Intercooler Upgrade - adding a fan

[Duff Junior Member Find all posts View Profile Close Duff]

Re: Intercooler Upgrade D4D

Sorry Mick, by band aid solution, i wasnt doubting it works, I just meant that the problems of air to air are rectifed by air to water.
Just looked back and re-read and thought i might have sounded rude. ops:

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade D4D

Just looked back and re-read and thought i might have sounded rude

Not at all :wink:

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade D4D

I'm working through a control circuit design using the speed sensor as an input. I'd like the fan on from idle up to something like 40 to 50kph.

I've canned this idea... after much dicking around I couldn't get it to work without having an effect in the original signal and thus stuffing the factory speedo up.

Taking a different approach I am now planning to control the fan based on intake temperature.

I've just ordered a small controller and probe from Auber Instruments in the US which should do the job nicely.



More to follow when it gets here....

Mick

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade D4D

The Auber controller I ordered arrived from the good old US of A today. It's a good quality unit and while it's set up from the factory as a EGT (Exhaust Gas Temperature) gauge it is fully programmable and takes multiple probe types (K, J, PT100, PTD) which makes it very versatile and adaptable to a number of uses.

It also has adjustable high and low alarm, on board relay with NO/NC contacts, adjustable hysteresis,3 min/max peak memorys with time and duration and can be dimmed with dash lights.

I gave it a quick test in the shed and took some (poor) pics. As you can see the unit is very compact.







Very happy with the value for money on this and it should be perfect for the job.

Mick

[DocK Member Find all posts View Profile Close DocK]

Re: Intercooler Upgrade D4D

Gosh Mick that looks impressive - it looks like it cost more than the fan though! I have been checking out some more efficient fan designs, more compact in depth and having a specialised shroud encasing it. If I find one I will post it up for others to consider - Heatcraft has a good catalog and I am in the process of measuring up clearances and sizes at the moment.
Do you think its helping the 1KZ at all?
Cheers
DocK

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade D4D

Do you think its helping the 1KZ at all?

I'm sure it is off the line after idling for awhile (say like in traffic at the lights) but it's all bum in seat testing at this stage :wink:

I also have my fan off the vehicle at the moment.... also looking for a better design.

it looks like it cost more than the fan though

$48 US for the controller.
About $100 AUS with probe and postage.

Mick

[DocK Member Find all posts View Profile Close DocK]

Re: Intercooler Upgrade D4D

Had a little stroll thru the wreckers yard the other day and stumbled across of condenser fan from a Mercedes 190E. Happens to be just about the right size and not too deep in the body to fit in the available space. I did need to trim the blades about 6-7mm to ensure it did not strike the sides and removed the cowl to make it fit without fouling. This fan moves a serious amount of air compared to the 8 inch fan I had tried previously. The scanguage shows the air intake temperature falls much more quickly and it reaches ambient sooner especially when going slow or stationary. I can just hear the noise over the engine at idle but can't when moving. Still have a simple on and off switch to trigger it. Well here it is - it is still a simple mod and I hope that this will be better than the little tiddler I had on before. Mick - How is yours going?

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade D4D

Mick - How is yours going?

Just got a new fan, it arrived today. 9 inch Ebay special. The control circuit is still a work in progress :roll: Just no time... maybe this coming long weekend I'll have a chance to get back into it.



Mick

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade - adding a fan

Got the new fan mounted today.

I did a couple of modifications to the fan. I had to flip the blades over to turn it into a "Push" fan as it was set up to pull air (the curved blades mean you can't just reverse the motor).
I also put loctite on the hub nut and motor mounting screws just for a little extra insurance.

I'm also not convinced the rubber seal contacts the intercooler duct all that well so I added a layer of 5mm foam to the top of the duct.

I've mounted the fan so it sits about 20mm above the core of the intercooler (the blade it's self is another 10mm higher again). The low profile design of the motor means it only sits 15-20mm above the duct and has miles of clearance to the nearest part of the bonnet (at least 40mm)

I'm also not convinced with using the temperature controller to run the fan, it works ok but is a little slow to react. I still like the idea of using a speed signal to run the fan so I'm gonna do some more tinkering with it.

Testing as follows: (with the K probe inserted between the fins of the cooler, the tip located approx in the center)

Ambient temp - 16 degrees

Engine hot and left to idle for 5min, vehicle stationary - 65 degrees
Driving at 50km/h - 25 degrees
Fan installed but not on and driving at 50km/h - 25 degrees
Fan on, engine hot and left to idle for 5min, vehicle stationary - 18 degrees.

The fan is very quiet, it can't be heard above the idle of the engine with the bonnet closed.








Mick

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

Re: Intercooler Upgrade - adding a fan

I'm also not convinced with using the temperature controller to run the fan, it works ok but is a little slow to react. I still like the idea of using a speed signal to run the fan so I'm gonna do some more tinkering with it.


Mick

Hi Mick
Just a thought, how about using a voltage switching relay using the signal from the intake air temp sensor to switch the fan when the temp is high?
http://store.autospeed.com/Items/22876? or
http://www.jaycar.com.au/productView.as ... rm=KEYWORD

Is the output from the speed sensor analogue or digital? If its analogue the above switch should work for that too.

Regards

Adrian

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade - adding a fan

Hi Mick
Just a thought, how about using a voltage switching relay using the signal from the intake air temp sensor to switch the fan when the temp is high?
http://store.autospeed.com/Items/22876? or
http://www.jaycar.com.au/productView.as ... rm=KEYWORD

Is the output from the speed sensor analogue or digital? If its analogue the above switch should work for that too.

Adrian,

I still want to run the fan based on road speed (idle to 40kph for instance)

What I have done is build Julian Edgar/SiliconChip's frequency switch which is similar to the one you mention but obviously sences a rising or falling frequency signal instead of voltage.

The sensor on the R150 manual is a Hall effect/digital signal.

I'll throw up some photos and info as things come together.


Mick

[oldsalt Member Find all posts View Profile Close oldsalt]

Re: Intercooler Upgrade - adding a fan

Hi, I need some help here please.

I have power from the aux battery running to a fuse box.

From the fuse box, I have a power wire and a negative wire connected to a rocker switch in the dash.

From the dash I have a power and neg wire running from the switch into the engine compartment.

I have not received my 9" fan as yet and I am getting everything ready to install it.

I bought a Narva 4 pin normally open relay.

The relay states:
Pin 30=Power in
Pin 85= Earth
Pin 86=Switch
Pin 87=Power Out ACC1.

I have no idea on how to hook the fan up to the ignition, therefore all I want to do is run the fan from the aux battery using the switch on the dash.

Can anyone please tell me what wires from the switch and the fan go to what pin number on the relay? ops:

EDIT:
Does this sound right?

Remove all wires from switch and start again.

Pin 30 to fuse block. (Power in)
Pin 85 to Ground
Pin 87 to the black wire on the fan (pos)
Pin 86 to the switch.

Blue wire on fan to ground?

I am told that I don't need an earth wire on the switch as the earth of the relay will do it all?

Am I getting close?

I have found these instructions, however, it all means nothing to me.
http://www.toymods.net/forums/showthread.php?t=95

[MickL Addicted PP Member Find all posts View Profile Close MickL]

Re: Intercooler Upgrade - adding a fan

Oldsalt,

Here is a link to a site that explains the workings of the relay and give a basic circuit diagram as you will need. (BTW the Narva relay is a copy of a Bosch unit);

12v Relay

I hope this gets you sorted.

Mick

[oldsalt Member Find all posts View Profile Close oldsalt]

Re: Intercooler Upgrade - adding a fan

Thanks Mick.

I have it all sorted, all I need to do now is install the fan, connect the power wire to Pin 87 and the gnd to the fuse box.

[oldsalt Member Find all posts View Profile Close oldsalt]

Re: Intercooler Upgrade - adding a fan

Finished