Technical Information. FDCA Fan Drive Control Assembly

Transcription

1 Technical Information Fan Drive Control Assembly

2 CONTENTS Description...3 Features...3 Theory of Operation... 4,5 Technical Data... 5, Dimensions...7 Ordering Nomenclature Chart...8 Accessories...9 Service Parts...9 Wiring Information and FDC Service Part Cross Reference General Machine Wiring Guidelines... 0 Set-up Software Toolbox...0- Using Set-Up Software...-5 Set-up Software Parameter Log... Ordering Information... 7 Customer Service Contacts... 7 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

3 DESCRIPTION Sauer-Danfoss electronic fan drive controllers are designed to control the speed of an engine fan in proportion to cooling demand by modulating oil flow to the hydraulic motor driving the fan. Flexible microcontroller hardware, comprehensive software and integrated hydraulic valve packaging allow one controller to be applied to all Sauer-Danfoss hydraulic fan drive system configurations. Depending on hydraulic system components, fan drive control may be accomplished with either a stand-alone electronic Fan Drive Controller (FDC) or an integrated hydraulic valve/electronic control package designated Fan Drive Control Assembly (). The consists of a proportional solenoid cartridge valve mounted in an aluminum manifold to which an FDC electronics module is attached. The FDC electronics module supports up to three analog temperature input signals, one engine computer PWM input signal and two auxiliary input switches. Input signal(s) sent to the FDC are processed by the microcontroller and an output signal proportional to the cooling circuit having the greatest cooling demand is sent to the solenoid valve. The is typically used to control either gear pump/gear motor or open circuit piston pump/gear motor systems. In gear pump/gear motor systems the provides a pilot pressure signal to a flow divider valve located at the gear motor inlet. In open circuit piston pump applications, the is installed in the pump load sensing circuit. FEATURES Rugged hardware design, including die cast zinc housing and thermally conductive potted electronics, that withstands mobile machine operating conditions including shock, vibration, EMI/RFI, high pressure wash downs, temperature and humidity extremes. Hardened electronics operate over a range of 9 to 3 volts with reverse battery, negative transient and load dump protection. Infrared communication eliminates exposed connector pins. Robust application software controls all available Sauer-Danfoss fan drive system configurations. Input sensor and valve output parameters configured by easy-touse set-up software. Integrated electronic and hydraulic packaging. Valve hysteresis less than 5% of rated pressure over operating range. Maximum pressure drop of 0.3 bar (50 psid) at full current. BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 3

4 THEORY OF OPERATION The modulates hydraulic fan drive system pilot pressure in response to input electrical signals from temperature sensors and switches. A current signal proportional to required cooling demand is sent from the FDC Electronics Module to the normally closed proportional solenoid valve causing pilot pressure to change. Increased current to the valve opens the valve, lowering pilot pressure. The pilot pressure provides a hydraulic signal to a flow control device which modulates fan motor oil flow and hence fan speed. Typical flow control devices are: Switch Valve In a gear pump/gear motor fan drive system the switch valve, a normally closed flow diverter device, is usually located on the inlet to the gear motor. Changes in pilot pressure cause the valve to divert oil flow either to or away from the motor, thus modulating fan speed. When cooling demand is high, the increases pilot pressure which signals the switch valve to proportionally divert more oil to the fan motor, thus increasing fan speed. Conversely when cooling demand diminishes, the decreases pilot pressure which signals the switch valve to by-pass flow away from the fan motor, thus decreasing fan speed. Open Circuit Piston Pump Load Sensing Fan Drive Control In an open circuit piston pump application, the pump load sensing control line is connected to the reservoir through the proportional solenoid valve. Pressure in the load sensing line is regulated by either opening or restricting flow across the proportional solenoid valve. A command for increased cooling causes the output current to the proportional solenoid valve to drop, causing the valve to restrict flow, thus building pressure in the load sensing control line. This pressure is additive to the pump s load sensing spring setting and commands the pump to increase flow, hence fan motor speed, until a system pressure is reached that is high enough to balance the load sensing control. Conversely, a command for less cooling causes the proportional solenoid to open, thus reducing pressure in the load sensing line. This lower pressure commands the pump to lower flow, hence, fan motor speed, until a system pressure is reached that is low enough to balance the load sensing control. Software The FDC is a six input, one output micro electronic fan speed controller. The application software program is loaded into the device at the factory and cannot be changed by the user. Set-up software allows application software control parameters to be configured for specific engines, cooling system designs and temperature conditions. The following information describes the theory of operation of the application software. On power-up, the microcontroller initializes and starts the temperature control application program. Each time the program is executed, the microcontroller looks to see which of the temperature and switch inputs are enabled. For each enabled temperature input (analog temperature, PWM input), the program establishes a relationship between the measured temperature and the required current output for that temperature. The current output controls the flow of oil to the fan motor and hence fan speed by establishing the position of the proportional solenoid valve. If more than one temperature input is enabled, the program compares all inputs, and the input requiring the most cooling (highest fan speed) is the input that controls the output current sent to the valve. If the microcontroller detects the absence of an enabled temperature input, it will 4 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

5 THEORY OF OPERATION (CONTINUED) default the output to that required for maximum cooling. The two auxiliary input switches can be enabled through set-up software and can be configured to be either normally open or normally closed. Each switch can be configured to drive the microcontroller output to demand maximum (on) or minimum (off ) cooling when the switch is activated. Each time the application program is executed, in addition to looking at temperature inputs, the program looks at enabled switch inputs. If an enabled switch input is configured to drive the fan to a pre-configured higher speed when the switch is activated, the program will give this output equal priority with the other calculated outputs. The higher speed is configured via set-up software. If a switch input is configured to drive the fan to off (minimum speed), this output is given priority over all other calculated outputs. This is an emergency fan shutdown condition. Requested output current can be inverted through set-up software, allowing the use of one FDC software program in Fan Drive systems using either normally open or normally closed proportional solenoid valves. TECHNICAL DATA! Auxiliary switches are powered by a protected FDC voltage source. Do not connect external voltage sources. This section reviews all of the available inputs. Refer to pages 9 through 9 for enabled input options for specific part numbers. Inputs THREE ANALOG TEMPERATURE THERMISTOR INPUTS. Each can be enabled or disabled by set-up software. Each sensor is powered by a protected FDC voltage source. No input can exceed the reference voltage of 5 Vdc. Sensor voltage is measured to determine temperature. Sensor temperature ranges and ramp rates for increases or decreases in fan speed are adjustable through set-up software. FDC software is designed to recognize open and grounded temperature inputs. Either condition will cause a full fan speed default. ONE ENGINE ELECTRONIC CONTROLLER PWM INPUT. This input can be hardware configured (per the ordering nomenclature) to be either pull up or pull down, depending on the type of engine controller. This input is assumed to be a square wave in the range of 40 to 00 Hz that is either open/grounded or open/ battery voltage. The input PWM duty cycle is assumed to be directly proportional to engine cooling demand and, therefore, to required fan speed. The input maximum and minimum PWM duty cycles can be configured through the set-up software. Ramp rates for increases and decreases in fan speed are also configurable. TWO DIGITAL AUXILIARY INPUTS. Each switch input can be enabled or disabled and configured as normally open or closed using set-up software. Both can be configured to turn the fan on or off. If configured to turn the fan on, output current to the valve or EDC is configurable in set-up software, allowing less than full fan speed conditions. Ramp times for increases or decreases in fan speed are also configurable. Switches are powered by a protected internal FDC 5 Vdc power source. BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 5

6 TECHNICAL DATA (CONTINUED) Electronics module BAT+ should be connected to ignition (not accessory) circuit.!! User must specify whether supply voltage to the is V or 4 V when ordering. Outputs ONE VALVE OUTPUT. Output is a high current (.5 A max.) PWM signal. A smart FET solid state switch controls PWM output. When on, it acts like a low impedance connection to battery (+). When off it appears as open. Output wave forms are adjustable through set-up software in a range of 40 Hz to 00 Hz. Output is fully protected from shorts or excessive loads. Power Supply The allowable input power range for the FDC electronic module is 9-3 Vdc. V and 4 V coils are available for the solenoid. Communication An infrared port is provided for asynchronous data communication between the FDC and a personal computer via an infrared communicator. This port follows protocol established for RS3 communication data transferred via an infrared interface. Electrical Connectors Refer to pages 9 through 9 for connector information relating to specific part numbers. Connector Pinout Diagrams Refer to pages 9 through 9 for connector information relating to specific part numbers. Valve Maximum inlet port pressure: 4,4 bar (3500 psi) Maximum outlet port pressure:,9 bar (00 psi) Maximum flow rate:,9 lpm (0.5 gpm) Internal relief pressure setting at zero current: 0,9 + 0,7/-0 bar at /-0 lpm ( /-0 psi at /-0 gpm) Pressure drop at full input current: 0,3 bar max at /-0 lpm (50 psi max at /-0 gpm) ENVIRONMENTAL Operating Temperature Range -40 C to 05 C (-40 F to F) Moisture Valve Coil: IP 7/NEMA + Electronics: Protected against 95% relative humidity and high pressure wash downs Vibration 5 to 000 Hz with resonant dwell for million cycles for each resonant point run from to 0 Gs Shock 50 Gs for ms in all three axes for a total of 8 shocks EMI/RFI 35 V/M in range of MHz to GHz BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

7 DIMENSIONS PILOT SUPPLY PORT - SAE Port Straight Thread O-Ring Boss 84 mm 3.30 in 80,4 mm 3. in 3, mm.93 in 305 ±,7 mm to end of connector ±.05 in 0,4 mm.80 in X M8 x.5-h THD x,7 mm DP TORQUE FASTERNERS TO: 9, ±.0,5 mm Nm 8 ± 5 in lb 38,mm.50 in 08,7 mm 4.8 in 7, mm 3.00 in 58,4 mm.30 in TANK RETURN PORT - SAE Port Straight Thread O-Ring Boss 58,4 mm.30 in 7, mm 3.00 in 5,4 mm. in 50, mm 5.93 in 9,9 mm.39 in 0A BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 7

8 ORDERING NOMENCLATURE CHART XX H X X X X X X X X X 3000/0 XX FAN DRIVE CONTROL ASSEMBLY MACHINE BATTERY VOLTAGE = VDC 4 = 4 VDC FDC OUTPUT CURRENT H = HIGH SOFTWARE PROGRAMMING F = FACTORY DEFAULTS C = CUSTOMER SPECIFIC PWM INPUT PRESENT Y = YES, PULL UP (DETROIT DIESEL) D = YES, PULL DOWN (CUMMINS, CAT, DEERE) N = NO PWM OF TEMPERATURE SENSORS PRESENT 0 = NO SENSORS = ONE SENSOR = TWO SENSORS 3 = THREE SENSORS VALVE LOGIC NC = NORMALLY CLOSED NO = NORMALLY OPEN VALVE RELIEF SETTING 3000/0 = 0 BAR (3000 PSI) * FIFTH CONNECTOR DESCRIPTOR (SPECIFY TYPE) / OF S * FOURTH CONNECTOR DESCRIPTOR (SPECIFIC TYPE) OF S * THIRD CONNECTOR DESCRIPTOR (SPECIFY TYPE) / OF S * SECOND CONNECTOR DESCRIPTOR (SPECIFY TYPE) / OF S * FIRST CONNECTOR DESCRIPTOR (SPECIFY TYPE) / OF S OF AUXILIARY SWITCHES PRESENT 0 = NO SWITCH = ONE SWITCH = TWO SWITCHES * Consult factory for designation. 8 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

9 ACCESSORIES Temperature Sensors Sauer-Danfoss liquid and air temperature sensors must be used in conjunction with Sauer-Danfoss devices. The liquid temperature sensor part number is The air temperature sensor part number is Refer to BLN for complete product information. Set-Up Toolbox An FDC Electronics Module Set-Up Toolbox, Sauer-Danfoss part number , is required to communicate with the FDC, allowing device software parameters to be configured. For a description of Toolbox components, refer to pages 0 through 5. Electrical Mating Connector Kits Sauer-Danfoss has assembled mating connector components into a kit for each connector. Refer to pages 9 through 9 for electrical mating connector kit part numbers. SERVICE PARTS FDC The FDC electronics module attached to the is not repairable and must be replaced if a failure occurs. Since FDC replacement parts must contain the same software tuning parameters as the original part, each has a specific FDC service part. Refer to pages 9 through 9 for FDC service part numbers. FDCM The following Fan Drive Control Manifold (FDCM) service components are available: K744 k745 K74 K748 Coil Nut Vdc Coil 4 Vdc Coil Weather Seal Kit WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE The following ten pages contain mating connector wiring information, hardware nomenclature and FDC Service Part numbers for all part numbers. For software tuning parameter information consult Customer Service in Minneapolis (see Customer Service, page 7). BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 9

10 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCN PWPS PWPS HIRF3 3000/0 NC HCN PWPS PWPS HIRF3 3000/0 NC HCN PWPS PWPS HIRF3 3000/0 NC J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K03383 (J), K807 (J3) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - WEATHER-PACK SHROUD ON SOCKETS (8-0 AWG) SOCKETS (4- AWG) MATES WITH J3, - WEATHER-PACK SHROUD ON SOCKETS (8-0 AWG) SOCKETS (4- AWG) J-A J-B J3-A J3-B J3-C J3-D J3-E J3-F Pinout Information FUNCTION BATTERY - BATTERY + SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR + TEMP SENSOR - J3 7 WIRE COLOR BROWN RED GREEN BLUE WHITE BLACK BLACK/WHITE BROWN/WHITE 0 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

11 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCN PWPT PWPT HIRF3 3000/0 NC J 8 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K03377 (J), K0 (J3) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - WEATHER-PACK TOWER ON MATES WITH J3, - WEATHER-PACK TOWER ON J-A J-B J3-A J3-B J3-C J3-D J3-E J3-F Pinout Information FUNCTION BATTERY - BATTERY + SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR + TEMP SENSOR - J3 9 WIRE COLOR BROWN RED GREEN BLUE WHITE BLACK BLACK/WHITE BROWN/WHITE BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

12 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCY3 DCP DCR8 HIRF3 3000/0 NC J J3 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K93 (J3), K90 (J) DESCRIPTION VENDOR VENDOR PART MATES WITH J, 8- DEUTSCH ON W/LOCK SOCKET TERMINALS S DEUTSCH DEUTSCH DEUTSCH DEUTSCH DTM 0-85A WM-8S MATES WITH J3, - DEUTSCH ON DEUTSCH W/LOCK DEUTSCH TERM DEUTSCH S DEUTSCH DTM O4-P WM-P QUANTITY REQUIRED J- J- J-3 J-4 J-5 J- J-7 J-8 J3- J3- J3-3 J3-4 J3-5 J3- Pinout Information FUNCTION BATTERY - BATTERY + SWITCH + SWITCH - SWITCH + SWITCH - PWM TEMP SENSOR + TEMP SENSOR - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR 3 + TEMP SENSOR 3-0 WIRE COLOR BROWN RED GREEN BLUE VIOLET GREY YELLOW/BLACK GED WHITE BLACK BLACK/WHITE BROWN/WHITE RED/WHITE ORANGE/BLACK BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

13 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCD00 PWPT PMPF HIRF3 3000/0 NC HCD00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC NOT AVAILABLE HCY00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC HCY00 PWPT PMPF HIRF3 3000/0 NC NOT AVAILABLE HCD00 PWPT PMPF HIRF3 3000/0 NC NOT AVAILABLE HCD00 PWPT PMPF HIRF3 3000/0 NC NOT AVAILABLE HCD00 PMPF HIRF3 PWPT 3000/0 NC HCY00 PMPF HIRF3 PWPT 3000/0 NC HCD00 PMPF HIRF3 PWPT 3000/0 NC J 3 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K30 (J), K78 (J3) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - METRI-PACK SHROUD ON TPA MATES WITH J3, - WEATHER-PACK TOWER ON J-A J-B J3 Pinout Information FUNCTION BATTERY - BATTERY + PWM J3 WIRE COLOR BROWN RED YELLOW/BLACK BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 3

14 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCY00 PWPT PMPS HIRF3 3000/0 NC HCD00 PWPT PMPS HIRF3 3000/0 NC HCY00 PWPT PMPS HIRF3 3000/0 NC J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K03383 (J), K78 (J3) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - WEATHER-PACK SHROUD ON TERM, SOCKET MATES WITH J3, - WEATHER-PACK TOWER ON J-A J-B J3 Pinout Information FUNCTION BATTERY + BATTERY - PWM J3 WIRE COLOR RED BROWN YELLOW/BLACK 4 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

15 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCN0 PWPS HIRF3 3000/0 NC NOT AVAILABLE HCN0 PWPS HIRF3 3000/0 NC NOT AVAILABLE 0907 HCN0 PWPS HIRF3 3000/0 NC 0908 J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K35 (J) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - WEATHER-PACK SHROUD ON TERM SKT 8-0 TERM SKT 4- CABLE CABLE CABLE J-A J-B J-C J-D J-E J-F Pinout Information FUNCTION BATTERY - BATTERY + TS + TS - TS + TS - 7 WIRE COLOR BROWN RED WHITE BLACK BLACK/WHITE BLACK/WHITE BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 5

16 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCY3 PWPT3 PWPT4 PWPT HIRF3 3000/0 NC J 4 J3 5 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K0830 (J), K03378 (J3), K0 (J4) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, 3- WEATHER-PACK TOWER ON MATES WITH J3, 4- WEATHER-PACK TOWER ON MATES WITH J4, - WEATHER-PACK TOWER ON J-A J-B J-C J3-A J3-B J3-C J3-D J4-A J4-B J4-C J4-D J4-E J4-F Pinout Information FUNCTION POWER + PWM INPUT POWER - SWITCH + SWITCH - SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR 3 + TEMP SENSOR 3 - J4 9 WIRE COLOR RED YELLOW/BLACK BROWN GREEN BLUE VIOLET GRAY WHITE BLACK BLACK/WHITE BROWN/WHITE RED/WHITE ORANGE/BLACK BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

17 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCY0 PMPM7 HIRF3 3000/0 NC J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K408 (J) DESCRIPTION VENDOR VENDOR PART MATES WITH J, 7- METRI-PACK ON SECONDARY LOCK SOCKETS QUANTITY REQUIRED 5 5 J-A J-B J-C J-D J-E J-F J-G Pinout Information FUNCTION BATTERY - BATTERY + PWM INPUT BLOCKED OUT SWITCH + SWITCH - NOT USED WIRE COLOR BROWN RED YELLOW/BLACK GREEN BLUE BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 7

18 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HFN PMPM8 HIRF3 3000/0 NC HFN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC HCN PMPM8 HIRF3 3000/0 NC 0909 J 7 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K409 (J) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, 8- METRI-PACK 50 SERIES ON SECONDARY LOCK TERMINALS, SOCKET J-A J-B J-C J-D J-E J-F J-G J-H Pinout Information FUNCTION BATTERY - BATTERY + TEMP SENSOR + TEMP SENSOR - SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - WIRE COLOR BROWN RED BLACK/WHITE BROWN/WHITE GREEN BLUE WHITE BLACK 8 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

19 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCY0 PWPT PMPF PWPT4 HIRF3 3000/0 NC J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K78 (J), K30 (J3), K03378 (J4) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, - WEATHER-PACK TOWER ON MATES WITH J3, - METRI-PACK ON TPA MATES WITH J4, 4- WEATHER-PACK TOWER ON S J-A J3-A J3-B J4-A J4-B J4-C J4-D Pinout Information FUNCTION PWM INPUT POWER - POWER + SWITCH + SWITCH - SWITCH + SWITCH - J3 3 J4 5 WIRE COLOR YELLOW/BLACK BROWN RED GREEN BLUE VIOLET GRAY BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 9

20 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART 0909 HFY3 AMP5 HIRF3 3000/0 NC HFD3 AMP5 HIRF3 3000/0 NC HFY3 AMP5 HIRF3 3000/0 NC HFD3 AMP5 HIRF3 3000/0 NC J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K3383 (J) DESCRIPTION VENDOR VENDOR PART MATES WITH J, 5- AMP MATE-N-LOCK ON TERMINAL SOCKETS AMP AMP AMP AMP QUANTITY REQUIRED 3 J- J- J-3 J-4 J-5 J- J-7 J-8 J-9 J-0 J- J- J-3 J-4 J-5 Pinout Information FUNCTION BATTERY - BATTERY + SWITCH + SWITCH - SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR + TEMP SENSOR - TEMP SENSOR 3 + TEMP SENSOR 3 - PWM INPUT 8 WIRE COLOR BROWN RED GREEN BLUE VIOLET GRAY WHITE BLACK BLACK/WHITE BROWN/WHITE RED/WHITE ORANGE/BLACK YELLOW/BLACK 0 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

21 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART 0908 HCD00 HIRF3 AMP5 3000/0 NC 0908 J Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K3383 (J) DESCRIPTION VENDOR VENDOR PART MATES WITH J, 5- AMP MATE-N-LOCK ON TERMINAL SOCKETS AMP AMP AMP AMP QUANTITY REQUIRED 3 J- J- J-3 J-4 J-5 J- J-7 J-8 J-9 J-0 J- J- J-3 J-4 J-5 Pinout Information FUNCTION BATTERY - BATTERY + PWM INPUT 8 WIRE COLOR BROWN RED YELLOW/BLACK BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

22 WIRING INFORMATION AND FDC SERVICE PART CROSS REFERENCE PART FDC SERVICE NOMENCLATURE PART HCN3 HIRF3 PMPM8 PWPT 3000/0 NC J 7 J3 Sauer-Danfoss Electrical Mating Connector Kit Part Number(s): K409 (J), K03377 (J3) DESCRIPTION VENDOR VENDOR PART QUANTITY REQUIRED MATES WITH J, 8- METRI-PACK 50 SERIES ON SECONDARY LOCK TERMINALS, SOCKET MATES WITH - WEATHER-PACK TOWER ON J-A J-B J-C J-D J-E J-F J-G J-H Pinout Information FUNCTION BATTERY - BATTERY + TEMP SENSOR + TEMP SENSOR - SWITCH + SWITCH - TEMP SENSOR + TEMP SENSOR - 8 WIRE COLOR BROWN RED BLACK/WHITE BROWN/WHITE GREEN BLUE WHITE BLACK BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

23 GENERAL MACHINE WIRING GUIDELINES! Unused pins on mating connectors must be plugged.. All wires must be protected from mechanical abuse. Wire can be run in flexible metal or plastic conduits.. Use 85 C wire with abrasion resistant insulation. 05 C wire should be considered near hot surfaces. 3. Use #8 gage wire. 4. Separate high current wires such as solenoids, lights, alternators, or fuel pumps from control wires. 5. Run wires along the inside of, or close to, metal machine frame surfaces where possible. This simulates a shield which will minimize the effects of EMI/RFI radiation.. Do not run the wires near sharp metal corners. Consider running the wire through a grommet when rounding a corner. 7. Do not run wires near hot machine members. 8. Provide strain relief for all wires. 9. Avoid running wires near moving or vibrating components. 0. Long unsupported wire spans should be avoided.. All sensors and valve drive circuits have dedicated wired power sources and ground returns. They should be used.. Sensor lines should be twisted about one turn every 0 cm (4 inches). 3. It is better to use harness anchors which will allow wires to float with respect to the machine frame rather than rigid anchors. SET-UP SOFTWARE TOOLBOX The Sauer-Danfoss part number Fan Drive Controller Set-up Toolbox provides all of the accessories required to communicate with, and change control parameters in, Sauer-Danfoss electronic fan drive controllers (FDC). FDC temperature control software can be configured for a wide array of vehicle cooling applications by using set-up software installed on a personal computer (PC) to change parameters. Serial communication between a PC and the FDC is accomplished using an infrared communicator. The infrared communicator is connected to the PC by a DB9 serial cable and interfaces with infrared sensors located on the underside of the FDC, allowing serial transfer of data to the FDC. The FDC Set-up Toolbox consists of an infrared communicator, power supply for the communicator, alignment fixture, serial cable and FDC set-up software. TOOLBOX COMPONENT PART S Serial Cable K55 Fan Drive Controller Set-up Software, CD Media Fan Drive Controller Infrared Communicator Infrared Communicator Power Supply K3047 Fan Drive Controller Alignment Fixture K783 Two Fan Drive Controller Alignment Fixture Screws K035 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 3

24 SET-UP SOFTWARE TOOLBOX (CONTINUED) The communicator is designed to be used in indoor or sheltered, nonhazardous environments. Do not expose the communicator or its power supply to moisture. Operating temperature range is from -0 C to +50 C (-4 F to F). Operation in bright sunlight may cause intermittent communication disconnects. Note that alignment fixture screws have english threads. Do not attempt to use the screws that attach the FDC to the hydraulic manifold. These screws have metric threads.!! TECHNICAL INFORMATION Serial Cable The cable is feet long, DB9 style RS3, male/female extension cable. It connects the PC to the Infrared Communicator. FDC Set-up Software The set-up software allows the user to read and write application parameters such as temperature ranges and ramp rates and enables and disables FDC application software options. FDC set-up software is designed to be installed on personal computers running the Windows 95 operating system. For a detailed explanation of how to use FDC set-up software to change parameters, see Using FDC Set-up Software. Infrared Communicator The infrared communicator serves as the interface between the FDC and a PC. Infrared sensors on the Communicator interface with infrared sensors on the FDC allowing serial transfer of parameter data. Communicator Power Supply The Toolbox infrared communicator operates on a 5 Vdc, 750 ma power supply. The power supply is designed to be plugged into a 0 Vac outlet. Alignment Fixture The alignment fixture allows the FDC and communicator infrared sensors to be held in a fixed geometric relationship with each other, ensuring trouble free communication between the FDC and PC (see Alignment Fixture with Communicator and FDC diagram, below). The FDC is attached to the alignment fixture using the two screws included with the fixture. The infrared communicator is clamped to the opposite end of the alignment fixture from the FDC. Be sure that the infrared sensors on the FDC are facing the infrared sensors on the communicator. Alignment Fixture with communicator and FDC 00B 4 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

25 USING SET-UP SOFTWARE Machine battery voltage must be applied to the FDC when changing tuning parameters. Power must be connected to the infrared communicator power supply when changing tuning parameters.!! ESTABLISHING COMMUNICATION WITH THE FDC. Follow installation instructions on the software package to install fan drive set-up software on a PC. Minimum PC requirements are a 48/ MHz processor with MB of memory running Windows 95. Sauer-Danfoss logo icon will be installed on the PC desktop.. Remove the FDC from the hydraulic manifold and attach it to the alignment fixture using the screws provided with the alignment fixture. 3. Clamp the infrared communicator to the opposite end of the alignment fixture, making sure that the infrared sensors on the communicator are facing the sensors on the bottom of the FDC. 4. Connect the serial cable to the infrared communicator and PC. 5. Connect the infrared communicator power supply.. Click on the Sauer-Danfoss icon to run the set-up software parameter change screen. 7. Click on the arrow (run) icon located in the upper left corner of the parameter change screen. 8. The communication dialog box on the parameter change screen will indicate that communications have been established. It may be necessary to adjust the alignment of the communicator and FDC to establish communications. USING SET-UP SOFTWARE TO ADJUST FDC CONFIGURATION PARAMETERS How To Use the Parameter Set-Up Screen to Configure an FDC To access FDC set-up software and establish communications with the device, click on the Sauer-Danfoss icon on the PC desktop as described above. Apply power to the FDC and click on the arrow (run) icon located in the upper left corner of the parameter change screen ( Screen ). When communications have been established, the FDC Device Number, Software Revision number, Date Assembled and Parameter Revision number will be displayed in the upper center of the screen. The yellow communications dialog box in the lower right corner of the screen displays communications messages. These messages will indicate the status of communications between the PC and FDC. Communications baud rate is indicated in the lower left of the communications dialog box. BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 5

26 USING SET-UP SOFTWARE (CONTINUED) FUNCTION BUTTONS BELOW THE COMMUNICATIONS DIALOG BOX PROGRAM Clicking on this button will download control parameters that have been entered on the PC screen into FDC memory. Note: This button must be used to save changes made on the screen to FDC memory. LOAD DEFAULTS Clicking on this button will load the factory-set default parameters into FDC memory. UNDO CHANGES Clicking on this button will undo parameter changes made since the last time communication was established with the FDC. EXIT Clicking on this button will exit the set-up program. Note: A communication status color bar is located in the upper center of the screen. If this bar is green, communications between the set-up software and FDC are established. If red, no communication is occurring. The yellow communications dialog box will report fault information. The Control Status dialog box in the upper left corner of the screen indicates which of the inputs is controlling the FDC output. The color bar to the right of the words control status will be green under normal conditions. Red indicates either an abnormal condition or a normal condition where no input is requesting a cooling output. The yellow communications dialog box will report the abnormal condition. Buttons along the bottom of the screen allow the user to enable or disable each of the three analog temperature inputs, one PWM input and two auxiliary switch inputs. Note: If an input is disabled, the microcontroller will ignore a sensor, signal or switch connected to the disabled input. The PWM Input Normal button allows the user to reverse the logic of the input PWM signal. In normal condition, a low PWM duty cycle indicates high cooling demand and therefore a high fan speed. Clicking on the button will cause the PWM input to be inverted so that a low PWM duty cycle indicates low cooling demand. The Valve Output Normal button has two modes: Normal, meaning output PWM is connected to a normally closed valve (increases in output duty cycle reduce fan speed) and inverted meaning that the PWM output is connected to a normally open valve (increases in output duty cycle increase fan speed). CONFIGURING SENSOR INPUTS AND OUTPUTS Parameters for the output PWM signal, three input temperature sensors, and one input PWM signal are configured using the displays along the left side of the screen: VALVE PWM FREQUENCY (HZ) sets the output PWM frequency being sent to the proportional solenoid valve or EDC. Available range is Hz. MINIMUM VALVE CURRENT (AMPS) adjusts the PWM duty cycle to deliver the minimum effective current to the valve, defined as the minimum amount of current required to initiate valve movement. Available range is 0-.5 A. MAXIMUM VALVE CURRENT (AMPS) adjusts the PWM duty cycle to deliver the maximum effective current to the valve, defined as the amount of current required to fully stroke the valve. Available range is 0-.5 A. BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

27 USING SET-UP SOFTWARE (CONTINUED) MAXIMUM VALVE CURRENT (AMPS) continued. The two meters in the upper right corner of the screen indicate the status of the output current. The requested current meter indicates the output current required to satisfy the controlling input. The actual current meter indicates the current actually being output to the proportional solenoid valve. The difference between the two meters shows the effect of configured ramp rates. SENSOR,, 3 Up to three analog temperature sensors can be connected to the FDC. The method of changing parameters is the same for each sensor. MAXIMUM CONTROL TEMPERATURE (C) sets the upper end of the temperature control range. Maximum control temperature is 5 C (57 F). MINIMUM CONTROL TEMPERATURE (C) sets the lower end of the temperature control range. Minimum control temperature is 50 C ( F). RAMP FAN OFF (SEC) sets the time required for an output signal controlled by this sensor to cause the fan to go from maximum to minimum speed. Available range is 0-50 sec. RAMP FAN ON (SEC) sets the time required for an output signal controlled by this sensor to cause the fan to go from minimum to maximum speed. Available range is 0-50 sec. Each temperature sensor has a visual bar graph and digital indication of the actual temperature being measured by the temperature sensor. Each sensor has a fault indicator button. If red, a fault condition exists whereby a sensor that has been enabled is not communicating to the microcontroller. This fault will cause the FDC output to direct maximum fan speed. INPUT PWM status dialog box indicates the status of the input PWM signal, if enabled. The color bar to the right of the words Input PWM will be green under normal conditions. Red indicates abnormal conditions. The abnormal condition will be reported in the PWM status dialog box. MAXIMUM INPUT PWM (PERCENT DUTY CYCLE) signal expected from the engine computer. Maximum value accepted is 00%. MINIMUM INPUT PWM (PERCENT DUTY CYCLE) signal expected from the engine computer. Minimum value accepted is 0%. PWM RAMP FAN OFF (SEC) sets the time required for the fan to go from full on to full off as the PWM input signal travels full range. Available ramp time range is 0-50 sec. PWM RAMP FAN ON (SEC) sets the time required for the fan to go from full off to full on as the PWM input signal travels full range. Available ramp time range is 0-50 sec. INPUT PWM DUTY CYCLE is indicated (in percent) digitally and visually on the bar graph to the right of the PWM parameters. Input PWM frequency is also displayed. AUXILIARY SWITCH. Two auxiliary switches can be connected to the FDC. The Auxiliary Switch description also applies to the Auxiliary Switch. The method of changing parameters is the same for both switches. The color bar above each set of auxiliary switch parameters indicates whether the switch is on or off. Red is off. Green is on. AUXILIARY CONFIGURATION. Each auxiliary switch can be configured to be normally open or normally closed. BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 7

28 USING SET-UP SOFTWARE (CONTINUED) AUXILIARY CONTROL configures the control action that will occur when the switch logic changes from normal condition. Available control actions: Fan on or Fan off. AUXILIARY MINIMUM CURRENT (AMPS) is the current that will be sent to the valve when the switch logic changes from normal condition. Range is from 0-.5 A for the high current FDC. Note: The parameter allows the user to command the fan speed to some intermediate position between full off and full on. AUXILIARY RAMP FAN OFF (SEC) sets the time required for the fan to go from a full on to a full off condition. Auxiliary switch has a maximum ramp time of 000 seconds. Auxiliary switch has a maximum ramp time of 50 seconds. AUXILIARY RAMP FAN ON (SEC) sets the time required for the fan to go from a full off to a full on condition. Auxiliary switch has a maximum ramp time of 000 seconds. Auxiliary switch has a maximum ramp time of 50 seconds. Note: If an auxiliary switch is configured to turn the fan off when the switch logic changes, this input to the microcontroller has priority over all other inputs. The microcontroller will drive the fan to an off condition. Set-Up Software Parameter Change Screen 059B 8 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

29 SET-UP SOFTWARE PARAMETER LOG SIGNAL PARAMETER SETTING INPUT PWM MAXIMUM INPUT PWM (%) MINIMUM INPUT PWM (%) PWM RAMP FAN OFF (SEC) PWM RAMP FAN ON (SEC) SENSOR MAXIMUM CONTROL TEMP ( C) MINIMUM CONTROL TEMP ( C) RAMP FAN OFF (SEC) RAMP FAN ON (SEC) SENSOR MAXIMUM CONTROL TEMP ( C) MINIMUM CONTROL TEMP ( C) RAMP FAN OFF (SEC) RAMP FAN ON (SEC) SENSOR 3 MAXIMUM CONTROL TEMP ( C) MINIMUM CONTROL TEMP ( C) RAMP FAN OFF (SEC) RAMP FAN ON (SEC) AUX SWITCH AUX SWITCH CONTROL OUTPUT CONFIGURATION (NO OR NC) CONTROL (RAMP FAN ON OR OFF) MINIMUM CURRENT (AMPS) RAMP FAN OFF (SEC) RAMP FAN ON (SEC) CONFIGURATION (NO OR NC) CONTROL (RAMP FAN ON OR OFF) MINIMUM CURRENT (AMPS) RAMP FAN OFF (SEC) RAMP FAN ON (SEC) VALVE PWM FREQUENCY (HZ) MINIMUM VALVE CURRENT (AMPS) MAXIMUM VALVE CURRENT (AMPS) PWM INPUT NORMAL OR INVERTED VALVE OUTPUT NORMAL OR INVERTED BLN June 003 Copyright 003, Sauer-Danfoss (US) Company. 9

30 ORDERING INFORMATION For complete product ordering information, including part number, consult Customer Service in Minneapolis (see Customer Service on this page). The ordering part number assigns both hardware and software. Reference Ordering Nomenclature Chart, page 8, for information required to designate a part number. For installation instructions and electrical pinout information consult Customer Service in Minneapolis (see Customer Service on this page). CUSTOMER SERVICE Order From Sauer-Danfoss (US) Company Customer Service Department 3500 Annapolis Lane North Minneapolis, Minnesota Phone: (73) Fax: (73) Sauer-Danfoss (Neumünster) GmbH & Co. Order Entry Department Postfach 40, D-453 Neumünster Krokamp 35, D-4539 Neumünster Phone: Fax: Device Repair Return to: Sauer-Danfoss (US) Company Return Goods Department 3500 Annapolis Lane North Minneapolis, Minnesota For devices in need of repair or evaluation, include a description of the problem and what work you believe needs to be done, along with your name, address and telephone number. 30 BLN June 003 Copyright 003, Sauer-Danfoss (US) Company.

31 OUR PRODUCTS Hydrostatic transmissions Hydraulic power steering Electric power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Radial piston motors Orbital motors Transit mixer drives Planetary compact gears Proportional valves Sauer-Danfoss Hydraulic Power Systems Market Leaders Worldwide Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market. Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others. We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partner ship with them. Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design. Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world. Directional spool valves Cartridge valves Hydraulic integrated circuits Hydrostatic transaxles Integrated systems Fan drive systems Electrohydraulic controls Digital electronics and software Battery powered inverter Sensors Sauer-Danfoss (US) Company 800 East 3th Street Ames, IA 5000, USA Phone: , Fax: Sauer-Danfoss (Neumünster) GmbH & Co. HG Postfach 40, D-453 Neumünster Krokamp 35, D-4539 Neumünster, Germany Phone , Fax: Sauer-Danfoss (Nordborg) A/S DK-430 Nordborg, Denmark Phone: , Fax: Sauer-Danfoss (US) Company 3500 Annapolis Lane North Minneapolis, Minnesota Phone: , Fax: BLN April 00