Introduction
The Flex-A-Lite Variable Speed Controller is designed for automotive dual-fan electric cooling systems. This controller integrates a relay function, eliminating the need for external relays. It features an adjustable activation temperature range and manages fan speed based on engine coolant temperature. The system also includes a post-shutdown fan operation to dissipate residual heat. This kit provides a comprehensive solution for controlling electric cooling fans in 12-volt systems.
Key Features
- Integrated relay function, removing the requirement for external relays.
- Adjustable activation temperature range from approximately 160°F to 240°F.
- Variable fan speed control: initiates fans at 60% power and increases to 100% as coolant temperature rises.
- Post-shutdown operation: fans run for up to 25 seconds after vehicle shutdown to reduce radiator heat.
- Includes a 1/4-inch NPT threaded temperature probe with 3/8-inch and 1/2-inch thread adapters.
- 45-amp rating, compatible with 12-volt systems.
What's in the Box
The Flex-A-Lite Variable Speed Controller kit includes:
- Variable Speed Control Module
- Thread-in Temperature Sensor (1/4-inch NPT)
- 3/8-inch and 1/2-inch Thread Adapters
- Wiring harness
- Electrical terminals
- Max amp inline fuse
Image: Complete kit contents, showing the control module, various wires, terminals, fuse, and the threaded temperature sensor with adapters.
Setup and Installation
Proper installation is crucial for the optimal performance and longevity of your Flex-A-Lite Variable Speed Controller. It is recommended that installation be performed by a qualified automotive technician.
Mounting the Control Module
Select a secure, dry location for mounting the control module, away from direct engine heat and moving parts. Ensure adequate ventilation around the module. Use appropriate fasteners to secure the module firmly.
Image: The variable speed control module, highlighting its design and terminals.
Temperature Sensor Installation
The kit includes a 1/4-inch NPT threaded temperature probe. Install this sensor into a suitable threaded port in your engine's cooling system, such as a thermostat housing or radiator tank. Use the provided 3/8-inch or 1/2-inch thread adapters if necessary to match your vehicle's port size. Ensure a tight, leak-free seal.
Wiring Connections
Follow the detailed wiring diagram provided with your kit. Key connections typically include:
- Power (12V): Connect the main power wire to a constant 12-volt source, protected by the included max amp inline fuse.
- Ground: Connect the ground wire to a clean, chassis ground point.
- Fan Connections: Connect the fan motor wires to the designated outputs on the control module.
- Ignition/Accessory: Connect the ignition wire to a switched 12-volt source that is active when the ignition is on.
- Temperature Sensor: Connect the temperature sensor wires to the corresponding inputs on the module.
- A/C Trigger (Optional): If your vehicle has A/C, connect the A/C trigger wire to a source that provides 12V when the A/C compressor is active. This ensures fan operation when the A/C is on.
Ensure all connections are secure and properly insulated to prevent short circuits and corrosion. Route wires away from hot or moving engine components.
Operating Instructions
The Flex-A-Lite Variable Speed Controller operates automatically once installed and configured.
Temperature Adjustment
The controller features an adjustable temperature setting. Locate the adjustment screw or dial on the module. Turn the adjustment to set the desired activation temperature within the 160°F to 240°F range. It is recommended to start with a lower setting and adjust upwards if needed, monitoring engine temperature closely.
Image: Visual representation of the adjustable temperature range for the controller.
Variable Speed Operation
When the engine coolant temperature reaches the set activation point, the controller will initiate the electric fans at approximately 60% power. As the engine temperature continues to rise, the controller will gradually increase the fan speed, reaching 100% power if necessary to maintain optimal cooling.
Post-Shutdown Cooling
After the vehicle's ignition is turned off, the controller may continue to run the electric fans for up to 25 seconds. This feature helps to remove residual heat from the radiator and engine bay, contributing to overall engine health and component longevity.
A/C Activation
If the A/C trigger wire is connected, the fans will activate when the air conditioning system is engaged, providing additional cooling for the condenser and engine, regardless of the coolant temperature setting.
Maintenance
The Flex-A-Lite Variable Speed Controller is designed for minimal maintenance. Regular checks can help ensure continued reliable operation:
- Wiring Inspection: Periodically inspect all wiring connections for signs of wear, corrosion, or looseness. Ensure all terminals are secure.
- Fuse Check: Verify the inline fuse is intact and free from corrosion. Replace only with a fuse of the same amperage rating.
- Sensor Condition: Check the temperature sensor for any physical damage or signs of leakage.
- Module Cleanliness: Keep the control module free from excessive dirt, dust, and moisture.
Troubleshooting
If you experience issues with your Flex-A-Lite Variable Speed Controller, consider the following:
Fans Not Activating
- Check all power and ground connections for continuity and secure contact.
- Verify the inline fuse is not blown.
- Ensure the temperature sensor is properly installed and connected.
- Confirm the engine coolant temperature is above the set activation point.
- Test the electric fans directly to ensure they are functional.
Fans Running Constantly
- Check the temperature sensor and its wiring for shorts or damage.
- Ensure the A/C trigger wire is not receiving a constant 12V signal if the A/C is off.
- Verify the controller's temperature setting is not set too low.
Erratic Fan Operation
- Inspect all electrical connections for intermittent contact or corrosion.
- Ensure the temperature sensor is fully submerged in coolant and making good contact.
- Check for proper grounding of the module and fans.
Specifications
| Feature | Specification |
|---|---|
| Model Number | 31163 |
| Brand | Flex-a-lite |
| Material | Metal, Plastic, Semiconductor |
| Item Weight | 16 ounces |
| Lower Temperature Rating | 160 Degrees Fahrenheit |
| Upper Temperature Rating | 240 Degrees Fahrenheit |
| Measuring Range | 160 - 240 °F |
| Maximum Supply Voltage | 12 Volts (DC) |
| Response Time | 25 seconds (post-shutdown fan run) |
| Mounting Type | Threaded (for sensor) |
| Output Type | Electrical signal |
Warranty Information
The Flex-A-Lite Variable Speed Controller (Model 31163) comes with a one-year manufacturer's warranty. This warranty covers defects in materials and workmanship under normal use. For specific warranty claims or details, please refer to the documentation included with your product or contact Flex-a-lite customer support.
Support
For technical assistance, installation questions, or troubleshooting beyond this manual, please contact Flex-a-lite customer support. You can find contact information on the official Flex-a-lite website or through your product's packaging.
Visit the official Flex-a-lite store for more information: Flex-a-lite Store