VW Electrics Dash Fan Control Upgrade (PWM) - Revision history

CovKid at 15:05, 4 August 2016

2016-08-04T15:05:07Z

← Older revision		Revision as of 15:05, 4 August 2016
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	Facia panel refitted.		Facia panel refitted.

	[[File:~~Pwmcontroller6~~.jpg]]		[[File:Pwmcontroller7.jpg]]

CovKid at 15:04, 4 August 2016

2016-08-04T15:04:47Z

← Older revision		Revision as of 15:04, 4 August 2016
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	[[File:Pwmcontroller6.jpg]]		[[File:Pwmcontroller6.jpg]]

			Facia panel refitted.

			[[File:Pwmcontroller6.jpg]]


	I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.		I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.

	Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.		Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.

CovKid at 15:03, 4 August 2016

2016-08-04T15:03:03Z

← Older revision		Revision as of 15:03, 4 August 2016
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	Back to fitting control knob!		Back to fitting control knob!

	See following photos for reference. I haven't been specific by including measurements as your control knob assembly may be different from mine but the principles remain the same. A dremel-type tool makes much easier work of it.		See following photos for reference. I haven't been specific by including measurements as your control knob assembly may be different from mine but the principles remain the same.

			A dremel-type tool makes much easier work of it but you'll need to cut through the back layer and clear plastic layer, just enough so the control knob assembly fits in there and butts up against the printed and facia layers.

	[[File:Pwmcontroller3.jpg]]		[[File:Pwmcontroller3.jpg]]

			This is the front (below). I actually like the knob that came with it as it matches the blue on the facia perfectly but you could fit what you like.

	[[File:Pwmcontroller4.jpg]]		[[File:Pwmcontroller4.jpg]]

			Feeding the control knob plugs through the original controller hole in the dash.

	[[File:Pwmcontroller5.jpg]]		[[File:Pwmcontroller5.jpg]]

			Plugs connected, the whole panel is ready to refit. Use a little glue to ensure the back layer isn't loose.

	[[File:Pwmcontroller6.jpg]]		[[File:Pwmcontroller6.jpg]]

	I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.		I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.

	Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.		Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.

CovKid at 14:56, 4 August 2016

2016-08-04T14:56:59Z

← Older revision		Revision as of 14:56, 4 August 2016
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	See following photos for reference. I haven't been specific by including measurements as your control knob assembly may be different from mine but the principles remain the same. A dremel-type tool makes much easier work of it.		See following photos for reference. I haven't been specific by including measurements as your control knob assembly may be different from mine but the principles remain the same. A dremel-type tool makes much easier work of it.

			[[File:Pwmcontroller3.jpg]]

			[[File:Pwmcontroller4.jpg]]

			[[File:Pwmcontroller5.jpg]]

			[[File:Pwmcontroller6.jpg]]
	I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.		I couldn't find a reliable way to reuse the original knob since its an entirely different fitting and araldite did not appeal to me in the slightest.

	Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.		Ensure that the printed circuit on the control knob assembly does not foul the metal dash. Either insulate it well or cut a slightly larger hole where the original switch went to give a little more clearance.

CovKid at 14:18, 4 August 2016

2016-08-04T14:18:08Z

← Older revision		Revision as of 14:18, 4 August 2016
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	Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.		Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.

	PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less current is used.		PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less current is used plus the luxury of being able to set any speed.

	Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8		Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8

CovKid at 14:17, 4 August 2016

2016-08-04T14:17:21Z

← Older revision		Revision as of 14:17, 4 August 2016
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	Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.		Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.

	PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less ~~power~~ is used.		PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less current is used.

	Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8		Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8
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	Heres the basic setup (uninstalled). The blower fan (left) is hooked up to the controller (~~top~~ right) and speed is controlled by the small potentiometer (bottom right).		Heres the basic setup (uninstalled). The blower fan (left) is hooked up to the controller box (right) and the speed is controlled by the small potentiometer (bottom right).

	[[File:Pwmcontroller2.jpg]]		[[File:Pwmcontroller2.jpg]]

CovKid at 14:15, 4 August 2016

2016-08-04T14:15:55Z

← Older revision		Revision as of 14:15, 4 August 2016
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	Heres ~~how it works~~. The blower fan (left) is hooked up to the controller (top right) and speed is controlled by the small potentiometer (bottom right).		Heres the basic setup (uninstalled). The blower fan (left) is hooked up to the controller (top right) and speed is controlled by the small potentiometer (bottom right).

	[[File:Pwmcontroller2.jpg]]		[[File:Pwmcontroller2.jpg]]

CovKid at 14:14, 4 August 2016

2016-08-04T14:14:47Z

← Older revision		Revision as of 14:14, 4 August 2016
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	Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.		Usually, a PWM controller works out cheaper than using resistors to control fan speed, its more efficient, arguably less of a fire risk, and you get infinite control right up to the flat out speed of the motor.

			PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less power is used.

	Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8		Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8
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	[[File:Pwmcontroller2.jpg]]		[[File:Pwmcontroller2.jpg]]


	PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less power is used.

	To install one (see photo below), you completely bypass the resistors but you'll need to get to the relevant cables.		To install one (see photo below), you completely bypass the resistors but you'll need to get to the relevant cables.

CovKid at 14:14, 4 August 2016

2016-08-04T14:14:02Z

← Older revision		Revision as of 14:14, 4 August 2016
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	Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8		Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8

	Heres how it works. The blower fan (left) is hooked up to the controller and speed is controlled by the small potentiometer ~~on the~~ right.

			Heres how it works. The blower fan (left) is hooked up to the controller (top right) and speed is controlled by the small potentiometer (bottom right).

	[[File:Pwmcontroller2.jpg]]		[[File:Pwmcontroller2.jpg]]
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	[[File:Pwmcontroller1.jpg]]		[[File:Pwmcontroller1.jpg]]

CovKid at 14:13, 4 August 2016

2016-08-04T14:13:13Z

← Older revision		Revision as of 14:13, 4 August 2016
Line 7:		Line 7:

	Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8		Some time ago I gave a video demo on how it works. See: https://www.youtube.com/watch?v=3GzJ8N1Rqp8

			Heres how it works. The blower fan (left) is hooked up to the controller and speed is controlled by the small potentiometer on the right.

			[[File:Pwmcontroller2.jpg]]


	PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less power is used.		PWM means pulse width modulation - the power being switched on and off at high speed rather than as with resistors, excess current used up in heat. With resistors, you'll use the same power regardless of speed, with PWM, the lower the speed, the less power is used.