SPAL FAN-PWM-V3 Instructions For Use Manual
FAN-PWM-V3
Instructions
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1
Parts Included In Kit
FA N-PWM CONTROLLER
HARDWARE BAG
INSTRUCTION BOOKLET
20 AMP FUSE
20
BCU+
FAN-PWM-V3 Controller (1)
MAIN HARNESS
FA N-PWM CONTROLLER
ITEMS INCLUDED IN KIT
HARDWARE BAG
INSTRUCTION BOOKLET
FUSE HOLDER
20 AMP FUSE
30 AMP FUSE
YELLOW RING CONNECTORS (2)
30
20
BCU+
DT06-3S
C B
Main Harness (1)
MAIN HARNESS
SPAL TEMP SENSOR HARNESS
FA N-PWM CONTROLLER
ITEMS INCLUDED IN KIT
HARDWARE BAG
INSTRUCTION BOOKLET
FUSE HOLDER
20 AMP FUSE
30 AMP FUSE
YELLOW RING CONNECTORS (2)
BLUE RING CONNECTORS
(2)
YELLOW BUTT CONNECTOR
(1)
30
20
BCU+
BA
DT06-3S
C B
SPAL Temp Sensor Harness (1)
OEM TEMP SENSOR HARNESS
MAIN HARNESS
SPAL TEMP SENSOR HARNESS
FA N-PWM CONTROLLER
ITEMS INCLUDED IN KIT
HARDWARE BAG
INSTRUCTION BOOKLET
FUSE HOLDER
20 AMP FUSE
30 AMP FUSE
YELLOW RING CONNECTORS (2)
BLUE RING CONNECTORS
(2)
YELLOW BUTT CONNECTOR
(1)
SELF TAPPING SCREWS
(4)
30
20
BCU+
BA
DT06-3S
C B
OEM Temp Sensor Harness (1)
OEM TEMP SENSOR HARNESS
MAIN HARNESS
POWER HARNESS
SPAL TEMP SENSOR HARNESS
FA N-PWM CONTROLLER
ITEMS INCLUDED IN KIT
HARDWARE BAG
INSTRUCTION BOOKLET
ZIP TIES
(12)
FUSE HOLDER
20 AMP FUSE
30 AMP FUSE
YELLOW RING CONNECTORS (2)
BLUE RING CONNECTORS
(2)
YELLOW BUTT CONNECTOR
(1)
SELF TAPPING SCREWS
(4)
30
20
BCU+
BA
DT06-3S
C B
Power Harness (1)
Hardware Bag
Fuse Holder (1)
Yellow Butt
Connector (1)
Self Tapping
Screws (4)
Zip Ties (12)
86
87
87a
85
30
FRH
OPTIONAL ITEMS
20
BCU+
20 Amp Fuse (1) 30 Amp Fuse (1)
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
30
20
BCU+
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
30
20
BCU+
Yellow Ring Connectors (2)
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
BCU+
Blue Ring Connectors (2)
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
BCU+
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
BCU+
86
87
87a
85
30
SPAL SENSOR
FRH
OPTIONAL ITEMS
BCU+
86
87
87a
85
30
SPAL SENSOR
FRH
30
20
Optional Equipment
86
87
87a
85
30
FRH
(Fan Relay Harness)
SPAL Sensor
86
87
87a
85
30
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2
Suggested Fuse Values
PULLER # PUSHER # DESCRIPTION AIRFLOW (CFM) RECOMMEDNED FUSE
9”
30102061 30102053 9” High Performance Fan / Paddle Blade 740 25
30100392 30100381 9” Fan 590 10
10”
30102057 30102058 10” High Performance / Paddle Blade 1120 25
30100360 30100374 10” Fan 650 10
11”
30102052 ------------- 11” Dual High Performance Fan / Pull 2780 30/Per Motor
30102054 30102040 11” High Performance Fan / Paddle Blade 1360 30
30101500 30101502 11” Medium Profile Fan 970 15
30100364 30100365 11” Fan 810 10
12”
30102130 ------------- 12” High Performance Dual Fan / Curved Paddle 3170 30/Per Motor
30102029 30102030 12” High Performance Fan / Curved Blade 1450 30
30102038 30102025 12” High Performance Fan / Paddle Blade 1640 30
30101504 30101505 12” Medium Profile Fan 1230 20
30100375 30100384 12” Fan 870 10
13”
30102044 30102045 13” High Performance Fan / Curved Blade 1640 30
30101507 30101508 13” Medium Profile Fan 1250 20
30100398 30100399 13” Fan 1030 10
14”
30102041 30102055 14” High Performance Fan / Striaght Blade 1650 30
30102042 30102056 14” High Performance Fan / Curved Blade 1780 30
30101509 30101510 14” Medium Profile Fan 1280 20
30100385 30100382 14” Fan 960 10
16”
30102113 ------------- 16” Extreme Performance Fan / Pull 2315 30
30102036 30102082 16” High Performance Fan / Straight Blade 2035 30
30102082 ------------- 16” High Performance Fan / Paddle Blade 1880 30
30102048 30102049 16” High Performance Fan 2025 30
30101516 30101517 16” Medium Profile Fan 1610 20
30100400 30100401 16” Fan 1300 15
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3
New Features of 3rd Generation PWM
**WHY THIS MAY BE IMPORTANT FOR YOU**
• Ability to reset to any one of 3 preset temperature ranges when using FAN-PWM-TS sensor
• Smart fan diagnostics detects stalled or over current fans to prevent module damage
• New 16 bit MCU for increased resolution on temperature sensor input
• Primary fan low power starts to reduce the current spike on electrical system
• Onboard status LED and status output for vehicle interior status light
• Quality Deutsch IPD connectors on the premium harness made in USA
• Silicone rubber button membrane and case seals for improved durability
• Improved AC input timing to minimize fan operation during defrost cycles
• Single unit capable of use with both 12VDC and 24VDC systems
In an effort to add features and improve quality of the FAN-PWM the functionality of the
unit may impede previous ‘creative’ installations of FAN-PWM’s.
• A brushed DC motor MUST be connected to the fan output or the unit will report an
error code. Possible use with very low power (<4A) fans and non SPAL products may
also cause fan not found error code. SPAL USA will not guaranty this products function-
ality with NON SPAL fans as too often specications are unknown.
• Over current protection means that the output will SHUT DOWN if the measured fan
continuous run current increases above 30A for extended periods. If running a fan ap-
proaching this amount of current draw (>25A), SPAL USA recommends that the installa-
tion also include a status light so the operator will be aware of fan status. See page 8 for
status light wiring.
• Because of timing sequences on the AC input wire when using a manual override
switch there will be a delay before the fan turns on/off with the switch.
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4
Introduction / Overview
Congratulations on your purchase of the SPAL FAN-PWM! Due to the various in-
stallation congurations, please carefully read the entire manual before installing
the FAN-PWM. This SPAL Electric Fan Controller (FAN-PWM) will vary the speed
of the fan based on engine temperature by using Pulse Width Modulation tech-
nology. A second fan can be added but requires the use of an additional relay to
control the secondary fan (SPAL part number FRH). The secondary fan will not be
variable speed; it will be ON/OFF only.
Because the FAN-PWM was designed to alter the speed of the fan, SPAL USA
suggests setting the High 10° to 20° above the thermostat rating and setting the
Low at least 10° below the High.
Instruction Manual Highlights
Wiring 15 - 19
Programming 11 - 14
Trouble Shooting 21 - 24
Frequently Asked Questions (FAQ) 25 - 26
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5
Operation
The FAN-PWM is equipped with 2 LED’s: a ‘STAT’ LED and a ‘FAN’ LED.
‘STAT’ LED will be lit when the unit is powered on, system checks are OK, and
the fans are not running.
The 3 color ‘FAN’ LED indicates when the fan output is active, and is also used
during programming. Each color represents the following: AMBER for temperatures above LOW, RED for temperatures above HIGH, and GREEN when the
A/C input has been activated.
When the Low temperature setting is reached, the ‘FAN’ LED will light AMBER,
and the fan will run at 50% or ½ speed. The fan will then gradually increase
in speed as the engine temperature rises. If the high temperature setting is
reached, the ‘FAN’ LED will light RED, and the fan will now be running at full
speed. (continued next page)
Front View of PWM
ENTR PRG STAT FAN
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6
Operation
(continued)
Mounting
The SPAL FAN-PWM is water resistant and can be mounted in the engine bay or
inside the vehicle. Keep the controller away from high heat sources such as the
engine exhaust. Above the wheel well, on the radiator support, or rewall are
good examples of proper locations.
When the ‘FAN’ LED lights RED, a negative output will be sent on the gray wire.
This gray wire can be used to trigger a fan relay, an indicator light, etc. If you are
using dual fans with the recommended wiring setup (refer to pages 18/19) your
2nd fan will turn on full speed at this time.
If the cooling system is able to lower the coolant temperature approximately 5°
below the High setting, the ‘FAN’ LED will turn from RED to AMBER and the fan
will slow in speed; at this time the second fan output will stop as well. If the cooling system is able to continue to lower the coolant temperature to approximately
5° degrees below the low setting, the ‘FAN’ LED will turn off, the ‘STAT’ LED will
light GREEN, and the fan will stop completely.
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7
Temperature Sensor Connection
The FAN-PWM can be used with most vehicle’s original temperature sensor
circuits and aftermarket electric temp gauges. This eliminates the need for an
additional sensor. Some older cars’ sensors (as those circa the 1970’s) may not
work. If you experience problems, please call our technical support line for assistance 1-800-454-7725.)
Vehicles With known issues:
• Ford modular engine’s coolant/head temp (4.6/5.4L) range switching @ ~200 degrees
• GM Duramax (could be other new GM also) multi range switching @ ~160 degrees
With these sensors the same voltage will exist at multiple temperatures. If you
set the controller above the switching point of the sensor range it will technically work. The problem is that the fan will turn on at cold startup initially, turn
off, before coming on again at the proper temperature.
• Please see the PROGRAMMING section on pages 11-14.
• If using this type of sensor, the SPAL FAN-PWM must be programmed to your desired
temperature points as the default settings will not be properly calibrated.
Note: Both large and small gauge ground wires must be grounded.
Single Fan: Please see SINGLE FAN WIRING instructions on Page 16 and 17.
Dual Fan: A dual fan set-up requires a Fan Relay Harness (SPAL part number
FRH) to power the secondary fan. Please see DUAL FAN WIRING
instructions on Page 18 and 19
Connecting To A Factory OEM Temperature Sensor
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8
Temperature Sensor Connection
If your vehicle is not equipped with an OEM temperature sensor, you can purchase a SPAL temperature sensor (SPAL part number FAN-PWM-TS) that plugs
directly into the fan controller harness. This sensor should be located in the engine for optimal performance.
• When using the SPAL temperature sensor, the fan controller has a factory
preset with a Low setting of ~190° and High setting of ~205°.
• If different settings are required, please see the PROGRAMMING section
on pages 11-14.
Optional Status Output
The FAN-PWM provides a negative output for an external device such as a LED
(not provided) to be used to remotely show the status of the system. With the
vehicle’s ignition on, the status output will indicate the following:
• No output: All checks OK, fan not running
• Output on: Fan output is active (fan could be running low to high speed)
• Blinking output: Indicates an error code; watch ‘STAT’ LED on module for
error code (See page 21)
STA T US LIGHT/LED
- STA T US OUTPUT (BROWN)
+ 12VDC IGNITION POWER
12V
SPAL Temperature Sensor (FAN-PWM-TS)
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