E32/34 sword repair info collection

[shogun]

Here are all info I found on sword repairs, pinout of the module for the control and other items related to this. Pls add if you have more links or info to have all here
http://www.bimmerboard.com/forums/posts/136145/
http://www.bimmerboard.com/forums/posts/426626/
http://www.bimmerboard.com/forums/posts/425604/
http://www.bimmerboard.com/forums/posts/220273/
http://www.bimmerboard.com/forums/posts/91956/

sword repair pics by Shayne
http://www.bimmerboard.com/forums/posts/355700/
http://www.bimmerboard.com/forums/posts/355705


http://www.bmwe34.net/e34main/maintenance/electrical/sword.htm

[shogun]

sword/microfilter removal
http://www.bimmerboard.com/forums/posts/54597

[shogun]

additonal info
fan blower and sword
http://www.bmwe34.net/E34main/Maintenance/Electrical/Sword.htm
and more
heater valve
http://www.bmwe34.net/E34main/Maintenance/Electrical/HeaterValve.htm
heating problems
http://www.bmwe34.net/E34main/Trouble/Heating.htm
R134a retrofit
http://www.bmwe34.net/E34main/Upgrade/AC_upgrade.htm
parked ventilation
http://www.bmwe34.net/E34main/Upgrade/Ventilation.htm

[shogun]

another success story with details
http://www.bimmerboard.com/forums/posts/704823

[shogun]

There are now some diagrams on my website
Shogun's Repair Guides for BMW Seven Series (http://twrite.org/shogunnew/topmenu.html)
under reference data>>sword schematic

more here with plug pinout etc Heizschwert (http://www.e32-schrauber.de/bmw/s-heizschwert.htm)

[shogun]

and another one in German language, many pics main page http://proto-web.asuscomm.com/index-2.html
[FIXED] Repaired "sword", yet blower won't turn off when switch set to "0" https://www.bimmerforums.com/forum/showthread.php?2369645-Repaired-quot-sword-quot-yet-blower-won-t-turn-off-when-switch-set-to-quot-0-quot

[shogun]

Yesterday I went to the bi-annual inspection to get a new roadworthy sticker. While the inspection was no problem and I got my new sticker after paying road/weight tax, suddenly the blower fan started to run only on full speed and even was running on full speed when I switched off the blower fan complete on the IHKA control panel.
When I came back home I removed the sword and connected another repaired one on the wire loom without installing it and that worked fine, installed it and blower fan works fine in all speeds.
To remove the 2 screws which hold the sword in place you need a long T20 screwdriver, a small T20 bit is not long enough, as the screws and about 2 cm deep in the casing/hole of the sword. http://www.meeknet.co.uk/e32/BMW_E32_Common_Problems_htm_files/9.jpg
Sword and filter removal DIY http://www.bimmerboard.com/forums/posts/54597
Sword repair http://www.bimmerboard.com/forums/posts/355700/ http://www.bimmerboard.com/forums/posts/136145/
I have read from some electronic wizzards on the German forum following comments:
Best is to use BUZ11, they can stand more than the original ones.
In case the fan now only switches off while switching off the ignition, then one or several of the MOSFET's in the sword are defective and give permanent signal to run.This has nothing to do with the relay in the sword handle. This relay only activates at "max fan speed" adjustment respect. defects.
The BUZ 74 have 12A and 40 Watt, the BUZ11 have 25-30A and 75 Watt!
To cover the soldered items and protect them against moisture and damages, they either use UHU hard (if you have that in the U.S.), that is a glue which dries quickly,suitable for flexible material and all materials, moisture resistant and heat resistant from -50 to 100 degree celsius. Or any other glue to protect the soldered items. Or a 2-component glue, if you want to make it faster to dry. It should seal all to protect against moisture, that is the most important. And of course it must be resitant against certain temperatures as mentioned above. So any all purpose glue will do probably.

More info http://www.bimmerforums.com/forum/showthread.php?2020166-E32-heater-sword-repair-info
http://www.bimmerforums.com/forum/showthread.php?1967304-E32-Sword-Repair-Success
http://www.bimmerforums.com/forum/showthread.php?1322942-Question-about-the-sword-MOSFETS
http://bmwe32.masscom.net/johan/ihka/ihka.html
http://www.nmia.com/~dgnrg/page_15.htm
http://www.bimmerforums.com/forum/showthread.php?2237734-1989-535i-Sword-repair
IHKA repair http://www.bimmerboard.com/forums/posts/402448/

[shogun]

Inside the Sword case you will see 3 capacitors marked 3.3 uF/50V. They are C1, C4, C5.

You can buy Panasonic EEU-EB1H3R3S capacitors from DigiKey.be for E 0,23 each. They are polarized, so there is a + on the board.
You could also order a variable resistor such as P160KNP-0QD20B50K

For testing on your workbench, a 50 watt headlamp is a more convenient load than the blower motor. (Big, heavy, and in your car!)

One terminal of the lamp goes to pin 5. The other terminal of the lamp goes to 12V.

Testing blower fan:
if you bridge 4 and 5 on the sword, blower fan must run.Even easier, connecting PIN 5 directly to ground has the same success. Or simply turn on the IHKA control panel the knob driver side into the MAX notch. Then the relay is switched through.
Is there voltage at the fuse? Also behind the fuse? If so, fan motor defective or cable broken.If not, might be a fault in the fuse box

[shogun]

New findings on this problem, that the blower fan does not stop:
German:
Ergaenzung: Heizschwert- Geblaese geht nicht aus. Nach dem hier nun oefters die Frage gestellt wurde, warum das Geblaese nicht ausgeht, obwohl der Schalter auf "0" steht, hier nun des Raetsels Loesung: Es ist der Leistungs-FET. Er ist durchgeschlagen, d. h. hat einen Kurzschluss. Test: In der Stellung "MAX" laeuft das Geblaese geringfuegig schneller als in dem Regelbereich. Das liegt an dem Relais, welches bei "MAX" die FETs brueckt. Um den defekten FET zu finden, muessen alle FETs ausgeloetet werden und wie in dem Anhang gezeigt, getestet werden. Mit zwei Fingern abwechselnd 1 und 2 (AN) und 1 und 3 (AUS) beruehrt werden. Es handelt sich um BUZ71, BUZ11 kann ebenso verwendet werden. Also auch diese Fehlervariante kann am Heizschwert auftreten.

Link with pic how to test: http://www.7-forum.com/forum/showthread.html?t=111467

English: Additional info: Heater sword does not stop the blower fan.....This question was aked before several times, why the blower does not stop, although the switch is on "0", here now the solution:

It is a defective Power MOSFET . It has a short circuit.
Test: In the "MAX" position, the fan runs slightly faster than in the control range. This is due to the relay, which bridges the FETs at "MAX". To find the faulty FET, all FETs must be de-soldered and tested as shown in the appendix. With two fingers alternately 1 and 2 (ON) and 1 and 3 (OFF) are touched. It is BUZ71, BUZ11 can also be used. So this error variant can occur on the heater sword too.

https://www.bimmerforums.com/forum/showthread.php?2369645-Repaired-quot-sword-quot-yet-blower-won-t-turn-off-when-switch-set-to-quot-0-quot

[shogun]

DIY -BMW E34
M5 Blower Motor Replacement https://www.bimmerforums.com/forum/showthread.php?2198420-DIY-BMW-E34-M5-Blower-Motor-Replacement
https://www.m5board.com/vbulletin/e34-m5-discussion/467337-diy-blower-motor-replacement.html
E34 530 https://www.bimmerforums.com/forum/showthread.php?2326198-DIY-Blower-Motor-Replacement
E38 http://www.bimmerboard.com/forums/posts/45351
E36 https://www.dvatp.com/bmw/hvac_blower

comment by demetk: The sword can fail without notice. On my failed sword I replaced the transistors but it still would not power the blower motor. Upon closer examination of the curcuit board I found and fixed some solder joint failures and it finally worked again. You can test for power to blower motor at the sword or at the blower motor. If you have power then suspect the blower motor. I usually apply 12 volts to the blower motor to test if it works.
Here's the locations of the broken solder joints I found,
https://i.postimg.cc/nh5s3qk0/sword_2.jpg

[shogun]

Also look for these failed solder joints, resolder them
https://i.postimg.cc/g0CZ23Ln/sword_1.jpg
https://i.postimg.cc/nh5s3qk0/sword_2.jpg

[shogun]

To add my own experience and a caveat:
The symptom my car(89 535)exhibited was the fan running any time car was on. Seemed to be speed #3 as turning to 4 increased speed slightly. Autopsy revealed 3 of the 4 MOSFETS were bad.
I ordered BUZ11a MOSFETs as I read they are more robust.
10 ST Microelectronics brand ordered from Ebay seller giorgio11185. Good thing he sells by 10 as three(perhaps 5) were bad. I only found this out after performing the repair and having only high speed function.
After dismantling again the MOSFETs were tested and two of the four installed were bad. Another from the pkg was also bad and two others gave odd results.
SO, given the tedious nature of this job I advise that these always be tested BEFORE installing.
After the second repair (all four tested BEFORE soldering in) the FSU is working as intended. Too soon to comment on durability of these MOSFETs but given the rate of defect out of the gate I don't recommend buying them.
Thank you for all the info and advice previously posted by others.
info by ross1

[shogun]

more info for download for the IHKA control module, next to the sword: Modification of the IHKA control unit (E32/E34) due to possible overheating
2.39 MB!! (Text copied) The IHKA control unit repeatedly failed after about one hour of driving. In “cold condition” (directly after starting) the unit worked perfectly. The possible root cause was overheating of the entire unit. The housing is completely closed and on the PCB there are several components generating considerable heat. As a solution an active cooling was built in. The cut-outs are located over the components which generated the largest amount of heat. The two fans (30x30x7) were built into the “step” of the housing; there is enough space to the opposing electronic components. At the upper end of the PCB both +12V (KL 15) and ground can be found. There are two massive tracks adjacent to each other. Here a connector was soldered on (after removal of the protection coating, of course. Grind it until you see shiny copper…). There are 5 diodes (1N4001 or eqiv.) between +12V and the fans. The fans are running more silently at 10V (13.8V – 5 x 0.7V). For testing this modification the temperatures at two components (heat sink left – Temp 1, resistor right – Temp 2) were measured. Until about 4400 sec. (1 ¼ h) the control unit was idling – just supplied with 13.8V, no switching, no stepper driving, nothing – but 65°C at the resistor! Then the fans were switched on…
During messing around with the IHKA control unit to determine the cause of the malfunction I tried to find out more about how the IHKA was built up. Unfortunately the main components (microcontroller, driver IC’s,…) are marked with a special code – sorry, no proven information about these items.Thus: all following information is based on my own fuzzy thoughts about how this unit may work…(Picture and overview at the end of this document)
The IHKA control unit is diagnosis capable, i.e. (almost) all of the currents / voltages are measured and supervised. This is done by the power resistors together with the LM2901’s which compare analog values (set/actual) and deliver a corresponding digital signal to the main controller. This may evolve to a real PITA as each signal which is not exactly inside the defined limits will trigger an error message. If some values drift over the years there may be error messages where no errors are…
The stepper motor’s four windings are switched low side (ground) by the ULN2003’s. The bit pattern is stored by the stepper controller into the shift registers (HEF4094) which pass the signals on to the ULN2003’s. There are two driver-IC’s for switching the heating valves etc. (unfortunately these IC’s are coded: L475D). And exactly here is one of the big puzzles of the circuit: adjacent to these drivers there are two 120 Ohm power resistors. But those are not in a ground path due to current measurement or similar, they are just powered – a heating! Why? No clue… I only know one reason for providing such a “senseless” load: even in idle mode the control unit draws a defined amount of current and may be detected by other components of the entire car system. But: exactly those resistors generate a considerable amount of heat! All pictures I found in the web show a nicely tanned area on the PCB around
these resistors… thus I milled the openings in the housing directly above them. The next heater is the PTC of the fan of the interior temperature sensor. A PTC acts like a fuse. In normal operation it has a low resistance and passes current through. If there is too much current (e.g. a short), it gets hot and changes to a high resistance. The problem: if it gets heated from the “outside” (the overheated housing) it will change to a high resistance and the main controller gets the error message: “short in the fan”. This may be the main problem of the IHKA control unit…Last not least there is the main switch transistor. It is located on the same heat sink as the 5V voltage regulator for the digital circuitry. The transistor switches the KL30 supply (always hot) onto the internal KL15 (hot on ignition). Thus the control unit is powered during the often cited two minutes after engine stop and is switched off after this time. Again a problem: the main transistor itself is switched by secondary switching transistors. Latter ones are the said BC337’s. If they burn out the main transistor is permanently powered and it will never shut down the control unit – the battery will be empty soon enough (…it needs to power the fancy 120 Ohm heating…).
The main controller is very likely one of the Motorola MC6805 family. Some of the pins can be determined with a high probability (supply, Xtal,...). The reset pin was very interesting – the trace leads to one of the LM2901. In the original condition this part of the PCB was very sensitive, as the circuit remained in reset state if I touched one of the inputs of the LM2901 with the scope probe (!). After having changed the “surrounding” capacitors, this phenomenon has disappeared…
If the IHKA control unit is already opened and the soldering iron is ready I would change the two BC337 and the capacitors which are populated nearby the heat sink (2 x electrolytic caps, 2 x tantal caps).

http://www.e32-schrauber.de/bmw/daten/ihka/IHKA_Modifikation.pdf

[shogun]

Interior Blower Fan Sword Repair
Our interior (coupe) fan started to only work at full speed (setting 4) and sometimes at 3, 2 or 1. Reading a lot about this over the years I knew it was probably time to do the "sword" repair so I started by removing the glove box and side panels on the right (passenger) side in the car. The glove box is very easy to remove. So is the 4 other panels I needed to remove to gain good access to the sword.

Once the panels were disassembled I could see a few connectors all the way forward towards the firewall and floor. One yellow, one blue and one brownish. The blue and yellow connect to the IHKA control unit, and the brown 5-pin one connects to the sword. I disconnected the brown connector and used a philips driver to remove the two screws that hold the sword into the blower assembly. Then just pull it straight out to the side.

Since I know it will take some time for me to order and get time to do the actual soldering and fixing of the sword I decided to figure out how I could at least get the blower fan to run or not when needed while the repair is taking its sweet time in my shop. This was actually very easy and I ended up soldering in 3 wires and connecting a relay instead of the sword. Here is how the wiring and function of the sword connector works:
Pin Wire color .................................................. .................................. Description....................................... .............................. Functional description
1 Brown............................................. ............................... Grounding......................................... ............................. Directly and always connected to ground
2 Black / White .................................................. ............ Output to blower fan motor............................................. When fully grounded fan blows max speed. Allows speed change by adjusting the grounding level
3 Black / Blue.............................................. ......................... Full speed enable..........................................Wh en speed knob is set to 4, max speed, this wire is connected to +B and enables a by-pass relay in the sword assembly
4 Yellow / Green............................................. .......................... Ignition power............................................. When ignition is in position 2 this wire is connected to+B
5 Forgot color............................................. .............................. Blower speed signal..................................... Variable voltage between 0 and +5V supplied from the blower speed knob. About 1.3V at 1, and 2.5V at 3. 5V at 4.

Please note that the above table is not quite finished yet, the pin-numbering and wire-coloring will be double checked and the table will be updated soon.

I bypassed the sword function and allow the blower to either not run, or run at full speed by inserting a relay that controls the connection between grounding and the output to the blower motor. This short table explains my temporary setup while repairing the sword:
Relay pin......................Connected to................................................ ............................................. Description
30......................... Brown wire.............................................. .................................................. . Grounding
87........................ Black / White............................................. ................................................. Output to blower motor
86........................... Black / Blue.............................................. .................................................. . Full speed signal, +B when full speed set
85............................ Brown wire.............................................. .................................................. .. Grounding

To avoid destroying the sword connector, I just soldered into the wires just before the connector with the necessary 4 new wires and insulated the joints afterwords. Then I can just remove the relay later and connect the repaired sword. And if it ever breaks again, I can just put that relay back in.

The sword actually contains one relay to allow for the full speed setting (knob setting 4) that bypasses the electronics in the sword.

In my case one of the BUZ71S semiconductors probably failed and made the other 3 fail when they then became overloaded. These 4 BUZ71S semiconductors work in parallel and do the actual current controlling like an advanced resistor between grounding and the blower motor ground connector. They will now be replaced by new higher current capable semiconductors which probably will long outlive the life of the car.

Opening the sword is easy. 4 small philips screws hold two pieces of black plastic casing at the end of the sword. There is a small strip of weatherstrip insulation between the plastic case and the rest of the sword to avoid damp and moisture from entering the electronics. The whole PCB is also covered in a layer of laquer to protect against weather and moisture. You do not have to open the sword case to fix the BUZ71S. They are nailed and glued to the PCB and metal heat sink.

Before removing the BUZ71S test the NTC as below, and then use a knife and carefully pry under the big lumps of glue over the 3 pins that the BUZ71S are soldered to the PCB with. Just pry off this glue. Its relatively easy and just takes a few minutes of fiddling. Careful not to damage the PCB tracks in the process.

Then remove the small nut that holds the small NTC thermistor to the heat sink. This is an overheating protection that tells the electronics to cut out if the heat sink gets very hot. It should measure 300-330 ohms when at room temperature. And that resistance should drop when heated up. I used a lighter to slightly warm up the NTC to see if it worked. That might be a good test to perform before replacing the BUZ71S.

To remove the BUZ71S and replace them, I suggest using a 5mm metal drill and carefully drill out the nails from both the heat sink and PCB side. You do not need to drill far, just enough to remove the top part that sticks to either the PCB or heat sink. Do not worry about drilling into the PCB or tracks when you drill out the nails. There is plenty of PCB left to carry the current under operation later.

I then used some desoldering wire and desoldered the 3 pins of each BUZ71S. Then just pry the heat sink of the BUZ71S and the PCB. Careful not to bend the PCB too much so its tracks crack.

Then its just a matter of cleaning of some more glue and soldering in the new BUZ71S, assemble the heat sink and NTC thermistor. Use some spacers and bolts and nuts instead of the original nails to secure the BUZ well to the heat sink so that they can transfer as much heat to the heat sink and not burn out under load.

When all assembled I would have used to spray glue or clear paint to weather-proof the BUZ71S again.

Connect to your car and hope it all works well again.
Troubleshooting for finding whats at fault

If the blower fan does not work at full speed, then the relay in the black plastic casing is at fault. Also if the blower fan only works at full speed, I would suggest checking that relay first. All other intermittent speeds are controlled by the BUZ71S semiconductors and they will be at fault if 1,2 or 3 settings dont work.

from here http://www.ow.no/index.php?option=com_content&task=view&id=117&Itemid=13

[shogun]

MICROFILTER REPLACEMENT AND SWORD REMOVAL RHD http://www.meeknet.co.uk/E32/Microfilter/Index.htm
More E32 repairs http://www.meeknet.co.uk/E32/Index.htm