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 Posted: Sun Feb 12th, 2017 06:02 pm
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Ryan Blazei
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I was rewiring my Emerson 166666 stator and found that the wires have frayed in an extremely detrimental and angering place. 

I was about to heat shrink it when I noticed it moved with little effort. This is when I noticed what turned out to be wires. I checked with a multimeter to see what was frayed, and it was the wire coming from the stator. The wires already frayed close to comfort, but they frayed again right at the stump. Has anyone got any advice for this situation, because I'm not willing to continue this and risk damaging it. This is really a terrible situation ive stumbled into... 


:cry:

Last edited on Sun Feb 12th, 2017 06:15 pm by Ryan Blazei

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 Posted: Sun Feb 12th, 2017 08:33 pm
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Steve Sherwood
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This is what I would do, get a razor knife and cut off the insulation on the piece hanging off. See what you have left. You should only need a 1/4" or 1/8" to solder a new wire on. It looks like there might be enough sticking up from the motor lead to make a connection. Be careful those wires are fragile. If you can't get shrink tubing on the exposed wire, use some liquid tape. Also cut the insulation off that piece sticking out of the motor.Then you will know what you have.

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 Posted: Mon Feb 13th, 2017 05:43 am
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Cory Baughn
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Honestly if possible I would push the stranded wire thru the stator and attach all new stranded cloth covered wire to the single magnet wire in the windings themselves. Start all new, no old wire.

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 Posted: Mon Feb 13th, 2017 07:06 am
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Charlie Forster
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Get a spray or brush on can of insulation and  re-coat all the wires you see.
keep it out of the area where the rotor goes

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 Posted: Mon Feb 13th, 2017 10:23 am
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Lane Shirey
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If you gently heat those old wires with a heat gun, they'll soften enough to move them more easily. 

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 Posted: Tue Feb 14th, 2017 03:08 am
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Chris Benbow
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I'm with Corey.You need to go back to the leads at the end of the coil if at all possible. You want to find the wire coming out of the coil and attach a new headwire to that.
If possible.

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 Posted: Thu Feb 16th, 2017 01:02 am
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Jeff Jones
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I usually try to do the same as Cory when replacing head wires.  Take it all the way to the magnet wire. Its a more difficult job, but if its going to be a fan I plan to use even somewhat regularly I want all new wire.  
Some of the old DC ones I have that I only run here and there for a few minutes once and awhile I will attach to the existing wire but any of the ones I plan to use get all new.

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 Posted: Fri Feb 17th, 2017 08:36 pm
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Ryan Blazei
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It appears as if it goes strait into the coil next to it, but I can't tell for sure. There are other wires running around it making the identification difficult. This will be ran often, so I want to go with the best repair. 

If anyone has experience with the wiring of this particular fan, it would be greatly appreciated. Another option is to send it off to someone local or ship it who has the experience I do not.


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 Posted: Sat Feb 18th, 2017 01:32 am
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Charlie Forster
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See if there is a club member close to you that could help you out
Russ Huber is in Wisconsin and may be able to help or  put you in contact with someone that can send Russ a private message

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 Posted: Sat Feb 18th, 2017 02:39 am
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Chris Benbow
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Hard to tell from the pic but, if your confident that the lead is coming directly from the coil then use it!

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 Posted: Sat Feb 18th, 2017 03:19 am
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Russ Huber
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Dear fellow Cheese head, 


PM me if your stuck and need help. I don't bite.  I just figure it out as I go.  A little trial and error and ....shazzam. :D 

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 Posted: Sun Feb 19th, 2017 01:17 am
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David Hoatson
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Once the wires are ready to solder, clean the copper with fine sandpaper or lightly scrape it with a knife so it's shiny, then solder it to the new headwire. I insulate connections with friction tape like it originally was done. It conforms to odd shaped spaces without stressing the fine wire like heatshrink can. You can also add tape around the headwire inside the motor cover, where the wire comes out, as a strain relief. 

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 Posted: Sun Feb 19th, 2017 05:26 am
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Charlie Forster
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We some times take a small piece of brass and solder the coil wire on one end and the head wire on the other and helps strengthen the coil wire , a old relay contact strip works good  for that .

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 Posted: Sun Feb 19th, 2017 01:00 pm
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Tom Newcity
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Ryan,
Was this motor running before disassembly?

Have you ever replaced an Emerson head wire?


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 Posted: Sun Feb 19th, 2017 01:23 pm
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Ryan Blazei
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Hello Tom, Yes the motor was running and no I have not replaced an Emerson head wire. 
The problem I'm facing is trying to find where the coil meets the frayed wires, it's all wrapped up nice and tight from the Emerson factory. 

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 Posted: Sun Feb 19th, 2017 01:40 pm
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Tom Newcity
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Ryan,



There will be 3 wires coming from the stator, which will be hook-up wires (aka pig tails).  These wires are for connecting the head wire to the stator windings.  The factory soldered the 3 head wires to the 3 pig tails, wrapped them with friction tape and stuffed them all back in the housing.  If the connections are still factory, you will see a big clump of tape wrapped wire on all three, and that will be the solder connection.  That is where I separate the old head wire from the stator. 




This image is an Emerson 6-pole that I am installing a head wire on this morning.




If you feel that this process may be a bit too much for you, send it to me and I'll take care of it, no charge.  You'll only be out the postage costs.  And you'll have an example of how it should be done.

























Attached Image (viewed 215 times):

emerson stator hook up wires.jpg

Last edited on Sun Feb 19th, 2017 01:44 pm by Tom Newcity

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 Posted: Sun Feb 19th, 2017 02:01 pm
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David Hoatson
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A great gesture from the Emerson master. It would be nice to see a sequence of photos. 

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 Posted: Sun Feb 19th, 2017 02:20 pm
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Russ Huber
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Ryan,


I am sorry if my post freaked you out, if it did. I am screwball. :D  The good news is Tom Newcity chose the Emerson fan motor line to apply his fan restoration skills as a wise choice.  Emerson designed their fan motors not only for durability and longevity, they designed them to be repaired without great difficulty.

I found some time ago that an original head wire that appears to be in good condition can fool you. If you intend to use this fan on a regular basis it would be wise you replace it.  In past when I was restoring an Emerson fan, I decided to give the aged intact head cord a tug and twist with both hands. It ripped nearly in half, I kid you not. 


FWIW....your fan would take a 18" length of new 3 wire cloth sheathed, or 3 strands of braided 3 cloth covered wire head cord. I used OTR 3 wire cloth sheathed as it is more supple.


The Newcity is smooth as they come. He will get you straight.  I see your in Green Bay, I wish you were closer. Good luck! :clap:

Last edited on Sun Feb 19th, 2017 02:33 pm by Russ Huber

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 Posted: Sun Feb 19th, 2017 11:40 pm
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Tom Newcity
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David Hoatson wrote: A great gesture from the Emerson master. It would be nice to see a sequence of photos. 
David,

This is a quick sequence of the stator that I worked on today.

Image 1 is the stator and head wire leads being stagger trimmed in the correct position to exit the back of the motor and still clear the nearby stud.

Attached Image (viewed 169 times):

emerson stator head wire trimming wires.jpg

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 Posted: Sun Feb 19th, 2017 11:42 pm
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Tom Newcity
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Image #2 is a head wire lead being wrapped to a tinned stator lead.  They are wrapped and soldered one at a time. 

Attached Image (viewed 169 times):

emerson stator head wire connecting.jpg

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 Posted: Sun Feb 19th, 2017 11:44 pm
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Tom Newcity
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Image #3 is showing all three connections made.  Next step is to slip the heat shrink in place and heat.

Attached Image (viewed 166 times):

emerson stator head wire soldering.jpg

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 Posted: Sun Feb 19th, 2017 11:47 pm
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Tom Newcity
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Image #4 is the head wires and the stator wires secured together and out of the way of causing a clearance problem.  Lacing cord has been wrapped to keep it from slipping through the grommet. 

Attached Image (viewed 165 times):

emerson stator head wire finishing.jpg

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 Posted: Mon Feb 20th, 2017 01:13 am
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David Hoatson
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Thanks. Is that a rewound stator?  Looks great. 

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 Posted: Mon Feb 20th, 2017 03:04 am
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Chris Benbow
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Looks like this Newcity guy knows what he's doing!
Beautiful work that we can all aspire to...
Pre tinned wires, stagger trimmed, good strain relief, period correct cord.

Last edited on Mon Feb 20th, 2017 03:05 am by Chris Benbow

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 Posted: Mon Feb 20th, 2017 06:28 am
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Charlie Forster
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Tom
 See if you can get the forum guys to put this info in the Restoration and Repair  section so it can be easily in the future .
 Charlie

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 Posted: Wed Feb 22nd, 2017 12:56 pm
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Lucas Beshara
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Tom I am new to this but you inspired me to start over on this 29645!  Not quite there with the string wrap but I am trying...

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