

| Subject: | AC high current problem fixed and improved AC performance |
| From: | Ed McLean |
| Date: | Tue, 13 Nov 2001 20:46:42 -0500 |
I also have had problems with high current draw from my '86 Westy air conditioning fan. After a little thought I developed a good solution that had the added benefit of significantly improving the performance of the air conditioning system. I found my Westy air conditioning fan was drawing a enough current to overheat the fan switch. In my case, the fan switch would last about a year before the high speed switch contacts would overheat and fail. I eliminated the problem with the switch by installing a gang of three 40 amp load reduction relays inside the air conditioning cabinet to provide the current to drive the evaporator fan. The current for the fan was provided by the +12 VDC terminal in the wiring connection box in the engine compartment via a heavy gauge wire and an 50 amp circuit breaker. The relays were controlled by the original air conditioning fan switch, one for each speed. All wiring connectors were crimped and soldered. I found the high speed relay would stick after long runs so I piggybacked a second relay in parallel to split the current draw. This has worked very well with no problems for several years. One unexpected benefit is now the air conditioning fan is supplied with power that has not suffered the considerable voltage drop from the original fan switch and small gauge wire. I did not measure the voltage available at the fan in the stock configeration but it had to me much less than it is now. The air conditioning now works much better because the fan blows much stronger. The present Low speed is about equal to the previous Medium speed. The High fan speed is awesome and is more than adequate in blowing cold air up to the driver and front seat passenger in hot weather and is actually too strong except for initial cooling off after sitting in the sun. In fact, I had previously installed a second evaporator unit over the glove compartment (another story altogether) to cool the folks in the front. With the improved fan operation, the second air conditioning unit would not have been necessary. I highly recommend adding load reduction relays to provide adequate voltage to the air conditioning fan.
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