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Old 08-11-2012, 09:04 PM   #1
jleidel
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Default S4 and Greater Fan Control Module

All, I've been working through an interesting project in our [my company's] circuit/electronics lab. Thanks to `soontobered84`, I have a nicely fried fan control module from an S4->newer 928. Thankfully, the folks are also gear heads [Cobra kit, 308 Ferrari, etc]; so they graciously reverse engineered the entire circuit board for us. Typically, owners will replace the MOSFET's [aka, "fets"] in the unit. Rather that putting together a simple fix, we decided to reverse engineer the entire circuit in order to upgrade it to modern components. In order for us to calculate the appropriate costs, I would like to gauge the community interest in buying/transferring their S4 fan control switch to a brand new circuit design [fabbed on a modern process].

I _do not_ yet have any costs. Its highly dependent upon volume. It will likely be competitive with or less than current used/refurb models.

Thoughts//Comments?

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Old 08-11-2012, 10:47 PM   #2
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If I may, I would add my $0.0928.... Most semiconductor suppliers today have automotive qual'd parts that are designed to operate up to 175C junction temp. For the FETs, Infineon, ON Semi and International Rectifier have good stuff.

For the logic, I would look at Freescale and ON Semi.

Also, today's ceramic caps (MLCC) have enough energy storage capability so electrolytics that dry out and fail.
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Old 08-11-2012, 10:59 PM   #3
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interested
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Old 08-11-2012, 11:05 PM   #4
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Quote:
Originally Posted by 3.2 Targa View Post
If I may, I would add my $0.0928.... Most semiconductor suppliers today have automotive qual'd parts that are designed to operate up to 175C junction temp. For the FETs, Infineon, ON Semi and International Rectifier have good stuff.

For the logic, I would look at Freescale and ON Semi.

Also, today's ceramic caps (MLCC) have enough energy storage capability so electrolytics that dry out and fail.
Logic for Freescale and ON Semi? We're not looking for ARM Cortex A8's. Most of the logic parts are simple 'and' gates. They're easily accessible from TI or ST Micro. If we consolidate logic, we're still into small TI EPROMs or ST Micro units.
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Old 08-11-2012, 11:14 PM   #5
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Quote:
Originally Posted by 3.2 Targa View Post
If I may, I would add my $0.0928.... Most semiconductor suppliers today have automotive qual'd parts that are designed to operate up to 175C junction temp. For the FETs, Infineon, ON Semi and International Rectifier have good stuff.

For the logic, I would look at Freescale and ON Semi.

Also, today's ceramic caps (MLCC) have enough energy storage capability so electrolytics that dry out and fail.
You're new here. We generally don't even discuss anything less than military grade, combat tested components for our cars.....

I'm interested...it's just a matter of time...
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Old 08-11-2012, 11:19 PM   #6
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Sweet John, glad to see you have taken this on. A few if us have place bets on who in our DFW crew would do it.

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Old 08-11-2012, 11:57 PM   #7
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We have the whole circuit mapped out... time to condense and see what the fab costs are locally. The board is a simple, two layer unit. It shouldn't be terribly expensive to have farmed out. Stay tuned...

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Sweet John, glad to see you have taken this on. A few if us have place bets on who in our DFW crew would do it.

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Old 08-12-2012, 12:01 AM   #8
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John--

The 'weakest link' seems to be the FETs themselves. Will your modern redesign use something different for those final output pieces?
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Old 08-12-2012, 12:07 AM   #9
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Depends... modern FETs are much more resistant to heat and normal wear/tear. To that end we may use similar, but much more modern FETs. The individual doing the circuit rework is actually an expert in power bus technology, so I trust his judgement on the power circuit design [he is also restoring a Ferrari 308, so he understands the implications of vehicle circuits].

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John--

The 'weakest link' seems to be the FETs themselves. Will your modern redesign use something different for those final output pieces?
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Old 08-12-2012, 01:12 AM   #10
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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.
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Old 08-12-2012, 01:26 AM   #11
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I've had two units go out on me this past year, so I would be up for a couple of new units. Thanks for the heads up.
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Old 08-12-2012, 09:47 AM   #12
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There is a few of us out here that are certainly interested, we seem to have a lot of these units failing at present.
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Old 08-12-2012, 10:42 AM   #13
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I'm interested. As Rob said, it's only a matter of time before I have to repair my control unit. I am partial to keeping the flap system working as designed. It is part of the cool factor for me.

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Old 08-12-2012, 05:57 PM   #14
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Sounds like we have a reasonable quorum for a small fab run. In my experience, most of the local fabs here in DFW don't like running boards in less than quantities of 20. [different for larger/more complex boards]. The nice thing is, these boards are single layer, two sided units. Very easy to build.
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Old 08-12-2012, 06:03 PM   #15
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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, 06:03 PM
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