Fan-Drive Controller

Fan-Drive Controller
Fan-Drive Controller
ESLF101/ELLF101
S Fan speed is controlled to match system requirements
S Any target value for temperature can be set
S For reversible and non-reversible fan motors
1
Description
1.1 General
1.2 Models
The ESLF electronic unit is designed to provide fan control
in any make of equipment. The fan motor operates in a hy­
draulic circuit with a bypass function. Its primary field of ap­
plication is engine cooling in mobile machines. The plug-in
card is therefore available in an encapsulated version for
harsh environments.
The fan control is not an on/off type, but is based on a micro­
controller. A maximum of 3 temperature sensors, type PTC
or NTC, can be connected. Any target temperature can
therefore be adjusted individually by the user.
The card can be ordered with a 31-pin edge connector to
DIN 41617 or with screw terminals. For applications in high
air humidity, or in equipment with high vibration levels, a fully
encapsulated version is available.
2
1.3 Application example
S Fan control system for the only-as-needed cooling of in­
ternal combustion engines in mobile machines.
Technical data
2.1 Plug-in card
General characteristics
Description, value, unit
Supply voltage
12 V ... 28 V DC
Reference voltage (Vref)
8 V DC max. 20 mA
Temperature inputs
3 (P1, P2, P3)
Temperature: sensor processing (VSensor)
all PTC or all NTC (pay attention to the sensor-selection input)
Temperature: target value
can be set to suit choice of temperature
minimum resistance at target temperature: Rmin =
maximum resistance at target temperature: Rmax =
(condition: VTP = 3.5 V)
500 Ω
2000 Ω
Temperature: diagnostics range
max: target temperature + approx. 160 °C
min: target temperature - approx. -40 °C
Pay attention to the working range of the sensors!
Setting:
input for sensor definition (PTC or NTC), can be altered online
trimming potentiometer for each sensor, can be altered online
the sensor type
the setup adjustment
Proportional solenoid output for fan motor
- max. fan speed
- min. fan speed
max. output current
with minimum current
with set maximum current
Imax
Imin
Imax
= 2.1 A
= 0.2 A
= 1.4 A ... 2.1 A via
potentiometer P4
Reference: 100-P-700063-EN-01
Issue: 08.2015
1/8
General characteristics
Description, value, unit
Diagnostics
LED for each solenoid output and control diagnostics
Reverse mode
Imax = 1.5 A; braking and acceleration, each approx 10 s
2.2 Fan PCB
General characteristics
Description, value, unit
Connection
Multi-pin connector to DIN 41612 type D, or screw terminals
Connecting cable for temperature sensor
LiYY 2 x 0.5 cm2, max. length 10 m
Protection
non-encapsulated and encapsulated versions
Dimensions
100 mm x 100 mm x 25 mm (W x H x D)
Temperature range of the electronics
-20 °C ... +50 °C
2.3 Enclosure
General characteristics
Description, value, unit
Connection
AMP socket, CPC Series 1, male contacts (crimp),
terminals of the electronics and the plug are connected 1:1
Protection class
IP65 when a protective cap for the plug is fitted.
See Accessories
Dimensions
160 mm x 120 mm x 55 mm (W x H x D) without side-entry plug
3
Block diagram
Min. fan
speed
Adjustment S1 Analog input
Option
On/off out
Control block for
reverse operation
µC
Adjustment S2 Analog input
Temperature
sensors
ADC 8 bit
RAM:
Data memory
EPROM:
Data memory
Prop. out
Adjustment S3 Analog input
Sensor type: Switch:
NTC / PTC Reverse
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Fan
motor
100-P-700063-EN-01/08.2015
Fan-Drive Controller ESLF101/ELLF101
4
Function and dimensions
5.0
5.0
4.1 Card
ISolenoid prop.
ISolenoid on/off
Control
Control
15
14
13
12
11
P1
P1, Adjustment
P2
P2, Adjustment
P3
P3, Adjustment
P4
P4, min. speed
P5
P5, Option
10
100
9
8
7
6
TP3 TP2
5
TP1
TP4
4
TP5
3
5.0
90,5+0,5
Type with multi-pin connector
16
2
1
5.0
20.0
95.0
100.0
Trim potentiometer - max. 20 turns
P +
TP1 - TP5
P1 - P3
-Q
= test points
= trim potentiometers for sensors 1 - 3
TP1
TP2
TP3
TP5
TP4
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Fan-Drive Controller ESLF101/ELLF101
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4.2 Reverse mode
In reverse mode, the fan changes its direction of rotation
and then operates at full speed.
To do this, the speed is first slowly reduced (10 s) to the min­
imum. The on/off output is energised and the speed is con­
tinuously increased to the maximum and then held there un­
til the button is released.
This function can be used to blow debris out of the radiator.
Fan speed
to minimum
~
Reverse
direction of rotation
“Reverse” switch
is pressed
Fan speed
to maximum
Maintain
fan speed
~
Control
Fan speed
to minimum
Automatic mode off
Normal
direction of rotation
Control speed
is restored
~ = “Reverse” switch is released
5
Connection diagram
5.1 Connection diagram for ESLF101 card
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5A fast-acting
10
9
8
7
6
5
4
3
2
Vref
T1 (+)
- Vb
T2 (+)
- Vb
T3 (+)
- Vb
VSensor
11
- Vb
12
+ Vb
13
Prop. Sol. (-)
14
Prop. Sol. (+)
15
On/off sol. (-)
On/off sol. (+)
16
- Vb
Multi-pin connector
Sensor 1
Sensor 2
1
Screw terminals
Sensor 3
Wiring for PTC
VBatt
12V-28V
Wiring for NTC
Reverse ON (V > 4V)
Reverse OFF (V < 4V)
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Fan-Drive Controller ESLF101/ELLF101
5.1.1
Note
S With PTC, every free temperature-measurement channel
must be closed with a wire jumper. With NTC the meas­
urement channel remains open.
S The input for recognition of the type of sensor in use must
be connected.
S PTC and NTC sensors must not be mixed.
S If reverse operation is not needed, the input and the out­
put do not need to be connected.
S Potentiometer P4 can be used to set the card's maximum
output current to the proportional solenoid.
S The "Option" potentiometer is not used.
S If the processor is not encapsulated with the rest of the
card, it is possible to exchange the processor, and thus
the software. The software is noted on the lettering; ap­
pearing after "LF101", it is shown as "Vx".
5.2 Connection diagram for ELLF101 enclosure
View A (AMP connector)
7
11
15
3
8
12
4
1
5
2
9
16
13
14
10
6
The terminals of the plug-in card (see
Section 5.1) and the contacts of the
AMP connector are connected 1:1.
6
Initial start-up
Connect the ESLF101 / ELLF101 in accordance with the
connection diagram. Select the sensor type by connecting
terminal 2 (pins 3, 4). For PTC sensors, connect the refer­
ence voltage output (Vref) at terminal 9 (pins 17, 18) to ter­
minal 2. For NTC sensors, connect terminal 10 (pins 19, 20)
to terminal 2.
7
A
If no sensor type is selected, the fan speed will be set to
maximum.
After the sensor type has been selected, all unused sensor
inputs must be connected as follows:
Unused PTC sensor inputs are short-circuited. With NTC
sensors, unused inputs are left open.
Setup procedure
1. Set the required target value (from the sensor data sheet)
with a reference resistor (e.g. potentiometer), alternatively
bring the sensor itself to the required target temperature.
Then repeat for all sensors.
2. Connect the potentiometer/sensor to the first sensor in­
put, terminal 8 (pins 15, 16) and terminal 7 (pins 13, 14). With
a voltmeter, measure the voltage V1 at TP1 relative to
ground (terminal 10) and use the trimming potentiometer P1
to set the voltage as follows:
For PTC: V1 = 3.5 V
For PTC: V2 = 3.5 V
For NTC: V2 = 1.5 V
4. Connect the potentiometer/sensor to the third sensor in­
put, terminal 4 (pins 7, 8) and terminal 3 (pins 5, 6). With a
voltmeter, measure the voltage V3 at TP3 relative to ground
(terminal 10) and use the trimming potentiometer P3 to set
the voltage as follows:
For PTC: V3 = 3.5 V
For NTC: V3 = 1.5 V
For NTC: V1 = 1.5 V
3. Connect the potentiometer/sensor to the second sensor
input, terminal 6 (pins 11, 12) and terminal 5 (pins 9, 10).
With a voltmeter, measure the voltage V2 at TP2 relative to
ground (terminal 10) and use the trimming potentiometer P2
to set the voltage as follows:
100-P-700063-EN-01/08.2015
Fan-Drive Controller ESLF101/ELLF101
5. Set the minimum fan speed with the potentiometer P4.
When the system is cold i.e. the fan speed is not being con­
trolled by the electronics, the solenoid valve current after
switch-on is at maximum (1.4 A < Imax < 2.1 A). By means
of the hydraulic bypass, this current determines the minim­
um fan speed.
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8
Ordering code
8.1 ESLF101 (plug-in card without enclosure)
Model
Description
Ordering code
Fan controller, encapsulated
screw terminals
ESLF101-81***
100025627
Fan controller, non-encapsulated
screw terminals
ESLF101-91***
contact Bucher Hydraulics
Fan controller, encapsulated
multi-pin connector
ESLF101-80***
contact Bucher Hydraulics
Fan controller, non-encapsulated
multi-pin connector
ESLF101-90***
contact Bucher Hydraulics
Description
Ordering code
8.2 ELLF101 (plug-in card with enclosure)
Model
Fan controller in an enclosure
encapsulated
ELLF101-01***
100026621
Fan controller in an enclosure
non-encapsulated
ELLF101
contact Bucher Hydraulics
IMPORTANT!:
S Software can be modified for particular applications and customers - please contact us.
S The type of sensor to be used (PTC, NTC), non-connected temperature channels, and the target temperature
of each channel must be specified in the order.
S Standard setting: PTC:
9
P1 = not connected
P2 = 90 °C
P3 = 70 °C
Accessories
9.1 Plug-in card
Item
Ordering code
Application
Plug: Phoenix Contact, MSTB 2,5/16-STF-5,08
connection to 16-pin male connector
Bosch PTC temperature sensor 0538009203
measurement of air temperature (sensor
type 1)
Bosch PTC temperature sensor 0538009252
measurement of oil/water temperature
(sensor type 2)
IFM PT1000 temperature sensor
TS 2051
measurement of liquid and gaseous media
IFM PT1000 temperature sensor
TT 1050
measurement of liquid and gaseous media
9.2 Enclosure
Accessories for plug base
Protective cap
Ordering code
100609804
Description
AMP CPC Serie 1
16-pole cable connection
Ordering code
Description
Cable connector (crimp)
100609807
AMP CPC Serie 1
Cable strain relief
100609808
AMP for CPC 1 cable connector
Crimp contact (socket)
100609809
AWG 24-20 (d = 0.5 - 0.8 mm2)
Crimp contact (socket)
100609810
AWG 18-16 (d = 1.0 - 1.3 mm2)
Cable entry seal
100609811
AMP for CPC 1 cable connector
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Fan-Drive Controller ESLF101/ELLF101
10 Fault finding
10.1 Fault finding by no hydraulic function
No hydraulic function
Reverse mode:
Is reference voltage present at terminal 1
when switch is operated?
No
Yes
Power supply at terminals 12 (+12V/24V) and
terminal 11 (ground) - is polarity correct?
No
Yes
Check power supply and wires
for polarity and continuity.
Temperature sensors:
is voltage at terminals 8, 6
and 4 U > 0V
No
Yes
Is 8 V reference voltage
present at terminal 9?
Yes
No
Check the switch
wiring.
Disconnect temperature sensor. Is a voltage of
approx. 7.8 V in each case present?
Yes
No
Card is faulty.
Is minimum fan speed
reached before reverse
mode is activated?
No
Yes
Check the
temperature control
(see at left).
Check the
solenoid output
(see at left).
Is 8 V reference voltage
present at terminal 9?
Yes
Temperature sensor is faulty,
or there is a line short circuit.
No
Card is faulty.
Yes
Check hydraulic
system.
Temperature control:
Is the solenoid current adjustable in the range:
approx. 0.7 A - 1.8 A for 12 V ?
approx. 0.3 A - 0.9 A for 24 V ?
No current
Max. current
Check solenoids leads
and solenoid for short cir­
cuit / ground short circuit.
Does short circuit exist?
No
Yes
Is output voltage for solenoids
between terminals 14 and 13
approx. 12 V / 24 V ?
Is green LED on?
Yes
No
Solenoid lead is
broken or solen­
oid is faulty.
Eliminate
short circuit.
Disconnect solen­
oid. Is voltage
present now?
Yes
No
Short circuit in
solenoid leads
or solenoid.
Card is faulty.
* If not specified, the reference point for voltage measurements is the negative side of the supply voltage
10.2 Fault finding for incorrect temperature control
Incorrect temperature control:
fan speed goes to min. or max.
Check temperature sensors,
see above
Is the wiring for the switch type
PTC / NTC in place?
Is the fan motor in a hydraulic circuit
that has bypass control?
Check all installation aspects for the sensors
(see above)
Check setup/adjustment for the sensors
100-P-700063-EN-01/08.2015
Fan-Drive Controller ESLF101/ELLF101
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info.kl@bucherhydraulics.com
www.bucherhydraulics.com
E 2015 by Bucher Hydraulics GmbH, D-79771 Klettgau
All rights reserved.
Data is provided for the purpose of product description only, and must not be construed as warranted characteristics in the legal sense. The
information does not relieve users from the duty of conducting their own evaluations and tests. Because the products are subject to continual
improvement, we reserve the right to amend the product specifications contained in this catalogue.
Classification: 470.710.710
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100-P-700063-EN-01/08.2015
Fan-Drive Controller ESLF101/ELLF101
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