system fan acting crazy

I would look at processor core temps in Windows. If high, (either real or imagined) the Asetek unit is just doing what it is told to do by MIO-Board. If too high, Asetek unit might not be mounted properly. CPU-ID HW-Monitor is good (and should catch any spikes) but it would also be wise to see what Thermal Controller is saying because it's a good monitor of MIO-Board.

Test MIO-Board outside of Windows with BIOS-F12 Dell Diags (or create bootable copy).

See my post here:

en.community.dell.com/.../20128296.aspx

And here are my wiring notes:

MotherBoard Connections:
MB USB1 - MIO-Board (one USB channel for MIO, one for FlexBay)
MB USB2 - Front-Top Panel (2 x USB 2.0 Ports)
Front_Panel - Front-Top Panel (Power Switch, Power Light, HDD Light)
Front_Panel - BLINK header on MIO-Board (wires in parallel with others ... 2 wires on each pin)
Firewire - Front-Top Panel (1 Firewire port)
Audio - Front-Top Panel (analog heaphone and mic)
Chipset Fan
MB_CPU_Fan - 3-pins of the 26-pin cable that goes to the MIO-Board (MB_MIO)

MIO-Board Connections:
Power supply - Molex 4 pin (5v/12v)
MotherBoard USB (MB_USB)
MotherBoard Front_Panel (BLINK)
MotherBoard MB_CPU_Fan (3-pins of the 26-pin cable that goes to MB_MIO)
Top Lighting Board 26-pin (MB_MIO)
FlexBay (USB Card reader)
BlueTooth Module
All exterior lights
Large case fans

"Top Lighting Board" Connections:
CPU_Pump (Asetek Cooler) pump
Sys_Fan (Asetek Cooler) radiator or main system fan
CPU_Fan - No connection
Mem_Fan (small case fan in top for memory)
Arrow - "Rear of case" external white lighting with switch (to help view external connections)

I tested the MIO outside of windows as suggested, everything passed but it said no CPU pump or ambient sensors were installed?  Is that saying that it's not recognizing those pieces of hardware?  Would the fan work and not the pump?  How could the sensors not be installed?

Sometimes it's called System Fan and other times CPU fan. But neither shows and you can't "exercise" it?

Pretty sure sensors show on mine (I think I would have noted if they were not detected). If they don't, would explain the erratic behavior.

If yours is different than mine below, take a picture of your screen.

My Notes:

Use bootable Dell Diags disc you created
-or-
Press F12 on Boot

Boot to Utility Partition

Test System - Diagnostics

Custom Test

Master IO USB Device

CPU Fan on/off

- This test will speed up and slow down System/Radiator fan. Mine shows between 1200-4000 rpm

- - You might have to exit Diags and reboot to get fan speed back down to normal.

There is another test right below it that will show stats on all sensors/fans. Maybe run that one first. In this test, the "CPU Fan" is correctly called "System Fan".

You can also play with the lights while in there to make sure the MIO-Board is working.

You can also burn a bootable CD with the latest version of Dell-AW Diagnostics, and use that instead.

Details about each test:

Sensors Test
-------------
- System Fan (Correct name for Radiator fan)
PWM 100 , RPM 1188

- CPU Pump
PWM 100 , RPM 1404

- the above are correct, but I notice some others are incorrect or miss-placed.
A newer diags software version might have fixes. This is the old version loaded on my Aurora back in 2009.

CPU Fan Test (Incorrect name for System/Radiator fan)
------------
RPMs should be 1200-4000
On-Off test will work (low to high) but might leave fan on high and require a reboot to get back down to normal

Master IO USB Device
-------------------
This test is at the very bottom (might have to scroll down) ... but only if the MIO-Board is detected and not locked up

I will do this test later, but I re installed the command center and after rstart got this error.

"System.IO.FileLoadException: Could not load file or assembly 'ThermalControls.Tools, Version=2.7.25.0, Culture=neutral, PublicKeyToken=bebb3c8816410241' or one of its dependencies. The located assembly's manifest definition does not match the assembly reference. (Exception from HRESULT: 0x80131040)

File name: 'ThermalControls.Tools, Version=2.7.25.0, Culture=neutral, PublicKeyToken=bebb3c8816410241'

  at AlienLabs.ThermalControls.Controller.App.AppStartup(Object sender, StartupEventArgs args)

  at System.Windows.Application.<.ctor>b__1(Object unused)

  at System.Windows.Threading.ExceptionWrapper.InternalRealCall(Delegate callback, Object args, Int32 numArgs)

  at MS.Internal.Threading.ExceptionFilterHelper.TryCatchWhen(Object source, Delegate method, Object args, Int32 numArgs, Delegate catchHandler)

WRN: Assembly binding logging is turned OFF.

To enable assembly bind failure logging, set the registry value [HKLM\Software\Microsoft\Fusion!EnableLog] (DWORD) to 1.

Note: There is some performance penalty associated with assembly bind failure logging.

To turn this feature off, remove the registry value [HKLM\Software\Microsoft\Fusion!EnableLog]."

Would this have anything to do with it? BTW i'm not that knowledgeable about registry but I'm not a noob.

I also ran the diagnostic, everything passed with similar results to what you posted.  I also ran the sensor test and got the following results:

on board: 27c

CPU Pump: not installed

GFX pump1: 27c

GFX pump2: not installed

Ambient 1 not installed

Ambient 2 not installed

Ambient 3 27c

Messages like that usually mean the Command Center software is having a problem communicating with the MIO-Board.

Try Power Dissipation fix.

I tried the power dissipation fix and still had the same result.  I did some searching and came across another post with a similar issue and you gave advice on accessing the "gaming desktop" portion of the devices.  There you said to manually uninstall the drivers for "Master IO Filter Driver".  When I go that section I do not have master IO Filter, I have "HID compliant device".  The "USB Input Device" Is there.  Could this be the issue?

EDIT:  I managed to get command center installed using another of your techniques.  I installed it on a new user account.  It is reading properly but my fan is still running fast.

EDIT:  I managed to get command center installed using another of your techniques.  I installed it on a new user account.  It is reading properly but my fan is still running fast.

I also ran the diagnostic, everything passed with similar results to what you posted.  I also ran the sensor test and got the following results:   on board: 27c   CPU Pump: not installed   GFX pump1: 27c   GFX pump2: not installed   Ambient 1 not installed   Ambient 2 not installed   Ambient 3 27c

but my fan is still running fast.

The fan is connected to sys fan.  How do you perform a "clean windows install"?

I performed the clean install of windows and there was no improvement.  I guess I'm just out of luck.

Issue solved!  I took out my fan and pump, reapplied thermal compound and re-seated the connections.  I guess everything was running to hot in the end.  Thanks for all your help tesla.