Denison Hydraulics Digital Fan Controller Unit. 700-00013-0: Application and Information Manual

DENISON HYDRAULICS
Digital Fan Controller Unit.

700-00013-0
Application and Information
Manual.
Publ. DFC-1-K Replaces Publ. DFC-1-J
1
Digital Fan Controller Unit - 700-00013-0
Manual Index:
Page 3) Product Compatibility. Page 18) Retry ALL faults.

Cooling Application Areas. PC hardware requirements
System Component part numbers. Opto-link communications
User Information. Set-up software.
Page 4) System Introduction. Page 19) Software set-up guide ( menu bar )
Page 5) Product Advantages. Page 20) Software set-up guide ( menu bar ) Cont..
Page 6) CE and EMC notes Page 21) Software set-up guide ( Observation page )
Page 7) Do’s and Don'ts Page 22) Software set-up guide ( OEM / Prof. page )
Page 8) Controller electrical specifications. Page 23) Software set-up guide ( Settings )
Page 9) Thermistor requirements. Page 24) Thermistor Selection.
Switched Inputs Page 25) Thermistor Calibration from Table values.
Page 10) Charge Air Feature Page 26) Thermistor Calibration ‘Custom’
Fan ‘ON’ delay. Page 27) Thermistor Calibration ‘Custom’ Cont..
Page 11) Fan control Logic Page 28) Opto-Link Interface.
Password Protection. Page 29) Dimensional Information
Page 12) Fan Noise Test Feature. Mechanical Data.
Power Supply and valve Voltage. Page 30) Alarm Connection.
Page 13) Proportional Output Fan Speed Manual Override.
Fan Max speed setting Page 31) Manual ‘Purge’ connection
Fan Min speed setting General Maintenance.
Ramp settings. Page 32) Manual or Auto ‘Purge Profile.
Dither Frequency setting. Page 33) Typical Hydraulic Operation.
Page 14) Fan reverse ( Purge ) output. Page 34) Error codes and alarm Conditions.
Reverse / Purge sequence information. Page 35) Controller Mounting
Manual fan reverse settings Page 36) FAQ’s.
Auto-reverse settings Page 37) Controller Qwik-Ref Guide.
Page 15) Diagnostic Indicators. Page 38) Controller Qwik-Ref Guide Cont..
Power ON/Opto-Link transmitter. Page 39) Controller Qwik-Ref Guide Cont...
Opto-link receiver. Page 40) Controller Qwik-Ref Guide Cont...
Proportional valve output. Page 41) Controller Qwik-Ref Guide Cont...
Manual trigger reverse sequence. Page 42) Temperature Converter Tables.
Reverse valve output. Manifold Blocks.
Thermistor input status.
Page 16) Error indicator.
Error indicator location.
Page 17) Alarm Output.
Data Logging option.
Internal data logging
Connectors.
Start-up delay feature.
The information contained in this literature is the sole intellectual property of Denison Hydraulics Inc. and should be considered as
strictly company confidential. It shall not be copied or transmitted by any format to any third parties without our knowledge and
express written permission.
ALL information contained herein is copyrighted to Denison Hydraulics Inc., Marysville, Ohio, 43040, U.S.A. © 2001-2002
2
Product This product has been designed to interface directly with the Denison
Compatibility: Hydraulics range of vane pumps, motors and manifold blocks currently
available for this and other projects, however, the unit will also control
proportional pressure, flow or pump strokers with ease to fit the required
application.
Please contact the factory by the e-mail address given below or nearest
Denison Hydraulics distributor for further technical information and availability.
Cooling • Hydraulic system oil.

Application • Automatic Transmission fluid.
Areas:
• Engine sump oil.
• Air conditioner refrigerant.
• Engine Charge air.
• Engine water jacket.
• ‘External Attachment’ system fluids.
• Diesel fuel.
System • DFC controller Module:-………………………………………....700-00013-0

Component
Part Numbers: • Opto-link interface Unit:-…………………………………………700-00012-0
• DFC controller software:-………………………………………..720-00004-0
• Controller info manual:-………………………………………….DFC-1-K
• See manifold block selection guide.
User Information • E-Mail to : DFC@denisonhydraulics.com
• General Info : www.denisonhydraulics.com
IMPORTANT NOTE:-
Denison Hydraulics Inc. reserves the right to upgrade, revise or better any e-product controller as
technology improves without notice being given.
Wherever possible, full downwards compatibility for both hardware and software on replaced controllers
will be maintained but it is the users responsibility to ensure that the latest technical details or literature is
being used for application reference.
If you are unsure of the literature, hardware or software revisions you have, or suspect that it is an older
revision, please send an e-mail request for the latest releases to DFC@denisonhydraulics.com
3
System Introduction:
This product has been designed to give the user new levels of fan cooling control while integrating
seamlessly into a typical discrete cooling system.
It can control a hydraulically driven fan proportionally or in an ON/OFF manner based on user
settings, system configuration and cooling needs with three independent inputs ( zones ) that will
interface with industry standard NTC, two wire thermistors.
Standard features include a robust vibration, flame proof package, two part heavy duty connectors,
manual and auto reversing ( Purge ) function, Alarms interface, intelligent diagnostics, self
protection that enable the controller to operate reliably under arduous environmental conditions
and a ‘real-time’ graphing and data logging facility that allows the user to observe and then record
several operating parameters that are saved in a common file format for later examination in
Microsoft Excel®.
Local on-board diagnostic LED indicators are available for power ON, each thermistor input,
proportional output, reversing output and trigger and a specific error code LED which all show
through observation, the current status of the controller and connected peripheral devices.
Easy to use ‘set-up’ and diagnostic software that is provided with the unit, works in conjunction with
the Denison Hydraulics ‘Opto-Link’ interface unit to provide high speed data communications
between the controller and the host computer and runs on any PC with a Windows® O/S platform.
Once the profile for a particular cooling requirement has been established, the software
allows the developer to up/download the complete personality into other blank controllers
giving the user a high level of application specific security and keeping company
confidential information in-house.
The inputs can be configured to interface directly with pre-set range ON/OFF Bi-metallic
temperature switches without the proportional control offered by the thermistors but giving savings
advantages where absolute accuracy is not required and system cost is at a premium.
There are no external or onboard potentiometers, switches or adjustments for user settings to
ensure controller integrity and operation under harsh environmental and operator conditions.
The set-up software allows the controller to be very flexible regarding settings and system
configuration with password levels invoked to ensure that characteristics cannot be changed
without the proper authority.
Each password level entered, affords the user more options and available settings that are kept
transparent to the operator or observer to avoid confusion.
ALL inputs and outputs on the controller are fully protected and continuously monitored by the
software for open and short circuits.
Readings are also taken and stored of highest temperatures seen in each active zone, supply
voltages and other parameters to allow event correlation and system diagnostics if required at a
later date.
4
Product Advantages:
EMC compliant product to EN50081-1 and EN50082-2 ( heavy industrial )

EMC compliant product to EN-12895:2000 ( Industrial Trucks )
Fail safe design gives full fan cooling even with catastrophic controller failure.
Wide supply voltage range ( 8 – 40VDC )
Field and time tested and proved electronic circuit design.
Fully programmable via provided software package.
Qwik select, fan speed noise test facility for In-Situ inspection.
Mount ‘anywhere’ encapsulated modular format.
Full remote (PC) and local ‘smart’ visual diagnostics ( with optional Opto-Link ).
Product integrity maintained under extreme operational environments.
Fully ‘isolated’ design for improved safety and ease of application in difficult areas.
Three independently selectable and configurable temperature sensing inputs
Fully protected ( shorts, opens and reverse connection ) Inputs and Outputs.
Unit status ‘Diagnostic’ LED’s user visible and functional at all times.
Low cost compared to other available modules with comparative functions.
Rugged two part heavy duty, screw type polarised connector.
Radiator element ‘Manual and auto ‘purge’ feature.
NO external adjustments to maintain system integrity in the field.
‘Ruggedised’ design allowing use on ‘Internal’ OR ‘External’ applications.
Set-up & unit configuration up/downloadable to PC/diskette for backups.
Coded error indicator for real time diagnostics in-situ.
Flame proof resin encapsulation.
Retarded ‘Charge Air’ cooling until engine warm feature.
Fan ‘ON-Delay’ feature to reduce starting requirements on a hot system.
5
CE and EMC notes:
Controller The Digital Fan Controller (“DFC”) 700-00013-0 has been tested to
700-00013-0 comply with the current EN-50081-1 ( Emissions ) and
Test Criteria: EN-50082-2 ( Immunity ).
The unit has been further tested to the new Euro-Norms of:-
EN-61000-6-4:2001 ( Emissions ) & EN-61000-6-2:2001 ( Immunity)
which will become the new standard in July 2001.
The controller was also voluntarily tested to EN-12895:2000 which
covers industrial Truck requirements.
Use of this controller under conditions not specified by EN-12895:2000
will require the user to clarify the application with Denison Hydraulics
technical staff before proceeding.
To maintain compliance with the tested EMC specifications listed above,
the controller ( 700-00013-0 ) must only be connected to the vehicle
battery supply and must NOT be allowed to control or operate the fan
system while the vehicle is connected to ANY external power supply (
I.e. battery Charger or engine warmer e.t.c.) and must be fully isolated
from external supplies if this situation occurs .
This controller has been designed to operate with the Denison
Hydraulics range of fan drive motors and fluid control manifold blocks as
noted in this manual.
Use of the controller with products other than those mentioned above or
for applications outside those shown will require clarification with
Denison Hydraulics technical personnel at:
dfc@denisonhydraulics.com
Opto-Link: The Opto-Link interface unit ( 700-00012-0 ) is intended for

temporary use during static system set-up, commissioning and DFC
module programming only.
It is not designed for continuos connection and operation, and should not
be used or applied in areas where intense radio Frequency fields ( RF )
are present as unit resetting may occur, system diagnostic information
sent or received may be corrupted or the opto-link unit damaged.
If any of the above problems are seen, dis-continue operation until the
source of the RF has been identified and stopped.
6
Do’s and Don’ts:
ALWAYS
9 Take a few minutes to FULLY read THESE information's / data sheets BEFORE starting!!
9 Check the supply voltage is correctly wired and fused for the controller.
9 Make sure the controller supply voltage is the same as the coils on the valves being driven !
9 Ensure that you are aware of the limits, location & available adjustments in the software.
9 Know the Hydraulic circuit you are working on and the anticipated performance expected.
9 Make sure you have the correct ‘tools’ to do the intended job ( i.e. PC, D.V.M. ) e.t.c.
9 Ensure you have the correct PC version software loaded and operating correctly.
9 ‘Isolate’ this unit from all other equipment BEFORE any form of welding takes place.
9 Check ALL connections to and from this unit to ensure NO short / Open circuits.
9 Operate the units within specified operating temperature for best & reliable performance.
9 Ensure that any unused wires / terminals are terminated safely and not shorted together.
9 Change the Opto-Link battery or connect the mains adapter BEFORE starting any set-up.
9 Contact DENISON Hydraulics for more information if you are unsure of connecting this unit.
9 Follow the set-up procedures in this manual for best operational results.
NEVER
8 Arc Weld or Charge Batteries with this driver unit connected as damage can occur.
8 Attempt to use this unit if you are unsure of connections or expected operation.
8 Attempt to use this unit in Areas where AC or DC coils HAVE NOT been fully suppressed.
8 Use a power supply that is not rated for the correct required O/P current under full load.
8 Allow wires TO or FROM the unit to short circuit ( to each other or chassis / cabinet e.t.c. ).
8 Attempt to use this unit in areas of intense ‘RF’ without adequate screening measures.
8 Disconnect or connect wires to or from this unit unless it it isolated from the power supply.
8 Keep High Voltage AC cables separate from Low Voltage DC signal and supply cables.
8 Use this unit in temperatures that exceed those specified as operation may be effected.
7
Controller Electrical
Specifications:
1) Board Style: Denison Hydraulics Unique Size and Mounting.

2) Connector Types: Two part, polarised heavy duty screw type
3) Input Supply Voltage: 10 – 40VDC ( Absolute Maximum )
5) Input Supply Current ( Max ): Valve(s) Current Setting + 200mA Quiescent (Max)
6) User Output Voltages: Not applicable.
7) Command Input Type(s): 2 wire Thermistor, temperature switch ( software selectable )
8) Command Input Value(s): Ohms only ( Max temp = 50 Ohms, Min temp = 2Mohm )
9) Available adjustments: All adjustments in software, see attached literature.
10) Dither Frequency : Software adjustable, 31.5 to 250Hz ( menu selectable )
11) Environmental: Totally ‘ENCAPSULATED’ Printed Circuit Board.
12) IP Rating: IP 68 ( MIN ) ( circuit only ) derate connectors as required.
13) NEMA Rating: NEMA 6P ( circuit only ) derate connectors as required.
14) Humidity: 95 - 100% Non Condensing.
15) Storage temp.: -40 to +85 Deg C ( Max )
16) Working temp.: -30 to +75 Deg C ( Max ) Inc Ambient.
8
Thermistor The controller operation is based on input from up to three temperature

requirements: measured zones.
One, two or all three inputs can be used depending on the system
requirements with all three thermistor inputs able to be enabled or disabled
independently within the set-up software.
The inputs can be from NTC ( Negative Temperature Coefficient )
Thermistors or Bi-Metallic temperature switches and the choice can be
made in the set-up software ( see bottom of page ).
If ‘Charge Air’ temperature is to be monitored in the system, the
controller MUST have the Charge Air sensor connected to channel 2
and the engine warm sensor connected to channel 1. This is because
these channels are associated with the ‘Engine warm’ feature only.
Two wire NTC thermistors sensors with both wires brought back to the
unit are required for each zone being monitored.
DO NOT use thermistors with one lead grounded as the sensor and
the measuring accuracy will be severely degraded !
The controller is compatible with most automotive type thermistors with
Borg Warner, Delphi and Ford IAT sensors being pre-configured and
selectable on a drop down menu.
Other transducers not pre-set may have their profiles added and stored
under user selectable names for future use ( see pages 23 to 26 ).
If other thermistors are to be added, the acceptable Ohmic range is
50ohms at the maximum temperature that can occur in the system to
2Mohm at the minimum temperature that can occur in the system.
Open (> 2 M ohm) or shorted (< 50 ohms) thermistor inputs will be
detected and cause full fan speed output and indicate with the
appropriate alarm response and error code to aide diagnosis of the
problem.
The thermistor inputs can also be used as switch inputs
Switched Inputs: Switch inputs to the controller MUST indicate HIGH temperature by
disconnecting ( open circuit ) or tying the input(s) to the units power supply
voltage and indicate LOW temperature by grounding the input.
This switching convention is required to provide ‘Fail-safe’ operation as the
input(s) is normally internally pulled to +5VDC with a current limiting resistor.
When a input(s) reads a HIGH temperature ( NOT grounded ), it produces a
fixed error value that is acted upon by the controller to determine the fan
speed ( on or off ).
9
Charge Air feature: There can be a special case of cooling requirements when the engine is
warming up from a cold start. For this situation, the controller has a ‘Cold
Engine Fan Limit’ option available to the user which if enabled, will
temporarily stop the fans rotation to prevent excessive cooling.
The ‘Charge Air’ temperature can easily exceed its desired setpoint value
while the Engine Coolant temperature is still too cold to let the standard
mechanical thermostat open.
Normal operation would allow the ‘Charge Air’ temperature to capture the fan
control, cooling any other above ambient liquids in the radiator.
This would typically cause a sudden introduction of cold water when the
engine does eventually warm up enough to cause the thermostat to open,
resulting in the chance of engine damage with thermal shock.
‘Charge Air’ based fan control can also slow down engine warm-up time
generating unnecessary pollution, inefficient running and excess fuel usage.
On a cold start, reversing the fan during a ‘purge cycle’ will have a similar
effect as most radiators will then be cooled by the air sucked from around the
cold engine.
The ‘Cold Engine Fan Limit’ feature avoids these problems by not allow the
Charge Air OR Reversing inputs to take control of the Fan speed while the
Engine Coolant temperature is less than the ‘Engine Warm Temp’ setpoint.
‘Charge Air’ temperature reaching the user entered ‘Overtemp’ setpoint’ will
override the ‘Cold Engine Fan Limit’ and go to full fan forward rotation while
the condition exists, to ensure that damage does not occur and that the
Overtemp condition is reduced.
The Engine Coolant sensor MUST be connected to Thermistor 1 input
and set to type Thermistor.
The ‘Charge Air’ sensor MUST be connected to Thermistor 2 input and
may be set to type Thermistor or Switch.
Fan control by the thermistor 1 and 3 inputs is not limited by the ‘Engine
Warm Temp’ setpoint. While the unit is waiting for thermistor 1 to reach
engine warm temperature, clearing the ‘Cold Engine Fan Limit’ will not exit
the waiting mode.
Fan ‘ON’ delay : The fan ‘ON’ delay feature is intended to hold the fan at no rotation to
avoid unnecessary windage forces and allow the engine to start with
minimum loading possible.
This ‘Start Up Delay ‘ is programmable by the user via the software set-up
program and can be set from zero (0) to sixty ( 60 ) seconds in one second
increments.
This delay is activated every time the main power supply input is removed
and re-applied to the controller.
In the case of a normally acting proportional valve, the current is held at
zero output for the delay time.
If a reverse acting valve is used, the output current is held at the maximum
set in the software to ensure the fan is fully OFF.
10
Fan control logic: The controller uses "PI" to regulate the temperatures to be no more than
the Setpoints entered by the user.
The P and I terms act on temperature error, with the P term used to
instantaneously respond to temperature errors and should be adjusted to
respond quickly to large temperature changes, but have little impact
otherwise.
The I term is used to track the average fan current required to keep the
hottest temperature measured closest to its setpoint and should be set-up
for slow and smooth response while giving accurate control round the
setpoint.
General operation default values for the P & I terms are embedded in the
software but may be altered by users with the proper password level of
authorisation to fine tune a system.
Temperature error is the difference between the actual measured
temperature and the ‘temperature setpoint’, scaled by the difference
between the ‘temperature setpoint’ and the ‘'Overtemp' alarm setpoint.
The scaling is required to allow comparison of all the thermistor inputs on
an equal basis.
The active thermistor input with the largest scaled error above its setpoint
will be used by the PI process.
If all temperatures are below their user setpoints, the thermistor closest to
it’s set point will be used to give control.
In a properly tuned system, this process will result in the fan turning just
fast enough to keep one temperature regulated to its setpoint and all other
temperatures less than their Setpoints.
If a thermistor input is shorted or open, the unit will ramp to full fan speed.
This error behavior will continue until power is turned off if the user
programmable ‘Retry All Faults’ is NOT selected, otherwise, it will resume
normal operation when the fault is cleared.
A thermistor reaching ‘Overtemp’ is an error that results in ramping to full
fan speed. The ‘Overtemp’ error condition is automatically cleared if the
thermistor drops below ‘Overtemp’, ramping to the PWM% value
demanded by the PI loop.
Password Password protection has been provided to ensure that damage cannot be
protection: caused once commissioning is completed. There are three levels of
security, all of which may only be accessed via the Opto-link and PC
software and with the proper password level of authorisation:
Level 1:- ( NO Password ) Monitor controller operation only, no

change in parameters allowed.
Level 2:- ( OEM Password ) Authorised user has access to
the functions that are needed for programming and
set-up.
Level 3:- ( Professional Password ) Denison Engineering level
which allows access to ALL base controller settings and
some RESET functions.
Contact Denison Hydraulics on the e-mail address
( dfc@denisonhydraulics.com ) for password .
11
Fan Noise test The controller allows the user to set a pre-determined value of output
sequence: current to the proportional valve that will equate to the required 70%
forward fan speed required for the noise inspection.
Once set to the desired level, this value is saved to the controller then
allows the user to quickly demonstrate the noise level of a forward
driven fan by following the sequence below:-
1) Turn controller power supply OFF.

2) Depress and hold the ‘Manual purge’ sequence button.
3) Apply power to the controller.
4) Continue to hold the ‘manual purge’ button down for
approx. 5 seconds after power application then release to
enter the ‘ Test mode ‘.
5) This ‘ Test mode ‘ will drive the fan in the forward direction
for 3 minutes( this time is fixed ).
6) When the time period has expired, the fan will return to
normal system operation and cannot be put back into test
mode unless points 1) thro 4) are re-applied.
NOTE:-
• This is an OPEN LOOP test feature which even after accurate factory setting, can be marginally effected by
external conditions such as ambient and oil temperature, oil viscosity and system condition.
• The sequence can be stopped / reset at any time during the 3 minute test period by removing the power supply.
• The ‘Test mode’ period is pre-set to 3 minutes by the manufacturer and is not changeable by the user.
• The set-up software allows the user to pre-set the fan forward speed that is used during this ‘ Test mode ‘.
Power Supply and For most accurate smooth control with best resolution, protection and
Valve coil voltage : product reliability, the following combinations of power supply and valve coil
voltage should be adhered to:-
Proportional coils ( fan speed control….NO PURGE OPTION FITTED ):-

8 – 14VDC:- Use 12V valve coil.
Directional coil ( Fan direction control..NEEDED FOR PURGE OPTION ) :-

12
Proportional Output: A variable current output is used for driving a proportional valve to control
the fan speed.
BOTH wires from the valve coil must be connected to the controller where
indicated by ‘+Prop Valve O/P’ and ‘-Prop Valve O/P’.
The output is fully protected against shorted or mis-wired coils with errors
being both indicated locally on the associated LED and annunciated on the
controller software if the program is running on a PC connected to the unit.
Shorted coils or connection wires are detected only when the controller tries
to drive the coil and is indicated with a RED FLASHING output LED.
Open circuit coils or connection wires are detected only when the controller
tries to drive the coil and is indicated with a GREEN FLASHING output
LED.
In either of the above cases, the ‘Alarm output’ comes ‘ON Steady’ to
indicate an error and if connected, the PC program will show annunciators.
The proportional valve coil selected must be capable of withstanding the
power supply's maximum voltage or the user must set the maximum output
current ( I Max ) to a safe value.
User adjustable minimum current ( I Min ) and selectable PWM frequency
( 31 to 250 Hz ) allows tuning for smoothly starting the fan from a stop.
The proportional output is rated for a 3.3A coil current maximum at the
connected supply voltage.
The software allows user selection of driving normally open and normally
closed proportional valves.
The proportional output is turned off if the units internal temperature sensor
temperature exceeds 80 C.
Fan Max speed This is called ‘ Max Vlv Current %’ in the software and allows current to be
setting: adjusted from 0 – 100 % PWM output.
If Max Valve Current is set to zero (0) all other settings will also go to zero.
Fan Min speed This is called ‘ Min Vlv Current %’ in the software and allows current to be
setting: adjusted from 0 – 100 % PWM output set by ‘Max Vlv Current’ above.
Ramp settings: The user programmable ramp Up and Down times are applied to limit the
controllers rate of change in output current to a value that prevents
damaging the hydraulic system components and the fan blades.
The ramp rate is set in seconds (s) for a full scale current output change in
the range of 1 to 10 seconds.
This ramp time should be set low enough not to interfere with the
temperature control loop response but high enough to give smooth system
operation.
Dither frequency The set-up software allows the dither frequency ( PWM frequency ) to be set
setting: from 31.5 to 250Hz to cater for the known range of proportional valves that
could be used for this application.
13
Fan Reverse ( Purge ) This feature is designed to ‘de-clog’ the fan protection guard and cooling
Output : elements and not as a permanent running option.
The output drive to the coil is rated to 3.3Amps maximum ( at controller
supply voltage ) and is either ON or OFF with no proportionality or ramp
functions associated.
The two individual ‘Purge’ methods and the possible adjustments are noted
below.
Purge sequence: The ‘Purge’ sequence is specific to avoid damage to the fan blades and the
motor/hydraulic system and is as follows:-
1. Reverse command detected ( manual or Auto purge signal ) .
2. Fan proportional control valve ramped DOWN to give zero fan speed
at ramp rate set in software
3. Fan stopped ‘Dwell’ time starts if ( seconds ) value set in software.
4. Reverse valve O/P switched ON ( change hydraulic state )
5. 100mS after 4., Proportional valve ramped UP to reverse current limit
set in software
6. Reverse command released ( manual or Auto purge signal ).
7. Fan proportional control valve ramped DOWN to give zero fan speed
at ramp rate set in software
8. Reverse valve O/P switched ( change hydraulic state to original )
9. 100mS after 8., Proportional valve ramped UP to required Forward
speed.
Manual Fan Reverse For this feature to be activated, the operator must initiate the sequence by
( Man-purge ) sending a momentary or pulsed voltage signal ( vehicle supply level ) to the
Input: input marked ‘REVERSE I/P +’ on the controller. Upon receiving this signal,
the controller will follow the purge sequence to ensure correct and safe
operation.
Re-initiation of the manual ‘Purge’ signal during a ‘Purge’ sequence will be
ignored by the controller.
Purge Notes:- The software controls the purge feature such that if the momentary manual
input is continuously activated ( I.e. short circuited ), the sequence will
complete once, ensure the fan is re-activated in the forward direction and
wait until the input is cleared and then re-initiated before another purge
sequence is allowed.
Auto Fan Reverse This automated feature can be used to ensure free air flow through the
( Auto-purge ) radiator on a regular basis without operator intervention.
option :
Adjustments are available in the set-up software for:-
• Auto Purge feature ON/OFF select
• Auto Repetition rate ( set in minutes upto a maximum of 180 )
• Time to run in reverse ( Purge time ) direction set in seconds ( 60 max ).
• Speed of fan in reverse ( as a % of fan maximum forward speed )
The manual ‘Purge’ feature can be actioned between automated operations
as required.
14
Diagnostic Indicators: The unit is fitted with LED indicators to show real time diagnostic
information and indicate by error codes in a visual manner the current
operational status and if a fault develops with the system, where the
fault may be originating from.
Power ON / Opto-link The red LED indicates power supply status with the LED ‘OFF’ for less
transmitter: than 8 volts and flashes ‘ON/OFF’ for more than 40 volts. This LED
also acts as the communications transmitter when connected to the
Opto-link unit.
Opto-link Receiver: The clear LED is used only for ‘Infra-Red’ communications when
connected to the Opto-link unit and never shows any visible light.
Proportional Valve The proportional coil PWM% LED is fully RED for 0% PWM and fully
Output: GREEN for 100% PWM, with shades of red, orange, yellow and green
indicating intermediate values.
Manual Reverse The RED LED for the reversing coil trigger input comes ON only when
Trigger: the input is connected to the +Supply voltage indicating that the manual
reverse sequence has been initiated. Once this sequence has been
started,and in the duration of the purge cycle, new or multiple manual
trigger inputs will be ignored as will any automatic purge sequence
signals.
Reverse Valve The RED LED for the reversing coil output comes on with the output.
( Purge ) Output: The LED blinks on for about 0.1 seconds and then off for about 0.1
seconds to indicate shorts and blinks on for about 0.5 seconds and then
off for about 0.5 seconds to indicate opens. In either cases, the alarm
output comes on ‘Steady’ to indicate an error.
Thermistor input The RED LED for the thermistor that is controlling the fan comes on
status: steadily while the other thermistor LEDs are off, if no more than one
thermistor is above setpoint. If multiple thermistors are above setpoint,
the thermistor that is controlling the PI process has a blinking LED and
the others above setpoint are on steady.
Power ON / Opto-link Opto-link receiver Proportional Valve

transmitter output ‘ON’.
Manual trigger Reverse

Valve sequence
Activated.
See page 11 for

Thermistor details
input status
Reverse Valve
( Purge ) Output ‘ON’.
Two part,
polarised heavy
duty connectors
15
Error Indicator: The RED error led that flashes an ‘Error code’ when fault conditions that
have no other visual indicator have been detected.
The LED blinks error codes if faults have been detected with the
thermistor inputs, module temperature, module memory and alarm output.
The blink code will occur at a rate of 0.5 seconds on and 0.5 seconds off
with a two second pause before repeating.
Only the highest priority blink code will be displayed.
See table below for blink codes, with the lower number of blinks having
higher priority.
A controller unit temperature greater than 80C will be indicated by the
error LED ‘ON’ until retried if "retry fault" is selected, or until power is
cycled OFF then back ON.
The unit calculates the checksum of the internal FLASH program and the
user settings data file at power up.
If the checksum is incorrect, the unit is corrupt and will turn OFF all
outputs (except for alarm) and flash ALL LEDs except for the Power LED
which is required for OptoLink communication and the Reverse Input LED
that is driven directly by the Reverse Input.
This condition is cleared by re-loading the FLASH program and/or the
stored user characteristic data file.
This above situation should never occur unless power is lost during file
storage or up or download.
If memory checksum failure occurs without an attempt to update
FLASH or the user data file, the corrupted unit should be returned
without correcting the problem to Denison Hydraulics Inc. for failure
analysis.
The other fault conditions stop flashing when the triggering error is cleared
or if unit power is cycled depending on the ‘Retry Fault’ user setting.
Error Indicator
Location:
No. of blinks Fault / Error
1 Memory checksum error

2 Unit temperature greater than ( > ) 75C
3 Selected thermistor input shorted
4 Selected thermistor input open
5 Alarm output shorted
6 Over temp reached on one or more
thermistor inputs.
16
Alarm Output This low side on / off output is able to output 3.3A current maximum,
and is capable of driving inductive or resistive loads and is Protected
against shorted and miswired loads with shorted load detection only able
to be detected when driven.
The output has two modes of operation, ‘Steady ON ‘ and ‘Pulsing
ON/OFF’.
The ‘Steady ON’ mode is linked to NON critical errors or those that
would allow the unit to keep functioning. This type of error can be dealt
with in due time.
The ‘Pulsed ON/OFF’ state is intended to show that a critical error has
been detected and that the controller/system MUST be stopped and
examined immediately or damage may result.
Data logging The facility exists to allow the user to ‘LOG’ data of the thermistors and
option: several other controller functions for later or fault / trend examination.
The files can be individually named to suit the application and is suffixed
with a *.csv extension for direct and easy reading into Microsoft® Excel® for
graphical plotting and mathematical calculations as required.
Internal data The unit records the controller serial number, date first setup (born date)
logging: with a PC, highest supply voltage, the highest temperature of each
thermistor input (other than during calibration) and the highest module
temperature. The user can not reset these values without a password.
Shorted or open thermistor faults will not be recorded as a high temperature.
Connectors: The connectors used on this controller are of the two part, polarised,
heavy duty screw variety to suit the intended application environment
while still allowing easy cable access, installation, pre-looming and
normal maintenance.
The controller comes complete with all the connectors, male
( on the unit ) & female user wire connections, necessary for immediate
installation.
Connector:- Weidmuller style SLA and BLS.
Startup delay This is a timed function and is intended to allow the vehicle to be started
feature: and running before applying the extra the load of the hydraulic fan and
associated hydraulic pump demand.
The delay time can be adjusted in the set-up software and is calibrated in
seconds from zero (0) to a maximum of 60S.
This feature is initiated at every power ON/OFF cycle.
17
Retry ALL Faults: The user setting “retry all faults” determines if the unit will retry faults
that are detected with the controller or peripheral devices after 4 seconds
or if NOT selected, the unit will stop operation until the power supply is
turned OFF and back ON.
If after a power reset, the fault is cleared, the unit will return to normal
operation. If the fault persists, the controller will once again stop and
repeat the procedure above.
PC Hardware • Windows® 95 or 98, 98SE, ME, NT & 2000 operating system.

requirements:
• 2mB free hard disk.
• 68mB memory( min )
• Unallocated DB9 serial communication port OR
• Unallocated USB port with user supplied USB to DB 9 hub, powered
and with USB driver software installed correctly.
Opto-link This is the method by which the fan controller is set-up and monitored
Communications: and is explained more fully on page 28 of this manual.
The initial Opto-Link unit ( 700-00012-0 ) must be ordered separately to the
main controller but this is a universal communications adapter which will be
used with other upcoming Denison Hydraulics controllers and products.
Set-up software: • DFC Set-up software to Ver 1.0 ( 720-00004-0 ).

Denison has realised that digital electronics comes with the need for the
user to communicate with the controller and with this comes a new set of
practical problems associated with having to learn and become proficient
with the set-up software and hardware connections.
The controller-to-PC communications is taken care of by the Opto-Link
unit ( see page 27 of this manual ) which is plug and play in that all the
user needs to do is physically connect the unit and run the provided
software for the full automatic setup.
The software loads itself into a subdirectory ( the user is urged to allow the
default directory paths ) called C:\Denison\DFC, and creates a new
Denison folder on the desktop as well as a short cut in the start menu bar
with a full uninstall feature as standard.
This new generation of controller setup programs is specifically designed
to be easy-to-use with a non threatening approach and with only the
necessary items displayed ( determined by password levels ) to give a
non-cluttered display that is clear and understandable to both the
professional and casual user.
It is intended that full operational software will be available with each
controller product and that updates will be available from Denison
Hydraulics as needed.
18
Software Setup
guide ( Menu Bar ):
The ‘FILE’ tab brings the ‘SAVE’ and ‘RESTORE’ options to the user.
Temporary Memory -> Permanent Memory:- transfers all data from

PC to the connected module for onward unattended operation at the
current profile settings ONLY. NO backup copy is made !
Temporary Memory -> Permanent Memory & File:- transfers all
data from PC to the connected module for onward unattended
operation at the current profile settings ONLY. Opens window to allow
user to select stored file name and location for backup copy of profile.
Permanent Memory -> Temporary Memory:- transfers all data from

the connected module to the PC for editing the current profile being
used.
File -> Permanent and Temporary Memory:- transfers all data from
a hard copy PC file to the connected module and onto the PC for
editing.
Clicking the I/O Display tab brings up the ‘real-time’ controller

information page which allows the user to observe the status, alarms
and access the diagnostic features.
NO adjustments can be done from this page.
Depending on the password level, Clicking the Unit Settings tab

brings up the available user adjustable windows for setting the
controller profile.
( shown here at ‘professional’ level with ALL options displayed ).
19
Software Setup
guide ( Menu Bar ):
At ‘OEM’ and ‘Professional’ password levels only, Clicking the Trouble Codes
tab allows the user to observe a log of any error codes that have been triggered.
The currently displayed Event log can be reset from both of these levels.
Event times and number of occurrences are NOT recorded, rather that the error
occurred at least once from the last log reset.
At ‘OEM’ password level only, Clicking the Permanent Log tab allows the user to
observe list of ‘trapped’ data that indicate the maximum levels that the controller
has ever seen from initiation:-
1. The ‘Unit Serial Number’ is unique to every controller.

2. The ‘Motor Serial Number’ is entered at commissioning if required.
3. ‘Date First Set Up with PC’ is the ‘Born Date of the controller for warranty uses.
4. Thermistor 1 – 3 Highest temperatures ever seen.
5. ‘Unit Highest Temp’ is the actual controllers internal temperature max. reading.
6. ‘Power Supply Highest Voltage’ is the maximum supply applied to the controller.
At ‘Professional’ password level only, items 2,3 and 4 can be observed and reset.
At any password level, Clicking the Help tab allows the user to see contact
information, web and e-mail addresses as well as software and hardware
revisions for the actual product currently in use.
At any password level, Clicking the Quit tab turns OFF the Opto-link and exits the
program in the correct manner
20
13
Software Setup
guide Observation Page:
5 6
11
4 10
12
8 7
9
1
At the observer level, I/O Display, Help and Quit is the only General display area for controller information and input /
options available on the menu bar. output status.
10
2
Alarm and Error text window. Analogue needle display and digital readout of ‘real-time’
output current to proportional valve drive.
Error messages are in RED text.
The window stays as above while there are no errors or 11
Analogue bar graph and digital readout of ‘real-time’ output
alarms reported by the system and/or controller. current as a % of the maximum set.
3 12
Clicking this button starts the data logging process. Status of the reverse ( Purge ) cycle ( auto or manual ) if
reverse is enabled and/or triggered.
ALL of the parameters available in the item 5 drop down
menu as well as other profile settings are logged for a
13
period of 256 samples . After the logging period, a popup Clicking the ‘O’ in Denison prompts the user for the
window asks for file name and storage location. password level required:-
This file is saved with a *.csv extension which allows direct
import, reading and graphing in Microsoft Excel.
4
Window where ‘Real-time’ graphing of selected parameter
in 5 is displayed.
5
Drop down list of available parameters for display.
13
6
Digital representation of the parameter being displayed in 4
7
Selects Slow, Medium or Fast graph time base setting.
8
Selects Graphic window scaling between FULL scale or
AUTO. Auto gives better resolution for lower values.
21
Software Setup
guide OEM / Professional
Set-up Page:
1
5 6
4
10
8 7
The main differences between the OEM level and the Professional level passwords is the ability at
the Professional level to ‘ RESET’ data values in the ‘Permanent Log’ that have been stored during
the controllers operation.
Both levels allow the user full access to all controller parameters so password confidentiality should
be of a high priority.
1 5
At OEM and Professional password levels, the full menu Drop down list of available parameters for display.
bar options are displayed and available.
2 6
Alarm and Error text window. Digital representation of the parameter being displayed in 4
Error messages are in RED text.

The window stays as above while there are no errors or 7
Selects Slow, Medium or Fast graph time base setting.
alarms reported by the system and/or controller.
3
Clicking this button starts the data logging process. 8
Selects Graphic window scaling between FULL scale or
ALL of the parameters available in the item 5 drop down AUTO. Auto gives better resolution for lower values.
menu as well as other profile settings are logged for a
period of 256 samples . After the logging period, a popup
window asks for file name and storage location. 9
General parameter set-up area for controller. See following
This file is saved with a *.csv extension which allows direct section in this manual for further details.
import, reading and graphing in Microsoft Excel.
4 10
Window where ‘Real-time’ graphing of selected parameter Thermistor Enable and set-up controls. See following
in 5 is displayed. section in this manual for further information.
22
Software Setup
guide:
1 16
1 2 17
Click the ‘down arrow ‘ and select from the menu for
3 18
‘Proportional or ON/OFF’ type output current. In ON/OFF
mode, no Min, Max, Test or Rev Vlv current settings are 4 19
available and the output will be dependent on the supply 20
voltage to the controller.
5 7
In ON/OFF mode the ramps are left active to aide the use 6 8
of a ‘soft-shift’ valve if used.
9
2
Click the down arrow and select from the drop down menu,
10
the dither frequency between 31.5Hz and 250Hz that is 21
nearest to the recommended value for the proportional 11
valve product being driven. 12
3 13
Use the up/down arrows on each box or directly enter a
22
4 value ( in seconds ) in the range 0 – 10S for the ramp UP 14
and DOWN. 15
5
Clicking this button will disable the reversing ( purge )
feature and remove from the display items 6 7 8 23
6
Clicking this button will enable or disable the ‘Auto-purge’
feature but still allow the manual ‘Purge’ feature to operate.
15
In ‘Manual Purge’, items 3 4 7 need to be set. Click this button to enable or disable the entire controller.
This button on a new controller is defaulted to disabled.
7
Sets the time ( 1 – 60 seconds ) that the fan will spend in The first time that a controller is enabled, the date from the
the reverse ( Purge ) direction. connected PC is ‘Trapped’ and taken as activation date
8
information.
Sets the time ( 1 – 180 Minutes) between fan reverse
16
( Purge ) cycles when Auto-Purge is enabled. Click this button to allow inverted current output to control
reverse acting proportional valves.
9
Clicking this button Enables the ‘cold engine fan limit’ 17
feature and will prevent the fan from operation until the Set the Maximum valve current here from 0 – 100%.
temperature seen in 10 is reached. Maximum current ( 100% ) depends on coil Ohmic value
and supply voltage and will determine the fans maximum
If this feature is Disabled, item 10 is removed from the speed.
display.
This setting must be entered first and the software ensures
If Thermistor 1 or 2 are disabled, item 9 is removed from that no other settings can be greater than this.
the display.
18
Set the Minimum valve current here from 0 – 100% of the
Both Thermistors 1 & 2 must be enabled for this feature to maximum current in. 17 This current will determine the
work with Thermistor 2 being allocated for the warm engine fans starting speed.
sensor and Thermistor 1 being allocated to the CHARGE
AIR SENSOR. Software ensures that this setting cannot be greater than
the maximum setting.
11
Sets the units of temperature displayed throughout the 19
software from Degrees Centigrade ( °C ) to Degrees Set the Test valve current here from 0 – 100% of the
Farenhieght ( ° F ). maximum current in. 17 This setting determines the fan
speed for the noise test mode.
12
Sets the ‘Integral constant of the controller. Software ensures that this setting cannot be greater than
the maximum setting.
13
This feature is intended to allow vehicle starting with
20
minimum loading and holds OFF controller action until the Set the Reverse valve current here from 0 – 100% of the
time entered her in seconds ( 0 – 60S ) expires. maximum current in. 17 This setting determines the fan
speed for the Purge mode.
14
Click this button to enable ‘retry all faults’ which will allow Software ensures that this setting cannot be greater than
the controller to automatically try an error reset every 4 the maximum setting.
seconds to see if the fault has cleared.
21
See the ‘Thermistor Set-up ‘ section in this manual.
If this feature is disabled, any error will trigger the controller
22
to shutdown and stop functioning until a ‘Power On Reset’
is applied. 23
23
Thermistor Selection :
2 3
5 6 7
2a 9
10
11
12 13
1
The DFC-1 software includes several pre-characterized thermistor calibration profiles. These are
accessed by pressing <Unit Settings>, <Setup> (for the thermistor to be calibrated), <Select Profile>.
This allows selecting one of these thermistors from a drop down list.
This procedure is carried out for each channel which will allow different sensors to be used for different
liquid / medium measurement.
1 The window showing Thermistor settings is only 3 Clicking the ‘Save Profile’ button, saves the thermistor
available with OEM and professional password points to a file called [Name].dtp in the same directory and
levels and when the menu bar ‘Unit Settings’ tab will then appear in the [Select profile] list.
is clicked.
4 This window displays the current profile selected for the
The figure to the right shows the three thermistor relevant channel. To change the profile, follow step 2 and
inputs with Thermistor 1, enabled as a thermistor press accept.
and with the ‘Setup’ button depressed.
Clicking on the radio button marked ‘Setup’ opens a box called 10 The value in this window is the ‘Setpoint’ that the controller
‘Thermistor Setup’ shown to the right. will attempt to maintain be altering fan speed.
Thermistor 2 is shown enabled as a thermistor and with the This value must be between –40 or +300 Degrees F.
‘setup’ button as normal.
11 The value in this window is the ‘Overtemp’ alarm threshold
Thermistor 3 is shown NOT enabled. In this state, the options that will cause the alarm output to activate if reached.
associated with the thermistor are removed from the screen for
clarity. This value must be greater than the ‘Setpoint’ value.
2 Clicking this arrow will roll down a menu list [ Select Profile ] If the difference between Setpoint and Overtemp is to
( see 2a above ) of transducer profiles available. Default profiles small, the controller may keep going into alarm condition as
are supplied and all other ‘user created’ files will be shown if the actual temperature is controlled around optimum.
stored in the default file locations.
12 Push this button to accept displayed data and return to the
main program.
12 Push this button to disregard all displayed data and return

to the main program.
NOTE:-
The set-up software has embedded default settings for Borg Warner, Delphi and Ford AIT sensors
available. These files are write protected to prevent accidental editing and should be left in this state for
‘Reset to Datum Operation’ purposes.
24
Thermistor Calibration
( from table values ) :
If the sensor to be used is NOT on the list, the user will be able to manually calibrate the controller
/thermistor settings by entering the Temperature V’s Resistance values of the device that will be
available with the product or from the products manufacturer.
The data will take the form of calibration points provided with the sensor for HIGH, MID and LOW with
corresponding resistances.
For best accuracy, the three calibration points should be as widely separated as the thermistor type,
data sheet or actual cooling system High, Mid and Low running temperatures allow.
Smaller calibration ranges, as would typically be seen in an actual cooling systems, need to still be as
far apart as is practical or accuracy and temperature reporting outside of these ranges will be
degraded.
If the spacing of the calibration points are very close together ( I.e. 5 degrees ) the calibration process
can fail and the program will not allow using the calibration produced.
Once this ‘ user data ’ has been entered and accepted, the option will be given to store the information
in the data base for later usage and transport to other controllers as required.
Temp. Ohms
-50 441300 To enter NEW thermistor calibration data, follow these steps:-
-45 323600
-40 239700 1. Enter new file name in window 11
-35 179200
-30 135200
-25 102900
2. Enter thermistor data ‘pairs’ I.e. temperature point ( 0°C ) and resistance
-20 78910 ( 29490 ohms) for each window separately. 1 4 2 5 3 6
-15 61020
-10 47540
-5 37310 3. Click ‘Translate’ 7 button to ‘normalize’ the data in the controller.
0 29490
5 23460 4. Click save profile button 9 to save data set to hardrive.
10 18790
15
20
15140
12270
5. Click ‘accept’ 10 to return to main program with new values installed and
25 10000 active.
30 8196
35
37
6754
6260
6. Click ‘Cancel’ 8 at any time to leave data alone.
40 5594
45 4655
50 3893
55 3270
60 2760
65 2338 9
70 1990 Typical temperature
75 1700 11
V’s Resistance table
80 1457
85 1254 for NTC thermistor.
90 1084 1 4
95 939.2
2 5
100 816.8
105 712.7 3 6
110 623.7
115 547.6
120 482.1
125 425.7
130 376.9
135 334.6
140 297.9 7 8
10
145 265.8
150 237.7
25
( Custom ) :
Creating new profiles can be done from the Thermistor Setup page (<Unit Settings>, <Setup> ). The
first step is to assign the new thermistor type a name and press the <Save Profile> button to store
the profile on the PC. Profiles saved on a PC can be shared with other users and programmed into
additional DFC-1s.
Calibration of each thermistor for each channel may be required if the tolerance of the thermistor is too
wide to allow using typical thermistor values found in one channel for all the other channels while
maintaining desired accuracy. The DFC-1 will contribute less than 2% resistance error to the
temperature measurement, which results in less than 2% temperature error.
All NTC thermistors can be characterized by an equation that predicts the resistance at any
temperature. This equation describes the temperature V’s. resistance curve. The equation requires
three pairs of resistance and temperatures to fully characterize a thermistor. The temperature V’s.
resistance curve is very non linear, which prevents interpolating the Mid pair between the High and
Low pairs.
The DFC-1 software requires that the temperatures used in calibration are -40, 54.4, and 148.9.
Because the user will not likely be able to find data for exactly those temperatures, the DFC-1 has a
Translate button to convert the pairs the user can find to the ones required. The three pairs of data
must be accurately measured to avoid incorrect temperature readings or impossible mathematical
operations from the equation. The equation will attempt impossible operations if the pairs entered are
not close enough to the family of curves that can be produced by real thermistors. The further apart in
temperature the three pair are, the more tolerant of calibration value error the results are. The DFC-1
will report "Temp and Resistor Range is Invalid" if an impossible operations is attempted when the
Translate button is pressed. This can also produce other error indications and will often set the Low,
Mid and High resistances to 2,000,000. The user must pick temperature values that are further
apart, or re-measure the resistances and temperatures, if this happens.
The best way to calibrate the DFC-1 is to select thermistors that have good accuracy and repeatability
and simply type the low, mid and high temperature V’s resistance values from the data sheet. The
thermistor manufacturers can typically provide data pairs near -40C, 54C and 150C. It is not required
that the spacing between the three points is exactly equal, but it should be close. Excellent results will
be obtained for Low to High spreads of only 100C. Temperature spreads of less than 20C risk
inaccurate results or illegal operations.
The user will have to physically and manually measure three resistance V’s temperature pairs when
they desire to calibrate the DFC-1 to a thermistor family that does not have a data sheet.
The user can calibrate the thermistor in the system by measuring the first pair with the engine cold,
then at a temperature half way between the cold and hot engine temperatures and finally at the engine
hot temperature. The user must type in the actual temperature into the correct window, and then press
the Learn button to record the thermistors actual resistance for each pair in turn.
Measuring in the system can be difficult due to the problem of having to temporarily introduce an
independent thermometer next to the thermistor and the problem of obtaining a sufficiently large
temperature separation between the LOW, MID and HIGH pairs. It is also necessary that the
temperature change slowly enough that both the thermometer and the thermistor have thermally
‘settled’ to the same temperature.
26
( Custom Cont.. ):
‘Settling’ can be observed by graphing (in <Scale Auto>) the thermistor that is being calibrated and
observing that the thermistor and thermometer are simultaneously steady at a given temperature for
more than the thermal time constants of both devices. In some cases, this may require several
minutes to ensure a constant steady measurement.
The user should select the existing thermistor profile that produces a temperature readout closest to
that of the thermometer at the Mid temperature. While this profile may not provide accurate results, it
will allow detecting when the thermistor has settled. The independent thermometer should be
selected for accuracy and resolution of better than 1% and a settling time that is faster than that of the
thermistor under calibration. This typically requires a thermometer that can measure at least one digit
right of the decimal point and will settle in less than a minute.
The user can calibrate the thermistor on the bench if ‘in system calibration’ is not practical, dangerous
or does not produce sufficiently accurate results. The easiest way to do this is to submerge the
‘Independent thermometer and thermistor' into a cup of water, being careful that the water does not
have access any to bare wires connected to the thermistor. In all cases, wait for the thermometer and
thermistor to settle to constant values before making measurements. For the Low temperature pair, fill
the cup with ice and water. For the Mid temperature pair, fill the cup with room temperature water.
For the High temperature pair, fill the cup with boiling water and cover it with a thermal insulator to
keep the temperature as constant as possible. Better accuracy can be obtained if the user can
regulate the water or air temperature to more evenly separated values.
Typical NTC Thermistor Curve
450000
400000
350000
Resistance
Temperature
300000
Resistance Ohms
250000
200000
150000
100000
50000
0
0
30
65
10
20
37
45
55
75
85
95
5
5
5
0
0
0
10
11
14
12
13
-4
-3
-2
-5
-1
Degrees Centigrade
27
Optical Link Interface:
Denison's OptoLink ( P/No. 700-00012-0 ) is

required to interface between the fan controllers
infrared communications LED port and the PC /
laptop RS-232 port.
This optically coupled interface is provided as an
external item which must be ordered separately
from the controller unit and allows setup,
monitoring and limited data logging from the fan
controller unit on the bench, or in the system, via
a laptop PC running standard Windows®
software.
The unit is fully compatible with Windows® 95, 98, 98SE, ME, 2000 and NT versions.
If the user has only USB port styles available on the host PC / Laptop, the USB to DB 9 hub must
be supplied by the user, with the correct software installed onto the host PC / Laptop.
This style of ‘non contacting, non electrical communications port’ has been chosen and developed
because it is extremely rugged in physical nature, the method is not prone to connector breakage
or ‘clogging’ with foreign matter from the working environment and is free from failure caused by
electrolysis or common short circuits as seen with other communications alternatives used by
others.
The optical communications also allows very high speed data transfer between the host PC and
the controller for real time diagnostics and fast set-up programming and allows all the available
units inputs, outputs and options to be displayed from within the user software which is supplied
with the controller unit.
Controller profiles that have been saved or need to be saved as well as new unit software can be
up/down loaded through this port as required.
The OptoLink and controller requires that the correct interface software is loaded onto the host PC
and run to establish communications with a compatible controller.
The program will automatically poll all of the com ports available , detect and check the opto-link
unit for operation, allocate the respective port for communications while at the same time setting
the fastest reliable baud rate and default port settings.
The opto-link software provides an ‘EXIT’ button on the user screen ( not the ‘X’ in normal
Windows top left corner ). This should be used as this not only exit’s the current program
but also turns OFF the opto-link unit to preserve battery life.
The opto-link driver software monitors the battery voltage and indicates to the user on the PC /
Laptop screen that there is a problem. If this warning is not seen or ignored, and If the Opto-link
battery voltage is becoming low, the communications will be unstable with typically, the port being
re-initialized on a regular basis. If this situation occurs, switch to the external power adapter
provided or change the battery.
The Opto-link unit comes complete with DB 9 Male / Female extension cable, standard 9V battery
and external power supply unit ( 110VAC @ 60 Hz )
The latest software updates and current versions are free with the controller and can be requested
if required by e-mail at:- dfc@denisonhydraulics.com .
28
Dimensional
Information: I
A B
PWR OK
PROP VLV PWM%
COM IN
THERM 3
THERM 2 REVERSE O/P ON
THERM 1 ERROR
REVERSE I/P ON
DIGITAL FAN
CONTROLLER
Label Inches Millimetre
P/No:- 700-00013-0 REVERSE I/P +
A 1.825 46.355 C S/No:- DFC 00000

+V POWER I/P
G
THERMISTOR 3 SIG + PROP VLV O/P
B 0.2 5.08 THERMISTOR 3 GND + REVERSE VLV O/P
C 3.1 78.74 THERMISTOR 2 SIG - REVERSE VLV O/P
D 3.25 82.55 THERMISTOR 2 GND ALARM O/P
E 0.7 17.78 THERMISTOR 1 SIG - PROP VLV O/P
F 0.5 12.7 THERMISTOR 1 GND 0V POWER I/P
G 3.7 93.98 H
3XH 0.2 5.08 MADE IN H
U.S.A.
I 3.65 92.71
B
D
Mechanical Data:
Housing Type:- Denison unique ‘encapsulated’ block.

Housing Material:- None, solid, flameproof epoxy resin block.
Housing Colour:- Black / dark Grey.
Surface Finish:- Gloss
Housing Thickness:- 12mm ( main module ) 25mm incl. Connectors.
Unit size:- See above size detail drawings.
Unit Weight:- Approx.... 400 grams ( including Encapsulation material )
Wire entry:- Via heavy duty, polarised, two part screw type connector.
Encapsulation:- Flame Resistant, Black , Two Part Epoxy Resin.
Mounting:- Via through holed ( 3 ) suitable for No. 10 ( 4mm ) screw .
Temperature range:- - 40 to +75 degrees Centigrade ( operational )
29
Alarm Connection: +V supply

Alarm output shown driving a
simple lamp to indicate fault /
THERM 3 PROP VLV PWM% error condition has occurred.
THERM 1 ERROR This same connection circuit can

REVERSE I/P ON
DIGITAL FAN be used with a relay or solenoid
CONTROLLER – DFC-1
P/No:- 700-00013-0
to facilitate system integration as
REVERSE I/P +
S/No:- 700-00013-0
+V POWER I/P required such that engine
THERMISTOR 3 SIG + PROP VLV O/P shutdown could be initiated if the
THERMISTOR 3 GND
THERMISTOR 2 SIG
+ REVERSE VLV O/P
- REVERSE VLV O/P
fault continued un cleared.
THERMISTOR 2 GND ALARM O/P
THERMISTOR 1 SIG - PROP VLV O/P
The maximum switching current
THERMISTOR 1 GND 0V POWER I/P of this output is 3.3amps at
MADE
supply voltage.
IN
U.S.A.
NOTE:-
‘Flyback’ diodes
should be used with
inductive loads such
as solenoid coils e.t.c.
0V supply
Fan Speed manual NOTE:- ALL other external connections and peripheral
Override: equipment have been removed from these drawings for
clarity.
THERM 3 PROP VLV PWM% NOTE:-

The switch MUST be rated to carry
+V supply
THERM 1 ERROR
at least 5 amps at 24VDC.
REVERSE I/P ON
DIGITAL FAN
P/No:- 700-00013-0 REVERSE I/P +
S/No:- 700-00013-0
+V POWER I/P
THERMISTOR 3 GND + REVERSE VLV O/P
THERMISTOR 2 SIG - REVERSE VLV O/P
THERMISTOR 2 GND ALARM O/P The system using the ‘Reverse acting’
THERMISTOR 1 SIG - PROP VLV O/P proportional pressure relief valve ( as shown in
0V POWER I/P
THERMISTOR 1 GND
this manual ) is designed to fail-safe I.e. to full
MADE
IN fan speed in the event of a power supply failure
U.S.A.
or damage to the controller.
The user may also initiate full fan speed regardless
of the controller settings by simply turning the unit ‘
OFF ‘ via a simple switch as shown opposite.
0V supply This option can be used on initial commissioning or
during service to prove the hydraulic continuity
circuit if required.
Once the unit is switched back ‘ ON ‘ , the controller will re-initialise and the real time temperature
measurements in each zone used once again to dictate the ideal fan speed.
NOTE:-
If the unit power supply is turned ‘ OFF ‘ to force fan full speed, the ‘Purge’ function, diagnostic indicators
and alarm output will not operate until power is restored to the unit.
30
Manual ‘Purge’
Connection: +V supply
THERM 3 PROP VLV PWM%

REVERSE O/P ON
NOTE:-
THERM 2
THERM 1 ERROR Manual ‘Purge’ initiation switch
REVERSE I/P ON should be ‘momentary variety for
DIGITAL FAN
best results.
P/No:- 700-00013-0 REVERSE I/P +
S/No:- 700-00013-0
+V POWER I/P
THERMISTOR 3 GND + REVERSE VLV O/P If the manual ‘Purge’ input is short circuited or the
THERMISTOR 2 SIG
THERMISTOR 2 GND
- REVERSE VLV O/P
ALARM O/P
operator keeps the button depressed, the software
THERMISTOR 1 SIG - PROP VLV O/P will allow the controller to complete one ‘Purge’
THERMISTOR 1 GND 0V POWER I/P cycle and will ignore the continuous input after this.
MADE
IN
U.S.A.
The next manual purge sequence will only be
allowed after the input has been cleared and re-
initiated by the user.
The Auto-purge feature, if set, will continue to
operate at the specified interval and period
0V supply regardless of the manual input condition.
NOTE:- ALL other external connections and peripheral equipment have been removed from these
drawings for clarity.
General Maintenance:
The controller printed circuit board and components are sealed and impervious to hydraulic oils, other
non corrosive liquids and hostile environments.
If the controller is dirty, wipe clean with a cloth only. DO NOT use abrasive cleaners as this will
degrade the units information label.
If the controllers diagnostic indicator LED’s are broken, the unit will continue to function
normally with no adverse effects and will maintain the fully sealed rating.
The unit should be replaced as soon as possible if any of the LED indicators are damaged or broken to
allow full local diagnostic information on controller operation.
• E-Mail to : DFC@denisonhydraulics.com
• General Info : www.denisonhydraulics.com
31
‘Purge’ Profile ( Reverse acting Pressure Valve ):
Fan speed Profile.
6 12
4 10
7 9
3 13
8
Controller Output
1
2 5 11
14
profile to inverting type
pressure control valve.
Reverse output to
directional valve.
1 8
Normal ‘Forward’ running fan Fan at maximum speed for
speed determined by controller. Reverse time period set in
software. This speed may be less
2 than forward to protect fan.
Manual or automatic ‘Purge’ or
reverse fan trigger detected here. 9
‘Purge’ timing cycle expired, ramp
3 fan to zero at ‘Ramp Down’ rate
Fan speed decays to zero at
set in software.
‘Ramp Down’ rate set in
software. 10
‘Dwell’ timer started to allow fan
inertia to fully dissipate and fan
4
‘Dwell’ timer started to allow fan stop.
inertia to fully dissipate and fan
11
stop. Reverse output turned OFF to
de-energise directional valve.
5
Reverse output turned ON to 12
energise directional valve. Output signal to proportional
valve started 100mS after reverse
6 valve signal to prevent hydraulic
Output signal to proportional
‘lock’
valve started 100mS after reverse
valve signal to prevent hydraulic 13
Fan rotation increased to
‘lock’ ‘Forward’ running speed
determined by user setting at
7
Fan rotation increased to ‘Ramp Up’ rate set in software.
‘Reverse’ running speed
14
determined by user setting at Normal ‘Forward’ running fan
‘Ramp Up’ rate set in software. speed determined by controller.
32
NTC Engine &
Multi-path Transmission
Radiator Motor
Mounted
Manifold Block Thermostat
Water Jacket Coolant
Water
Pump
Cooling
Typical Hydraulic Operation:
Fresh air
Directional Proportional
intake Valve Relief Valve
Exhaust
Drive Drive Gasses
NTC Coolant / Oil / Other
NTC Charge Air Intake

Hydraulic Fan System and Digital Controller.
Turbo-
Ch #1
Charge charger
CH #3 Air +V
ON/OFF
Coolant switch
/ Oil /
CH #2 Other
CH# 1 Digital Fan
Engine Controller
Water
Jacket CH# 3 700-00013-0 Manual ‘Purge’ switch
Alarm
Alarm Output Load
CH# 2
Temperature
zone inputs
33
Proportional REVERSE REVERSE Output Power
Condition Error LED Alarm Output PWM Output LED Thermistor Leds Cleared By
Valve Output Output LED LED
Memory Checksum Same As Green / Off With

One Blink Off Off Same As Error No Change All Same As Error Reload Flash Or Data File
Failure Error Error
Same As Power Off Till Unit

Unit > Than 75C Two Blinks Regulating No Change No Change No Change No Change No Change
Error Temperature < 70c
Unit Temperature > Same As Power Off Till Unit

Two Blinks Off Red / Off With Error Off Same As Error No Change All Same As Error
Than 80C Error Temperature < 70c
Thermistor Input Three

On Full Fan No Change No Change No Change No Change Shorted Same As Error Power Off Till Fault Corrected
Shorted Blinks
Four
Thermistor Input Open On Full Fan No Change No Change No Change No Change Open Same As Error Power Off Till Fault Corrected
Blinks
Alarm Output Shorted Five Blinks Off Regulating No Change No Change No Change No Change No Change Power Off Till Fault Corrected
Thermistor Input Over

Six Blinks On Full Fan No Change No Change No Change No Change O'temp Same As Error Corrected
Temp
PWM Output Shorted Off On Off Flashing Red / Off No Change No Change No Change No Change Power Off Till Fault Corrected
PWM Output Open Off On Off Flashing Green / Off No Change No Change No Change No Change Power Off Till Fault Corrected
Reverse Output Shorted Off On No Change No Change Off Flashing Quickly No Change No Change Power Off Till Fault Corrected
Reverse Output Open Off On No Change No Change Off Flashing Slowly No Change No Change Power Off Till Fault Corrected
Set Power Supply Between

Power Supply < 8 Volts Off Off Off Off Off Off Off Off
8 And 40 V
Power Supply Between

No Change No Change No Change No Change No Change No Change On No Change
8 And 40 Volts
Power Supply > 40 Set Power Supply Between

No Change On No Change No Change No Change No Change Blinking No Change
Volts 8 And 40 V
Running In Reverse Off Off Purge No Change On On No Change No Change
Fan Min, All

Thermistors Below Off Off Minimum No Change No Change No Change No Change All Off
Setpoint
Fan Slowing, All
Closest To Setpoint Is
Thermistors Below Off Off Slowing No Change No Change No Change No Change
On
Setpoint
Only One Thermistor
Off Off Regulating No Change No Change No Change No Change Selected Is On
Input Above Setpoint
Selected Is Flashing,
Several Thermistor
Off Off Regulating No Change No Change No Change No Change Others Above Setpoints
Inputs Above Setpoint
Are On
Unit diagnostics, Error Codes and Alarm Conditions
34
Controller Mounting:
The electronic components used in this controller released by Denison Hydraulics, conform to the
Commercial temperature range which is -40° to +75 ° Centigrade. This rating means that the
components will work reliably and give a good life span if the operating temperature is kept within
these ( absolute maximum ) limits.
The controllers when in operation do generate and dissipate internal heat. The amount of heat
generated is dependent on the amount of work that the controller is being asked to do as well as other
factors such as supply voltage, type and voltage of coil being driven e.t.c. with the worst case
combination being a 24VDC supply with a 12V coil.
In order for the unit not to exceed the +75°C maximum operating temp and cause a ‘self-protection’
shut down situation, the user must mount the controller in a position that is ergonomically preferred
especially for visual inspection and system maintenance and also provide for adequate ventilation to
ensure that the unit is cooled to maintain operation.
In addition to ventilation, the system designer must also look at the mounting arrangement for the
cards / controllers and be aware that adequate space should be left around, in-front and behind to
allow the above ventilation to take effect.
It should be noted that temperatures are ‘Additive’ which means that with a high ambient temperature,
the units internal temperature rise need only be quite small to reach the maximum specified levels.
If controllers are going to be used in High ambient temperature or unusual application areas, please
contact the electronic controls personnel in Denison Hydraulics for advice on cooling and mounting.
Notes:-
• Enclosures should have an ‘IN’ and an ‘OUT’ vent for correct cooling air circulation.
• Mount the controller so the operator can see it if required to do so.
• Use ‘fan-blown’ air wherever possible to increase air exchange rate.
• DO NOT mount controllers in direct sunlight.
• Mount controllers with ‘air-gaps’ to allow correct ventilation.
• Do not mount controllers in non-ventilated sealed box’s especially in high ambient areas.
• DO NOT mount controllers ‘face-face’ or densely as this will cause over-heating problems.
• Read the literature and observe the max operating temp figures and work to them.
• Remember…High temp. ambient air used for ‘cooling’ is not a good solution !!
35
FAQ’s:
Set-up program does not reflect user changes made immediately:-

If the controller is in any mid sequence ( I.e. reverse timer was set to a long period and now a new
shorter period is entered ), the controller will normally only reflect the new settings once the currently
running sequence has ended. The only way to ‘reset’ this type of occurrence is to physically power the
controller down and then back up. Once Opto-link communications have been re-established, the new
settings will be valid and seen.
The Opto-Link keeps losing communication or keeps resetting:-
This is normally caused by a bad ‘mechanical’ connection between the Opto-link head not being
attached to the controller securely or by the Opto-Link battery level being to low or external power
supply not being connected.
To remedy, Check that the communications head is
attached firmly, that the two small holes are NOT filled with
foreign matter and that the controller LED’s are not
damaged or dirty.
Replace the internal 9V battery or check the external power
supply for connection and operation.
The controller shows an error saying “unit not communicating”:-
This error is reported usually if the PC is connected or the set-up program is started after the controller
is working.
Cycle the controller power ON/OFF to reset the link or wait to see if the communications will
synchronise after a few minutes.
If the problem still persists, look at the Opto-Link power supply and ensure this is correct.
The controller does NOT recognise open circuits on the valve coils”:-
The controller senses open circuits by passing a very small current all the time through the connected
coils to ensure connectivity and winding integrity. This ‘non reporting’ error is caused by the valve coil
plug having a light bulb fitted that appears to the controller to be an electrical load. Remove the light
bulb or use an LED variety that uses less current.
36
Controller Qwik-Ref:
Static text written on screen

[Text written on button or pull down list or labeling an entry box], also brackets appear around units of
measure.
(Alternate text for button when pressed) / (Separated by slashes)
Meter or box displaying constantly changing value or value not under user control, multiple, mutually
exclusive, text possibilities separated by commas
Notes explaining what will appear on the screen, or functionality
Find Opto-Link When the Setup program is launched, it must first find the OptoLink to allow
communicating with the unit. The Find Opto-Link window pops up while the setup program searches
for an OptoLink on serial ports Comm 1 through 4. Automatic Comm port selection will occur if the
OptoLink is plugged in and if allowed by the operating system. Each Comm port is listed with its
status of
Unavailable , Available and a
[Select] check box that allows manually selecting that comm port and exiting the Find Opto-Link window.
This must be used when a USB to serial adapter is used, or the operating system is NT or Win 2000
based. The Find Opto-Link window will periodically pop up briefly if unit communication is not
established on the selected port, but it will continue to attempt communication only on the selected
port.
OS Name displays the name of the PC's operating system.
OS Version displays the version of the PC's operating system.
[ABORT] button exits the Setup program.
[Go Offline] button exits the Find Opto-Link window, stops looking for an OptoLink, and allows the Setup
program to be used without communicating with a unit. Used to create, edit or view User Setting files
offline.
Opto-Link Not Found, Opto-Link has no power, Found Opto-Link status is displayed after each round
of checking all ports.
[Go Offline] button appears when the unit is not communicating, but the OptoLink has been located.
Going Offline allows the Setup program to be used without communicating with a unit. Used to create,
edit or view User Setting files offline.
Open popup window appears to prompt the user to select a User Data file to edit or view when the [Go
Offline} button is pressed.
[Go Online] button appears when the unit is Offline. Pressing the [Go Online] button will cause the Setup
program to try to establish communication with the unit. The user settings must be saved to file if they
are to be preserved. The Offline edited User Settings will be lost once communication with the unit is
established.
[Quit] button
[Log Data] / (Cancel) button. All user settings are recorded and everything that is graphed, metered or
displayed is logged, including error messages. Canceling the log in progress allows you to save the
shortened log or cancel the save. Default name data log.csv.
Log Sample ### for data logging, 0 to 255, starting at 0.
Logs Taken ### if not taking a log or Logging Data while taking a log, 0 to 255 starting at 0.
[Data Log File Save] dialog box pop up in a window after first log is finished. Additional logs are
appended to the same file. The user may change the default file name and location.
[O] The ‘O’ in Denison brings up a password screen that allows entering a password and displays the
current privilege level of the user. The password screen shows the user privilege level.
[Unit Settings] brings up the Settings screen displaying user settings without hiding the graph and Errors
screens, requires OEM password or greater.
[I/O Display] brings up the I/O Display screen showing input and output values and statuses without hiding
the graph and Errors screens.
37
[File][Save][Save Temporary Memory -> Permanent Memory] buttons becomes a big (Saving to
Permanent Memory) annunciator while the save is occurring.
[File][Save][Save Temporary Memory -> Permanent Memory & File] buttons becomes a big (Saving to
Permanent Memory) annunciator while the save is occurring, and then becomes a (Save As) pop up
window that allows the user to enter or select a file name and location to save the unit settings to. The
file extension of .dat is automatically appended to the name the user enters.
[File][Restore][Permanent Memory ->Temporary Memory] buttons
[File][Restore][File -> Permanent and Temporary Memory] buttons open pop up window that allows the
user to enter or select a file name and location to save the unit settings to. The file extension of .dat is
automatically appended to the name the user enters. After the file is selected a (Saving to
Permanent Memory) annunciator becomes a big (Saving to Permanent Memory) annunciator while
the save is occurring.
Note: The user screens and the unit's label call the inputs Thermistor 1, Thermistor 2 and Thermistor 3.
These input names are stored in the unit's data file, but can only be edited by manufacturer to assure
that the software names match the label and that the unit has a unique part number. The software will
allow for up to 20 characters. Use the names from the data files in every occurrence of display, data
entry or error message, never hard code Thermistor 1, 2 or 3.
[Temp units F/C] toggle box, default C, selects temperature units for all displays and data logs.
Thermistor 1, 2 or 3 There are three Thermistor inputs, each having a group of controls unique to that
thermistor.
[Enable] button determines whether or not a thermistor contributes to the temperature regulation process,
and is checked for error conditions. Enabling a Thermistor brings up the [Switch] check box and P[]
and I[] entry boxes.
[P] entry box for the process P term, 0 to 255, default T.B.D.
[I] entry box for the process I term, 0 to 255, default T.B.D.
[I Time[S]] entry box for the I update time, 0.1 to 25.5
[Switch] button unchecked brings up the [Setup] button to allow setting up the thermistors calibration
constants, Setpoint and Overtemp settings. When checked, the thermistor is treated as a switch.
Thermistor 1,2,3 [F,C]: temperature and resistance Ohm annunciators appear on the I/O page and
temperature degrees is also graphed when not a switch.
Thermistor 1,2,3 Open, Shorted , Overtemp annunciators appear in the Error window.
[Setup] button brings up a popup window for the following parameters for that thermistor:
[Select Profile] pull down menu allows selecting thermistor calibration profiles that are loaded as files in
the same directory as the Control Program.
[Name] box displays name of the profile selected, and allows entering a name for a new profile to be
saved.
[Save Profile] button saves the thermistor calibration pairs to a file named [Name].dtp in the same
directory as the Control Program. These calibration files may be manually added to the same
directory and will appear in the [Select Profile] list. This button does not cause the profile to be used,
the user must still press the [Accept] button.
38
Temp-Deg [F,C] Res-Ohms

LOW [Degrees] entry box [Ohms] entry box [Learn]
MID [Degrees] entry box [Ohms] entry box [Learn]
HIGH [Degrees] entry box [Ohms] entry box [Learn]
These entry boxes allow typing in Temperature - Resistance pairs from data sheets to calibrate the
thermistor. Temperature range and resistance ranges for all entry fields through out the program is -40
to +300F or -40 to 149C and 10 ohm to 2 MegOhm. Low must be the lowest temperature and High
must be the highest temperature. Alternately, the user can type in the Temperature and press the
[Learn] button when that temperature is reached for that sensor in the system. Pressing the [Learn]
button enters the thermistor resistance that is measured for that sensor into the corresponding Res-
Ohms entry box. Error messages will appear if the values entered are not valid, but may go away
when all calibration fields have been updated.
[Setpoint [F,C] entry box, default 190 F
[Overtemp [F,C] entry box, default 220 F
[Accept] button allows accepting a calibration and exiting the popup window. This button only appears if
the Low, Mid and High Temp entries are -40, 130, 300 F or -40, 54.4, 148.9 C. This button only
causes the calibration values to be used until power is lost; the user must save them to Permanent
memory or File if that is desired.
[Translate] button only appears when the [Accept] button does not. The [Translate] button translates user
entries in the Low, Mid and High Temp entries to -40, 130, 300 F or -40, 54.4, 148.9 C to allow
saving in standard format.
[Cancel] button closes the popup window without changing the setup of the thermistor.
Default values are all Thermistors enabled, all of type Thermistor and all of Thermistor Type 5028-01666.
[Startup Delay [s]] entry box, 0 to 60 seconds, default 20 seconds.

[Retry all faults] check box, allows retrying shorted or open thermistors, shorted and open coils and unit
over temp. Default not checked, will not retry.
[Disable Reversing] check box, default checked. When unchecked, the following buttons appear:
[Auto Purge Time in Rev. [s]] entry box, 1 to 60 seconds. Do not subtract the time spent ramping up or
down from this value, the fan will spend this time at the programmed reverse speed. Default 30.
[Reverse PWM [%]] entry box. The current to run the fan at when in full reverse speed. Default 100%.
Limited to >= Min PWM% and <= Max PWM%. The [Make Proportional into On / Off Valve] check box
must also be selected for this box to be visible.
[Enable Auto Purge] check box, default disabled. When checked, the [Auto Purge Delay Time[m]] button
appears.
[Auto Purge Delay Time [m]] entry box, 1 to 180 minutes. Do not subtract the time spent in reverse from
this value, the next Auto Purge timer starts when the unit goes back to forward fan. Default 180.
Fan Direction Reverse, Forward indicates that the Reverse Output is On (Reverse) or Off (Forward).
Reverse Output Shorted, Open annunciators appear in the Error window. Will not appear if Enable
Reversing is not checked.
39
[Reverse Acting PWM Valve] check box. PWM% commanded by PI loop or error condition must be
inverted to drive output. Default checked.
[Make Proportional into On / Off Valve] check box. Cause the prop output to be fully on when
temperature regulation or error behavior would have commanded the PWM% to be greater than
minimum or zero, and fully off when PWM% would have been equal to minimum or zero. Default not
checked. Unchecking this box makes the following buttons visible:
[Dither Freq] list box, 31.5 to 250 Hz, default 200 Hz.
[PWM%-Ramp Up [s]] entry box, 1 to 10 seconds, default 10 seconds.
[PWM%-Ramp Dn [s]] entry box, 1 to 10 seconds, default 10 seconds.
[Max PWM% [%]] entry box. The output PWM% will not exceed this value. Default 100%.
[Min PWM% [%]] entry box. The output PWM% will not go below this value unless the output is turned off
by an error condition. Coerce to less than or equal to Maximum Prop Output value. Default 0%
[PWM%-Noise Test [%]] entry box. Default 70%.
[Cold Engine Fan Disable] check box. Default off. Grayed out unless Thermistor 1 and 2 are both
enabled and Thermistor 1 is not type switch.
[Warm Temp [F,C]] entry box. Default 180 F. Grayed out unless [Cold Engine Fan Disable] is checked.
See specifications for which password level is required to view, edit and reset "Permanent data logging"
and "Trouble Code" parameters. Note that these values are saved into the data file, but never over
written by it.
Trouble Codes Note that trouble codes will not be displayed for inputs and outputs that are not enabled
or are in a mode that can not have that trouble code.
[Clear Trouble Codes] button allows resetting all stored Trouble Codes to their present condition.
Proportional Valve Open True,False Short True,False
Reverse Valve Open True,False Short True,False
Alarm Output Short True,False
Thermistor 1 Open True,False Short True,False
Thermistor 1 Over,High Temp ### [F,C] The highest temperature is stored and is labeled as High or
Over to indicate the condition is normal or an error.
Unit Over,High Temperature ### [F,C] The highest temperature is stored and is labeled as High or Over
to indicate the condition is normal or an error.
Power Supply Over,High Voltage ##.# V The highest power supply voltage is stored and is labeled as
High or Over to indicate the condition is normal or an error.
40
Permanent Log Note that Permanent Log values will not be displayed for inputs and outputs that are not
enabled or are in a mode that can not have that error value.
[Unit Serial Number] filled in from label by Manufacturer.
[Motor Serial Number] filled in from by Denison.
[Set,OK] buttons appear next to [Unit Serial Number] and [Motor Serial Number] to allow filling in the values
when pressed.
[Date First Setup with PC] default blank.
[Clear] button appears next to [Date First Setup with PC] to allow setting the value to blank when pressed.
Thermistor 1 Over,High Temp ### [F,C] The highest temperature is stored and is labeled as High or Over to
indicate the condition is normal or an error.
Unit Over,High Temperature ### [F,C] The highest temperature is stored and is labeled as High or Over to
Power Supply Over,High Voltage ##.# V The highest power supply voltage is stored and is labeled as High or
[Reset] buttons appear next to Thermistor 1,2,3 , Unit Over,High Temperature and Power Supply Over,High
Voltage to allow resetting to current values when pressed.
DFC-1 Setup V##.##

Unit Application V##.##
Setup Program incompatible with Application Program, update your Setup Program will appear if the
Setup program detects that the Application Program is newer and incompatible.
Reverse Input On , Off annunciator and graph selection
PWM % bar graph and PWM % graph selection
Output Current meter [A] and graph selection and Shorted and Open annunciators for proportional output.
Power Supply display box [V] and Power Supply Voltage graph selection and Power Supply Too High (more
than 40V) and Power Supply Too Low (less than 8V) annunciators.
Alarm output On, Off annunciators appear in the Error window.
Which input is in control: Fan Controlled by Thermistor 1, Fan Controlled by Thermistor 2, Fan Controlled
by Thermistor 3, Fan Controlled by Reversing , Fan Controlled by Fan Noise Test, Minimum Valve
Current%, Maximum Valve Current%
Auto Purge Cycle Status title placed over a phase display box which will say Ramping Into Reverse, Auto
Purge Reversing, Ramping Out Of Reverse, Time Till Next Auto Purge that indicates the phase of auto
reverse if any, placed over a time display box Min ### Sec ## that indicates time remaining in that phase.
This group of text and displays is only visible if Enable Auto Purge is selected or the Reverse input is on.
Module Temp annunciator. Temperature number is also graphed.
Module Over Temp Shutdown annunciator appear in the Error window when the temperature is above 80C.
Module Over Temp Warning annunciator appear in the Error window when the temperature is above 75C.
FLASH Memory Checksum Error Shutdown annunciator appear in the Error window when the FLASH
memory checksum fails at power up.
Data File Checksum Error Shutdown annunciator appear in the Error window when the data file stored in
"EE" checksum fails at power up, turn off only Reverse and Proportional outputs.
41
Temperature Converter
Tables:
The table opposite will allow easy conversion of Deg C Deg F Deg C Deg F Deg C Deg F
Centigrade to Fahrenheit when needed during -50 -58 18 64.4 86 186.8
set-up or NTC thermistor selection. -48

-46
-54.4
-50.8
20
22
68
71.6
88
90
190.4
194
-44 -47.2 24 75.2 92 197.6
The yellow regions indicate the limits of -42 -43.6 26 78.8 94 201.2
-40 -40 28 82.4 96 204.8
temperature that the controller will accept when -38 -36.4 30 86 98 208.4
the user is attempting the manual calibration of -36

-34
-32.8
-29.2
32
34
89.6
93.2
100
102
212
215.6
the controller / thermistor. -32 -25.6 36 96.8 104 219.2
-30 -22 38 100.4 106 222.8
-28 -18.4 40 104 108 226.4
-26 -14.8 42 107.6 110 230
-24 -11.2 44 111.2 112 233.6
-22 -7.6 46 114.8 114 237.2
-20 -4 48 118.4 116 240.8
-18 -0.4 50 122 118 244.4
-16 3.2 52 125.6 120 248
-14 6.8 54 129.2 122 251.6
-12 10.4 56 132.8 124 255.2
-10 14 58 136.4 126 258.8
-8 17.6 60 140 128 262.4
-6 21.2 62 143.6 130 266
-4 24.8 64 147.2 132 269.6
-2 28.4 66 150.8 134 273.2
0 32 68 154.4 136 276.8
2 35.6 70 158 138 280.4
4 39.2 72 161.6 140 284
6 42.8 74 165.2 142 287.6
8 46.4 76 168.8 144 291.2
10 50 78 172.4 146 294.8
12 53.6 80 176 148 298.4
14 57.2 82 179.6 150 302
16 60.8 84 183.2 152 305.6
Manifold Blocks:
To allow the system to be modular and flexible in application, two types of manifold blocks are
being offered.
Both are designed to be OFF MOTOR mounting to reduce the un-usable cooling area behind the
fan center hub and to maximise the effective remaining surface area of the radiating element
around the small size motor unit.
Type 1 will be used for situations where the Reverse or Purge feature is not required. This
block has the porting arrangement for a Cetop 5 valve but is covered with an adapter plate to seal
this off.
Type 2 comes complete with the Cetop 5 directional valve fitted to allow the reversing / Purge
feature to operate.
The manifolds are further offered in two material specifications to match pressure ranges that
allow the user to tailor the system to achieve a cost effective system.
HE30 for system pressures upto 4500 PSI
HE15 for system pressures upto 3000PSI
Part numbers for these blocks and their derivatives will be available from Denison Hydraulics Inc.
42
Europe Germany
Denison Hydraulics Inc. Asia-Pacific Denison Hydraulics GmbH.
14249 Industrial Parkway Herderstrasse 26
Australia Austria
Marysville, OH 43040 40721 Hilden, Germany
Denison Hydraulics PTY Denison Hydraulics GmbH
Tel :937-644-3915 Zweigneiderlassung Linz Tel : +49 (2103) 940 600
41-43 St Hilliers Road
Fax :937-642-3738 Haibachstraße 69 Fax : +49 (2103) 940 888
P.O.Box 192
Auburn N.S.W. 2144, Australia 4061 Pasching, Austria
Sales Offices Nationwide : Tel : +61 (2) 9646 5200 Tel : +43 (72 29) 48 87
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Denison Hydraulics Digital Fan Controller Unit. 700-00013-0: Application and Information Manual

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Denison Hydraulics Digital Fan Controller Unit. 700-00013-0: Application and Information Manual

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DENISON HYDRAULICS

Digital Fan Controller Unit.

Publ. DFC-1-K Replaces Publ. DFC-1-J

Page 3) Product Compatibility. Page 18) Retry ALL faults.

Cooling • Hydraulic system oil.

System • DFC controller Module:-………………………………………....700-00013-0

User Information • E-Mail to : DFC@denisonhydraulics.com

• General Info : www.denisonhydraulics.com

 EMC compliant product to EN50081-1 and EN50082-2 ( heavy industrial )

CE and EMC notes:

Opto-Link: The Opto-Link interface unit ( 700-00012-0 ) is intended for

Do’s and Don’ts:

1) Board Style: Denison Hydraulics Unique Size and Mounting.

Thermistor The controller operation is based on input from up to three temperature

Level 1:- ( NO Password ) Monitor controller operation only, no

1) Turn controller power supply OFF.

Proportional coils ( fan speed control….NO PURGE OPTION FITTED ):-

Directional coil ( Fan direction control..NEEDED FOR PURGE OPTION ) :-

Power ON / Opto-link Opto-link receiver Proportional Valve

Manual trigger Reverse

See page 11 for

No. of blinks Fault / Error

1 Memory checksum error

PC Hardware • Windows® 95 or 98, 98SE, ME, NT & 2000 operating system.

Set-up software: • DFC Set-up software to Ver 1.0 ( 720-00004-0 ).

Temporary Memory -> Permanent Memory:- transfers all data from

Permanent Memory -> Temporary Memory:- transfers all data from

Clicking the I/O Display tab brings up the ‘real-time’ controller

Depending on the password level, Clicking the Unit Settings tab

1. The ‘Unit Serial Number’ is unique to every controller.

Error messages are in RED text.

12 Push this button to disregard all displayed data and return

Typical NTC Thermistor Curve

Optical Link Interface:

Denison's OptoLink ( P/No. 700-00012-0 ) is

A 1.825 46.355 C S/No:- DFC 00000

Housing Type:- Denison unique ‘encapsulated’ block.

Alarm Connection: +V supply

THERM 1 ERROR This same connection circuit can

THERM 3 PROP VLV PWM% NOTE:-

THERM 3 PROP VLV PWM%

• General Info : www.denisonhydraulics.com

‘Purge’ Profile ( Reverse acting Pressure Valve ):

Fan speed Profile.

NTC Charge Air Intake

Memory Checksum Same As Green / Off With

Same As Power Off Till Unit

Unit Temperature > Same As Power Off Till Unit

Thermistor Input Three

Thermistor Input Over

Set Power Supply Between

Power Supply Between

Power Supply > 40 Set Power Supply Between

Running In Reverse Off Off Purge No Change On On No Change No Change

Fan Min, All

Unit diagnostics, Error Codes and Alarm Conditions

• Mount the controller so the operator can see it if required to do so.

• Use ‘fan-blown’ air wherever possible to increase air exchange rate.

• DO NOT mount controllers in direct sunlight.

• Mount controllers with ‘air-gaps’ to allow correct ventilation.

Set-up program does not reflect user changes made immediately:-

Static text written on screen

Temp-Deg [F,C] Res-Ohms

EMC compliant product to EN50081-1 and EN50082-2 ( heavy industrial )