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Old 08-12-2012, 06:11 PM   #16
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John, would this cure the "magic blower" issue and other issues we have with the A/C head unit? If so, I would be interested.

Wrong fans.

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Old 08-12-2012, 06:30 PM   #17
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Thanks Speed.
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Old 08-12-2012, 07:21 PM   #18
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I'm interested in one or more of these depending upon the target price.

It is interesting to note that all the folks above chiming-in for a new controller are from warmer climates. I'll consider it anecdotal - if not statistically significant yet - that the controller's lifetime is a function of how much time it spends 'on' doing work. I've never, yet, found a dead one in a car that's lived its life in Yankee Land.
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Old 08-12-2012, 08:13 PM   #19
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dr. bob, that is the idea. We want to maintain the original housing given its location. The next step in the process is to do a board layout such that it fits in the current chassis. Currently, we believe we can get away with removing the small heat sinks attached to the fet's. Modern fet's are much more efficient and manufactured using modern materials. Removing the heat sinks will give us a bit of leeway on how we do the actual layout.

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John, add me to the interested list. Will the new boards/circuits rerofit into the existing housing?
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Old 08-12-2012, 08:47 PM   #20
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dr. bob, that is the idea. We want to maintain the original housing given its location. The next step in the process is to do a board layout such that it fits in the current chassis. Currently, we believe we can get away with removing the small heat sinks attached to the fet's. Modern fet's are much more efficient and manufactured using modern materials. Removing the heat sinks will give us a bit of leeway on how we do the actual layout.
Since newer gear doesnt create as much heat..does this happen to mean that the fans will see a higher voltage, and run faster/pull more air?
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Old 08-12-2012, 09:39 PM   #21
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Since newer gear doesnt create as much heat..does this happen to mean that the fans will see a higher voltage, and run faster/pull more air?
Nope. The unit will electrically function as before. It just so happens that the newer components are just electrically more efficient, so it will create less heat.

We kicked around building an 'enhanced' unit that accepted the same input voltage but allowed you to connect a variable speed fan or fans. Not sure how interesting that is.
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Old 08-12-2012, 11:21 PM   #22
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I believe that it's just a matter of time before ALL of these units will need to be replaced. Heat seems to be the problem for these original units.

If I may suggest, John, that the new units be produced independent of the the old units, else, you will always have the problem of "cores". Additionally, are you sourcing the plug as part of the new unit or planning to reuse the old plug. I would up for 2 of these, BTW.
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Old 08-13-2012, 12:20 AM   #23
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Nope. The unit will electrically function as before. It just so happens that the newer components are just electrically more efficient, so it will create less heat.

We kicked around building an 'enhanced' unit that accepted the same input voltage but allowed you to connect a variable speed fan or fans. Not sure how interesting that is.
So the benefit is less CE Panel draw then. Less heat wasted for the same old output.
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Old 08-13-2012, 12:21 AM   #24
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Yes I am keen - count me in

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Old 08-13-2012, 01:37 AM   #25
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Well i am he the land of way to hot as well so mark me down for one as well!
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Old 08-13-2012, 02:24 AM   #26
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Quote:
Originally Posted by Speedtoys View Post
So the benefit is less CE Panel draw then. Less heat wasted for the same old output.
The fans draw directly from the panel through dedicated feeders. They do pass through the panel via a dedicated fuse for each fan. I'm not sure that there will be any net change in load, since we are looking for the same amount of work from the same fan motors.

DaveC: My thinking is that module failures are a telltale that the fan motors are drawing excess current as they age. For those of us in the warmer climates, that means more fan runtime and perhaps accelerated fan wear. I plan to do a little Ammeter testing on my "current" fans before I pull them and replace bearings and such. Then an 'after' set of readings to see if my theory as anywhere close to fact.
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Old 08-13-2012, 02:27 AM   #27
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The fans draw directly from the panel through dedicated feeders. They do pass through the panel via a dedicated fuse for each fan. I'm not sure that there will be any net change in load, since we are looking for the same amount of work from the same fan motors.
Then where is the less heat being account for.

Its coming & drawing from something fused in the CE panel..right?


Its either less heat = more V's to the fans, or less heat = less draw to run the unit from the CE.

Not trying to argue..just trying to understand where a # of watts of heat is no longer being drawn from...that makes THAT subsystem more stable as well.
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Old 08-13-2012, 02:53 AM   #28
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Bought my '95 with this part having already failed, now I am replacing it. Not sure anyone bothered to diagnose that it failed or even knew it had failed before I bought the car, but I have a used one on the way and with all my other cars I am certain to see several of these fail, so a cheaper better alternative would be a HUGE benefit to me!

I agree with the thought that these are going to be failing with greater frequency as they age... Just like the injection brains on the S4's...
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Old 08-13-2012, 05:53 AM   #29
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The newer ouput FETs have lesss internal resistance when turned on than the old ones. It is this resistance times the draw current squared that gives the power that needs to be disspated by the box/heatsink.

As Dr Bob says, the fan current is fixed by the fans themselves.



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Then where is the less heat being account for.

Its coming & drawing from something fused in the CE panel..right?


Its either less heat = more V's to the fans, or less heat = less draw to run the unit from the CE.

Not trying to argue..just trying to understand where a # of watts of heat is no longer being drawn from...that makes THAT subsystem more stable as well.
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Old 08-13-2012, 10:15 AM   #30
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John, add me to the interested list. Will the new boards/circuits rerofit into the existing housing?
That wouid be nice if it did use the original housing. I am also interested. If we are looking at 20 to make it cost effective I wonder if we could find 10 pre-orders and find a vendor to take on the other 10 for future sales.
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Old 08-13-2012, 10:15 AM
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