PULL CHAIN SPEED CONTROL REVERSE SWITCH XTR MOTOR

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1 PULL CHAIN SPEED CONTROL REVERSE SWITCH The Casablanca 4-Speed series of fans feature a 4-speed, pull chain fan control and a forward/reverse slide switch. XTR MOTOR PRINTED CIRCUIT BOARD LIGHT KIT PULL CHAIN VII 7.4s. 1

2 Description The four speed pull chain control is mounted in the switch housing and plugs into the printed circuit board. The pull positions of the switch are: PULL#1 PULL#2 PULL#3 PULL#4 PULL#5 HIGH SPEED MEDIUM SPEED MEDIUM LOW SPEED LOW SPEED OFF NOTE: Pull chain switch wires are pushed into self holding solderless sockets. They can be removed by sliding a miniature screwdriver down the socket next to the wire while pulling on the wire. To re-connect push 1/4" bared wire into correct pull chain switch socket number. VII 7.4s. 2

3 Replacement To replace a faulty pull-chain switch, trace the brown, yellow, blue, black, purple and yellow leads from the switch to the printed circuit board connector. Unplug the plastic connector from the circuit board. Unscrew the knurled nut on the outside of the switch housing. When replacing the control, slide the new switch and chain through the switch housing hole, making sure the lockwasher is between the switch and the inside of the housing. Then, securely tighten the nut to hold it in place. (Do not use pliers to tighten the nut.) Plug the keyed connector into the correct position. Be sure the connectors are properly mated before testing. QUICK STEPS: Step 1 Unplug the 5-way connector from the printed circuit board. Step 2 Remove the knurled nut holding the switch in the switch housing. Step 3 Push the switch back to remove. Step 4 Insert the new switch - don't forget the washer! Step 5 Screw on the knurled nut - finger tight only! Step 6 Plug in the 5 -way connector making sure the pins are lined up and that the yellow wire is on the end. 4 - SPEED PULL CHAIN SWITCH ASSEMBLY ELECTRONIC TESTING CIRCUIT DIAGRAM Rating: 6A125VAC Operation The four speed pull chain switch is a four position rotary switch that selects run capacitors on the PCB (Printed Circuit Board) to alter the fan speed. One of the positions (D) does not select a capacitor so the fan turns off. PULL #1 HIGH SPEED BROWN A PULL #2MEDIUM SPEED YELLOW, BLUE & PURPLE B PULL #3MEDIUM LOW SEED BLUE & PURPLE C PULL #4 LOW SEED PURPLE C PULL #5OFF (120V AC) BLACK D Testing Remove the socket connector from the PCB. With a continuity checker or resistance meter check as follows: Connect one probe to Pin 1 then check that when the other probe is placed on Pin 2, then Pin 3 then Pin 4 then5 that infinite ohms (no continuity) is measured in one position of the pull chain. This is the OFF switch position. Now pull the chain once and measure 0 ohms (continuity) between 1 and 2, pull again for 0 ohms (continuity) between 1 and 3, 4,5 pull again for 0 ohms (continuity) between 1,4 and 5. VII 7.4s. 3

4 MOUNTING CLIP Slide Reverse Switch Switch is held in place by spring mounting clip. It is important that the tangs on the switch are in-between the mounting plate and switch housing. PRINTED CIRCUIT BOARD CONNECTOR Description The reverse switch is mounted in the switch housing, and plugs onto the printed circuit board. It is a two position slide switch that reverses the direction of rotation. REVERSE SWITCH (SLIDE) FOR DAMP LOCATION REVERSE SWITCH (PULL CHAIN) Description The pull chain reverse switch is used on fans that are used in damp locations, and plugs into the printed circuit board. It is a two position pull chain switch that reverses the direction of rotation. IMPORTANT NOTE Fans installed in a damp location, a slide switchis not used. But a pull chain switch is used to meet U.L. requirements for 'damp' environment operation. VII 7.4s. 4

5 Replacement To remove the faulty reverse switch trace the white, gray, yellow and purple leads from the reverse switch to the connector on the circuit board. Unplug the reverse switch connector from the circuit board. Then, slide the switch up and away from the switch housing's spring clip. When installing a new subassembly, slide the reverse switch's end flanges down between the switch housing and the spring clip. With the reverse switch in place plug its connector back into the PCB, making sure that it is positioned correctly. QUICK STEPS Step 1 Unplug the 4-way connector from the printed circuit board. Step 2 Slide old switch out of housing. Step 3 Push the new switch back into the housing being careful to keep the reverse switch tangs in-between the clip and switch housing. Step 4 Plug the three pin connector back into the printed circuit board. REVERSE SWITCH ASSEMBLY ELECTRONIC TESTING Testing The readings are made with the reverse switch assembly disconnected from the electrical circuit. If the above results are not obtained the reverse switch assembly is defective and needs to be replaced. Operation The reverse switch is a two position slide switch that connects the power to ether the forward direction winding, or the reverse direction winding of the 4-Speed motor. PROBES SLIDE READINGS 1-3 left open 2-4 left 0 ohms 2-3 right 0 ohms 2-4 right open VII 7.4s. 5

6 Replacement To replace a faulty reverse switch, trace the brown, blue, purple and yellow leads from the switch to the printed circuit board connector. Unplug the plastic connector from the circuit board. Unscrew the knurled nut on the outside of the switch housing. When replacing the control, slide the new switch and chain through the switch housing hole, making sure the lockwasher is between the switch and the inside of the housing. Then, securely tighten the nut to hold it in place. (Do not use pliers to tighten the nut.) Plug the keyed connector into the correct position. Be sure the connectors are properly mated before testing. QUICK STEPS: Step 1 Unplug the 4-way connector from the printed circuit board. Step 2 Remove the knurled nut holding the switch in the switch housing. Step 3 Push the switch back to remove. Step 4 Insert the new switch - don't forget the washer! Step 5 Screw on the knurled nut - finger tight only! Step 6 Plug in the 4 -way connector making sure the pins are lined up and that the yellow wire is on the end. REVERSE SWITCH ASSEMBLY ELECTRONIC TESTING Testing The readings are made with the reverse switch assembly disconnected from the electrical circuit. If the above results are not obtained the reverse switch assembly is defective and needs to be replaced. PROBES SLIDE READINGS Operation The reverse switch is a two position pull-chain switch that connects the power to ether the forward direction winding, or the reverse direction winding of the 4-Speed motor. 1-3 pull open 2-4 pull 0 ohms 2-3 pull 0 ohms 2-4 pull open VII 7.4s. 6

7 XTR 200 MOTOR WIRING DIAGRAM Description: The XTR motors is a 20 pole, permanent split capacitor induction motors. Simply put, this means the motor runs on AC power and has a capacitor connected across its two windings. The capacitor 'kicks' the motor into action and also smooths out the AC power so that it does not run with an annoying hum. The motor has two windings inside so that the direction of rotation can be changed by switching connection of the AC power from one winding to the other. The moving parts are made of a rugged die cast aluminum constructions. With 200mm x 20mm silicon low carbon steel laminations. A heavy cast iron flywheel is built-in for smoother operation-perfectly balanced. Making the XTR-200 motor Quiet, no vibration and a very reliable direct drive motor. VII 7.4s. 7 Motor Information - (CONTINUED) -

8 If the motor is found to be defective, call the Service Department for replacement instructions. If the readings below are not obtained, the motor is defective and needs to be replaced. VII 7.4s. 8

9 PC BOARD used in fans that are rated for DAMP LOCATION. (Figure #1) (Figure #2) Note: The 4 Speed fans use one of two PC Boards, for fans with the UL rating for uses in damp location. The PC Board with part number is used as shown in (Figure #2). All other 4 Speed fans use PC Board with part number as shown in (Figure #1). The only difference between the two boards is that the Start Capacitor has be positioned upright and not flat as shown. On the damp location fans a reverse pull chain switch is used and the start capacitor must be placed upright or the reverse pull chain switch will not fit into the switch housing. 4-SPEED PRINTED CIRCUIT BOARD (PCB) Description The printed circuit board (PCB) allows connection of the XTR- 200 Motor, Pull Chain Speed Switch and Reverse Switch. Line voltage is brought to the PCB from the canopy via Pin 1 of the XTR-200 Motor socket. It is next routed directly to D of the pull chain speed switch via the PCB and Pins on the pull chain connector. The pull chain switch position determines which motor run capacitor (s) is used on the PCB and this in turn determines the fan speed. Which winding will receive the voltage is determined by the position of the reverse switch i.e. forward or backward. Line voltage return is from the center tapped motor windings. VII 7.4s. 16

10 Replacement To replace a faulty PC Board, this can be done with the fan hanging from the ceiling. With the POWER turned OFF at the circuit breaker, remove the glass and light kit from the fan. Remove the switch housing cap as shown in (Figure #1) so that you have easy access to the electronics of the fan. Remove the reverse and speed control switch as shown in (Figure #2). Then remove the PC Board from the switch housing as shown in (Figure #3) and (Figure #4), the PC board is held into the switch housing by 4 STANDOFFS as shown in (Figure #5). Make sure that you keep the FISH PAPER as shown in (Figure #5); the FISH PAPER will be needed and installed with the new PC Board. Once you have installed the new PC Board, check and make sure that the plugs are plugged into the PC Board correctly as shown in (Figure # 6). (Figure #1) (Figure #2) (Figure #3) (Figure #4) (Figure #5) (Figure #6) VII 7.4s. 17

11 IMPORTANT NOTE! There are no field serviceable components on the printed circuit board. If a fault condition is determined the complete assemble must be changed. Be sure to inspect the run capacitor to identify that it matches the one that you are removing and is the correct PCB for the motor. Mechanical Disassembly The printed circuit board is mounted inside the switch housing, with four stand-offs and insulation paper. Three connectors are plugged into the printed circuit board as shown. Before doing any in-depth troubleshooting, it is wise to give the ceiling fan a good visual inspection for mechanical problems or poor electrical connections. To do this thoroughly: 1. Spin the fan blades by hand to be sure that they rotate freely and are not rubbing against any fan surfaces. 2. Remove the switch housing bottom cap and check all the wire connections at the printed circuit board. Unplug each connector or set of connectors one at a time. Inspect the wire-lead side of each connector; each wire should be fully inserted. 3. Inspect for shorted wires to the switch housing. The reverse switch leads must have adequate clearance to the switch housing. EDGE VIEW Printed Circuit Board Insulation paper Stand-off The EDGE VIEW shows the positioning and placement of the Printed Circuit Board, Insulation paper, and a Stand-off. The wire has lifted out of the connector, and is NOT making electrical continuity. VII 7.4s. 18

12 Description The light kit pull chain is mounted inside the switch housing, if a light kit is installed. The pull chain provides ON - OFF control of the light kit: PULL # LIGHT FUNCTION #1 ON #2 OFF NOTE: This light switch is optional and not required for fan operation. LIGHT KIT PULL CHAIN SWITCH ASSEMBLY ELECTRONIC TESTING Ohm. meter readings: PROBES: PULL #: READINGS: P/N # A + B #1 open A + B #2 0 ohms The readings are made with the pull chain switch assembly disconnected from the electrical circuit. If the above results are not obtained, the pull chain assembly is defective and needs to be replaced. VII 7.4s. 19

13 NOTE: If a separate circuit is used to control the lights from a wall control, the BLUE D1-Option wire at the top of the fan should be connected to that circuit instead of the BLACK power wire in the canopy. Optional Light Kit Installation a) Refer to light kit instructions to assemble and attach your light kit correctly. b) Remove the two (2) 8-32 screws from the switch housing cap. c) Remove the plug from switch housing. d) Install pull-chain switch and finger tighten collar on switch. e) Connect one wire from pull-chain switch to the BLUE D1-Option wire. Secure splice with a wire nut. f) Connect other wire from pull-chain switch to BLACK wire from light kit. Secure splice with a wire nut. g) Connect WHITE wire from switch housing to WHITE wire from light kit. Secure splice with a wire nut. h) At the fan housing pole, connect the BLACK and BLUE wires. SWITCH HOUSING COLLAR Operation: Two pull-chain switches on the fan, control the fan and lights. Using the fan control pull-chain switch (Figure. 33): 1. Pull: fan ON, low speed 2. Pull: medium speed 3. Pull: high speed 4. Pull: fan OFF Using the optional light pull-chain switch: 1. Pull: light ON 2. Pull: light OFF Direction of blade rotation is controlled by the slide switch on the side of the switch housing. No changes in household wiring are required. SWITCH HOUSING VII 7.4s. 20

14 WIRING DIAGRAM 4-SPEED FANS VII 7.4s. 21

15 WIRING DIAGRAM 4-SPEED FANS UL DAMP LOCATION VII 7.4s. 22

16 TROUBLESHOOTING GUIDE FOR 4-Speed FANS TROUBLE POSSIBLE CAUSE POSSIBLE REMEDIES 1.0 Fan runs slowly in either direction if rotation is started by hand; will not reverse. 2.0 Fan will not operate at proper speeds or will not operate at any speed. 3.0 Fan is noisy during operation. 1.A Faulty reverse switch. 1.B Faulty capacitor. 1.C Open motor winding. 2.A Faulty four-speed pullchain switch assembly. 2.B Faulty capacitor. 3.A Loose glass or bulbs on light kit. 3.B Loose canopy. 3.C Loose blade holder screws. 3.D Loose motor housing screws. 3.E Loose wire nuts in switch housing or canopy. 3.F Interference between motor & switch housing. 3.G Motor noise caused by solid state wall speed control. 1.A Replace reverse switch assy 1.B Replace PCB assembly. 1.C Replace motor unit. 2.A Replace four-speed pull-chain switch assembly. 2.B Replace PCB assembly. 3.A Tighten thumb screws & bulbs. 3.B Tighten canopy screws & cross bar assembly. 3.C Tighten blade holder screws. 3.D Tighten motor housing screws. 3.E Check & adjust. 3.F Adjust case position & tighten screw. 3.G Replace with capacitor wall speed control. VII 7.4s. 23

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