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Step By Step How To Fix A Fan

Electric fan

Sometimes you may accumulate up to three floor standing fans which had stopped rotating. Had cleaned and oiled its shaft bearings and even changed the squarish capacitor but still not working.  This is a step by step guide to fix a fan with fault at home and offices;

steps to fix a faulty fan at home

Step 1: Materials Required

Electric fan

Electric fan

Firstly make available materials required. Below are required materials needed to fix a fan.

Cross head screw driver
Flat tip screw driver
Scissors or Pen knife
Soldering Iron and some Solder
Some string about 0.5mm in diameter
Spare wire, about 60cm long
Capacitor 1.4uF 450VAC (if required)
Thermal Fuse 130degree C, 1A, 250Vac

Step 2: Troubleshooting

The Schematics :
At this point, I assume you know and have verified that the timer and speed selector are working fine (i.e. voltages are seen at output of the speed selector (grey, orange and red wires)), see schematics and picture.

The colors of the wiring used in my fan may differ from yours, so make a note.

Troubleshooting the Thermal Fuse :
1. Unplug power to the fan you want to fix.

2. Open up the control unit cover.

3. Take your time to check the wiring and map down its color and position. It should be similar to the schematics above.

4. Making use of the spare wire, connect from point “A” to “B” to shunt the fuse. For my case, “A” was the blue “neutral” wire on the terminal block and “B”, the grey wire on the big squarish capacitor.

Once done, ensure that your fan (without the blades of course) is resting properly and securely as we are going to power it up. REASONS TO USE DIGITAL ANTENNA FOR TV AT HOME

5. Fix and power up the fan motor. If the fuse is faulty, the motor will rotate, mine did. If it did not, it might also be that point “C” was used instead of “B”, since you could not know which terminal it was. No worry.

6. Unplug power. Move point “C” to “B” and power up the fan again. If it still would not rotate, it’s likely the capacitor.

7. Unplug power and remove the spare wire.

Replacing the Capacitor:
1. Disconnect power.

2. De-solder (or cut) the wires at capacitor terminals and join them to a new capacitor (same type).

3. Power up the fan you want to fix. If the motor still refuses to rotate then It may be that the issue is in the motor windings and it’s time to buy a new fan fan.

Step 3: Thermal Fuse Replacement

Once the thermal fuse has been determined to be the cause, here we go…

Removing the Thermal Fuse:

Unplug power to the fan before proceeding.

1. To enable easy replacement of fuse, we need to free the motor from the control unit keeping its wiring harness as long as possible. The harness has 5 wires going into the motor housing. By tracing this harness, beginning from the motor housing, I found the Ground (green/yellow) and Neutral (blue) wires stopping at a terminal block and another three (grey, orange, red) ending at the speed selector.
2. Unplug the Ground and Neutral wire (no cutting required) from the terminal block. De-solder  the grey, orange and red wires at the speed selector, map their location first.

3. Using a flat tip screw driver as a lever, loose the motor housing mount rod away from the control unit.

4. Unplug the oscillating unit and detach the capacitor.
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5. Remove the metal housing screws. Carefully move out the rotor and the windings slowly by giving it enough slack from the harness.

6. The windings are tied by strings and coated with some kind of lacquer. We need to cut out some of them (see the “X” points in the picture) using pen-knife or sharp tip scissors. Look for a bulge (where the fuse is) and notice where it ends.

7. Carefully slice open the black sheath cover to expose the brown woven sheaths, also tied with strings.

8. Trace the blue Neutral wire from the harness towards the windings. You will notice it stopped inside the big sheath which is on top. This is our objective. Cut the strings tying this sheath.

9. This big sheath, which is flattened, holds the fuse and another sheathed wire. Use fingers to lift it and press on its sides to form back its tubular shape.

10. With wriggle, press and pull action, gently remove this sheath and the thermal fuse will be exposed. Put the removed sheath aside to be reused later.

11. Notice that one of the fuse’s leads is also sheathed to avoid electrical contact. Slice the SIDE of this sheath lengthwise about 10mm. Expose the lead through this cut.

12. With both leads exposed, cut them off as close to the fuse as possible. This will give us enough room to solder the new fuse.

13. Trim the leads of the new fuse to about 10mm and tin them with solder.

14. Solder the new fuse, polarity is not important but you may follow the old fuse direction.

15. Move the cut sleeve to cover back the lead exposed in step #11above.

16. Cover the fuse and its accompanying wire with the big sheath removed in step #10 above.

17. String the new fuse assembly to the windings as neat as you can. Fold back the black cover and string again. Make sure no string or black cover sheath is protruding into the rotor area.iPhone 11 features vs 2018 iPhone features

18. Gently place back the windings and rotor into the motor housing.

19. Secure the housing and mount back the oscillator and the capacitor.

20. Input the motor housing mount rod to the control unit, a little pressure is required here.

21. Put back the wiring harness and reconnect the Ground and Neutral wires to the terminal block. (For me, I had to solder back all the wires and join them with heat shrinking tubes. I also had to de-activate the oscillator to stop them from rubbing against each other)

23. Re-solder the grey, orange and red wires back to the speed selector.

24. Power on the fan to test. Close back the control unit and all is set.

Step 4: Finally…

To avoid overheating of your fan, modify the timer to disable the permanent “ON” selection. By making use of timing mechanism there will be resting time in between, when the fan is not been used.

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