CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC Page |1

APPLIANCES.

a. Parts of Flat Iron, Electric Fan

b. Test Troubleshoot and Repair Basic Appliances

ELECTRIC FAN

TECHNICAL TERMS
- Converts AC electrical energy into mechanical energy, producing a mechanical
AC Motor
rotary action that performs some type of work.
- A container which resists generation of triboelectric charge (frictionally
Antistatic generated) as the device is inserted into, removed from , or allowed to slide
around in it.
Bushing - A sleeve protecting a conductor where it passes through a hole in motor.
- A device used to boost the voltage to a motor. Running capacitors are used in
the starting winding to increase the running torque of the motor. Starting
Capacitor
capacitors are used in the starting winding to increase the starting torque of the
motor.
Capacitor for Start - A low reactance non-polar electrolytic capacitor connected in series with the
Motor start winding.
- A rotating electric machine which changes applied electrical energy or power
Motor
into mechanical output energy or power.
Rotor - The part of an electric motor that turns or rotates.
- The winding in an electric motor that provides the power for turning the rotor
Run Winding during operation. It has the larger wire of the two windings. The main winding of
the motor with comparatively low resistance and high inductance.
Rectifier - Diode circuit that converts AC to pulsating DC.
- Component made of material that opposes the flow of current and therefore has
Resistor
some value of resistance.
- Electromechanical device that has a rotating shaft connected to one terminal
Rotary Switch
capable of making, breaking a connection to one or more other terminals.
- The part of a rotor that carries other rotating members and that is supported by
Shaft
bearings in which it can rotate.
- The auxiliary winding of the motor with comparatively high resistance and lower
Start Winding
inductance.
Stator - The stationary part of the motor which the field windings are placed.
System Control - An integrated circuit that can recognizes and responds to commands from the
Microprocessor operator by monitoring the DC voltages at the output terminals.
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APPLIANCES.

- Illustration of an electrical or electronic circuit with the components represented

Schematic Diagram
by their symbol.
- Also called a short. Low resistance connection between two points in a circuit
Short Circuit
typically causing excessive current.
Solder - Metallic alloy used to join two metal surfaces.
- Process of joining two metallic surfaces to make an electrical contact by melting
Soldering
solder (tin and lead) across them.
Substrate - Mechanical insulating support upon which a device is fabricated.
Switch - Electrical device having two states, ON (closed) or OFF (open).
- Sequence of operations intended to verify the correct operation or
Test
malfunctioning of a piece of equipment or system.
An over current device that contains a heater element in addition to and
Thermal cutout affecting a renewable fusible member which opens the circuit. It is not designed
to interrupt short short-circuit currents.
Transformer - Inductor with two or more windings.
- Systematic approach to locate the cause of a fault in an electronic circuit or
Troubleshooting
system.
- An assembly of coils designed to act in consort to produce a magnetic flux field
Winding
or to link a flux field.

OPERATION OF AN ELECTRIC FAN

Electric Fan
is an air moving machine used to cool with an AC Motor connected to the 60 Hz power source which converts
electrical energy to mechanical energy in order to generate a moving air. It is a power driven machine capable of
providing high air flow parallel to the axis of the motor shaft where an axially mounted impeller or fan blade agitates
the air. The air velocity/delivery of the electric fan is controlled by a mechanical speed selector switch for old
models and electronically controlled speed selector switch for new models. Timer is also included for fully
automatic operations.

PARTS OF AN ELECTRIC FAN

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APPLIANCES.

 Front Guard a protective metal mesh wire used to prevent the fan blade from any physical contact with foreign
objects.
 Guard Mark a logo of the manufacturer of the electric fan which is mounted at the center of the front guard.
 Switch Box a panel board for the controls of the electric fan.
 Inner Pipe a metal tube inserted into the outer tube intended for proper height adjustment of the electric fan.
 Outer Pipe a metal tube attached to the base stand of the electric fan.
 Base Stand the bottom or lowest part of the electric fan where it stands as a foundation.
 Blade a propeller made out of plastic or metal which is attached in to the motor shaft and agitates air when the
motor rotates.
 Remote Control a transmitter device used to control the electric fan from a distance.

Block Diagram of Electronically-Controlled Electric Fan (ECEF)

 Power Controller – It is a circuit that controls the amount of power supplied to the motor.
 Sensor – It is the input receiver that detects input signal coming from remote control.
 Manual Control – It is a push button switch that controls manually operation of the electric fan.
 Timer – It is use to switch on or switch off automatically with predetermine time.
 Comparator – It is a processing circuit that accepts the input signal coming from remote control, manual switch
or timer switch. This circuit provides the triggering voltage to the power controller.
 AC Motor – A rotating electric machine which changes applied electrical energy or power into mechanical
output energy or power.
 AC Plug – It is a connector intended for connecting to the main source 220V.
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC Page |4
APPLIANCES.

TROUBLESHOOTING PROCEDURE
A. MECHANICAL FAULTS
PROBLEM/SYMPTOMS CHECKS TO MADE SYSTEM DEFECTS/FAULTS
A. Check for Bent Shaft Defective rotor
Doesn’t rotate
B. Verify if Shaft is seized Defective rotor and end belts
Starts to rotate by manually A. Check if the Motor is binding up Defective Motor
A. Check if shaft is slightly bent Defective rotor
Defective Rotor Inadequate
Rotation is slow B. Check for an Oil and dirt build up
lubricant with accumulated dirt
C. Verify if oil is sufficient Poor lubrication
A. Check for any Worn bearing Defective yoke or motor metal cover
B. Check for Loose guard mark Loose guard mark screw
C. Check Loose guard fitter Untighten guard mark fitter
D. Check for Improperly balanced blade or Effective fan blade
broken blade
E. Check for Loose spinner Untighten spinner
F. Check if there is too much front to back Worn out shaft washers
Noisy operation play in the motor shaft
Poor lubrication with accumulated
G. Check for an Oil and dirt build up
dirt
H. Check if oil is sufficient Inadequate lubricant
I. Check for any improper mounting of the Misaligned front and rear guards
front and/or rear guard
J. Check if there are Loose screws Untighten screws
K. Check for rotor rubbing against housing Misaligned and dirt buildup in the
insulation or wiring rotro
A. Check for broken, stripped or bent part Defective clutch assembly or knee
in clutch or knee joint system joint system
B. Check for Slippage or wear of worm Defective worm wheel
wheel
C. Check for Disengagement of clutch Untighten clutch cover
cover
D. Check for Disengage oscillating rod set Untighten oscillating rod set screw
screw
No oscillation or unsteady E. Check for Broken oscillating rod pin Defective knee joint upper part
oscillation assembly
F. Check for Disengage and loose gear set Untighten gear set screw
screw
G. Check for Bent oscillating rod Defective oscillating rod
H. Check for Disengaged and loose clutch Defective clutch shaft
ball
I. Check for Bent yoke (frame) shaft Defective yoke shaft
J. Check for Worn rotor shaft worm Defective rotor
Imperfect oscillation (clutch A. Check for Tight operation of oscillation Defective oscillating switch
lever system) switch
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APPLIANCES.

B. Check for Excessively high outer wire Misaligned fitting in the high outlet
position wire position
C. Check for Loosen outer wire set screw Untighten outlet wire set screw
A. Check for worm wheel Defective worm gear
B. Check for Excessive thrust Misaligned thrust
C. Check for Bent yoke (frame) shaft Defective shaft
D. Check for Loosen oscillating rod set pin Untighten set pin and calk pin
E. Check for Loosen oscillating rod screw Untighten rod set screws calk
Unsteady oscillation screws
F. Check for Excessive oscillating rod bore Defective oscillating rod
G. Check for Worm gear shaft metal Defective cover
H. Check for Disengaged gear set screws Untighten gear set screws
I. Check for Excessive gear thrust Misaligned thrust
Unsteady or imperfect A. Check for Clogging of free stop bushing Misaligned bushing
vertical movement

B. ELECTRICAL FAULTS
PROBLEM/SYMPTOMS CHECKS TO MADE SYSTEM DEFECTS/FAULTS
A. Check for Open stator Defective stator
B. Check for Open AC cord or wiring Defective wiring/AC cord
C. Check for Open AC line fuse Defective fuse
D. Check for Open thermal cut-off (inside Defective thermal cut-off
1. Doesn’t rotate the motor)
E. Check for Open speed selector switch Defective switch/electronic system
control
F. Check for Defective system control Defective module(system control)
2. Starts to rotate by A. Check for Shorted capacitor Defective capacitor
manually turning the shaft B. Check for Open start winding Defective stator

POSSIBLE FAULTS AND CORRESPONDING REMEDIES

TROUBLE POSSIBLE FAULTS CORRESPONDING REMEDIES
Bent shaft Replace (Note 1) motor assembly
Open switch Replace switch
Shaft is seized Replace rotor and end bell (Note 1)
Doesn’t Rotate Open stator Replace (Note 2) motor assembly
Open AC cord or wiring Repair or replace
Start winding is open Repair lead wire to winding or replace
Rotation Starts to rotate by
stator
manually turning
Shorted capacitor Replace capacitor
the shaft
Motor is binding up See Note 3
Bent shaft Replace (Note 1) motor assembly
Oil and dirt buildup Clean and lubricate
Rotation is slow
Lack of oil Lubricate
Worn bearing Replace yoke or its cover (Note 4)
Loose guard mark Fasten guard mark screw
Loose guard fitter Tighten
Noise Noisy Improperly balanced or Replace Blade
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APPLIANCES.

broken blade
Loose spinner Tighten
Too much front to back Adjust by adding shaft washers (Note 4)
play in the motor shaft
Oil and dirt buildup Clean and lubricate
Lack of oil Lubricate
Improper mounting of the Re – adjust
front and/or rear guard
Loose screws Tighten
Rotor rubbing against Disassemble, clean and adjust if necessary
housing insulation or wiring
No oscillation or Broken, stripped or bent Visually inspect and repair or replace as
Oscillation Unsteady part in clutch or knee joint necessary
oscillation system

TROUBLE POSSIBLE FAULTS CORRESPONDING REMEDIES

Slippage or wear of worm wheel
Disengagement of clutch cover
Disengaged rod set screw
Broken rod set pin
Automatic
oscillation Disengaged and loose gear set Tighten screw
system Non-oscillation screw
Bent rod
Disengaged and loose clutch ball Replace clutch shaft
Bent yoke (frame) shaft
Poor gear rotation
Worn rotor shaft worm
Imperfect oscillation Tight operation of oscillation
(clutch lever system) switch
Excessively high outer-wire
position
Loosen outer-wire set screw
Worn worm wheel
Excessive thrust
Bent yoke (frame) shaft
Unsteady Loosen rod set pin
oscillation Loosen rod set screw
Excessive rod bore
Worm gear shaft metal
Disengaged gear set screw
Excessive gear thrust
Height Unsteady or Clogging of free stop bushing
adjustment of imperfect vertical
standing fan movement
External Scratch, stain or Scratch
appearance breakage Dirt
Replace worm wheel
Tighten clutch cover
Tighten or calk screw
Replace knee-joint upper part
assembly
Adjust or replace rod
Adjust or replace
Adjust or disassemble and clean
Replace rotor
Replace oscillation switch
Adjust fitting
Tighten screw
Replace
Adjust thrust
Adjust shaft
Tighten and calk pin
Tighten and calk screw
Replace rod
Replace cover
Tighten screw
Adjust thrust with washer
Adjust bushing
Touch up with lacquer
Wipe off with cloth or soap and
water
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC Page |7
APPLIANCES.

COMPONENT REPLACEMENT
1. Determine the description of the values and ratings of the individual defective parts from the
manufacturer’s service manual
2. Identify the sources of replacement components/parts
 Original replacement components from the original factory sources
 Universal replacement components from independent factory sources
 Always consider the physical size of the replacement part
3. Consider the factors in the selection of specific part
 Quality – the ability to provide exact value or specification to replacement part
 Tolerance – the ability to provide exact value or acceptable parameters to replacement parts
 Availability – local access to parts and whether the parts are available
 Price – it refers to the affordability of the replacement parts at a reasonable price
4. Disconnect or remove properly the electrical/mechanical parts of an electric fan
5. Install correctly replacement part/components in existing electric fan

MAINTENANCE OF ELECTRIC FAN

1. Turn off the electric fan and remove the cord from the source of voltage
2. Apply lubricant to mechanical parts of the electric fan that requires lubrication through a drop of oil or
grease to assure smooth operation without grinding or squeaks.
3. Replace the bushings or end bells for squeaks with the use of appropriate tools if squeaks cannot be
corrected by applying lubricants.
4. Apply or spray anti-rust lubricants to all mechanical parts of the electric fan to drive out moisture, protect
corrosion, loosen rusted metal parts and even frees sticky mechanism.
5. Clean and check cooling louvers for any obstructions to avoid cutting off the air flow.
6. Clean or wipe dust and foreign particles at the PC Board and metal parts of the motor.
7. Replace worn or frayed AC cord and electrical wires

SOLVENTS FOR CLEANING

1. Use mild soap and damp cloth or rug when cleaning plastic front panel and cover. They are susceptible to
immediate and long term damage from solvents.
2. Apply denatured alcohol as the safest solvent to use for plastic front panel and cover with heavy stain. It
should be used only as a last resort and applied to areas with heavy stain.

PROCEDURE IN REPAIRING AN ELECTRIC FAN

1. Once the specific electrical/mechanical problem is located:
 Consider the techniques for the proper removal of the defective component or parts
 Anticipate what to do if the replacement part does not correct the problem
 Check the installation of the replacement or original part for any improper mounting in the mechanical
assembly or circuit board
2. Examine carefully the mounting of the replacement of original parts of the system
 Check the placement of the wires or leads of the replacement component
 Consider significant factors used in the original installation such as insulating washer, silicon grease
and locating mark for pin connections
 Observe proper placement of the component leads for electrical parts
3. Perform the techniques for the proper soldering of electrical parts
 Be careful not to damage adjacent components
 Be careful not to lift the copper conductive path from circuit board base material
 Avoid any solder bridges between board path
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APPLIANCES.

 Do not destroy the component being removed in case it is still functional and be careful not to damage
the component being installed
4. Verify all connections and harness
 Be sure that all components pre-positioned in a manner that will avoid the possibility of adjacent
component short circuit conditions
 Be sure to check or inspect all insulators and barriers between sections after working on any
model/brand of electric fan
 Check for frayed or broken insulation on all wiring including the AC line cord
 Be sure to replace fuses, resistors and capacitors with special designation such as flame proof to
components equal to the original value for both safety and liability purposes
5. Once the repair is completed, perform an AC leakage test on all exposed metal parts of an electric fan to
eliminate the possibility of electric shock
 Perform complete retesting of the electric fan to ensure the correctness of the actual repair
 Connect the electric fan into the 60Hz power to allow the time period required to let the new parts
settle in and operate as they are designed to work with each other.
 Recheck or inspect if the repair was done correctly and the unit functions properly to ensure successful
completion of the repair
6. Clean the electric fan before it would be returned to the customer
 Be sure that the blade, front and rear guards of the electric fan are properly cleaned
 Be sure that proper cleaning is given to the control panel or switch box of the electric fan

Know your fan

Parts Of Electric Fan
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC Page |9
APPLIANCES.

FLAT IRON

Flat iron- A domestic appliance used to press clothes.

Maintaining and Repairing a Flat Iron

Parts of Flat Iron

Is used to connect the unit to power

1. AC line cord
source

A type of switch used to select the

amount of heat required in ironing
2. Selector Switch
different types of fabrics. It can be a
rotary or slide type.

A safety protective device used to protect

3. Thermal Fuse the unit from damage when overheating
and short circuit occur.

A form of nichrome wire that assembles

properly inside the flat iron to provide
4. Heating Element
heat.
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC P a g e | 10
APPLIANCES.

A base metal that serves as fabric

5. Soleplate
pressing part made of metal.

The part of a flat iron by which it is,

6. Handle
carried or controlled.

Is used to protect the internal parts of the

7. Body/Case
flat iron.

SPECIFIC INSTRUCTIONS
To avoid a circuit from overload, do not operate another high wattage appliance on the same circuit. If an extension
cord is absolutely necessary, a 10 A cord should be used with a 120V iron or a 16A cord should be used with a
220V iron. Cords rated for less amperage may overheat. Care should be taken to arrange the cord so that it cannot
be pulled or rippled over.

IDENTIFYING THE FUNCTIONS OF THE PARTS OF A FLAT IRON.

PARTS FUNCTION PICTURE

Used to connect the unit to the

1.Ac line cord
power source.

Used to select the amount of heat

2. Selector switch required in ironing different types of
fabrics.
A safety protective device used to
3. Thermal fuse protect the unit from damage when
short circuit occurs.

A form of special wire that

4. Heating element assembles properly inside a flat iron
to provide heat.

5. Soleplate A base metal that serves as fabric

pressing part made of metal.
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC P a g e | 11
APPLIANCES.

The part of a flat iron by which it is

6. Handle held, carried or controlled.

Used to protect the internal parts of

7. Body/Case
a flat iron.

Troubles Possible Causes

1. Electric iron does not heat. Open circuit/terminal connection
Short Circuit
Terminal connections
Heat controller-selector switch
Blown fuse
2. Electric iron gives abnormal Grounded wire
temperature. Loose contacts between terminals
Heating element

MAINTAIN AND REPAIR FLAT IRON

Proper care to a Flat Iron

1. Prevent the iron from falling on heavily padded board.

2. Avoid excessive scratches on iron plate due to direct contact from buttons, hooks, zipper, etc.
3. Cool iron before storing. Do not wrap cord around iron especially when it is still hot.
4. Put iron on a safe place to cool.
5. Always store iron in an upright position, on its heel rest, so that soleplate will not be scratched.
6. Clean brown stains in soleplate by heating the iron to a high temperature and iron it over to salt in wax
paper. A non-scratchy household cleaner may also be used.

To use a flat iron

1. Adjust the temperature selector to a minimum position before plugging cord into electrical outlet.
2. Pre-heat the unit 2 minutes before using.
3. To improve dry ironing results, sprinkle garments evenly at least one hour before ironing.
4. Unplug iron by gripping plug and pulling it from the outlet. Never yank the cord!

To clean polished aluminum soleplate

1. Unplug the iron.

2. Make a paste of mild scouring powder and a little amount of water. Apply a small amount to soleplate using
a damp cloth and rub the soiled area. Wipe thoroughly.
3. Do not use metal scouring pads since they will scratch the soleplate.

Store Iron
When iron has cooled, wrap cord loosely. To protect soleplate, always store iron on heel rest.

Mail/travel iron
 CHAPTER 9 BASIC TEST, TROUBLESHOOT AND REPAIR OF BASIC P a g e | 12
APPLIANCES.

When iron is cool, pack it carefully. The original cartoon box is not suitable for mailing, instead provide a
durable box.

Important:

When using an iron, basic precautions should always be followed including the following:

1. Read the instructions first.

2. Use the iron only for its intended use.
3. To protect against risk of electric shock, do not immerse any part of the iron in water or other liquid.
4. The iron should always be turned to MIN position before plugging or unplugging from the outlet. Never
yank cord to disconnect from the outlet; instead grasp plug and pull it to disconnect.
5. Do not allow the cord to touch hot surfaces. Let iron cool completely.
6. Do not operate iron if it has been dropped or damaged in any manner, as such may cause temperature
setting in occasion or electric shock. Do not assemble the iron; take it to the dealer from whom the product
was purchased for examination or any professional technician. Incorrect assembly can cause electric
shock when the iron is used.
7. Close supervision is necessary for any appliances being used by or near children. Do not leave the iron
unattended when plugged into the outlet or in an ironing board. Always position the iron carefully to prevent
it from falling if ironing board is accidentally knocked or if the cord is pulled. When not in use, always stand
the iron on heel rest.
8. Burn can occur from touching hot metal parts.
9. The use of accessory attachment not recommended or sold by the appliance manufacturer may create a
hazardous situation or damage to your flat.
10. Do not use the iron outdoor.
11. Do not operate in the presence of explosive and/or flammable materials.

Activity:

Repair at least one appliances and give the trouble of the appliance?