### SAE HVAC Vehicle Operation Guide

Version 3 July 25, 2006

Creative Thermal Systems 2209 Willow Road

Urbana IL 61802

217-344-7663 FAX 217-344-7552 Email: info@creativethermalsolutions.com

Send suggestions and corrections to: Norman Miller nr-millr@uiuc.edu

# Topics

1. Loading and running dSpace ControlDesk

2. Starting STI data acquisition

3. Rezeroing the EXV

4. Permanently storing code in the system controll er (dSpace MicroAutobox)

5. Setting up instrumentation in dSpace ControlDesk

6. Setting up a data capture in ControlDesk and using the captured data

7. The control system model

8. Model variables that m ay require modification

9. Source code control (TortoiseSVN)

10. Hardware issues

Hardware Reference

### 1. Loading and running dSpace ControlDesk

The car m u st be running and the com m unica tion cable m u st be connected between the dSpace MicroAutobox and the suppo rt PC.

Communication cable connected to adapter

dSpace MicroAutobox

Click on the ControlDesk icon

to sta r t

Watch for a successful s t art (see Log View er at th e bottom of the page) with communication establish e d between the PC and the dSpace MicroAutob ox. The Log should end with “Sim ulation state: RUN”. Tr y restating the program if s t artup fails.

### Next click on File, then Open Experim e nt

### Select SAE_ HVAC.cdx in the directo r y wher e your code has been comp iled as shown below.

Unless y o u wish to

r e lo ad you r pro g r a m (as a f ter a

reco m p ile), click No

.



### If you have recom p iled and wish to reload, be certain the air conditione r is turned off and then click Y e s. After a reload, be sure to rezero the EXV (see Topic 3).

### The custom display screens are now visible, but data scanning is not started. The screens can be edited in this m ode. Click on the ic on indicated by the arro w to start updating the display screens.

The updating EXV screen is shown below.

### Click View Æ Fullscreen to view the s c reens f u ll size.

A full size s c reen app ears below. Press the “Esc” key to leave th e full screen m ode.

### 2. Starting STI data acquisition

1. Connect the Panasonic support com puter to the S T I data acquisition system using its comm unication cable (see photo).

2. Click on the STI icon labeled “STI_B12c” on the desktop.

3. The STI m u st be powered on ( box on rear tunnel of vehicle).

4. Click on File->Start Test.

5. Use the default Vehicle File and Config File.

6. Change Data File as desired. Notice the di recto r y where it is s t ored. Curr e n tly th e directory is C:\sti\65DP4229 2005 STS\data.

7. The screen should show all vehicle transducers.

8. Enter an integer 1, 2, 3, etc. to start saving data. T h e num ber 1 saves data at one second intervals.

### 9. Press F7 to stop the test and exit.

10. Open the data file you have just collected (suffix dat).

11. Click “Convert” on screen to convert file to a *.csv file compatible with Excel.

### 3. Re z eroing the EXV

It is advisable to rezero the EXV after loading code into th e MicroAutobox. After downloading code and starting sim u l a tion, be certain the AC system is switched off (see Topic 4). The Stepper box on the left of the C ontrolDesk EXV screen is used to establish valve zero.

Stepper box

1. Note the current controlled valve position. 2. Click the bu tton to p l ace the va lve in Manual Operating m o de. 3. Set the M a n u al valv e po sition to a n e gativ e number. -2000 w ill always co mpletely close the valve, but -1 m a y be sufficient. Try som e thing like - 50 and lis ten f o r the valve tapping when fully closed. (The ta pping is obvious in the car with the doors closed.) You can always us e a larger negative number if your first choice does not close the valve. 4. After the valve has audibly closed and stopped tapping, click th e button to disable the coils ( t his will pr eve n t the m o tor f r om really turning )

. 5. Set the M a n u al valv e setting to 0 and wa it for the red EXV Setpoint and green EXV Position curves to converge at ze ro. The controller’s counter and the physical valve position now m a tch at 0. 6. Click the button to return to norm a l coil sequencing. 7. Set the M a n u al valv e po sition to the position noted in step 1.

### 8. After the valve moves to that position (not e the EXV Setpoint a nd Position plots), click the top button to re turn to Control mode.

Note that this procedure should never be n ecessary if the system runs normally and the controller code is not reloade d. Note also that whenever th e car’s engine is switched off (ignition off event), the system goes through an automatic valve rezero operation. The valve is driven to -500 steps, the counter rese t to zero and then the valve is opened to the system default valve position.

### 4. Permanently storing code in the sy stem controller (dSpace MicroAutobox)

Start ControlDesk (see T opic 1).

Click on the Platform tab

Select Load Application to Flash (right click to show drop down m e nu)

Select the sd f f

ile

y ou wish to loa d

### The AC system should be switched off

This button toggles the AC system

Click yes to load the

contro l sof t ware into th e MicroAutobox’s Flash

m e mory and begin execution of the new cod e

### Note that control is lost dur ing download of code. This is why the AC system should be turned off during code download. After the c ode has been downloaded and starts running on the MicroAutobox, rezero the EXV (see Topic 3) since its position is sometimes lost when new code is loaded.

### 5

. Setting up instrumentation in dSpace ControlDesk

This sec tion illus t r a tes h o w to set up a plot ter a rra y. Other ins t rum e nts are set up in a sim ilar fashion. It is often convenient to copy and paste an existing instrum e nt.

Draw a box for the array on the disp lay surface. Select P l otter Array

Double click in the box and selec t Plotte r from the m e nu

### This tr ee f o llows the structu r e of the Sim u link controller model and is used to locate m odel variables. Click the model tab at the bottom of the page to display and select m odel variables.

Click and drag the desired variable onto the left side of the plo tte r to estab lish the variable link

### 6. Setting up a data capture in Contro lDesk and using the captured data

ControlDesk can capture and save buffers of data. Only data displayed on a plotter will be buffered and saved. T o include data on a pl otter, see Topic 5. The stored data duration and sam p le rate is established using the Capture Settings W i ndow.

Open Capture Settin g s W i ndow

The W i ndow m a y be hidden by the display windows, use the W i ndow dropdown m e nu to locate.

The base clock rate is 160/sec, so downsa m pling by 80 yields 2

sam p les/sec Length of the capture buffer in seconds

To capture a buffer of da ta, Auto Repeat s hould not be checked. (To view norm a l strip chart d i splays, check Auto Repeat and set Do wnsam p ling to 40 or so.) For a basic scan, Se l e c t Host se r v i c e : 2 f

o r use with the vehicle MicroAutobox

contro lle r

### no trigger is selected. Press “Start” to begin the scan. Wa it until the buffer is 100% full and press “Save” to write the buffer of data to a file. The file is a MatLab “.mat” file. The data is stored as a structure. (Use simple file names for compatibility with MatLab. In particular do not use a number at the begi nning of a file name and do not use characters like ‘-‘ or blanks. Use ‘_’ instead of bla nks.) CTS has developed a MatLab function “DSpaceExcel.m” that can convert either the enti re data file or a portion of the file into an Excel spreadsheet. The function is located in the directory ~\ CTS\(latest directory data)\data and has been placed under Tortoise SVN version control (see Topic 9). The function runs only under MatLab ver. 7. (T he Simulink control program must be compiled under MatLab ver. 6. Both versions of MatLab are available on the HP support computer.) The usage of this function follows (car_data is the *.mat file saved from a dSpace ControlDesk capture):

Usage:

load car_data DSpaceExcel(car_data, 'filename')

This exports all the data cleaning up the exported names and printing messages as it works.

Added features:

DSpaceExcel(car_data, 'filename', [2 5 7])

Will only export the second, fifth, and seventh data sets. Use sta ndard Matlab array notation to select which entries you need. For example, [1:5, 10:12] is the same as [1 2 3 4 5 10 11 12].

### 7. The control system model

It m a y be necessary or desi rable to modify and recom p ile the control system m odel.

The curren t code is located in directo r y ~\CTS\(lates t directory date)

The contro l code has been placed und er source co de contro l (s ee Topic 9).

The control code consists of a Sim u link model (SAE_HVAC.m dl) that uses two MatLab “m ” f iles to define constants and calib ration factors (SAE_HVAC_Cals.m and SAE_HVAC_Consts.m)

Double click on SAE_HVAC.mdl to start MatLab (version 6 – required to generate code for the MicroAutobox) and Sim u link. Load SAE_HVAC_Ca ls and SAE_HVAC_Consts from MatLab.

### Run the two MatLab “m ” f iles by first selecting one of the two “m ” f iles the n click i ng debug Æ Run. After running the first file, select th e seco nd and run it as well. This procedure places all co nstants and calib ration f actors in th e MatLab workspace and m a kes them availa ble to the Simulink model.

Click th is ic on to build the m odel. This process takes several m i nutes.

The code must be loaded into the MicroA utobox controller (see Topics 1 and 4).

### During ControlDesk startup, click Yes to load the new cod e into the volatile m e mory of the MicroAutobox

See Topic 4 to load code into the MicroAutobox’s FLASH mem o ry. Note that code written only to volatile mem o ry is persistent as long as vehicle battery power is not

rem oved. (It is suggested that vehicle batte ry power be rem o ved overnight by rem oving the supply f u se - see Topic 10.)

### 8. Model variables that m ay require modification

The file SAE_HVAC_Cals.m contains sy stems calibration constants and setup parameters. You may wish to change some of the values. An effort has been made to place the variables that may need to be modified near the start of the file and to document every variable. Many of them can be modifi ed during runs using dSpace ControlDesk. If a new set of constants are identified duri ng a run using ControlDesk, you will need to modify the constants in SAE_HVAC_Cals.m an d recompile and reload the code into the MicroAutobox to make the changes permanent (see Topic 7).

9. Source code control (TortoiseSVN)

The control code, the dSpace ControlDesk Experi ment files, as well as some support files have been placed under source code contro l using TortoiseSVN. When using Windows Explorer, controlled files (a nd directories containing contro lled files) will usually be indicated by a checkmark (if committed to the repository), or an excl amation point (if the latest version is not yet committed). The s ource code control system provides a way to return to previous version of the code. In particular, it is important to commit the entire development directory (Base_CTS_19_April at present) before making significant changes in the code. That way, mistakes can be rectified quickly by using the Revert feature of TortoiseSVN. The following shows how to start a new development directory and commit a copy of the code before beginni ng new development. Reversion to the last version of the code is also illustrated. See the TortoiseSVN help files for the many other features of this software. Note, the “repository” directory must never be deleted.

### Make a new directory and right click in the blank directory to display the m e nu shown. Select SVN Checkout.

Accept defaults and a set of the

newest

comm itted files will be p l ace d in this directory

In the case that you wish to revert to a previous version of controlled code:

### This directory contai ns modified files and you wish to restore the files from the repository.

Click to d i sp lay th is m e nu and select Torto i seSVN

### Select Revert to restore to the la st com m itted version.

### 10. Hardw a re issues

The entire s y stem is powered from a line attach ed dire ctly to the positiv e term inal of the vehicle battery. The system draw s current sufficient to run do wn the vehicle battery ev en when com p letely shut down. It is suggested that the system fuse be rem oved when the vehicle is not running for any extended period of tim e

.

System fuse

Fan fuse

12 Volt battery current consum ption when the ve hicle ignition is off, the key fob far from the vehicle, and with various loads is:

1. System fuse installed, 9 pin vehicle bus connector in trunk connected and STI system turned on (toggle sw itch on rear tunnel)– 4.35A 2. System fuse installed, 9 pin bus c onnector in trunk connected – 0.158 A 3. System fuse installed, 9 pin bus c onnector in trunk disconnected – 0.135 A 4. System fuse rem oved, 9 pin bus c onnector in trunk connected – 0.028 A 5. System fuse rem oved, 9 pin bus conn ector in trunk disconnected – 0.044 A

### Fan controller Trunk ventilation fan

A s m all SPAL fan (VA31-A101-46S) and contro ller (FAN-PW M) have been installed to exhaust air f r om the trunk into the fender vent. D o cum e nts that cover the fan and its

contro ller ap pear in the Hardw a re Reference at the end of this docum ent. The fender vent flap has not been removed or taped ope n, so im proved air flow could be obtained if necessary. Fan power is taken directly from the batte ry positive term inal ( w ith re turn grounded on the sam e ground post on the passeng er door upright as the control and data acquisition system ). The fan controller is ar m e d with an ignition line. The line is connected to the positive lead of the STI da ta acquisition system power cable. Thus the fan can only operate when the STI system is powered up. At present the f a n starts running at a tem p erature of 116 F and reaches full velocity at 150 F. The fan can easily be reprogrammed to other tem p erature thre sholds. For further inform ation see the docum ents in the appendix of go to www.spalusa.com

.

The custom Fujikoki stepper m o tor driver box is located in the trunk, accessible through the opening in the back seat. Th e driver is docum ented in the Hardw a re Reference that f

o llows.

### Hardware ReferenceSystem Mechanization

## MicroAutobox I/O Connector Pinouts

The I/O con n ector is a 1 56-pin Zero Inser tion Fo rce (Z IF) co nnector g i ving access to the input and output signals provided by MicroAutoB ox.

The following illus t ratio n shows the pin num beri ng of the I/O connector (front view of MicroAutoB ox):

Note

There are pins identified via capital letters (A, B, C, ...) and pins identified via sm all letters (a, b, c).

The following table shows the signals of the I/0 connector: P i ns used highlighted in yellow. Power (+12 Volt vehicle power) highlighted in red. C o mm on (ground) highlighted in black.

1 2 3 4 5 6

DAC 7 out DAC 8 out Gr oup 1 ch 1 out Gr oup 1 ch 2 out Gr oup 1 ch 3 out Gr oup 1 ch 4 out A

DAC 5 out DAC 6 out Gr oup 1 ch 5 out Gr oup 1 ch 6 out Gr oup 1 ch 7 out CT M ch 1 out B

DAC 3 out DAC 4 out CT M ch 2 out CT M ch 5 out CT M ch 6 out CT M ch 7 out C

DAC 1 out DAC 2 out CT M ch 8 out CT M ch 3 out CT M ch 4 out Gr oup 6 ch 1 out D

VDRIV E i n VSE N S out Gr oup 6 ch 2 out Gr oup 6 ch 3 out Gr oup 6 ch 4 out Gr oup 6 ch 5 out E

Gr oup 6 ch 6 out Gr oup 6 ch 7 out GND in GND in Gr oup 6 ch 8 out T P U ch 1 out F

T P U ch 2 out T P U ch 3 out GND in GND in GND in TPU ch 4 out G

T P U ch 5 out T P U ch 6 out GND in GND in T P U ch 7 out T P U ch 8 out H

T P U ch 9 out T P U ch 10 out T P U ch 11 out T P U ch 12 out T P U ch 13 out T P U ch 14 out J

T P U ch 15 out T P U ch 16 out Gr oup 2 ch 1 out Gr oup 2 ch 2 out Gr oup 2 ch 3 out Gr oup 2 ch 4 out K

Gr oup 2 ch 5 out Gr oup 2 ch 6 out Gr oup 2 ch 7 out Gr oup 2 ch 8 out Gr oup 3 ch 1 out Gr oup 3 ch 2 out L

Gr oup 3 ch 3 out CT M ch 1 in REMO TE in CTM ch 2 in CTM ch 3 in CTM ch 4 in M

Gr oup 6 ch 1 in Gr oup 6 ch 2 in Gr oup 6 ch 3 i n Gr oup 6 ch 4 i n Gr oup 6 ch 5 i n Gr oup 6 ch 6 i n N

Gr oup 6 ch 7 in Gr oup 6 ch 8 in T P U ch 1 in T P U ch 2 in T P U ch 3 in T P U ch 4 in PTPU ch 5 in TPU ch 6 in TPU ch 7 in TP U ch 8 in TPU ch 9 in TPU ch 10 in R

TPU ch 11 in TPU ch 12 in TPU ch 13 in TP U ch 14 in TPU ch 15 in TPU ch 16 in S

Group 2 ch 1 in Group 2 ch 2 in Group 2 ch 3 in Group 2 ch 4 in Group 2 ch 5 in Group 2 ch 6 in T

Group 2 ch 7 in ADC Type 1 Con 4 Ch 4 in Serial 2 K / LIN i/o Serial 2 L in Serial 1 TXD out Serial 1 RXD in U

ADC Type 1 Con 2 Ch 4 in ADC Type 1 Con 3 Ch 4 in VBAT in VBAT in CAN 1 low i/o CAN 1 high i/o V

ADC Type 1 Con 1 Ch 4 in ADC Type 1 Con 4 Ch 3 in VBAT in VBAT in VBAT in Group 2 ch 8 in W

ADC Type 1 Con 2 Ch 3 in ADC Type 1 Con 3 Ch 3 in VBAT in VBAT in CAN 2 low i/o CAN 2 high i/o X

ADC Type 1 Con 1 Ch 3 in ADC Type 1 Con 4 Ch 2 in Group 4 ch 1 in Group 4 ch 2 in ECU / IF RX+ in Group 4 ch 3 in Y

ADC Type 1 Con 2 Ch 2 in ADC Type 1 Con 3 Ch 2 in Group 4 ch 4 in Group 4 ch 5 in ECU / IFRXin Group 4 ch 6 in Z

ADC Type 1 Con 1 Ch 2 in ADC Type 1 Con 4 Ch 1 in Group 4 ch 7 in Group 4 ch 8 in ECU / IFTXout Group 5 ch 1 in a

ADC Type 1 Con 2 Ch 1 in ADC Type 1 Con 3 Ch 1 in Group 5 ch 2 in Group 5 ch 3 in ECU / IF TX+ out Group 5 ch 4 in b

ADC Type 1 Con 1 Ch 1 in VBAT prot out Group 5 ch 5 in Group 5 ch 6 in Group 5 ch 7 in Group 5 ch 8 in c

1 2 3 4 5 6

### MicroAutobox I/O Connector Signals by Pin

Name
Pin (MicroAutobox) Signal Name Wire color

A1 DAC7 Compressor command to STI

A2 DAC8 EAT setpoint to STI

A3 Group1 ch1 Fujikoki valve driver-phase 4

A6 Group1 ch4 Fujikoki valve driver-phase 2

B1 DAC5 Suction pressure to STI

B2 DAC6 Compressor torque to STI

B3 Group1 ch5 Fujikoki valve driver-phase 1

B4 Group1 ch6 Fujikoki valve driver-phase 3

C1 DAC3 Superheat to STI

C2 DAC4 Evap capacity to STI

D1 DAC1 COP to STI

D2 DAC2 Compressor current FB to STI

E1 VDRIVE

E2 VSENS

F3 GND Common

F4 GND Common

F6 TPU ch1 PWM (compressor command) brown

G3 GND Common

G4 GND Common

H3 GND Common

H4 GND Common

M3 REMOTE To vehicle ignition (system on)

T1 Group2 ch1 compressor request green/blk

V1 ADC Type1 Con2 Ch4 Compressor current FB light purple

V5 CAN1 low Low speed CAN low

V6 CAN1 high Low speed CAN high

W1 ADC Type1 Con1 Ch4 Suction Temperature orange/white

X1 ADC Type1 Con2 Ch3 Compressor outlet temperature

X3 VBAT +12 vehicle power

X4 VBAT +12 vehicle power

X5 CAN2 low High speed CAN low

X6 CAN2 high High speed CAN high

Y1 ADC Type1 Con1 Ch3 Discharge temperature orangeZ1 ADC Type1 Con2 Ch2 Cabin Temperature green

a1 ADC Type1 Con1 Ch2 Suction pressure yellow

b1 ADC Type1 Con2 Ch1 Cabin humidity

c1 ADC Type1 Con1 Ch1 Supply ref. feedback orange



### MicroAutobox I/O Connector Signals by MicroAutobox signal name

Name (MicroAutobox) Pin Signal Name Wire color ADC Type1 Con1 Ch1 c1 Supply ref. feedback orange ADC Type1 Con1 Ch2 a1 Suction pressure yellow ADC Type1 Con1 Ch3 Y1 Discharge temperature orange ADC Type1 Con1 Ch4 W1 Suction Temperature orange/white ADC Type1 Con2 Ch1 b1 Cabin humidity ADC Type1 Con2 Ch2 Z1 Cabin Temperature green ADC Type1 Con2 Ch3 X1 Compressor outlet temperature ADC Type1 Con2 Ch4 V1 Compressor current FB light purple CAN1 high V6 Low speed CAN high

CAN1 low V5 Low speed CAN low CAN2 high X6 High speed CAN high

CAN2 low X5 High speed CAN low

DAC1 D1 COP to STI

DAC2 D2 Compressor current FB to STI

DAC3 C1 Superheat to STI

DAC4 C2 Evap capacity to STI

DAC5 B1 Suction pressure to STI

DAC6 B2 Compressor torque to STI

DAC7 A1 Compressor command to STI

DAC8 A2 EAT setpoint to STI

GND F3 Common

GND F4 Common

GND G3 Common

GND G4 Common

GND H3 CommonGND H4 Common Group1 ch1 A3 Fujikoki valve driver-phase 4 Group1 ch4 A6 Fujikoki valve driver-phase 2 Group1 ch5 B3 Fujikoki valve driver-phase 1 Group1 ch6 B4 Fujikoki valve driver-phase 3 Group2 ch1 T1 compressor request green/blk

REMOTE M3 To vehicle ignition (system on)

TPU ch1 F6 PWM (compressor command) brown

VBAT X3 +12 vehicle power

VBAT X4 +12 vehicle power

VDRIVE E1

VSENS E25544332211DDCCBBAA+5_logicLogic_common+12_vehiclep1_cntlMotor_coil_1Motor_coil_2Motor_coil_3Motor_coil_4Vehicle_commonp2_cntlp3_cntlp4_cntlTitleSize Document Number RevDate: SheetofCTS_010 01Fujikoki Valve DriverA1 2Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_010 01Fujikoki Valve DriverA1 2Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_010 01Fujikoki Valve DriverA1 2Tuesday, July 25, 2006Connections to MicroAutoboxfrom Connector J1(positions numbered 1-10)1) To pin E2 - VSEN (+5V)2) To pin F3 - Ground3) To pin B3 - GP1CH5 (purple)4) To pin A6 - GP1CH4 (green)5) To pin B4 - GP1CH6 (pink)6) To pin A3 - GP1CH1 (white/red)7-10) not usedConnections from J2 to Fujikoki valve1) Phase 1 (orange)2) Phase 2 (black)3) Phase 3 (yellow)4) Phase 4 (red)5) Motor common and vehicle GND (grey)6) +12 vehicle power connected throughfuse to positive battery terminalCTS - Urbana, IllinoisC2100 microF16VD1D1N4740aJ26 Posn screw terminal123456A3Highside_driver+5_logicSignal_inLogic_common+12_vehicleCoil_power_outA2Highside_driver+5_logicSignal_inLogic_common+12_vehicleCoil_power_outA4Highside_driver+5_logicSignal_inLogic_common+12_vehicleCoil_power_outA1Highside_driver+5_logicSignal_inLogic_common+12_vehicleCoil_power_outC30.1 microFJ110 Posn screw terminal123456789105544332211DDCCBBAA+5_logicSignal_inLogic_common+12_vehicleCoil_power_outTitleSize Document Number RevDate: SheetofCTS_011 01Fujikoki Valve Driver - Highside DriverA2 2Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_011 01Fujikoki Valve Driver - Highside DriverA2 2Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_011 01Fujikoki Valve Driver - Highside DriverA2 2Tuesday, July 25, 2006High side coil driver circuit based on International RectifierIR3312 part.CTS - Urbana, IllinoisR15.11kU1IR3312InIfbVccOutR22kQ1ZVN4206A5544332211DDCCBBAATo pin V1 MicroAutoboxFrom pin F6 MicroAutoboxFrom pin H4 MicroAutobox+12 Vehicle+5V Driver BoxTitleSize Document Number RevDate: SheetofCTS_030 1Compressor Driver and Current SenseCTS - Urbana, IllinoisA1 1Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_030 1Compressor Driver and Current SenseCTS - Urbana, IllinoisA1 1Tuesday, July 25, 2006TitleSize Document Number RevDate: SheetofCTS_030 1Compressor Driver and Current SenseCTS - Urbana, IllinoisA1 1Tuesday, July 25, 2006greenpinkblueDiode across compressorcoil at compressor0.10 Ohm currentsense resistorredblueOmega OM5-IMV-100A-C voltage isolation module installedon OM5-BP-SKT-C board. Module converts 0 to 100 mVvoltage across the sense resistor (created by 0 to 1 Acurrent) to 0 to 5 volts signal for input to MicroAutobox.Module include 4 Hz filter to smooth the pulse widthmodulated current signal.OM5-BP-SKT-C+IN-IN +5V PCOMVoutI/O COML1Compressor CoilD2DIODED1DIODED3DIODER2510 OhmIPS 021INDSR1CADDOCK SR10-0.10-1%R310k Ohm

### Installa tion of current sense meas urem ent circuit (isola tion amplifier)

Install OM5-IMV-100A -C m odule on the OM5- BP-SKT-C board and connect as shown below. An explanation of certain con n ection s follows the diag ram

.

Jum p er RD EN/ to I/O comm on to enable output si g nal.

+5 V power and common – from 7805, 5 volt regulator in Driver Bo x Signal – goes ultim ately to pin V1 on MicroAutobox

Signal com m on – to MicroAutobox

common – a ny of pins F3,F4, G3, G4, H3, H4.

Jum p er J1 connects power and signal (I/O) commons. See

text.

Jum p er J2 must
not be installed.
Voltage drop across

curren t sens e resistor.

See the “Co m pressor Driver and Current Sens e” schem a tic diagram for connection across the current s e nse res i sto r . The curren t sense re sistor is lo cated in an extern al plastic enclosure.

Jum p er J1 should not be inst alled for this application.

The conditioned current sense resistor vol tage signal should go to pin V1 on the MicroAutobox connector. Rem ove t h e big conne ctor of the front of the MicroAutobox, you can see how the pins are arra nged (see the following diagram )

.

### You should be able to remove the Micr oAutobox connector and figure out the pinout from the diagram above (note looking into the connector will be a m i rror im age of the above – the pins are arranged as shown when looking at the back of the connector after

rem oving its shell. The power and ground pins are shown in red and black respectively. The green pin is the on e we are addin g. You will have to r e move the conn ector sh ell. Crim p a pin to a new wire and attach to te rm inal Vout of the OM5-BP-SKT-C board.

You can go to the dSpace help files and see the instructions on how to take off the connector shell and crim p and install a new pi n. (Search for the topic “How to Build the Connector”.)

The OM5-IMV-100A-C m odule converts the 0 – 100 m V signal across the current sense resistor (100mV corresponds to 1 A) to a 0 to 5 volt signal. T h e MicroAutobox converts the 0 to 5 volt signal to a num b er between 0 and 1. Thus the signal m easured by the MicroAutobox reads directly in Amps.

### Installation of K thermocouple for measu rement of compressor ou tlet tempera t ur e.

Install OM5-LTC-K2-C module on the OM5-BP -SKT-C board and connect as shown below. An explanation of certain con n ection s follows the diag ram

.

Jum p er RD EN/ to I/O comm on to enable output si g nal.

+5 V power – connect in parallel with

curren t sens e circu it. K therm o couple. Red is negative lead. Signal – goes to pin X1 on MicroAutobox

connecto r

Signal com m on – connect to sam e term inal on curren t sense circu i t

Jum p er J1 connects power and signal (I/O) commons. See

text.

Jum p er J2 must be insta lled f o r cold junction

com p ensation.

The “Com pressor Outlet Pipe Tem p ” therm o couple was wire 38 plugged into physical channel number 26 of the ST I data acquisition system

.
The installation of jum p e r J1 depends on th e ground status of the therm o c ouple. Use a DVM to check continuity between one of the therm o couple leads and chassis ground (available in the plastic power distribution box in the floor of the trunk near the bum per). If there is low resist ance to chassis ground, do not install jumper J1. If the resistance is larger than, say, 20,000 Ohm s , do install the jumper.

### The conditioned therm o couple signal s hould go to pin X1 on the MicroAutobox connector. Rem ove the big connector of th e front of the MicroAutobox, you can see how the pins are arranged (see the following diagram )

.

You should be able to remove the Micr oAutobox connector and figure out the pinout from the diagram above (note looking into the connector will be a m i rror im age of the above – the pins are arranged as shown when looking at the back of the connector after

rem oving its shell. The power and ground pins are shown in red and black respectively. The green pin is the on e we are addin g. You will have to r e move the conn ector shell.Crim p a pin to a new wire and attach to term inal Vout of the OM5-BP-SKT-C board.

You can go to the dSpace help files and see the instructions on how to take off the connector shell and crim p and install a new pi n. (Search for the topic “How to Build the Connector”.)

The OM5-LTC-K2-C module converts the thermocoupl e signal to a voltage such that 0 to 500C m a ps into 0 to 5 volts. The MicroA utobox converts the 0 to 5 volt signal to a

num b er between 0 and 1. This can be checked in the dSpace software. The signal is read by the dSpace system in the software m odule HW I O , DS1401 Analog Inputs – Mod Spd1. Right click on the ADC_T YPE1_M1_CON2 block and sele ct help. The help topic will tell you the inpu t voltage to internal units m a pping. Assum i ng the 5 volts m a ps to 1, the conversion relationship between conversion 

### and tem p erature is jus t:

C 500 ) ( o 

### • = conversion T

## 22 

# OM5-WMV/WV Analog Voltage Input Modules, Wide Bandwidth

FEATURES

● ACCEPTS MILLIVOLT AND VOLTAGE LEVEL SIGNALS

● HIGH LEVEL VOLTAGE OUTPUTS

● 1500Vrms TRANSFORMER ISOLATION

● ANSI/IEEE C37.90.1-1989 TRANSIENT PROTECTION

● INPUT PROTECTED TO 240VAC CONTINUOUS

● 100dB CMR

● 10kHz SIGNAL BANDWIDTH

● ± 0.05% ACCURACY

● ± 0.02% LINEARITY

● ± 1 μ

V/ ° C DRIFT

● CSA CERTIFIED, FM APPROVED, CE COMPLIANT

● MIX AND MATCH OM5 TYPES ON BACKPANEL

FIGURE 1. OM5-WMV/WV Block Diagram. 

## DESCRIPTION
Each OM5 wide bandwidth voltage input module provides a single channel of analog input which is amplified, isolated, and converted to a high level analog voltage output (Figure 1). This voltage output is logic-switch controlled, allowing these modules to share a common analog bus without the requirement of external multiplexers. The OM5 modules are designed with a completely isolated computer side circuit which can be floated to ± 50V from Power Common, pin 16. This complete isolation means that no connection is required between I/O Common and Power Common for proper operation of the output switch. If desired, the output switch can be turned on continuously by simply connecting pin 22, the Read-Enable pin to I/O Common, pin 19.
The input signal is processed through a pre-amplifier on the field side of the isolation barrier. This pre-amplifier has a gain-bandwidth product of 5MHz and is bandwidth limited to 10kHz. After amplification, the input signal is chopped by a proprietary chopper circuit. Isolation is provided by transformer coupling, again using a proprietary technique to suppress transmission of common mode spikes or surges. The module is powered from +5VDC, ± 5%.
A special input circuit provides protec tion against accidental connection of power-line voltages up to 240VAC.

Anti-Aliasing Filter

+In

–In

–EXC

Backpanel Term Block

1

2 6

5

3 NC Surge Suppression and Protection

Isolated Field-Side

Power 4

3

2

1 +EXC

–V +V V IN 4 NC

–V LPF

+V

Power Oscillator Isolated Computer-Side Power V OUT 20

22 I/O Common

RD EN\

+5V 17

16 Power Common 19 IsochopperTM

Amplifier Pat Pending

## 23 Module OM5-WMV OM5-WV Input Range ± 10mV to ± 100mV ± 1V to ± 40V Input Bias Current ± 0.5nA ± 0.05nA Input Resistance Normal 200M Ω 650k Ω (minimum) Power Off 40k Ω 650k Ω (minimum) Overload 40k Ω 650k Ω (minimum) Input Protection Continuous 240Vrms Max * Transient ANSI/IEEE C37.90.1-1989 * CMV, Input to Output Continuous 1500Vrms max * Transient ANSI/IEEE C37.90.1-1989 * CMR (50Hz or 60Hz) 100dB * NMR (–3dB at 10kHz) 120dB per Decade above 10kHz * Accuracy (1) ± 0.05% Span ± 10 μ V RTI (2) ± 0.05%(V Z (3) ) ± 0.05% span ± 0.2mV RTI (2)
± 0.05% (V Z (3) ) Nonlinearity ± 0.02% Span * Stability Input Offset ± 1 μ V/ ° C ± 20 μ V/ ° C Output Offset ± 40 μ V/ ° C * Gain ± 25ppm/ ° C ± 50ppm/ ° C Noise Input, 0.1 to 10Hz 0.4 μ Vrms 2 μ Vrms Output, 100kHz 10mVp-p * Bandwidth, –3dB 10kHz * Rise Time, 10 to 90% Span 35 μ s * Settling Time, to 0.1% 250 μ s * Output Range ± 5V or 0V to +5V * Output Resistance 50 Ω * Output Protection Continuous Short to Ground * Output Selection Time 6 μ s at C load = 0 to 2000pF (to ± 1mV of V OUT )* Output Current Limit ± 8mA * Output Enable Control Max Logic “0” +0.8V * Min Logic “1” +2.4V * Max Logic “1” +36V * Input Current, “0”, “1” 0.5 μ A * Power Supply Voltage +5VDC ± 5% * Power Supply Current 30mA * Power Supply Sensitivity ± 2 μ

V/% RTI (2) ± 200 μ V/% RTI (2) Mechanical Dimensions 2.28" x 2.26" x 0.60" (58mm x 57mm x 15mm) *

Environmental Operating Temp. Range –40 ° C to +85 ° C * Storage Temp. Range –40 ° C to +85 ° C * Relative Humidity 0 to 95% Noncondensing * Emissions EN50081-1, ISM Group 1, * Class A (Radiated, Conducted) Immunity EN50082-1, ISM Group 1, Class A (ESD, RF, EFT) *



## ORDERING INFORMATION

SPECIFICATIONS Typical at T A = +25 ° C and +5V Power.

* Same specification as OM5- WMV. NOTES: (1) Includes nonlinearity, hysteresis and repeatability. (2) RTI = Referenced to input. (3) V Z is the input voltage that results in 0V output.

MODEL INPUT RANGE OUTPUT RANGE
OM5-WMV-10A-C –10mV to +10mV –5V to +5V OM5-WMV-50A-C –50mV to +50mV –5V to +5V OM5-WMV-100A-C –100mV to +100mV –5V to +5V OM5-WMV-10B-C –10mV to +10mV 0V to +5V OM5-WMV-50B-C –50mV to +50mV 0V to +5V OM5-WMV-100B-C –100mV to +100mV 0V to +5V OM5-WV-1A-C –1V to +1V –5V to +5V OM5-WV-5A-C –5V to +5V –5V to +5V OM5-WV-10A-C –10V to +10V –5V to +5V OM5-WV-1B-C –1V to +1V 0V to +5V OM5-WV-5B-C –5V to +5V 0V to +5V OM5-WV-10B-C –10V to +10V 0V to +5V OM5-WV-20A-C –20V to +20V –5V to +5V OM5-WV-20B-C –20V to +20V 0V to +5V OM5-WV-40A-C –40V to +40V –5V to +5V OM5-WV-40B-C –40V to +40V 0V to +5V

## 30 

# OM5-LTC Linearized Thermocouple Input Modules

FEATURES

● INTERFACES TO TYPES J, K, T, E, R, S, N, AND B THERMOCOUPLES

● LINEARIZES THERMOCOUPLE SIGNAL

● HIGH LEVEL VOLTAGE OUTPUTS

● 1500Vrms TRANSFORMER ISOLATION

● ANSI/IEEE C37.90.1-1989 TRANSIENT PROTECTION

● INPUT PROTECTED TO 240VAC CONTINUOUS

● 160dB CMR

● 95dB NMR AT 60Hz, 90dB at 50Hz

● ± 1 μ

V/ ° C DRIFT

● CSA CERTIFIED, FM APPROVED, CE COMPLIANT

● MIX AND MATCH OM5 TYPES ON BACKPANEL



## DESCRIPTION
Each OM5-LTC thermocouple input module provides a single channel of thermocouple input which is filtered, isolated, amplified, linearized and converted to a high level analog voltage output (Figure 1). This voltage output is logic-switch controlled, allowing these modules to share a common analog bus without the requirement of external multiplexers. The OM5-LTC modules are designed with a completely isolated computer side circuit which can be floated to ± 50V from Power Common, pin 16. This complete isolation means that no connection is required between I/O Common and Power Common for proper operation of the output switch. If desired, the output switch can be turned on continuously by simply connecting pin 22, the Read-Enable pin to I/O Common, pin 19. The OM5-LTC can interface to eight industry standard thermocouple types: J, K, T, E, R, S, N, and B. Its corresponding output signal operates over a 0V to +5V range. Each module is cold-junction compensated to correct for parasitic thermocouples formed by the thermocouple wire and screw terminals on the mounting backpanel. Upscale open thermocouple detect is provided by an internal pull-up resistor. Downscale indication can be implemented by installing an external 47M Ω resistor, ± 20% tolerance, between screw terminals 1 and 3 on the OM5-BP backpanels. Signal filtering is accomplished with a six-pole filter which provides 95dB of normal-mode-rejection at 60Hz and 90dB at 50Hz. Two poles of this filter are on the field side of the isolation barrier, and the other four are on the computer side. After the initial field-side filtering, the input signal is chopped by a proprietary chopper circuit. Isolation is provided by transformer coupling, again using a proprietary technique to suppress transmission of common mode spikes or surges. The module is powered from +5VDC, ± 5%. A special input circuit provides protection against accidental connection of power-line voltages up to 240VAC.

FIGURE 1. OM5-LTC Block Diagram. –V LPF LPF +In

–In

–EXC

Backpanel Term Block

1

2 6

5

3 Surge Suppression and Protection +V

Isolated Field-Side

Power Isolated Computer-Side Power V OUT 20

19

22 I/O Common

RD EN\ 4

3

2

1 +EXC

–V +V 4

Thermocouple

Precision Reference

CJC

Temp Sensor +2.5V

Linearizer 100M Ω

Power Oscillator +5V 17

16 Power Common IsochopperTM

Amplifier Pat Pending NC

## 31 SPECIFICATIONS Typical at T A = +25 ° C and +5V power.

Module OM5-LTC Input Range –0.1V to +0.5V Input Bias Current –25nA Input Resistance Normal 50M Ω Power Off 40k Ω Overload 40k Ω Input Protection Continuous 240Vrms max Transient ANSI/IEEE C37.90.1-1989
CMV, Input to Output Continuous 1500Vrms max Transient ANSI/IEEE C37.90.1-1989 CMR (50Hz or 60Hz) 160dB NMR 95dB at 60Hz, 90dB at 50Hz
Accuracy See Ordering Information Stability Input Offset ± 1 μ

V/ ° C (1) Output Offset ± 20 μ V/ ° C Gain ± 25ppm/ ° C Noise Input, 0.1 to 10Hz 0.2 μ Vrms Output, 100kHz 300 μ Vp-p, 150 μ Vrms Bandwidth, –3dB 4Hz Response Time, 90% Span 0.2s
Output Range 0V to +5V Output Resistance 50 Ω Output Protection Continuous Short to Ground Output Selection Time 6 μ s at C load = 0 to 2000pF (to ± 1mV of V OUT ) Output Current Limit +8mA

Output Enable Control Max Logic “0” +0.8V Min Logic “1” +2.4V Max Logic “1” +36V Input Current, “0”, “1” 0.5 μ A Open Input Response Upscale Open Input Detection Time 10s Cold Junction Compensation Accuracy, 25 ° C ± 0.25 ° C Accuracy, +5 ° C to +45 ° C ± 0.5 ° C Accuracy, –40 ° C to +85 ° C ± 1.25 ° C
Power Supply Voltage +5VDC ± 5% Power Supply Current 30mA Power Supply Sensitivity ± 2 μ

V/% RTI (2)

Mechanical Dimensions 2.28" x 2.26" x 0.6" (58mm x 57mm x 15mm)

Environmental Operating Temp. Range –40 ° C to +85 ° C Storage Temp. Range –40 ° C to +85 ° C Relative Humidity 0 to 95% Noncondensing Emissions EN50081-1, ISM Group 1, Class A (Radiated, Conducted) Immunity EN50082-1, ISM Group 1, Class A (ESD, RF, EFT)



## ORDERING INFORMATION NOTES: (1) This is equivalent to ° C as follows: Type J 0.020 ° C/ ° C, Types K, T 0.025 ° C/ ° C, Type E 0.016 ° C/ ° C, Types R, S 0.168 ° C/ ° C, Type N 0.037 ° C/ ° C, Type C 0.072 ° C/ ° C. (2) Referenced to input.

MODEL TYPE INPUT RANGE OUTPUT RANGE ACCURACY † OM5-LTC-J1-C Type J 0 ° C to +760 ° C (+32 ° F to +1400 ° F) 0V to +5V ± 0.08% ± 0.61 ° C OM5-LTC-J2-C Type J -100 ° C to +300 ° C (-148 ° F to +572 ° F) 0V to +5V ± 0.08% ± 0.32 ° C OM5-LTC-J3-C Type J 0 ° C to +500 ° C (+32 ° F to 932 ° F) 0V to +5V ± 0.07% ± 0.36 ° C OM5-LTC-J4-C Type J -100 ° C to +760 ° C (-148 ° F to +1400 ° F) 0V to +5V ± 0.08% ± 0.70 ° C OM5-LTC-K1-C Type K 0 ° C to +1000 ° C (+32 ° F to +1832 ° F) 0V to +5V ± 0.08% ± 0.80 ° C OM5-LTC-K2-C Type K 0 ° C to +500 ° C (+32 ° F to +932 ° F) 0V to +5V ± 0.08% ± 0.38 ° C OM5-LTC-K3-C Type K -100 ° C to +1350 ° C (-148 ° F to +2462 ° F) 0V to +5V ± 0.08% ± 1.2 ° C OM5-LTC-T1-C Type T -100 ° C to +400 ° C (-148 ° F to +752 ° F) 0V to +5V ± 0.16% ± 0.80 ° C OM5-LTC-T2-C Type T 0 ° C to +200 ° C (+32 ° F to +392 ° F) 0V to +5V ± 0.13% ± 0.25 ° C OM5-LTC-E-C Type E 0 ° C to +1000 ° C (+32 ° F to +1832 ° F) 0V to +5V ± 0.10% ± 1.0 ° C OM5-LTC-R-C Type R +500 ° C to +1750 ° C (+932 ° F to +3182 ° F) 0V to +5V ± 0.10% ± 1.3 ° C OM5-LTC-S-C Type S +500 ° C to +1750 ° C (+932 ° F to +3182 ° F) 0V to +5V ± 0.10% ± 1.3 ° C OM5-LTC-B-C Type B +500 ° C to +1800 ° C (+932 ° F to +3272 ° F) 0V to +5V ± 0.15% ± 2.0 ° C † Includes conformity, hysteresis and repeatability. Does not include CJC accuracy.

## 48 

# OM5-BP-SKT-C ANALOG MODULE EVALUATION BOARD

FIGURE 19. OM5-BP-SKT-C Evaluation Board Dimensions And Pin Layout.

FIGURE 20. OM5-BP-SKT-C Evaluation Board Schematic. 

## DESCRIPTION
The OM5-BP-SKT-C is a single channel board with a test socket for OM5 module evaluation (Figure 19). All signal input/output, control, and power connections are connected to terminal blocks for ease of user access. A coldjunction temperature sensor circuit is included for evaluation of thermocouple modules. (See Figure 20 for schematic). The OM5-BP-SKT-C is mechanically compatible with DIN rail mounting using the following elements: 2 OM7-DIN-SF base elements with snap foot 2 OM7-DIN-SE side elements 4 OM7-DIN-CP connection pins
Two jumpers are provided for customer use. The first, J1, provides a current path between +5V Power Common (module pin 16) and I/O Common (module pin 19). A path must exist between the host control logic power common and module I/O Common for proper operation of the module output switch or track-and-hold circuit. If this connection exists elsewhere in the system, jumper J1 should be removed since possible ground loops could exist. Other connections of power ground and signal ground usually occur at the A/D or D/A converter of the host measurement system.
Jumper J2 is used in the cold junction compensation circuit. If it is installed,the compensation circuit is enabled and will provide the proper compensation voltage to correct for the thermoelectric effect at the +In and –In screw terminals. If an external simulation voltage is desired for cold junction compensation, J2 should be removed. The external voltage is applied at the sockets labled CJC+ and CJC–. An external voltage of 510.0 mV corresponds to an ambient temperature of +25 ° C. The transfer function of the onboard compensation circuit is V CJC = 0.510 –0.0025(T–25)V. Control Local I/O 0.25" (6.4mm) Typical 2.85" (72.4mm)

0.25" (6.4mm) Typical

RD EN\

WR EN\

Reserved

PCOM V OUT

I/O COM

V IN

I/O COM

TB3 +5V

PCOM J1

J2 – +

CJC

–EXC

–In +EXC

+In 4.25" (108mm)

TB4 TB1 TB2

OMX-1362-C

OMX-CJC-C

22
20
18
16

6 +In 4 +EXC
2 +SEN –In 5 –EXC 3
–SEN 1 23
21
19
17

PCOM I/O COM

–EXC +EXC –In +In V OUT I/O COM
V IN I/O COM RD EN\
WR EN\
Reserved

PCOM **TB1**

PCOM

**TB3** +5 PCOM

PCOM

**TB4** I/O COM

PCOM J1

CJC +

– **TB2**

NOTES: 1. J1 and J2 are factory installed. 2. SCMXCJC is a CJC temperature sensor. 3. Resistor SCMXR1 is an optional I/V conversion

resistor for current inputs, not factory installed. DZ1

LED

OMX-1362-C **OM5**

J2

OMX-CJC-CFAN-PWMINSTALLATION INSTRUCTIONSSPAL USA • 512 Tuttle Street, Des Moines, IA 50309-4618info@spalusa.com • www.spalusa.comMain/Sales: 800-345-0327 • Technical: 800-454-7725www.spalusa.comSPAL USALIMITED WARRANTY STATEMENTSPAL USA warrants this product to be free from defects in material and workmanship for a periodof 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 thewarranty period. The product should be returned, at the customer expense, to the location oforiginal purchase. This warranty does not cover any expenses incurred in the removal and/orreinstallation 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 repairedby anyone other than SPAL USA.This warranty is in lieu of other warranties, expressed or implied, including any implied warrantyof merchantability. No person is authorized to assume for SPAL USA any other liability concerning thesale of this product.IMPORTANT-KEEP YOUR INVOICE WITH THIS WARRANTY STATEMENT!The SPAL Electric Fan Controller (FAN-PWM) will Pulse Width Modulate a single SPAL electricfan allowing the unit to vary the fan speed based on engine temperature. A second fan canbe added with the use of an additional fan wiring kit (SPAL part number FRH). The secondfan will not be PWM controlled; it will be ON/OFF only.When the Low setting is reached the yellow LED will light and the fan will run at 100% for 1/2second to get the fan rotating. After the initial kick-start, the fan will run at 50%, or 1/2 speed.When the High setting is reached the red LED will light and the fan will run at 100%, or fullspeed, until the engine cools to the point that the fan can lower its speed. When the redLED lights, a negative output will also be sent on the grey wire. This is used to trigger asecondary fan relay.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 wheel well,the radiator support, or the firewall are good mounting locations.Single FanPlease see Single Fan wiring instructions on pages 5-8.Dual FanA 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 9-12.Factory (OEM) Temperature SensorThe 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. Someolder style sensors will not work.)-If using the factory OEM style sensor, the SPAL Fan Controller must be programmed.-Please see the programming section on pages 3 and 4.SPAL Temperature Sensor (FAN-PWM-TS)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 performance.-When using the SPAL temperature sensor, the Fan Controller is preset from the factorywith a Low setting of 160°, and a High setting of 200°.-If different settings are required, please see the programming section on pages 3 and 4.Low SettingHigh SettingWiring12Introduction / OverviewUnused WiresDepending 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 cut. However, if cutting the wires, be sure to coverthe ends of the wires with electrical tape or equivalent.If you are using Air Conditioning you can connect the Blue wire to the 12V wire of the airconditioning compressor. When the compressor turns on, the fan(s) will run at 100%. andthe green LED will light.Introduction / OverviewSuggested Fuse ValuesThe fusing of the FAN-PWM is dependent upon the size and style of fan used. Pleasereference the suggested fuse values table on Page 13.34LED’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.ProgrammingProgramming Section**The fan must remain unplugged during programming.**• 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 3seconds to set the “low temperature.”• Yellow LED will light.• When desired “high temperature” setting is reached, press and hold the “High”button for 3 seconds.• Red LED will light.• 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.LOW HIGH RED GREEN YELLOWExampleIf you want your fan to spin at half-speed at 160 degrees, and spin at full-speed at 200degrees, you would:•Unplug fan.•Warm-up vehicle to 160 degrees.•Press and hold Low Button for 3 seconds.• Yellow LED lights•Continue to warm-up vehicle to 200 degrees.• Press and hold High Button for 3 Seconds.• Red LED lights• 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 CONNECTORYTBATERCONNECT TO GROUND (WHITE)GROUND (BLACK)30 AMP FUSE MAXIMUMFUSEFAN GROUND (BLACK)FAN POSITIVE (RED)+12 VDC (RED)IGNITION INPUT (ORANGE)TEMPERATURE SENSOR (GREEN)TEMPERATURE SENSOR (BLACK)OPTIONAL SENSOR (PART#: FANPWM-TS)AVAILABLE SEPERATLYAIR CONDITIONING INPUT (BLUE) AIR CONDITIONING COMPRESSORGROUND+12VDC WHEN A/C IS ONYTBATERCONNECT TO GROUND (WHITE)GROUND (BLACK)30 AMP FUSE MAXIMUMFUSEFAN GROUND (BLACK)FAN POSITIVE (RED)+12 VDC (RED)IGNITION INPUT (ORANGE)TEMPERATURE SENSOR (GREEN)TEMPERATURE SENSOR (BLACK)OPTIONAL SENSOR (PART#: FANPWM-TS)AVAILABLE SEPERATLY56PWM Wire Connects To:Large GaugeRed Positive 12 VDC Directly to BatteryBlack Ground Directly to BatteryRed Primary Fan PositiveBlack Primary Fan GroundSmall GaugeOrange IgnitionBlue Air Conditioning InputGrey Secondary Fan Output (Not Used)Green/Black SPAL Temperature SensorWhite GroundPWM Wire Connects To:Large GaugeRed Positive 12 VDC Directly to BatteryBlack Ground Directly to BatteryRed Primary Fan PositiveBlack Primary Fan GroundSmall GaugeOrange IgnitionGrey Secondary Fan Output (Not Used)Green/Black SPAL Temperature SensorWhite GroundBlue Air Conditioning Input (Not Used)Single Fan - SPAL Sensor - with AC:Single Fan - SPAL Sensor - without AC: