Introduction: FAN Repair

I had accumulated three floor continuing fans which had stopped rotating. Had cleaned and oiled its shaft bearings and even changed the squarish capacitor merely still not turning. Was about to throw them away when I thought "... what'due south the harm in dissecting them, I could acquire something from it...!!"

I had asked a few servicemen and all I got was a short "...there's an internal thermal fuse...". I trawled the web for months but but could non notice whatever info on where the fuse was and how to replace it. Finally I decided to sacrifice one of the fans and dissected all the wires going into the windings.

From this came the schematics of the fan, but only upward to the motor windings.

This instructable comes in 2 parts: (I)Troubleshooting and (II)Fuse replacement.

Step 1: Materials Required

Cross caput screw driver
Apartment tip screw driver
Scissors or Pen knife
Soldering Iron and some Solder
Some string virtually 0.5mm in diameter
Spare wire, about 60cm long
Capacitor one.4uF 450VAC (if required)
Thermal Fuse 130degree C, 1A, 250Vac
(note: I could merely find a 2A 130deg replacement @$1.50SGD a piece from the local electronic component shops. Sorry I don't have equivalent office number from Mouser, RS n Digikey)

Step 2: Troubleshooting

WARNING:
If you are NOT trained in electrical repair, please STOP here.
It would be wise to spend the coin for a replacement fan and requite the faulty 1 to someone who knows. We are dealing with 250VAC, so be actress conscientious. Y'all continue at your ain risks.

The Schematics :
At this juncture, I assume y'all know and have verified that the timer and speed selector are working fine (i.e. voltages are present at output of the speed selector (grayness, orangish and red wires)), run across schematics and film.

The colors of the wiring used in my fan may be different from yours, and so make a notation.

Troubleshooting the Thermal Fuse :
1. Disconnect power to the fan.

2. Open up the control unit comprehend.

3. Take your fourth dimension to trace the wiring and notation down its color and location. Information technology should be similar to the schematics above.

4. Using the spare wire, connect from point "A" to "B" to shunt the fuse. For my case, "A" was the blueish "neutral" wire on the final block and "B", the grey wire on the big squarish capacitor.

Once washed, brand certain your fan (without the blades of course) is resting properly and securely as we are going to power it upwards.

5. Connect and ability upwards the fan motor. If the fuse is faulty, the motor will rotate, mine did. If information technology did not, it might too be that point "C" was used instead of "B", since y'all could non know which terminal it was. No worry.

6. Disconnect power. Movement point "C" to "B" and power upwardly the fan once again. If it yet would not rotate, it's likely the capacitor.

vii. Disconnect power and remove the spare wire.

Replacing the Capacitor:
1. Disconnect ability.

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

3. Power up the fan. If the motor notwithstanding refuses to rotate then I believe the problem is with the motor windings and it'due south time to say bye-bye to the fan.

Step three: Thermal Fuse Replacement

Once the thermal fuse has been adamant to be the cause, hither we get...

Removing the Thermal Fuse:

Disconnect power to the fan before proceeding.

i. To make fuse replacement easier, nosotros need to costless the motor from the control unit of measurement keeping its wiring harness as long as possible. The harness has 5 wires going into the motor housing. Past tracing this harness, starting from the motor housing, I establish the Ground (green/yellow) and Neutral (blue) wires catastrophe at a concluding block and another iii (grey, orange, red) ending at the speed selector.

two. Remove the Ground and Neutral wire (no cut required) from the terminal block. De-solder  the greyness, orange and red wires at the speed selector, note their location outset. (You may have noticed that I cut the whole harness near 10cm from the motor…big mistake...just that was manner earlier I decided to do this!!)

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

4. Remove the oscillating unit and disassemble the capacitor.

5. Remove the metal housing screws. Advisedly remove the rotor and the windings slowly past giving it enough slack from the harness.

6. The windings are tied past strings and coated with some kind of lacquer. We need to cutting some of them (see the "Ten" 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 piece open the black sheath cover to expose the dark-brown woven sheaths, also tied with strings.

8. Trace the blue Neutral wire from the harness towards the windings. You volition observe it ended inside the biggest sheath which is on acme. This is our target. Cut the strings tying this sheath.

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

10. With wriggle, printing and pull activeness, slowly remove this sheath and the thermal fuse will be exposed. Put the removed sheath bated to exist reused later.

eleven. Notice that one of the fuse'southward leads is also sheathed to prevent electric contact. Slice the SIDE of this sheath lengthwise most 10mm. Betrayal the lead through this cutting.

12. With both leads exposed, cut them off as shut to the fuse as possible. This will requite the states enough room to solder the new fuse.

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

fourteen. Solder the new fuse, polarity is non of import but you may follow the old fuse management.

15. Move the cut sleeve to cover dorsum the lead exposed in footstep #11above.

16. Comprehend the fuse and its accompanying wire with the big sheath removed in step #10 to a higher place.

17. String the new fuse assembly to the windings as smashing equally you can. Fold back the black comprehend and string once again. Ensure no string or black cover sheath is protruding into the rotor area.

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

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

twenty. Insert the motor housing mountain rod to the control unit of measurement, a niggling pressure is needed here.

21. Dress dorsum the wiring harness and reconnect the Ground and Neutral wires to the concluding block. (For me, I had to solder back all the wires and insulate them with estrus shrinking tubes. I too had to de-activate the oscillator to prevent them from rubbing against each other)

23. Re-solder the grayness, orange and red wires dorsum to the speed selector.

24. Ability on the fan to exam. Embrace back the command unit and you are washed.

Step 4: Finally...

I did non use lacquer to protect the windings and its been operating for nearly ii months now at around 6 hours a day.

To preclude overheating, I modified the timer to disable the permanent "ON" choice. By using the timing mechanism there will be resting time in between, when no ane is in the room or no intention to use the fan for a while.

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