Damn that blower gone again.

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Chris_C
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Re: Damn that blower gone again.

Post by Chris_C » 20 Apr 2013 07:34 pm

I've used the resistors you have their Anjo to dump a lot of power, but they have got very very hot.

My thoughts are move to something more modern, the golf (mk2) pack I ran for a while has no exposed coils, not done loaded temp tests though. Worth seeing what a scrappy BMW mini has maybe (they are my current "modern car that people will support for years" hopeful)
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

Ride_on
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Location: Belfast, N. Ireland

Re: Damn that blower gone again.

Post by Ride_on » 21 Apr 2013 06:27 pm

The 940 resistor pack is a ceramic coated module, so may not need the cutout, or the 940 may have fire resistant plastic around it. We need to replicate the original fire safety mechanism or modify to not require it. We can't just use parts form other cars without knowing the full story.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

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mac
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Re: Damn that blower gone again.

Post by mac » 13 May 2013 01:44 pm

Been playing around!

My test box made and working.

Image

Image

Results:-
Input V = 12.4

Speed 1. Momentary 6A runs @ 2A Full air flow pack @ 42c - no air flow peaks @ 110c
Speed 2. Momentary 10A runs @ 4A Full airflow pack @ 18c - no airflow peaks @ 92c
Speed 3. Momentary 15A runs @ 6A Full airflow pack @ 16c - no airflow peaks @ 18c

Going to play some more!

Mac.
88 5door Redline 1.7 52k - 19 XC60 Momentum Pro D4 AWD 17k
1950 pair of legs that don't work very well.

pettaw
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Re: Damn that blower gone again.

Post by pettaw » 16 May 2013 08:55 pm

Fantastic work Mac! Only a matter of time before you find a solution to this problem.

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Chris_C
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Re: Damn that blower gone again.

Post by Chris_C » 16 May 2013 11:16 pm

How did I miss this :D

Making decisions based on data, it'll never catch on ;)
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

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SteveP
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Re: Damn that blower gone again.

Post by SteveP » 17 May 2013 07:29 am

Fantastic work, watching with interest - especially as mine's broken :lol:
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

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mac
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Location: Needham Market U.K.

Re: Damn that blower gone again.

Post by mac » 17 May 2013 09:06 am

Ok chaps, I've now developed a technique to refurbish said resistors! I have had a couple of test units running on a rig for over 30mins on each speed with no problems. Blocking airflow or stalling motor causes the (new) thermal cutout to operate within 20secs. Restoring airflow allows almost instant automatic restart.

So far I have worked on the post 86 resistor pack that sits in "full" airflow, I have not yet looked at the earlier type that sits "upstream" of the fan in less airflow.

I would now like some guinea pigs (yes Steve - you?) with failed units who would be prepared to send them to me, (I will refurbish and return), and then "on car" test it in normal use.

Also I would like samples of the earlier (3 connection) unit to "play with".

Image

If all works out as I hope I should be able to offer some sort of refurbishment or exchange scheme BUT I have to be sure we have a viable "long term" solution - and this means testing in the "real world" not just on a rig.

Mac.
88 5door Redline 1.7 52k - 19 XC60 Momentum Pro D4 AWD 17k
1950 pair of legs that don't work very well.

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Chris_C
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Re: Damn that blower gone again.

Post by Chris_C » 17 May 2013 09:34 am

I have one or two "dead" ones saved here Mac, I could put them in the high speed getting things done pile (so it'll only take a couple of months?)
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

volvomania
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Re: Damn that blower gone again.

Post by volvomania » 17 May 2013 09:45 am

I've packed some already.
Life is a journey, so sit back and enjoy the ride!

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http://www.Born-Built-Beauties.eu

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SteveP
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Re: Damn that blower gone again.

Post by SteveP » 17 May 2013 10:00 am

Looks great!! Happily be a guinea pig - I'll reply to your PM :)
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

Ride_on
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Re: Damn that blower gone again.

Post by Ride_on » 17 May 2013 06:34 pm

Need the motor voltage(s) please if you still have it setup, and don't forget supply is more like 14V with engine running. Although relatively calculatable, I suppose I should work it out.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Damn that blower gone again.

Post by Ride_on » 17 May 2013 11:04 pm

At 12.4v it should be about 8.8V and 4.4V, which would equate to about 4x6A and 6x3A diode (P600 in maplin eg, about 0.85-0.9V drop @4A), however they would still dissipate the same power as resistors just perhaps over a wider area.

A PWM controller would be more efficient but also more expensive and might whine, the replacement cut out is the most sensible.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

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mac
Posts: 1403
Joined: 19 Apr 2006 11:02 am
Location: Needham Market U.K.

Re: Damn that blower gone again.

Post by mac » 18 May 2013 02:39 pm

As requested -

3 packs now fettled

Input voltage 12.4
Pack 1 voltages at motor are 6.3, 9.5, 12.2.
Pack 2 voltages at motor are 6.5, 9.6, 11.8.
Pack 3. voltages at motor are 6.3, 9.6, 11.8.

Mac.
88 5door Redline 1.7 52k - 19 XC60 Momentum Pro D4 AWD 17k
1950 pair of legs that don't work very well.

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Damn that blower gone again.

Post by Ride_on » 18 May 2013 03:53 pm

I guess the motor is not like a resistive load atall lol.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

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mac
Posts: 1403
Joined: 19 Apr 2006 11:02 am
Location: Needham Market U.K.

Re: Damn that blower gone again.

Post by mac » 23 May 2013 04:21 pm

Update

First customer "test" unit rec'd.

As received - with totally ff'd cut out.

Image

Image

Unit dismantled and Macs secret weapon employed,

Image

The resistive coils nestling in the cleaning bath after the first session,

Image

The rebuilt unit,

Image

Fitted to the test rig,

Image

And running at full speed!

Image

Unit now posted back to guinea pig who will report in due course.

I will keep the forum advised.

Mac.
88 5door Redline 1.7 52k - 19 XC60 Momentum Pro D4 AWD 17k
1950 pair of legs that don't work very well.

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