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Old 10-18-2005, 19:34   #1 (permalink)
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AU Fan - a better way to wire

There have already been a few AU fan installations detailed on this forum. The installation of the fans has usually been performed very well, but the electrical side has left a lot to be desired.

Knowing that none of the previous installations were to my standard, we knew that we would have to do some research.

The first thing was to find out how Ford wired up the AU fan on the AU falcons. Below is the circuit diagram.


http://www.fordforums.com/attachment...id=32983&stc=1



The PCM allows three options. The first is for no signal and no fans. The second involves a signal from EDF1, which runs the fans in series at low speed. The third involves a signal from EDF2, which runs the fans in parallel at high speed.

The next thing that we needed was some switches to do the job of EDF1 & EDF2. Before I could decide on the appropriate temperature for the switches we had to decide where we were going to locate the switches.

We chose to locate the switches at the exit point of the radiator. The reasons for this location were twofold. The first was that we didn’t want the switches to ever become exposed due to a loss of water from the radiator. The second was that we wanted to control the temperature of the water leaving the radiator. Switching at the thermostat or radiator inlet gives you little control of the temperature of the water leaving the radiator.


Next to decide was the style of switch. We quickly decided on the type that screws into the radiator. These are used by many car manufacturers such as Ford, Mitsubishi, Nissan etc. This decision was made easier by my past experiences with capillary switches and the $2 thermal switches.


Deciding upon suitable switching points was the next step. I run a 180 degree Fahrenheit thermostat, so the points had to be compatible with that. To choose the switching temperatures I chose to copy the automotive industry. Most cars running 193 degree Fahrenheit thermostats, so I was looking for a switching points around 13 deg. F lower.


Searching through electrical automotive catalogues, we managed to find a dual switch that fitted the bill.
It’s properties were:

Make: Tridon
Part number: 2FS 214
Low temperature switching points: On 80 off 75 deg. C
High temperature switching points: On 87 off 82 deg. C
Thread: M22 x 1.5
RRP: $140 (far less for trade)


Below is the switch installed in the radiator:

http://www.fordforums.com/attachment...id=32981&stc=1


The next step involved deciding upon the wiring. Obviously the wiring was to be based upon the factory setup, but using temperature switches instead of a computer. There was also some other features that we wished to include. Some people have reported that they have had trouble starting their cars when the fans were running. Therefore we wanted the fans to stop when the engine is cranking. This can easily be achieved by running a wire from the “start” terminal of the ignition to a normally open relay. We also wanted the fans to not run when the key is in the “off” position. This will eliminate the risk of the fan unexpectantly starting when working on the car. If the car is hot when you shut the motor down, you can easily leave the ignition in the “accessories” position allowing the fan to run.

Below is the wiring diagram that we came up with:


http://www.fordforums.com/attachment...id=32980&stc=1


For the relays, we chose to use a solenoid block like those that Ford used. Below is a picture of the installed relays:


http://www.fordforums.com/attachment...id=32982&stc=1




We hope you have found this information useful.

XBGS351 & SILICON
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File Type: jpg switch.JPG (38.6 KB, 182 views)
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File Type: jpg AUFan.jpg (83.6 KB, 146 views)
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Old 10-19-2005, 03:47   #2 (permalink)
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Re: AU Fan - a better way to wire

Thanks Just what I was looking into!
Where does this Tridon temp swicth sensor fit? I have a wider XC radiator.
Where would I find a M22 x 1.5 thread in the radiator?
Do you have a link to 2FS 214 stat?
I have the EF fans which have one single speed and one dual speed 3 wire motor so I dont thing the schematic will help.
But, Thanks again
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Old 10-19-2005, 04:22   #3 (permalink)
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Re: AU Fan - a better way to wire

Thats pretty much how I have my EL ones done. Just don't have the temp switch. I trigger mine manually. They won't turn on if the ignitions off.
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Old 10-19-2005, 05:03   #4 (permalink)
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Re: AU Fan - a better way to wire

Where in the radiator is the switch mounted and how is it mounted into the radiator?

Why does that battery only have one pissy little wire coming from the positive terminal? That's all I could make out in the pic anyway.
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Old 10-19-2005, 06:15   #5 (permalink)
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Re: AU Fan - a better way to wire

I just wired the two fans together. One relay and one manual switch.....easy option.

But the auto on/off would be nice. I'll fit that when I can get bothered.
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Old 10-19-2005, 15:40   #6 (permalink)
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Re: AU Fan - a better way to wire

Quote:
Originally Posted by shaynet
Where in the radiator is the switch mounted and how is it mounted into the radiator?

The adapter is a M22x1.5 nut that has been put in a lathe and had a step machined into it. The radiator has had a hole put in it and the area around it pulled out flat so the modified nut sits properly in it (step on nut fits into hole). The nut is then soldered in; this is easy with a propane torch/solder/baker's soldering fluid. Just take it easy on the heat application.

Why does that battery only have one pissy little wire coming from the positive terminal? That's all I could make out in the pic anyway.

All of the positive leads come off the remote starter solonoid under the battery tray, the thin red wire to the MSD is the only exception. You can just make out the heavy positive lead coming of the terminal to the solonoid as well.
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File Type: jpg HPIM0376.JPG (29.0 KB, 78 views)

Last edited by silicon; 10-19-2005 at 15:51. Reason: addition of detail
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Old 10-19-2005, 17:15   #7 (permalink)
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Re: AU Fan - a better way to wire

Quote:
Originally Posted by brenx
Thats pretty much how I have my EL ones done. Just don't have the temp switch. I trigger mine manually. They won't turn on if the ignitions off.
Your a braver man than I.
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Old 10-19-2005, 17:34   #8 (permalink)
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Re: AU Fan - a better way to wire

Quote:
Originally Posted by xbgs351
Your a braver man than I.
I also have a mechanical temp gauge. Most of the time I don't even need the fans on. I've travelled from Bendigo to Melb without fans. Almost got into Cranbourne before I even needed them. My engine stayed pretty cool.
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Old 10-19-2005, 17:35   #9 (permalink)
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Re: AU Fan - a better way to wire

Quote:
Originally Posted by xbgs351
Your a braver man than I.

I had my setup switched manually on a 3 way switch, up= both fans on, down = 1 only on and centre = off.....

I have now changed slightly as I did not want to take any chance of cooking the motor, I've added a inline thermal switch that turns on 1 fan at 200deg F and turns off again at 185deg F, this works well and I can also manually override the fans if I wish. As I have a 170deg F thermostat it suits me. My car sits on 180-190 while cruzing and I've never really need to have both fans running. Even in heavy traffic the auto fan holds the temp at 200 and goes no higher !! I've also switched the auto fan to the ignition so it does not keep running when I turn the car off, I reckon on a hot day the fan could keep going for 20mins or so before it cut off, that would kill the battery in no time at all.
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Old 10-19-2005, 18:53   #10 (permalink)
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Re: AU Fan - a better way to wire

I've got a thermal switch from VPW and have both fans wired to turn on at once automatically at high speed. Works a treat, and I only ever notice I have thermos when idleing. Care-free cooling at it's best and dead easy to wire up. Won't run unless key is turned to "on" also.
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