In addition to fan control, many other hydraulic control applications can be accommodated with this hardware and application-specific software.

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1 TECHNICAL DATASHEET #TDAX HYDRAULIC FAN CONTROLLER with Multiple I/O 3 Temperature Sensors and 1 PWM Temperature Signal 4 Digital Input Functions and 1 Analog Override Input 1 Proportional and 1 ON/OFF Outputs RS232 for User Configuration with a PC CAN port for SAE J1939 (on request) Description: The hydraulic fan controller provides precise, repeatable control of a proportional solenoid valve to adjust the speed of a hydraulic fan. Fan speed can be directly or inversely proportional to the current through the valve depending on the valve selected. An output to a LED provides the capability to connect a visual indicator of fan speed. A fan reverse function is provided with an output to a switch valve. P/N: AX Valve current control is based on up to three two-wire temperature sensor inputs. One PWM input is available for interface to an engine ECM (electronic control module) or PWM temperature sensor. The fan speed is proportionally controlled based on the measured temperatures. If one of the temperatures goes beyond its upper limit, the fan is set to maximum speed regardless of the condition of the other temperature inputs. If the temperatures are within specified ranges, the fan speed is controlled by a temperature with priority and as long as that fan speed is higher than a speed calculated on the base of all the other temperatures. Two digital inputs provide speed advance and speed retard functions when all the temperatures do not exceed their maximum levels. The third digital input allows a fan reverse function. A manual control input offers manual operation of the controller via an override potentiometer input. A +5V reference powers the override potentiometer. The fan controller has four operating modes: Main Mode; Maximum Speed Mode; Fan Reverse Mode; and Manual Mode. In Main Mode operation, the temperature inputs collected from the temperature sensor and PWM inputs control the fan speed. The controller enters Maximum Speed Mode if one of the active temperature inputs exceeds the maximum level. The Fan Reverse Mode involves switching the direction of the fan for a set time, after which the controller returns to the previously active mode. The fan reverse mode is also the initial mode after reset. In Manual Mode, when activated by the manual input, the override voltage input (potentiometer) controls the fan speed. All other inputs are ignored. The robust design accepts 9 32V power supply input and is packaged in an IP67 rated housing with a 24-pin connector. It is operational from -40 to 85 C (-40 to 185 F). The controller is designed for remote mounting. A RS-232 port interfaces to a PC for user configuration and diagnostics. The user can access the controller parameters and change setpoints at any time, independent of the operating mode. Optional CAN (SAE J1939) communications permit networking. In addition to fan control, many other hydraulic control applications can be accommodated with this hardware and application-specific software. Applications include: Hydraulic Fan Drives Industrial and off-highway (mobile) applications for control of hydraulic valves Ordering Part Number: Fan Controller with Multiple I/O P/N: AX It includes standard embedded software. (Application-specific software is available on request.)

2 Technical Specifications: The specifications represent a particular hardware platform with standard software (application-specific s/w on request). Input Specifications Power Supply Input - Nominal Reverse Polarity Protection Analog Inputs Temperature Sensor Inputs The user may also select different sensors. Upon ordering, provide details of the selected sensors specifications for factory programming of the controller. Sensors Ground Analog Input 1 Analog Ground PWM Input PWM Temperature Input Digital Inputs Digital Input 1 SPEED ADVANCE Digital Input 2 SPEED RETARD Digital Input 3 FAN REVERSE Fan Reverse Hold Time (T_rev) 12 or 24VDC nominal; 9 32 VDC power supply range Provided 3 temperature sensor inputs (User specifies sensor and setpoints.) The controller enters Maximum Speed Mode if one of the active temperature inputs exceeds the maximum level. There is a choice of sensor inputs. NTC = NTC Thermistor HF P/N: with mating connector Deutsch DT06-2S Delphi = Delphi coolant/fluid temperature sensor HF P/N: (Delphi P/N ) (See Table 1 for Temp/Resistance defaults for Delphi sensor in software.) PTC_RTD = Platinum, positive temperature coefficient RTD HF P/N: (Minco P/N: S102844PF10) with mating connector Packard P/N: Not_Active A common ground connection is provided. 0-5V (Default) 0-10 VDC, 4-20 ma, 0-20 ma are available. Option: V potentiometer (5K to 10K) (user configurable) Analog ground provided PWM pulse normal/reverse polarity up to 3 khz Adjustable from 0-100% Duty Cycle (5-95% default) For example, the controller could interface to a PWM signal from an engine ECM or an external PWM temperature sensor. Speed Advance (SA) Active Low The speed advance input adds a positive offset to the fan speed when all temperatures do NOT exceed their maximum levels. When active and all temperature inputs are lower than their max. setpoints, the fan speed is increased by RPM_adv [25% Default] relative to the value calculated based on the temperature inputs. When passive, the function is not applied. If SA and SR are applied simultaneously, both will determine the increase/decrease of the fan speed. Refer to Figure 1. Speed Retard (SR) Active Low The speed retard input adds a negative offset to the fan speed when all temperatures do NOT exceed their maximum levels. When active and all temperature inputs are lower than their max. setpoints, the fan speed is decreased by RPM_ret [25% Default] relative to the value calculated based on the temperature inputs. When passive, the function is not applied. If SA and SR are applied simultaneously, both will determine the increase/decrease of the fan speed. Refer to Figure 1. Fan Reverse (FR) Active Low for connection to a momentary switch (button). When active, the switch valve is open. (Max. solenoid current is limited by the Isw_max. setpoint which is user configurable with 0-2A.) When passive, the switch valve is closed. (Solenoid current is 0.) When the switch is pressed, the fan speed is set to the minimum without ramping for T_fan seconds. Then, when the fan stops, the switch valve is activated and the fan speed ramps back to the normal value. The fan starts rotating in the opposite direction. This phase lasts for T_rev time (10 sec. default). Then, the fan speed is set back to minimum without ramping for T_fan seconds and that brings the fan rotating in the opposite direction to a stop. Then, the switch valve is deactivated and the fan speed ramps back to normal. Refer to Figure sec. (Default) Adjustable from seconds. 2

3 Digital Input 4 MANUAL CONTROL Digital Ground Manual Control (MC) Active Low The manual control input switches the controller into the manual control mode. The fan speed in this mode is set by the Override Potentiometer or analog input. If MC is active, the fan speed is determined ONLY by the Override Input. If MC is passive, the fan speed is determined by the temperature and PWM inputs. A common digital ground connection is provided (and shared as PWM input GND, LED Status Output GND and RS-232 GND.) Table 1: Delphi Sensor Temperature vs. Output (Resistance) Table Temp [Deg C] Resistance [ohms] Res [+/- %] Ref Acc [+/- Deg C] Temp [Deg C] Resistance [ohms] Res [+/- %] Ref Acc [+/- Deg C] Note: The table only applies between 20 C to 120 C. Temperatures below this range are set to 20 C, and temperatures above this range are set to 120 C. Fan Speed 100% Speed Retard % Speed Advance - On Speed Retard and Speed Advance - Off Speed Advance % Speed Retard - On 0 AI1_low AI1_high Sensor Temperature Figure 1. Dependence of the Fan Speed from Sensor Temperature in Speed Advance and Speed Retard Modes (It is assumed that only Temperature Sensor 1 is Active). 3

4 Speed Momentary Switch is pressed Ramp to normal speed Ramp to normal speed Time Switch Solenoid Current Isw_max Phase 1 Phase 2 Phase 3 T_fan T_rev T_fan Time Switching Into Reverse Mode Figure 2. Switching Into Reverse Mode Time Diagram Output Specifications Maximum Current Output (High frequency PWM output) Reference Voltage LED Status Output Output Current Adjustments Superimposed Dither Ramp Rate High side driver Two independent outputs (up to 2A) Solenoid A: 1 proportional output for a proportional valve controlling fan speed Solenoid B: 1 on/off for connection to a switch valve for a fan reverse mode Overcurrent protection is provided. Short circuit protection is provided. On power up the proportional valve is set to the minimum fan speed for T_rev time (10 sec. default). +5V, 2.5 ma 20 ma Normally, a 20 ma LED connected to this output will indicate the following. OFF, Fan is idle. ON, Fan is at maximum speed. Blinking, Fan speed is between 0 and maximum. All current settings are adjustable from 0 to 2 Amps. Dither Amplitude: 10% I-max. (fixed) Dither Frequency: 200 Hz (factory default); Adjustable from Hz Ramps to I-max; 3 seconds (factory default) Adjustable from 0-5 seconds. 4

5 Configurable Parameters The following table illustrates the default software. Other control logic is available on request. Description Variable Name Default Range Unit Temp. Sensor Type Al1_type Al2_type Al3_type NTC NTC NTC {NTC, PTC_RTD, Delphi, Not _Active} Enumerator Temp. Sensor 1 Low AI1_low ºC Temp. Sensor 1 High AI1_high ºC Temp. Sensor 2 Low AI2_low ºC Temp. Sensor 2 High AI2_high ºC Temp. Sensor 3 Low AI3_low ºC Temp. Sensor 3 High AI3_high ºC Analog Input Filter Frequency Al_ff 60 {50, 60} Enumerator, Values are in Hz PWM Input Low PWM_low % D.C. PWM Input High PWM_hi % D.C. PWM Input Type PWM_type Normal {Normal, Reversed, Enumerator Not_Active} Input Priority Al_pri No_Priority {TS1, TS2, TS3, Enumerator PWMI, No_Priority} % Speed Advance RPM_adv % % Speed Retard RPM_ret % Invert Output Current Ips_inv True T/F - (Fan Reverse) Fan Reverse Hold Time T_rev sec Fan Reverse Stop Time T_fan sec Maximum Current (ON/OFF Valve) Isw_max ma Minimum Current (Proportional Valve) Ips_min ma Maximum Current (Proportional Valve) Ips_max ma Ramp Time Tps_ramp sec Dither Frequency Fps_dith Hz Dither Amplitude Aps_dith % of Ips_max General Specifications Microprocessor Control Logic CAN Interface Interface Electrical Connections Packaging and Dimensions Operating Conditions Vibration Protection MC56F8322 Standard software Application-specific software is provided on request. The user can access configuration and diagnostic modes while in operation mode. 1 CAN port Bosch Controller Area Network Specification (CAN 2.0B) Software support for SAE J1939 stack (on request) RS-232 port is provided for setpoint configuration, software upgrade and diagnostics. RS232 serial communication interfaces to a serial port (i.e. COM1) on a PC ( Baud Rate, N81, Xon/Xoff Flow Control) Tera Term or Microsoft HyperTerminal TM or an equivalent data terminal 24 pin Deutsch DTM series 24 pin receptacle (DTM13-12PA-12PB-R008) Mating plug: Deutsch DTM06-12SA and DTM06-12SB with 2 wedgelocks (WM12S) and 24 contacts ( ). 20 AWG wire is recommended for use with contacts Use dielectric grease on the pins when installing the controller. High Temperature Nylon housing Deutsch IPD PCB Enclosure (EEC-325X4B) 4.62 x 5.24 x 1.43 inches x x mm (W x L x H excluding mating plug) OEM specific packaging and connection styles are available. -40 to 85 C (-40 to 185 F) Vibration compliance is suitable for mobile equipment applications. IP67; Unit is conformal coated within the housing. Plugs carry an IP69 rating. 5

6 Connections: Grey Connector Black Connector Pin # Function Pin # Function 1 Override +5V Reference (Protected) 1 Temperature Sensor 1 2 Override Input 2 Temperature Sensor 2 3 Override GND 3 Temperature Sensor 3 4 Solenoid A- 4 Temperature Sensor GND 5 Solenoid B- 5 Digital GND/Status LED GND/ RS-232 GND (to DB-9 Female, pin 5) 6 Battery - 6 ECM Temperature Input (PWM) 7 Battery + 7 Speed Advance (DIN1) 8 Solenoid B+ (ON/OFF) 8 Speed Retard (DIN2) 9 Solenoid A+ (Proportional) 9 Fan Reverse (DIN3) 10 RS-232 Receive (to DB-9 Female, pin 3) 10 Manual Control (DIN4) 11 RS-232 Transmit (to DB-9 Female, pin 2) 11 CAN High 12 Status LED Output + 12 CAN Low NB. CAN Shield can be tied to the bolt used to secure the plastic housing to the chassis. 6

7 Using a PC and Tera term freeware, the user can select between displaying system parameters, changing system parameters, setting the default values, loading new software and showing the internal state of the controller (diagnostics). Setting Up PC Communications to the Controller Connect an RS-232 to DB-9 cable adaptor to the controller and a PC. Use a stable power supply. With the power supply OFF, connect the controller Power- to the power supply Ground, and the Power+ to the power supply +. Open Tera Term Pro, and set it up as shown below. (Free downloadable from Select Serial with the appropriate COM port. Go to Setup/Serial Port and change the settings exactly as shown below. Go to Setup/Terminal and verify that New-line Transmit and Receive are CR. Adjust the window size as desired by checking Term size = win size. Configuring the Controller - Main Menu To access the main menu for existing software, turn ON power to the controller. Follow the prompts on the screen to view or to change the configurable parameters, show diagnostics or flash new software. Form: TDAX /10/06 7