Existing wire(s) fromevaporator wiring harness

YTB A T E R

Ground

+12VDCFUSE

5A

Automated Cooling System

Trinary Diagram

This will allow your cooling fan and electric water pump to run until the engine has cooledpast the High setting. Once the coolant temperature goes below the High setting, the fanand electric water pump will turn OFF.

CCBB

AABB

AA

YTBA TER

GROUND (BLACK)

30 AMP FUSE MAXIMUM

+12 VDC (RED)

SWITCHED IGNITION INPUT (ORANGE)POWER HARNESS

CCAA

BBAA

BB

CCBB

AA SENSOR OF YOUR CHOICETEMP SENSORHARNESS

SECONDARY FAN-A/C HARNESS

8787

87a87a8686 8585

3030

8787

87a87a8686 8585

3030

SECONDARY FAN RELAY OUTPUT (GREY)

SWITCHED IGNITION INPUT (ORANGE)

GROUND

+12 VDC

DIODE

TO WATER PUMP +12VDC

Introduction / Overview

Please see Single Fan wiring instructions on pages 8-11.

A dual fan set-up requires a Fan Relay Harness (SPAL part number FRH) to power thesecondary fan.Please see Dual Fan wiring instructions on pages 12-15.

The SPAL Fan Controller can be connected to the factory (OEM) temperature sensor or anaftermarket electric gauge sensor. This eliminates the need for an additional sensor. (TheFAN-PWM is designed to use the OEM factory type sensor on fuel-injected vehicles andmost OEM gauge sensors. Some older style sensors will not work. If you experience prob-lems, please call our technical support line for assistance.)-If using the factory OEM style sensor, the SPAL Fan Controller must be re-programmed.-Please see the programming section on pages 6 and 7.

If your vehicle is not equipped with an OEM temperature sensor, you can purchase a SPALtemperature sensor that plugs directly into the Fan Controller.This sensor should be located in the engine head or intake manifold for optimal perfomance.

-When using the SPAL temperature sensor, the Fan Controller is preset from the factory with a Low setting of 160°, and a High setting of 200°.

-If different settings are required, please see the programming section on pages 6 and 7.

Depending on your specific system, you may have extra wires that are not being used.These wires can be coiled and contained in a non-conspicuous location. Or for a cleanerinstallation the unused wires may be removed from the Weather Pak connectors.

If you are using Air Conditioning you have two options for controlling the cooling fans:

1-If your A/C system has a trinary switch you may use it to trigger your cooling fans. Pleasesee the A/C Trinary Wiring Section on page 17.This is the preferred way to control your cooling fans as fan operation is based on the pres-sure of the coolant in the A/C system. Though the A/C pump may not be running, the pres-sure of the A/C system may require operation of the cooling fans to properly cool the A/Ccondenser.

2-If your A/C system does not have a trinary switch, connect the Blue wire directly to the12V wire of the air conditioning compressor. (Any time the compressor turns on, the fan(s)will run at 100% and the green LED will light.)

The fusing of the FAN-PWM is dependent upon the size and style of fan used. Please refer-ence the suggested fuse values table on Page 3.

Single Fan

Dual Fan

Factory (OEM) Temperature Sensor

SPAL Temperature Sensor (FAN-PWM-TS)

Suggested Fuse Values

16 5

Fan Override Options (For Use With Electric Water Pump)

Manual Fan Override Switch

If you would like to have your fan run after you have turned off the ignition you may use anoverride switch connected to the blue A/C input wire. Any time this wire is supplied +12VDCthe fan will run at full speed.

**If you choose this option, you will not be able to trigger the fan via the cars A/C circuit. **

SPAL USA recommends the fan override switch feature be used only on vehicles equipped withan electric water pump. The pump should be running any time the fan is running.

This will allow your cooling fan to run any time the override switch is ON.**SPAL USA suggests this override switch also control the electric water pump relay. This willallow a single override switch to control both the fan and electric water pump.**

Note: -The fan will continue to run indefanitely if the switch is not shut off.

-When running for extended periods of time the voltage should be monitored as to notoverly discharge the vehicle’s battery.

C CB B

A AB B

A A AIR CONDITIONING INPUT (BLUE)

YTB A T E R

GROUND (BLACK)

30 AMP FUSE MAXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

CCAA

BBAA

BB

CCBB

AA SENSOR OF YOUR CHOICETEMP SENSOR HARNESS


FAN OVERRIDE SWITCH

+12 VDC

Air Conditioning Input

If you do not have an electric water pump, allowing the fan to run after the ignition hasbeen turned off is NOT recommended. The purpose of the cooling system is to removeheat from the cylinder walls. Though the coolant in the radiator is being cooled, thecoolant in the block is not being cooled; therefore the water temp sensor will not cool asquickly as if the coolant were circulating. This will place a large burden on your electricalsystem as the fan may run for longer than 30 minutes.

6 15

LED’s:

Red: Indicates high temperature setting has been reached.•Fan(s) run at full speed.

Yellow: Indicates low temperature setting has been reached.•Fan starts at half-speed and increases until high temperature setting is reached.

Green: Indicates the Air Conditioning has been powered ON.•Fan(s) run at full speed.

Programming

Programming Section

The fan must remain unplugged during programming. If the fan is allowed to run, the cooling system may not get hot enough to program an acceptable High setting.

• Unplug fan.• Start vehicle.• Allow engine to warm-up to desired “low” temperature.• Once temperature has been reached, press and hold the “Low” button for 3

seconds to set the “low temperature.”• Yellow LED will blink.• When desired “high temperature” setting is reached, press and hold the “High”

button for 3 seconds.• Red LED will blink.• Programming is complete. Turn off ignition.• Allow vehicle to cool.• Plug in your fan.• Start vehicle and confirm the fan turns on at the correct temperatures.

**If all 3 LED’s blink, the low and high are too clse. Reprogram with a minimum of 20°between low and high.

LOW HIGH RED GREEN YELLOW

CCBB

A ABB

AA

YTB A T E R

GROUND (BLACK)

30AMPFUSEM

AXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

FAN POSITIVE (RED)


IGNITION INPUT (ORANGE)

OPTIONAL RELAY (PART#: FRH)

86

87

87a

85

30

+12V

DC(Y

ELLO

W)

FUSE

30AMPFUSEM

AXIMUM

FAN GROUND (BLACK)

CCAA

BBAA

BB SECONDARY FAN-A/C HARNESS

CCBB

AA

FACTORY (OEM) SENSOR

VARIABLE VOLTAGEGROUND

OEM GAUGE WIRE (WHITE)OEM TEMP SENSOR HARNESS

AIR CONDITIONING INPUT (BLUE)

AIRC

ONDI

TIONI

NGCO

MPR

ESSO

R

GROUND

+12VDC WHEN A/C IS ON

C CB B

AAB B

A A

YTB A T E R

GROUND (BLACK)

30AMPFUSEM

AXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

FAN POSITIVE (RED)




86

87

87a

85

30

+12V

DC(Y

ELLO

W)

FUSE

30AMPFUSEM

AXIMUM

FAN GROUND (BLACK)

CCAA

BBAA


NOT USED


CCBB

AA



OEM GAUGE WIRE (WHITE)OEM TEMP SENSOR HARNESS

***FANS MUST BE FUSED SEPARATELY***


Harness: Connects to:

Power HarnessRed Positive 12 VDC Directly to BatteryBlack Ground Directly to BatteryOrange Switched Ignition (+12VDC when vehicle is running)

Fan HarnessRed Primary Fan PositiveBlack Primary Fan Negative

Secondary Fan- A/C HarnessBlue Air Conditioning Input (+12VDC when vehicle is running)Grey Secondary Fan Output (To Grey Wire of FRH)

OEM Temp Sensor HarnessWhite OEM Temperature Sensor (Variable Voltage)

Secondary Fan Relay HarnessYellow Positive 12 VDC Directly to BatteryRed Secondary Fan PositiveGrey PWM Secondary Fan Output (Grey Wire from PWM)Orange Switched Ignition (+12VDC when vehicle is running)Black (from fan) Chassis Ground




Secondary Fan- A/C HarnessBlue Air Conditioning Input (Not Used)Grey Secondary Fan Output (To Grey Wire of FRH)



14 7

Dual Fan - OEM Sensor - with AC:

Dual Fan - OEM Sensor - without AC:

Example

The vehicle has a 195-degree thermostat, and we recomend the High to be 200 degrees,and the Low to be 160 degrees:

•Unplug fan.•Warm-up vehicle to 160 degrees.•Press and hold Low Button for 3 seconds.• Yellow LED will blink.•Continue to warm-up vehicle to 200 degrees.• Press and hold High Button for 3 Seconds.• Red LED will blink.• Turn off the vehicle.• Allow vehicle to cool.• Plug in your fan.• Start vehicle and confirm the fan turns on at the correct temperatures.

WIRE HARNESS CONNECTOR

8 13




Secondary Fan- A/C HarnessBlue Air Conditioning Input (+12VDC when A/C pump is On)Grey Secondary Fan Output (Not Used)

SPAL Temp Sensor HarnessGreen/Black SPAL Temperature Sensor




Secondary Fan- A/C HarnessBlue Air Conditioning Input (Not Used)Grey Secondary Fan Output (Not Used)


Single Fan - SPAL Sensor - with AC:

Single Fan - SPAL Sensor - without AC:

CCBB

AAB B

A A

YTB A T E R

GROUND (BLACK)

30AMPFUSEM

AXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

FAN POSITIVE (RED)




86

87

87a

85

30

+12V

DC(Y

ELLO

W)

FUSE

30AMPFUSEM

AXIMUM

FAN GROUND (BLACK)

CCAA

BBAA


CCBB

AASPAL TEMP SENSOR HARNESSSPAL SENSOR WIRE (GREEN)

SPAL SENSOR WIRE (BLACK)

SPAL SENSOR


AIRC

ONDI

TIONI

NGCO

MPR

ESSO

R

GROUND


C CB B

AABB

AA

YTB A T E R

GROUND (BLACK)

30AMPFUSEM

AXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

FAN POSITIVE (RED)




86

87

87a

85

30

+12V

DC(Y

ELLO

W)

FUSE

30AMPFUSEM

AXIMUM

FAN GROUND (BLACK)

CCAA

BBAA


CCBB



SPAL SENSOR

NOT USED




Harness Connects To:



Secondary Fan- A/C HarnessBlue Air Conditioning Input (+12VDC when vehicle is running)Grey Secondary Fan Output (To Grey Wire of FRH)



PWM Harness: Connects to:

Harness Connects To:



Secondary Fan- A/C HarnessBlue Air Conditioning Input (Not Used)Grey Secondary Fan Output (To Grey Wire of FRH)



12 9

Dual Fan - SPAL Sensor - with AC:

Dual Fan - SPAL Sensor - without AC:

CCBB

AABB

AA AIR CONDITIONING INPUT (BLUE)

AIRC

ONDI

TIONI

NGCO

MPR

ESSO

R

GROUND


YTB A T E R

GROUND (BLACK)

30 AMP FUSE MAXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

CCAA

BBAA

BB

C CBB

A ASPAL TEMP SENSOR HARNESSSPAL SENSOR WIRE (GREEN)


SPAL SENSOR


CCBB

A A

YTB A T E R

GROUND (BLACK)

30 AMP FUSE MAXIMUM

FUSE

+12 VDC (RED)


NOT USED

POWER HARNESS

CCAA

BBAA

BB

CCBB



SPAL SENSOR

10 11




Secondary Fan- A/C HarnessBlue Air Conditioning Input (+12VDC when A/C pump is On)Grey Secondary Fan Output (Not Used)





Secondary Fan- A/C HarnessBlue Air Conditioning Input (Not Used)Grey Secondary Fan Output (Not Used)


Single Fan - OEM Sensor - with AC:

Single Fan - OEM Sensor - without AC:

CCBB

AABB

AA AIR CONDITIONING INPUT (BLUE)

AIRC

ONDI

TIONI

NGCO

MPR

ESSO

R

GROUND


YTB A T E R

GROUND (BLACK)

30 AMP FUSE MAXIMUM

FUSE

+12 VDC (RED)


POWER HARNESS

CCAA

BBAA

BB

CCBB

AA



OEM GAUGE WIRE (WHITE)TEMP SENSOR HARNESS


CCBB

AAY

TB A T E R

GROUND (BLACK)

30 AMP FUSE MAXIMUM

FUSE

+12 VDC (RED)


NOT USED

POWER HARNESS

C CA A

B BAA

BB

CCBB

AA



OEM GAUGE WIRE (WHITE)TEMP SENSOR HARNESS

Documents

LIMITED W ARRANTY ST ATEMENT INST ALL ATION INSTRUCTIONS · INST ALL ATION INSTRUCTIONS SP AL USA ¥ 1731 SE Oralabor Road ¥ Ankeny , IA 50021 Email: [email protected] ¥ W eb: www