Sorry I forgot to post here - I solved the problem by reflashing the firmware using RBE.
After reading the docs and experimenting with different options I finally got it right. Many thanks to the fellow who created RBE - excellent program - and no thanks to Sapphire for programming a brain dead fan control alg.
As it turns out the card was totally fine except for the fan issue.
For anyone interested, these are the values I am using currently:
Using Transfer function (DC = DCmin + (T - Tmin) * Tslope / 16):
Tmin = 40 C
Tmax = 106 C (Tslope = 21%)
DCmin = 15%
Hysteresis = 24%
Tmin hysteresis = 4 C
Spin up cycle = 20%
Spin up interval = 7
PWM ramp enabled = 2%
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