PULL CHAIN SPEED CONTROL
REVERSE SWITCH
XTR MOTOR
The Casablanca 4-Speed series of fans
feature a 4-speed, pull chain fan control and a
forward/reverse slide switch.
PRINTED CIRCUIT BOARD
LIGHT KIT PULL CHAIN
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 1
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 2
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
PULL #2MEDIUM SPEED
PULL #3MEDIUM LOW SEED
PULL #4 LOW SEED
PULL #5OFF (120V AC)
BROWN
YELLOW, BLUE & PURPLE
BLUE & PURPLE
PURPLE
BLACK
A
B
C
C
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 3
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 4
QUICK STEPS
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.
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
2-4
left
left
open
0 ohms
2-3
2-4
right
right
0 ohms
open
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 5
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.
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.
PROBES
SLIDE
READINGS
1-3
2-4
pull
pull
open
0 ohms
2-3
2-4
pull
pull
0 ohms
open
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 6
XTR 200 MOTOR WIRING DIAGRAM
Description:
The XTR - 200 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.
Motor Information - (CONTINUED) Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 7
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 8
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 7801730 is used as shown in (Figure #2). All other 4 Speed fans use PC Board with part number 7801710
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 XTR200 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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 16
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 #6)
(Figure #5)
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 17
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 18
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
#2
ON
OFF
NOTE: This light switch is optional and
not required for fan operation.
LIGHT KIT PULL CHAIN SWITCH ASSEMBLY ELECTRONIC TESTING
Ohm. meter readings:
P/N #1037080
PROBES:
PULL #:
READINGS:
A+B
A+B
#1
#2
open
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.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 19
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
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 20
WIRING DIAGRAM 4-SPEED FANS
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 21
WIRING DIAGRAM 4-SPEED FANS
UL DAMP LOCATION
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 22
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.
1.A Faulty reverse switch.
1.B Faulty capacitor.
1.C Open motor winding.
wall speed control.
1.A Replace reverse switch assy
1.B Replace PCB assembly.
1.C Replace motor unit.
2.0 Fan will not operate at proper
speeds or will not operate at any
speed.
2.A Faulty four-speed pullchain
switch assembly.
2.B Faulty capacitor.
2.A Replace four-speed pull-chain
switch assembly.
2.B Replace PCB assembly.
3.0 Fan is noisy during operation.
3.A Loose glass or bulbs on light kit.
3.B Loose canopy.
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.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
3.F Adjust case position & tighten
screw.
3.G Replace with capacitor wall
speed control.
Casablanca Fan Co. - Factory Service Department - Technical Library
VII 7.4s . 23