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Variable Speed PWM Fan Control under $25 or less DIY

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Old 07-28-2023 | 05:39 PM
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Here are the last of the pictures of the 850 watt fan installed.



Vic boxed off the bottom portion.



He added a L-bracket on one side for the fasteners.



I added a little piece of weatherstripping foam on the side...



The foam is there to seal the shroud. It doesn't need it on the other side because the edge of the shroud fits firmly against the core and the other tank. On this side the lip had to be removed because the shroud goes past the core and overlaps the tank.



All of this is to demonstrate that mounting these fans doesn't take much effort.

Andrew​
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Old 07-29-2023 | 01:35 AM
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Wow! Thanks to you, it looks like it grew there! Nice work!
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Old 07-29-2023 | 09:50 AM
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Here is a test video of the 850 watt fan:


Andrew
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Old 07-30-2023 | 09:58 AM
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I am trying to use the Mazda/Mitsubishi PWM controller with my Holley HP ECU. I got it all hooked up, (correctly I believe), but it doesn't work. I had a C6 Corvette PWM controller in the car previously, but it stopped working, so I thought I would try the Mazda unit. I have the ECU set up using CTS and AC inputs on a PWM- input to the controller. What sort of input to the controller should I have? I have two Spal brushed fans.

Update: I had my fans wired such that I can flip a switch and get max fan speed, as well as have them run by the Mazda module. I did this in case the module fails, or I am in very heavy traffic, and it is very hot. I had two wires feeding each fan, one from the module and one from a relay that my switch controls, that is, switching from the module power to the fans or
straight 12v. I added a diode in each wire from the module to each fan to prevent back feeding when the switch is in the max mode. I determined the diodes were sapping about 7 volts which is not enough to run the fans. So, my fix is to eliminate the diodes and add another high amp relay to isolate each set of wires to the fans so there can be no back feeding to the module.

Last edited by Larry R; 07-31-2023 at 03:19 PM.
Old 07-31-2023 | 11:20 AM
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Originally Posted by Larry R
I am trying to use the Mazda/Mitsubishi PWM controller with my Holley HP ECU. I got it all hooked up, (correctly I believe), but it doesn't work. I had a C6 Corvette PWM controller in the car previously, but it stopped working, so I thought I would try the Mazda unit. I have the ECU set up using CTS and AC inputs on a PWM- input to the controller. What sort of input to the controller should I have? I have two Spal brushed fans.

Update: I had my fans wired such that I can flip a switch and get max fan speed, as well as have them run by the Mazda module. I did this in case the module fails, or I am in very heavy traffic, and it is very hot. I had two wires feeding each fan, one from the module and one form a relay that my switch controls, that is, switching from the module power to the fans or
straight 12v. I added a diode in each wire from the module to each fan to prevent back feeding when the switch is in the max mode. I determined the diodes were sapping about 7 volts which is not enough to run the fans. So, my fix is to eliminate the diodes and add another high amp relay to isolate each set of wires to the fans so there can be no back feeding to the module.
The diode is not necessary and will probably burn up unless you have a very heavy one. I also shunt the mazda module used to control my fuel pumps. I run the pumps slower for cruising and then shunt it with the relay for other times. No diode required if you wire it right. No need to isolate each wire, just one relay. But I don't remember off the top of my head how to wire it. One of the supply lines, not sure if it was the negative or positive sides, connect directly from the input to the output of the fans. I'll check later.

Last edited by LSswap; 07-31-2023 at 11:28 AM.
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Old 08-03-2023 | 06:53 PM
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Since these big fans draw a lot of power, they are generally hooked up directly to the battery with a large fuse.

I got this little Maxi fuse holder from Waytek Wire:







I may use the cover or I may just slip some 3:1 adhesive lined heat shrink tubing over the whole thing. I also got some 8 gauge ring terminals.

The fuse holder is Waytek PN: 46312 and the ring terminals are PN 36568.

Andrew
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Old 08-05-2023 | 07:33 AM
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Thanks Andrew. Those are nice and small. I've been using a breaker instead of a fuse, only cause I already had one. I wouldn't expect either the fuse or breaker ever to blow.



Circuit Breaker Ebay example
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Old 08-05-2023 | 07:12 PM
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Originally Posted by LSswap
Thanks Andrew. Those are nice and small. I've been using a breaker instead of a fuse, only cause I already had one. I wouldn't expect either the fuse or breaker ever to blow.



Circuit Breaker Ebay example
I like those, except they are huge and generally belong on a boat.

Andrew
Old 08-06-2023 | 01:44 PM
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post removed.


Last edited by Larry R; 08-13-2023 at 12:59 PM.
Old 08-13-2023 | 10:34 AM
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I got my Camaro 850 watt fan installed and wired up. I used 6 gauge power wires going directly to the battery, with a 100amp in-line fuse installed in the little holder that posted before. The fan is an absolute beast.


Andrew
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Old 08-13-2023 | 11:20 AM
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Originally Posted by Project GatTagO
I got my Camaro 850 watt fan installed and wired up. I used 6 gauge power wires going directly to the battery, with a 100amp in-line fuse installed in the little holder that posted before. The fan is an absolute beast.

https://youtu.be/fawmEKPBWbg

Andrew
Wow. You did that RIGHT, no messing around! Looks bulletproof, electrically.
Nice work! If that car ever overheats, it will NOT be because of the fan....
Old 09-02-2023 | 10:33 PM
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@TrendSetter suggested I check back in this thread.

Is it possible for me to convert my 1994 Taurus/Contour fan over to PWM?

I love those 6th gen fans but not sure they will fit my application.
Old 09-02-2023 | 11:01 PM
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Originally Posted by Pro Stock John
@TrendSetter suggested I check back in this thread.

Is it possible for me to convert my 1994 Taurus/Contour fan over to PWM?

I love those 6th gen fans but not sure they will fit my application.
It is quite possible!
1) Check the first post in this thread. It has an index of post #'s that is always updated for useful topics within the thread.
2) Check your own thread for a response by myself in reply to a question similar to the post this is replying to.
This place is FULL of resources!

Last edited by G Atsma; 09-03-2023 at 11:13 AM.
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Old 09-03-2023 | 09:40 PM
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Originally Posted by Pro Stock John
@TrendSetter suggested I check back in this thread.

Is it possible for me to convert my 1994 Taurus/Contour fan over to PWM?

I love those 6th gen fans but not sure they will fit my application.
Any news??
Old 09-04-2023 | 12:33 AM
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I did a little back reading, not sure how it all works yet.
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Old 09-04-2023 | 06:00 PM
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Originally Posted by Pro Stock John
I did a little back reading, not sure how it all works yet.
heres a video andrew did for the dominator: https://ls1tech.com/forums/forced-in...l#post19970004

heres the post with the fusion controller: https://ls1tech.com/forums/forced-in...l#post19973683

you basically buy a ford fusion fan control, power and ground input to box, power and ground output to fan, all big wiring. one small wire goes to a pwm- output on the dominator (i think thats what you are running?) then fill in the table per andrews video.
since you have a dominator, ignore all the arduino talk in the thread.
no relays, no big surge when its on, nice smooth fan speed control based on coolant temp.
i did my table a little bit different than andrew, i used VSS as one axis so it turns the fans off past a certain vehicle speed. some fan controls max out at 90%, not 100% like whats shown in my table.


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Old 09-05-2023 | 03:12 PM
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^^^^ Thanks sir, I'll be hanging out with Andrew at LS Fest this weekend and for sure discuss this with him.
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Old 09-05-2023 | 03:37 PM
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Originally Posted by Pro Stock John
^^^^ Thanks sir, I'll be hanging out with Andrew at LS Fest this weekend and for sure discuss this with him.
Andrew knows his stuff, as you well know (or should... lol)
He will give you good info!
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Old 09-10-2023 | 12:55 PM
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Default Power Distribution Box

First off, much appreciation to all of you for contributing to this thread. It’s been a huge help so far.

wondering if someone can help me figure this out.
I have Bosch brushless fans that run their power and control wire through their matching Battery junction box. Then control runs up to the ECU, which I swapped out.
what’s confusing me is the control wire coming out of the fuse box is 12v, low mA. My assumption is the old ecu was controlling PMW via -5v (or ground signal PMW via mosfet?)

this is where my understanding is fuzzy… I’d like to keep the power and control going through battery junction box as it already is fused and regulates shorts but that 12v coming from it to the ecu is confusing. Can’t recall exact reading but it’s a very low milliamp 12v signal.



Current existing setup.
Old 10-17-2023 | 03:38 PM
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Originally Posted by LSswap
V8_cowboy Try this for a starting point. I made the PWM for a/c on the same as if the engine was at 100c. Change that to your liking.

Code:
// This a test program, no warranties are implied or given. PWM Mercedes ext temp sensor V1
// Use, copy any modify this test program any way you want, at your own risk. Then test, test, test
// It reads a extermal 10K thermister temperature probe and controls a Mercedes PMW module/fan.
// fan: 90% duty = full, 20% = min, 10% = off, no PWM = full Freq = 11Hz, PWM signal is 5 volt, Temps in Centigrade
#include <PWM.h>
/*----------------------- User adjustable variables and preferences section ---------------------------------*/
// FYI a PWM duty ranges from 0 to 255. Set desired temperature range below
const int tempForFanStartup = 98; // target low temp. below this temperature, the fan will be off
const int tempForFanOnFull = 110; // target High temp. above this temperature, the fan will be on at full power
const int A_C_Start_temp = 100; // Als de A/C aan staat gaat de Ventilator vanaf 80 °C draaien

// adjust these for PWN to for fan off, fan start and fan full on
const int fanDutyOff = 63; // Duty Cycle for 25% ( Off Fan Speed ( 10% of 255 )
const int fanOnFullDuty = 229; // Duty Cycle for 90% ( Full Fan Speed ( 90% of 255 )

/*----------------------- end of User adjustable variables and preferences -----------------------------------*/
const int fanPwmOutPin = 9; // Arduino forces this pin to 0 or 5 volts.
const int tempSensorPin = A0; // Pin to read analog voltage from the temp sensor.
const int AC_ClutchPin = A1; // Pin to A/C Clutch via 1K/10K Voltage Devider

int pwmDuty;

void setup() { /* ++++++++++++++++++ Setup is run once when the arduino boots ++++++++++++++++++++++++++*/
Serial.begin(9600); // set up serial port for 115200 baud (optional)
InitTimersSafe(); // set pwm frequency to 11 Hz for mercedes module pwm
SetPinFrequency(fanPwmOutPin, 11); // set pwm frequency to 11 Hz for mercedes module
analogReference (EXTERNAL); // note, this is using the 3.3 volt supply as the analog reference for more accuracy.
} // end setup


void loop() { /* ++++++++++++++++++ Main Loop, continuously loops forever ++++++++++++++++++++++++++++*/
int tempReading = get_temperature_sensor(); // read and translate the temp sensor

if (analogRead(AC_ClutchPin) > 20 ) { // A/C is on
// When the A/C Clutch is On, Voltage > .32V at Analog Input ( is ~ 1.4V when A/C is On )
if (tempReading < tempForFanStartup) {
tempReading = A_C_Start_temp; // Override NTC Temp Sensor Reading with A/C On & Engine Cold
}
}

if (tempReading < tempForFanStartup) {
pwmDuty = 25; // Engine Cold & No A/C, Turn Fan Off with 10% duty
} else { // Calculate PWM Duty Cycle
pwmDuty = calculate_PWM_duty(tempReading); // calculate the needed pwm
}

pwmWrite(fanPwmOutPin, pwmDuty); // send PWM to output pin

Serial.print("Temperatuur Radiateur = "); Serial.print(tempReading); Serial.println(" °C ");
Serial.print("PWM Duty Cycle = "); Serial.println(pwmDuty);
delay(1000);
} // end main loop


int calculate_PWM_duty(int currTemp) { /* ++++++++ subroutine to calculate and set PWM duty cycle ++++++++++++++*/
int duty = map(currTemp, tempForFanStartup, tempForFanOnFull, fanDutyOff, fanOnFullDuty ); // calc PWM Duty
int contrainedDuty = constrain(duty, fanDutyOff, fanOnFullDuty ); // PWM duty is never allowed ouside of min or max duties
return(contrainedDuty);
} // end calculate_PWM_duty


int get_temperature_sensor() {/* +++++ returns temp for extermal 10K thermister temperature probe ++++++++++*/
float R0 = 10000; // The base resistance of the NTC sensor used. 10K with a 4000 Beta.
float Beta = 4000; // The Beta of the sensor used. Very commonly available
int tmp = analogRead(tempSensorPin); // read temperature sensor (range 0 to 1023)
float r = ((1023.0*R0)/(float)tmp)-R0; // for a 10K thermister with a beta of 4000
tmp = (int) (Beta/log(r/0.09919) - 273.15 + .499); // for a 10K thermister with a beta of 4000
return(tmp);
} // end get_temperature_sensor

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