INSTRUCTIONS FAN CONTROLLER 1. OVERVIEW

INSTRUCTIONS FAN CONTROLLER 1. OVERVIEW
INSTRUCTIONS
FAN CONTROLLER
®
1.
OVERVIEW
Congratulations on your purchase of the latest technology in cooling fan control. This compact,
weather resistant, all solid-state controller is short circuit and overload protected and can be mounted inside
or outside the vehicle cabin. It also features automatic detection and indication of Temperature Sensor faults
as well as internal over-temperature conditions. In the event that a sensor fault is detected, the Fan will turn
on and run continuously in fail-safe mode to prevent over-heating.
Three sensor inputs allow for simple one-time setup of temperature control, and an input for the A/C
Clutch will turn on the Fan when the air conditioner is used. It should be emphasized, however, that no fan
controller can prevent overheating. If your vehicle overheats when the fan is running, a fan controller will not
solve the problem. The job of the Fan Controller is to operate the fan efficiently, turning on the fan only when
the radiator alone cannot provide enough cooling. The benefit of this efficiency is prolonged life of the Fan
and Alternator.
SPECIFICATIONS
2.
Battery Voltage
10 - 16 VDC
Fan Load
1 or 2 Fans, total of 30 amps max, running
Temperature Range 1, Yellow stripe lead
180˚- 185˚ F, typical
Temperature Range 2, Orange stripe lead
185˚- 195˚ F, typical
Temperature Range 3, Red stripe lead
195˚- 205˚ F, typical
SPECIAL TOOLS REQUIRED
Proper wire terminations are essential for the safety, operation, and long term durability of your
vehicle’s electrical system. To install this Fan Control Unit you will need a heat gun and quality crimp tools.
A crimp tool such as the one shown should be used to crimp the non-insulated closed barrel terminals
provided in this kit. Note that the wire insulation butts up firmly against the terminal and that the crimp tool
creates a dimple in the terminal, securing the conductor without breaking any strands. Use a heat gun and a
piece of heat shrinkable sleeving included in the kit to insulate each crimped terminal. When the sleeving is
heated it should shrink tight around the terminal and the wire insulation. In this way the sleeving acts not
only as an insulator but also as a strain relief to minimize bending of the conductor at the crimped
connection, which can cause eventual breakage.
Proper Crimp
Crimp Tool
3.
MOUNTING AND GROUNDING
MAKE SURE THE BATTERY IS DISCONNECTED BEFORE PROCEEDING. The Fan
Controller should be mounted before you begin connecting any wires. We recommend mounting the unit
inside the vehicle cabin but it can be mounted outside the cabin, even in the engine bay if necessary, as far
away from heat sources as possible, especially exhaust headers or manifolds. It is normal for the controller to
get a little warm when operating the fan so it should be mounted to a metal panel that can dissipate heat such
as the fender well, firewall, frame, or body panel.
For maximum cooling and longer fan life we recommend connecting the fan and controller
ground leads directly to Battery Ground. If you connect the ground leads to the chassis, metal must be
clean, free from rust and paint where the connection is made. Refer to the wiring diagram for making all
other connections. When finished, install the vinyl caps over the two stud terminals for protection.
4.
TEMPERATURE SENSOR
The Temperature Sensor is built into the 3/8" ring terminal on one end of the Temperature Sensor
Cable assembly. The ring terminal should be mounted under the shortest thermostat housing bolt on the
engine in order to accurately read engine temperature. If that is not possible, use an intake manifold bolt
that's close to a water jacket. Hold the sensor to prevent turning and possibly damaging the sensor leads
while tightening the bolt. Cut the cable to desired length, leaving at least six inches of extra length and
connect the wire leads of the Temperature Sensor to the Controller as shown on the wiring diagram. Sensor
wire leads can be extended if necessary to lengthen the cable to the Controller.
5.
TESTING - READ THIS ENTIRE PROCEDURE BEFORE BEGINNING
Once you have completed installation, make sure the Ignition Switch and A/C system are both turned OFF,
then re-connect the Battery. The engine should be cold.
5.1
Turn the Ignition Switch to the Run position but do not start the vehicle. Verify the Red Status LED
illuminates on the Fan Controller. The Fan(s) should not turn on. If the LED flashes, count the
number of flashes and refer to the table on the wiring diagram to diagnose the Temperature Sensor
Cable problem. Note that the Fan will turn on if an open or short is detected on the Sensor cable. This
is a fail-safe feature to prevent engine overheating if this type of fault occurs.
5.2
Turn on the A/C system (if equipped) and verify the Fan(s) turn on and remain on until the A/C
switch is turned off. Note that the Fan(s) will run for about 30 seconds minimum. Even if you don't
have an A/C system you can still perform this test by temporarily connecting the blue Fan Controller
A/C Clutch wire to +12v. If the Fan(s) do not turn on check the Status LED. A rapidly flashing LED
indicates a short or overload on the Fan output. If this occurs turn off Ignition and A/C and check
Fuses and Fan wiring. If no problem is found, the Fan may be defective. When finished with this test
connect the blue A/C Clutch wire to ground if not used.
5.3
If the Status LED stays illuminated (flashing indicates some type of fault), and if the Fan turns on and
off using the A/C Clutch signal lead, then you're ready for warm engine testing. The best way to get
the engine up to temperature is to drive a couple of miles in moderate weather. There's really no easy
way to test in cold weather (below 40 F) since the engine may never get warm enough to need the
Fan. On a cold engine the Thermostat will be closed, but as the engine heats up, the water
temperature will usually climb 5-10 degrees above the Thermostat temperature before the Thermostat
opens. When it opens and coolant begins to flow, the water temperature will come down quickly. At
this point the Fan does not need to be on (and typically won't be) since the engine is being adequately
cooled by radiator coolant.
5.4
When you return from the short warm-up drive allow the engine to idle and monitor the Water Temp
gauge. After the entire engine coolant system reaches operating temperature, the Fan(s) will typically
turn on around 190 degrees or less. If the temperature gets up to 200 degrees and the Fan still hasn't
turned on, turn the Ignition off to stop the engine and make sure the Temperature Sensor red lead is
connected to the yellow striped wire (TMP-1) on the Fan Controller. The TMP-1 sensor input
provides the lowest turn-on temperature. You can also try moving the Temperature Sensor to another
bolt on the water neck, water pump, or intake manifold. NOTE: Our experience has shown that the
temperature difference from one water neck bolt to another can be as much as 20 degrees while
the engine is warming up.
5.5
If you want a higher turn-on temperature, use the orange (TMP-2) or red striped wire (TMP-3) on the
Fan Controller to increase the turn-on point. Repeat the test until you're satisfied with the turn-on
temperature. Typically, Fan turn-off will be approximately 5-10 degrees less than the turn-on
temperature.
5.6
Double-check all connections and remember to install the vinyl caps over the two stud terminals for
protection against accidental shorts. Use the heat shrink tubing in the kit to cover and insulate the
unused Temperature Sensor inputs (TMP-1, TMP-2, and TMP-3). Installation is complete.
Occasionally check the Status LED for faults (Ignition must be turned on to power the Controller). If
you mounted the Controller in the engine compartment you should check the Status LED after
driving, especially in hot weather. Three flashes indicates the Controller is getting too hot. It should
continue to operate but excessive heat may shorten the life. Move the Controller inside the vehicle or
to another location if this occurs.
4.
TECHNICAL SUPPORT
Free 24/7 tech support is provided online at: www.coachcontrols.com
or call 423-790-7905 M-F, 9am-5pm eastern.
5.
2 YEAR WARRANTY
Coach Controls, Inc. warrants for a period of 2 years to the original purchaser of this product that it
shall be free from defects in material and workmanship under normal use and service for which it was
intended. Our obligation under this warranty shall be limited to the repair or replacement at our option.
Coach Controls, Inc. shall not be liable for any injury, whether to person or property, or for any damages,
whether direct, indirect, consequential, or special, or any other damage resulting from the use, or misuse, of
this product. Any injury or damage so incurred will be limited to the original purchase price of the product.
Before returning any product, a Return Material Authorization (RMA) number must be obtained
from Coach Controls, Inc. and conspicuously printed on the outside of the box. Any item(s) returned without
an RMA will not be accepted.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR
IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE
AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART, AND WE NEITHER
ASSUME, NOR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR US, ANY OTHER
LIABILITY IN CONNECTION WITH THE SALE OF THIS PRODUCT. THIS WARRANTY SHALL
NOT APPLY TO THIS PRODUCT OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO
ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. WE MAKE NO WARRANTY
WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY US. THE TERM
“ORIGINAL PURCHASER” AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN
THAT PERSON OR ENTITY WHO ORIGINALLY PURCHASED THE PRODUCT.
THIS
WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL
UNITED STATES.
Fan Controller Wiring Diagram
c 2017
T O A/C COMPRESSOR
CL UTCH
R
F ROM A/C
T HERMOSTAT
Co n n ect to A/C Clutch
if no Trinary Switch.
AC CLUTCH SW
AC CLUTCH SW
RAD FAN SW
I n stall under shortest
th e rmostat housing bolt.
G RO UND
T O T AL POW ER
30 AMPS MAX
FAN
CO NDITION
LED
!
#10
#18
T RI NARY SW ITCH
I n stalls on High Pressure refrigerant line.
Wire colors may be different than shown.
T EM P SENSOR
O NE OR TW O
CO O LING FANS
#18
RAD FAN SW
The radiator fan switch closes when
the refrigerant pressure reaches
approximately 254 psi.
Co n stant On
Normal Operation
Blinking Fast
F a n Output shorted or overloaded
1 Flash
T e m p sensor open circuit
2 Flashes
T e m p sensor shorted
3 Flashes
Controller Overtemperature
Connect A/C Clutch wire
to GND if no A/C.
TMP-1 - Yel
A/ C CLUTCH
TMP-2 - Org
I G N / ACCY
TMP-3 - Red
G RO UND
Com - White
#10
T EM P SENSOR
L EADS
#18
#18
S T EEL
CHASSIS
G RO UND
For maximum cooling and fan life
co nnect directly to battery ground.
FAN
+12V
40 Amp
#10
F USE OR
CI RCUI T BREAKER
F AN CO NTROLLER
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