Mastering the Wind Comprehensive Rewinding Data for Old Model Fans 🛠️💨
Detailed specifications for table and wall fan motor repair,essential coil turns, wire gauges, and winding sequences for vintage models .
Fan Models and Key Data Points:
* AMERICAN (UNIVERSAL) OLD - Table Fan (4-Slot):
* Total Slot: 4
* Stamping length: 38mm
* Pitch: 1:2
* Running Coil: 4 coils, 480 turns, RWG: 30
* Starting Coil: Inbuilt fix starting copper plate
* Running Coil Sequence: 1:2, 2:3, 3:4, 4:1
* Winding Direction: Clock-wise
* ORIENT (ALL PURPOSE) OLD - Table Fan (4-Slot):
* Total Slot: 4
* Stamping length: 33mm
* Pitch: 1:2
* Running Coil: 4 coils, 520 turns, RWG: 31
* Starting Coil: Inbuilt fix starting copper plate
* Running Coil Sequence: 1:2, 2:3, 3:4, 4:1
* Winding Direction: Clock-wise
* KHAITAN (OLD) - Table Fan (4-Slot):
* Total Slot: 4
* Stamping length: 25mm
* Pitch: 1:2
* Running Coil: 4 coils, 640 turns, RWG: 32
* Starting Coil: Inbuilt fix starting copper plate
* Running Coil Sequence: 1:2, 2:3, 3:4, 4:1
* Winding Direction: Clock-wise
* CINNI (OLD) - Table Fan (4-Slot):
* Total Slot: 4
* Stamping length: 26mm
* Pitch: 1:2
* Running Coil: 4 coils, 450 turns, RWG: 28
* Starting Coil: Inbuilt fix starting copper plate
* Running Coil Sequence: 1:2, 2:3, 3:4, 4:1
* Winding Direction: Clock-wise
* RALLI (OLD) - Table Fan (8-Slot - 1:3 Pitch):
* Total Slot: 8
* Stamping length: 33mm
* Pitch: 1:3
* Running Coil: 4 coils, 605 turns, RWG: 35
* Starting Coil: 4 coils, 605 turns, SWG: 35
* Running Coil Sequence: 1:3:5:7:1
* Starting Coil Sequence: 2:4:6:8:2
* Winding Direction: Clock-wise
* ORIENT (OLD) - Table Fan (8-Slot - 1:3 Pitch):
* Total Slot: 8
* Stamping length: 23mm
* Pitch: 1:3
* Running Coil: 4 coils, 650 turns, RWG: 36
* Starting Coil: 4 coils, 600 turns, SWG: 36
* Running Coil Sequence: 1:3:5:7:1
* Starting Coil Sequence: 2:4:6:8:2
* Winding Direction: Clock-wise
* NIMMI (OLD) - Table Fan (8-Slot - 1:4 Pitch):
* Total Slot: 8
* Stamping length: 27mm
* Pitch: 1:4
* Running Coil: 4 coils, 800 turns, RWG: 35
* Starting Coil: 4 coils, 800 turns, SWG: 35
* Running Coil Sequence: 1:4:7:2:5
* Starting Coil Sequence: 1:6:3:8:5
* Winding Direction: Clock-wise
* BAJAJ (OLD) - Wall Fan (8-Slot - 1:4 Pitch):
* Total Slot: 8
* Stamping length: 22mm
* Pitch: 1:4
* Running Coil: 4 coils, 775 turns, RWG: 36
* Starting Coil: 4 coils, 685 turns, SWG: 36
* Running Coil Sequence: 1:4:7:2:5
* Starting Coil Sequence: 1:6:3:8:5
* Winding Direction: Clock-wise
* CROMPTON (OLD) - Table Fan (8-Slot - 1:4 Pitch):
* Total Slot: 8
* Stamping length: 23mm
* Pitch: 1:4
* Running Coil: 4 coils, 736 turns, RWG: 36
* Starting Coil: 4 coils, 706 turns, SWG: 36
* Running Coil Sequence: 1:4:7:2:5
* Starting Coil Sequence: 1:6:3:8:5
* Winding Direction: Clock-wise
* INOVA (OLD) - Table Fan (8-Slot - 1:4 Pitch):
* Total Slot: 8
* Stamping length: 25mm
* Pitch: 1:4
* Running Coil: 4 coils, 600 turns, RWG: 35
* Starting Coil: 4 coils, 600 turns, SWG: 35
* Running Coil Sequence: 1:4:7:2:5
* Starting Coil Sequence: 1:6:3:8:5
* Winding Direction: Clock-wise
* EMCO (OLD) - Table Fan (8-Slot - 1:2 Pitch):
* Total Slot: 8
* Stamping length: 35mm
* Pitch: 1:2
* Running Coil: 4 coils, 850 turns, RWG: 35
* Starting Coil: 4 coils, 850 turns, SWG: 35
* Running Coil Sequence: 1:2, 3:4, 5:6, 7:8
* Starting Coil Sequence: 2:3, 4:5, 6:7, 8:1
* Winding Direction: Clock-wise
* USHA DIPLOMAT (OLD) - Table Fan (8-Slot - 1:2 Pitch):
* Total Slot: 8
* Stamping length: 25mm
* Pitch: 1:2
* Running Coil: 4 coils, 1000 turns, RWG: 36
* Starting Coil: 4 coils, 1000 turns, SWG: 36
* Running Coil Sequence: 1:2, 3:4, 5:6, 7:8
* Starting Coil Sequence: 2:3, 4:5, 6:7, 8:1
* Winding Direction: Clock-wise
* CINNI (OLD) - Table Fan (8-Slot - 1:2 Pitch):
* Total Slot: 8
* Stamping length: 18mm
* Pitch: 1:2
* Running Coil: 4 coils, 980 turns, RWG: 36
* Starting Coil: 4 coils, 980 turns, SWG: 36
* Running Coil Sequence: 1:2, 3:4, 5:6, 7:8
* Starting Coil Sequence: 2:3, 4:5, 6:7, 8:1
* Winding Direction: Clock-wise
* RALLI (OLD) - Table Fan (8-Slot - 1:2 Pitch):
* Total Slot: 8
* Stamping length: 26mm
* Pitch: 1:2
* Running Coil: 4 coils, 1000 turns, RWG: 36
* Starting Coil: 4 coils, 1000 turns, SWG: 36
* Running Coil Sequence: 1:2, 3:4, 5:6, 7:8
* Starting Coil Sequence: 2:3, 4:5, 6:7, 8:1
* Winding Direction: Clock-wise
* USHA (OLD) - Table Fan (8-Slot - 1:2 Pitch):
* Total Slot: 8
* Stamping length: 18mm
* Pitch: 1:2
* Running Coil: 4 coils, 1100 turns, RWG: 37
* Starting Coil: 4 coils, 1100 turns, SWG: 37
* Running Coil Sequence: 1:2, 3:4, 5:6, 7:8
* Starting Coil Sequence: 2:3, 4:5, 6:7, 8:1
* Winding Direction: Clock-wise
* COMMERCIAL (TYPE: AIR COOLER, H.D FAN) - Table Fan (24-Slot):
* Total Slot: 24
* Stamping length: 53mm
* Pitch: 1:5
* Running Coil: 12 coils, 197 turns, RWG: 30
* Starting Coil: 12 coils, 197 turns, SWG: 30
* Running Coil Sequence: 1:5,3:7,5:9,7:11,9:13,11:15,13:17,15:19,17:21,19:23,21:1,23:3
* Starting Coil Sequence: 2:6,4:8,6:10,8:12,10:14,12:16,14:18,16:20,18:22,20:24,22:2,24:4
* Winding Direction: Clock-wise
Always count the original turns and measure the Standard Wire Gauge (SWG) of the wire removed from the motor first. The data provided here are for reference but verifying the original specification is crucial for a perfect rewind.
🌀 Decoding Vintage Fan Specifications: A Practical Introduction
The repair and restoration of old model table and wall fans is a rewarding skill. These vintage motors often boast robust construction, but over time, their coil windings can fail due to heat, moisture, or prolonged use. Successfully rewinding a motor requires precise data regarding the number of slots, stamping length, pitch, wire gauge, and coil turns.
The data compiled here covers numerous classic fans, including models from American (Universal), Orient, Khaitan, and Cinni, along with specialized models like the heavy-duty commercial fan. While the fan type is predominantly TABLE FAN, one notable exception is the BAJAJ (OLD) model, which is listed as a WALL FAN. All listed models share a common CLOCK-WISE direction of winding.
✨ Spotlight on 4-Slot Motors: Simplicity in Design
The 4-slot motor design represents one of the simpler fan motor constructions. In these models, the winding process is often streamlined. The running coil specifications across four brands AMERICAN (UNIVERSAL), ORIENT (ALL PURPOSE), KHAITAN, and CINNI all feature a PITCH of 1:2 and a running coil sequence of 1:2, 2:3, 3:4, 4:1.
A key characteristic of these 4-slot motors is the absence of discrete, listed starting coil data for turns and SWG; instead, the starting mechanism is listed as an INBUILT FIX STARTING COPPER PLATE. The running coils are consistently 4 in number.
Comparison of 4-Slot Running Coils:
- ➡️ AMERICAN (UNIVERSAL): Stamping length 38mm; 480 turns; RWG: 30.
- ➡️ ORIENT (ALL PURPOSE): Stamping length 33mm; 520 turns; RWG: 31.
- ➡️ KHAITAN: Stamping length 25mm; 640 turns; RWG: 32.
- ➡️ CINNI: Stamping length 26mm; 450 turns; RWG: 28.
The variation in coil turns and wire gauge (RWG) is directly influenced by the stamping length (stack height) of the motor. A shorter stamping length, like the 25mm of the KHAITAN fan, generally necessitates more turns (640) and a finer wire gauge (32 RWG) to achieve the required electromagnetic field. In contrast, the AMERICAN (UNIVERSAL) fan's 38mm length uses only 480 turns with a coarser 30 RWG wire.
The PITCH is the number of slots spanned by a coil, while the COIL SEQUENCE defines the path of the winding across the slots. For an 8-slot, 1:3 pitch motor, the running coil sequence might be 1:3:5:7:1, which ensures the coils are connected in series-parallel for proper motor operation.
🔍 Complex 8-Slot Fan Pitches: 1:3 versus 1:4
Moving into more complex designs, the 8-slot motors introduce specific and separate data for both running and starting coils. This design typically utilizes a capacitor start, capacitor run configuration, distinguishing it from the simpler 4-slot types. The 8-slot fans are categorized by their winding pitch: 1:3 or 1:4.
### The 1:3 Pitch Group (Ralli and Orient) 🍀
The RALLI (OLD) and ORIENT (OLD) 8-slot table fans use a 1:3 pitch. Their coil sequences are distinct from the 1:4 pitch models: the running coils follow the pattern 1:3:5:7:1, and the starting coils follow 2:4:6:8:2. Interestingly, the RALLI fan specifies 605 turns and 35 SWG for both running and starting coils. The ORIENT fan has a slight difference: 650 turns for running (RWG 36) and 600 turns for starting (SWG 36).
### The 1:4 Pitch Group (Nimmi, Bajaj, Crompton, Inova) ⚡
A more intricate winding pattern is seen in the 1:4 pitch models like NIMMI, BAJAJ (Wall Fan), CROMPTON, and INOVA. All these share the winding pitch of 1:4. The coil sequences also follow a different pattern compared to the 1:3 pitch: the running sequence is 1:4:7:2:5, and the starting sequence is 1:6:3:8:5.
The winding data for these 1:4 pitch fans demonstrates variation based on their specific function and motor size. For instance, the BAJAJ Wall Fan, with its small 22mm stamping length, specifies 775 running turns and 685 starting turns, both with 36 gauge wire. Conversely, the NIMMI table fan, with a 27mm stamping length, requires a much higher 800 turns for both running and starting coils, using 35 gauge wire.
🏆 The 8-Slot, 1:2 Pitch Club: High Turn Counts
The most numerous set of 8-slot fan data is for those utilizing a 1:2 pitch, featuring brands like EMCO, USHA DIPLOMAT, CINNI, RALLI, and USHA (OLD). These fans share a distinctive coil sequence: Running is 1:2, 3:4, 5:6, 7:8 and Starting is 2:3, 4:5, 6:7, 8:1.
A common thread among these fans is the exceptionally high number of turns required for both the running and starting coils. The EMCO model, for example, specifies 850 turns for both running (RWG 35) and starting (SWG 35) coils. USHA DIPLOMAT and RALLI both require an impressive 1000 turns for both sets of coils, using 36 gauge wire. The USHA (OLD) fan takes this further, demanding 1100 turns for both coils with a finer 37 gauge wire, despite having a short 18mm stamping length. The very short CINNI fan (18mm stamping length) is similar, calling for 980 turns with 36 gauge wire.
High turn counts, such as the 1100 turns found in the USHA (OLD) fan, necessitate careful and precise winding to ensure the coils fit correctly within the small slot area, especially with the use of a finer 37 SWG wire.
The table bellow highlights this high-turn requirement:
| Brand | Stamping Length (mm) | Running Turns/RWG | Starting Turns/SWG |
|---|---|---|---|
| EMCO | 35 | 850 / 35 | 850 / 35 |
| USHA DIPLOMAT | 25 | 1000 / 36 | 1000 / 36 |
| USHA (OLD) | 18 | 1100 / 37 | 1100 / 37 |
🔥 Advanced Rewinding: The 24-Slot Commercial Fan
The COMMERCIAL fan, which is also identified as an AIR COOLER, H.D FAN type, stands apart from the table and wall fans due to its massive 24 total slot design. This motor has a significant 53mm stamping length and employs a 1:5 pitch.
The number of coils is also greatly increased, with 12 coils for the running set and 12 coils for the starting set. Surprisingly, the number of turns is relatively low compared to the 8-slot models: only 197 turns for both running and starting coils, both using a 30 gauge wire (RWG 30 / SWG 30). This lower turn count per coil is a function of the much higher number of coils in the overall winding. This fan's coil sequences are the most extensive:
- 🛑 Running Coil Sequence: 1:5, 3:7, 5:9, 7:11, 9:13, 11:15, 13:17, 15:19, 17:21, 19:23, 21:1, 23:3.
- 🛑 Starting Coil Sequence: 2:6, 4:8, 6:10, 8:12, 10:14, 12:16, 14:18, 16:20, 18:22, 20:24, 22:2, 24:4.
The complexity here lies not in the high number of turns, but in maintaining the correct sequence and phasing of the 24 individual coils during winding and connection. This requires meticulous attention to the start (S) and end (E) points of each coil as they are connected to the main A.C. source and the condenser.
✅ Essential Principles & General Rewinding Techniques
When working with these old model fans, a few universal principals can prevent error. The first is to always wind in the specified CLOCK-WISE direction. Second, note that with the 8-slot motors, the running coils (labeled R) and starting coils (labeled S) are often depicted as physically overlapping in the stator diagrams, but they occupy separate regions within the slots. Third, the gauge of the wire is represented by RWG for running coils and SWG for starting coils. These gauges are crucial for maintaining the correct resistance and thermal profile of the motor.
It is important to notice the different coil structure and connection diagrams provided for the 4-slot models (e.g., American, Orient) compared to the 8-slot models (e.g., Ralli, Usha). The 4-slot model connections typically involve linking the end of one coil to the start of the next in a series-style progression before connecting to the A.C. source. In contrast, the 8-slot models show a clear separation of the running and starting circuits, with the starting circuit incorporating a CONDENSER (capacitor) to provide the necessary phase shift for starting torque.
When rewinding the motor, make sure to follow the corect pattern of the coils. The number of turns is important, but a slight difference in the wire size can also effect the moter's performance. Finer wire has higher resistance, which could lead to overheating or reduced speed if the turn count is not adjusted corectly. Always aim for a snug fit when placing the new coils into the statter slots, but avoid damaging the enamel coating on the wire, as this could cause a short circuit. Getting the guage and the turns rite is the key to a good rewind job. This type of motor repare can save a very good fan from the scrap pile. Remember, the stamping length, or motor stack height, is a direct factor in determining the overall number of turns, as it affects the magnetic flux density.
📊 Winding Specifications Quick Reference
To quickly reference the most critical data points for four representative models, see the simplified list below. This comparison highlights how brand and physical dimensions dictate the winding requirements:
- KHAITAN (OLD) Table Fan: 4 Slots, 25mm length, 640 Running Turns, RWG 32.
- ORIENT (OLD) Table Fan: 8 Slots, 23mm length, 650 Running Turns, RWG 36; 600 Starting Turns, SWG 36.
- USHA DIPLOMAT (OLD) Table Fan: 8 Slots, 25mm length, 1000 Running Turns, RWG 36; 1000 Starting Turns, SWG 36.
- CINNI (OLD) Table Fan: 4 Slots, 26mm length, 450 Running Turns, RWG 28.
💡 Final Connection Considerations
Regardless of the motor's slot count, the final connection phase is critical. In the 8-slot models, the Running Coils leads (R1, R2) and Starting Coils leads (S1, S2) must be correctly identified. The starting circuit involves the condenser, which is wired in series with the starting coil set and in parallel with the running coil set, and the combined circuit is then connected to the A.C. power.
For the 4-slot models where the starting system is an inbuilt fix starting copper plate, the connection simplifies, directly wiring the coil ends to the A.C. source. Ensuring all connections are well-insulated and securely soldered will guarantee the longevity and safety of the newly rewound motor.
This technical data should serve as a foundational guide for anyone undertaking the restoration of these robust, vintage electric fans. Proper data is the difference between a successful rewind and a failed motor.
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