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Crackling noise in fan  Rate Topic 
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 Posted: Sat May 16th, 2020 08:51 pm
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Anthony Lindsey
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I got a small brush motor fan and basically runs the same speed at all 3 speeds and it has a constant crackling sound.
Any idea's?

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 Posted: Sat May 16th, 2020 10:06 pm
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Alex Rushing
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Would like to see photos of the offending fan if possible!
Best to check the commutator(round part with copper pads on one end of the rotor). Check for lifted, damaged, or recessed places in the commutator. It may just need resurfacing. That can be done by putting the rotor in a drill and spinning just the commutator in fine sandpaper around it.
If the Commutator is good, then check the rotor end play to make sure the brushes are positioned in the Commutator area.


Sometimes the crackling noise is brush related. 
Usually the brushes are to small, brush holder is worn out/damaged, or brush is the wrong size.

And for the switch, check the choke coil or nichrome wind to see if there is an bypass of wiring. Sometimes if a nichrome winding, or choke, gets toasted; someone will "hotwire" the connections to bypass it.

Last edited on Sat May 16th, 2020 10:08 pm by Alex Rushing

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 Posted: Sun May 17th, 2020 12:41 pm
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Anthony Lindsey
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Here are a couple pictures 





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 Posted: Sun May 17th, 2020 06:50 pm
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Anthony Lindsey
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Here is picture of switch.   Nothing looks out of sorts but there is a burn mark on porcelain on one of the brass terminals.   Fan stopped working. 







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 Posted: Sun May 17th, 2020 08:02 pm
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Alex Rushing
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I bet the nichrome wire is shot. Common problem with fans using Nichrome.The burnt place is where the old wire arced the plate screw. It is possible the switch wingings got fused when it happened, removing speed changes.

But, the fan runs. Go over the checklist and make sure the Commutator and brushes are in order. That needs to be done regardless of the switch issue. That will more than likely fix your crackling issue!

Once the motor is in order, I'll post about a trick using a diode some members recommended on the AFCA. I used it to make a low speed on the resto project WE 7700.

This is what a strong and worked on Commutator motor should sound like. With brushes, you're always going to have some Commutator noise, because of the surface contact with the brushes and commutator. The noise should be smooth and strong though. :)


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 Posted: Sun May 17th, 2020 08:17 pm
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Anthony Lindsey
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Hi Alex,
Thanks!!.    I was fiddling with it and I have updates.

It stopped working all together for a bit so I removed the switch and cleaned everything I could remove and clean and replaced the connector that had an arc.  I put it back together and when I turned it on the blade moved for a second then nothing.   I unscrewed and removed the spring and I the thing on the end of the spring.  Is that a brush?  Re positioned it and put it back in.   Fan started working some.  Did the other side and it stopped working.   Took it out and put it in a couple times and now I have it working on 3 different speeds and it has gotten faster but nothing like the one in your video.

Also,   the crackling is gone.

But it is a looooonnnnggg  way from the one in the video.

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 Posted: Sun May 17th, 2020 09:29 pm
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Alex Rushing
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Excellent news! Means you've got good Nichrome and motor! Might not have to buy new brushes.
You can get the little carbon thing on the springs and measure the width. If it looks fairly long(length), you can use them, but it would be advisable to use DeOxit in the brush holders to make the contact better. And note which brush comes from each side, AND the orientation(mark which side is up and right/left). Try and keep them the same position going back in, now it works. The DeOxit might clear up and connection issues and help clean the Commutator a bit without taking the motor apart.

Congrats on a gorgeous fan that will work well!

Last edited on Sun May 17th, 2020 09:30 pm by Alex Rushing

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 Posted: Sun May 17th, 2020 09:33 pm
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Alex Rushing
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That little fan in the video is a speed monster. I am not familiar with your fan, so I am not sure of the speed it is capable of.

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 Posted: Sun May 17th, 2020 09:34 pm
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Anthony Lindsey
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The fan is a Menominee 8" oscillating fan.    No tag though.

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 Posted: Sun May 17th, 2020 09:42 pm
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Alex Rushing
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Awesome little Menominee! :)Nice early small-commutator Oscillator fan!

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 Posted: Sun May 17th, 2020 09:44 pm
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Anthony Lindsey
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Thanks,    I need a tag for it.

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 Posted: Sun May 17th, 2020 09:54 pm
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Anthony Lindsey
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Here is a picture with the cage.


NNot sure why pictures are sideways .

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 Posted: Sun May 17th, 2020 10:58 pm
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Alex Rushing
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Staghorn(cage brackets) is the nickname for these I believe. Quite collectible from what I've read!
I would contact Donald Coleman about having a tag made. His work is outstanding.

Last edited on Sun May 17th, 2020 10:59 pm by Alex Rushing

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 Posted: Mon May 18th, 2020 01:00 am
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Anthony Lindsey
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Thanks

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 Posted: Mon May 18th, 2020 01:10 am
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Alex Rushing
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Anytime, Anthony! 
Here is one Donald made from scratch!
Made with relief in the brass.


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 Posted: Mon May 18th, 2020 02:10 am
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Anthony Lindsey
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very nice

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 Posted: Mon May 18th, 2020 10:05 pm
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Richard Daugird
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I have some extra brushes if you want them, not sure what size you need.

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 Posted: Mon May 18th, 2020 10:06 pm
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Richard Daugird
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 Posted: Wed May 20th, 2020 01:16 am
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Anthony Lindsey
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I will pull them out and look at them.   I did earlier and I believe they have a rectangular shape but Let me check that again.
Thanks

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