This essential compilation of original ceiling fan winding data empowers technicians and enthusiasts. Discover the secrets behind various brands’ specifications for perfect rewinding

The Definitive Guide to Ceiling Fan Winding Data
This essential compilation of original ceiling fan winding data empowers technicians and enthusiasts. Discover the secrets behind various brands’ specifications for perfect rewinding.

🌀 Decoding the Fan Winding Data Matrix 🌀

The core of any ceiling fan's operation lies in its motor winding specifications. These details are crucial for successful motor repair and maintenance. The provided data, originally compiled by Suresh Mech Tech, offers a valuable blueprint for fan technicians, detailing the exact characteristics for dozens of fan models, particularly older or classic units from brands like Orient, GEC, Usha, and Crompton.

The table is structured to offer clear comparisons across several key parameters. The Brand and Stamping size (measured in millimeters, mm) provide the physical context for the stator. The Stamping dimension, for example, varies widely, from a small 13mm on some Shetal and Khetan models to a much larger 45mm on an old Usha unit. This physical size directly correlates with the amount of wire that can be packed into the slots.

All models listed share a Pitch of 1:2, a common standard indicating the winding skips one slot. The Total Coil count and the split between Starting Coil (No of coil) and Running Coil (No of coil) are also fundamental, defining the electrical layout of the motor. Most fans follow a symmetrical split, such as 8 Starting and 8 Running coils for a 16-coil fan (e.g., Crown), or 18 Starting and 18 Running coils for a 36-coil fan (e.g., Khetan). However, a few brands, such as Crompton and Bajaj, show a unique asymmetrical coil distribution, utilizing 9 Starting coils and 18 Running coils in their 27-coil stators.

📌 Hint Box: Stamping Depth 📌

The Stamping dimension is the depth of the stator core. A deeper stamping generally allows for more wire turns (or thicker gauge wire) for the same coil count, influencing the fan's torque and speed.

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⚡ Wire Gauge: The Heart of Efficiency (SWG and RWG) ⚡

The Standard Wire Gauge (SWG) is arguably the most crucial detail for performance and power consumption. The gauge number is inversely proportional to the wire's diameter: a higher number means a thinner wire. The SWG is specified separately for the Starting coil (SWG) and the Running coil (RWG).

A thinner wire (higher SWG/RWG) has greater electrical resistance. This higher resistance is typically compensated for by increasing the number of turns. For example, older, smaller motors (like the Orient 16mm stamping with 12 coils) may use 35 SWG wire for both coils, requiring around 575 to 600 turns. Conversely, larger motors or those designed for higher power might use a thicker wire, such as 32 SWG for an old Orient 18-coil motor. The Running coil usually handles the continuous load, and its gauge is balanced with the number of turns to achieve the desired speed and operating temperature.

Observe the common pairing of 35 SWG for Starting coils and 35 SWG for Running coils across many brands like Ashoka, Cool Home, and many Usha and Crompton models. This indicates a standard efficiency/cost balance for many typical ceiling fan designs. Some models, however, intentionally mix gauges, like the Khetan fan (35 SWG Starting, 37 RWG Running) or the Ralli model (34 SWG Starting, 35 RWG Running), to fine tune the motor's starting torque versus its running characteristics. This variation is key to understanding the specific engineering philosophy of each manufacturer.

⚙️ The Relationship Between Turns, Torque, and Speed ⚙️

The No of Turns is the most direct factor affecting the magnetic field strength of each coil. More turns mean a stronger magnetic field for the same current, leading to greater torque. The data shows a wide range in turns, from low values in the 200s for large 40-coil Orient and Cinni fans, up to very high counts exceeding 700 for smaller 16-coil GEC and Orient models.

Fans with a lower total number of coils (e.g., 12 or 16) generally require a significantly higher number of turns per coil to generate the necessary magnetic flux. For example, the 16-coil Orient (29mm) uses 730 Starting Turns and 600 Running Turns. In contrast, a 40-coil Orient (20mm) uses only 275 Starting Turns and 330 Running Turns. The total wire length, and thus the resistance, is distributed across more coils in the latter case.

Technicians must match the turn count precisely during a rewind. A slight deviation can alter the motor's impedance, causing it to run hot, draw excessive current, or fail to achieve its rated speed. The running coil generally has fewer turns than the starting coil in many models (e.g., Orient, GEC, Usha old), but a notable number of models, like the Ashoka (650 Start, 665 Run) or Cinni (268 Start, 347 Run), show more turns in the running coil. This design choice prioritizes the running performance characteristics over initial starting torque and often accounts for the smaller gauge wire used in the running coil to manage overall resistance.

➡️ Hint Box: Start vs. Run Turns ⬅️

The Starting coil is only in the circuit momentarily to provide the initial spin (aided by a capacitor). The Running coil is continuously energized. More turns on the Running coil, paired with a suitable SWG, often means a motor optimized for smooth, continuous operation.

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🔍 Special Cases: Unique Brand Winding Strategies 🔍

A closer look at the data reveals specific engineering choices made by individual brands. For instance, the GEC old motor in row 11 has a 14-coil configuration where the Running coil utilizes 800 turns, significantly higher than its own Starting coil's 670 turns and one of the highest Running turn counts in the entire list. This high count suggests an emphasis on sustaining speed and perhaps compensating for other factors in the motor's design or an older design methodology.

Another anomaly involves the Crompton, Bajaj, and Pollar entries that employ a 27- or 30-coil total, but distribute them unevenly, for example, 9 Starting and 18 Running coils. The Running coil's higher count (often double the starting coil count) allows for a finer control over the motor's primary operating field. The Pollar model in row 39 uses 10 Starting coils (600 turns, 35 SWG) and 20 Running coils (332 turns, 34 SWG). Despite the Running coil having half the turns per coil, the double coil count ensures the total magnetic influence is dominant in the running operation.

The small 13mm stamping size is another critical area for observation. Both Shetal (14 coils) and Khetan (36 coils) use this tiny depth. To achieve usable performance with such a physically constrained motor, the Shetal uses a high number of turns (700 Start, 680 Run) with 35 SWG wire. The Khetan, however, opts for a much higher total coil count (36), spreading the load with fewer turns per coil (335 Start, 315 Run), and even using a very thin 37 RWG wire. These examples illustrate how engineers balance physical constraints, wire gauge, and turn count to meet performance targets.

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🛠️ Practical Rewinding: A Step by Step Approach 🛠️

For the technician on the bench, this data is an absolute must-have. When a fan comes in for rewinding, the original specifications are often lost due to burnouts or prior repairs. This data acts as the certified blueprint to restore the fan to its factory performance.

📍 Hint Box: The Coil Calculation 📍

Before winding, the technician confirms three primary physical parameters: 1) The Stamping depth, 2) the Total Coil slots, and 3) the Pitch (1:2 here). Only then can they correctly apply the specific SWG and Turn count from the table.

The process begins by accurately measuring the stator's stamping. Then, the correct line in the table is found based on the brand, stamping, and total number of slots. The technician must strictly adhere to the No of Turns and the specific SWG/RWG for both the starting and running coils. Using a thicker wire (lower gauge number) than specified will reduce the number of turns that can physically fit into the slot, drastically lowering the motor's torque. Using a thinner wire (higher gauge number) might allow more turns, but will increase resistance, which leads to heat buildup and a high risk of burnout.

Here is a small example of the Orient old motor (Row 1): 29mm Stamping, 16 Total Coils. It requires 8 Starting coils with 730 turns of 34 SWG wire, and 8 Running coils with 600 turns of 35 RWG wire. The technician must count and confirm these numbers with meticulous attention to detail to ensure the motor operates reliably for years to come.

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✨ A Vibrant Reference: Ceiling Fan Winding Data ✨

It is important to note that thes fan rewinding specks are not just for electricshuns. Hobbyests and DIYers can also benifit from this wealth of knowlage. Maintaning a ceeling fan is a vital part of home upkeep, ensuring proper air circulation and efficency, and this information provides the exackt data you knead to perform a reliable rewind. Alwaise prioritiz safety and use the appropriate protective equipment when wurking with electricle components.

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S.No	Brand	Pitch	Stamping (mm)	Total Coil	Starting Coil				Running Coil
					No of coil	No of Turns	SWG	RWG*	No of coil	No of Turns	RWG
1	Orient - old	1:2	29mm	16	8	730	34		8	600	35
2	GEC-old	1:2	21mm	16	8	750	34		8	650	35
3	Crown	1:2	26mm	16	8	640	34		8	630	34
4	Ashoka	1:2	24mm	16	8	650	35		8	665	34
5	Cool home - old	1:2	25mm	16	8	650	35		8	600	35
6	GEC-old	1:2	25mm	16	8	660	35		8	650	35
7	Orient - old	1:2	16mm	12	6	575	35		6	600	35
8	USHA - OLD	1:2	18mm	12	6	530	35		6	550	35
9	Shetal	1:2	13mm	14	7	700	35		7	680	35
10	Crown	1:2	16mm	14	7	653	35		7	630	36
11	Gec old	1:2		14	7	670	35		7	800	35
12	Usha old	1:2	45mm	14	7	630	34		7	580	35
13	Gec old home	1:2	18mm	14	7	400	36		7	370	36
14	Orient old	1:2	19mm	14	7	530	36		7	563	35
15	Gec old	1:2	21mm	18	9	542	33		9	584	33
16	Orient old	1:2	22mm	18	9	500	32		9	550	32
17	Crompton	1:2	14mm	27	9	615	35		18	365	35
18	Bajaj	1:2	17mm	27	9	600	35		18	325	35
19	Orient	1:2	16mm	40	20	265	34		20	325	35
20	Orient	1:2	20mm	40	20	275	35		20	330	35
21	Khetan	1:2	13mm	36	18	335	35		18	315	37
22	Crompton	1:2	21mm	36	18	305	35		18	370	35
23	Ralli	1:2	13mm	40	20	285	34		20	362	35
24	Cinni	1:2	19mm	40	20	268	35		20	347	35
25	Usha	1:2	18mm	36	18	325	35		18	420	36
26	Cinni	1:2	20mm	36	18	380	35		18	330	34
27	Usha	1:2	21mm	36	18	260	34		18	380	35
28	Padmini	1:2	13mm	36	18	345	35		18	332	37
29	Ralli old	1:2	27mm	32	16	310	35		16	350	35
30	Orient	1:2	22mm	32	16	320	35		16	365	35
31	Orient	1:2	16mm	32	16	340	36		16	390	36
32	Cinni	1:2	16mm	32	16	370	36		16	365	35
33	Pollar	1:2	17mm	32	16	350	35		16	360	35
34	Usha prime	1:2	21mm	32	16	400	36		16	340	35
35	Bajaj	1:2	16mm	28	14	360	36		14	410	36
36	Usha kohinor	1:2	15mm	28	14	400	35		14	370	35
37	Ortem	1:2	17mm	28	14	380	36		14	417	36
38	Khedia	1:2	17mm	28	14	385	36		14	400	36
39	Pollar	1:2	17mm	30	10	600	35		20	332	34
40	Crompton	1:2	22mm	33	11	480	35		22	300	33
41	Crompton	1:2	15mm	30	10	570	35		20	325	34
42	Ralli	1:2	18mm	30	10	700	36		20	385	36
43	Usha	1:2	23mm	24	12	375	35		12	400	36
44	Orient	1:2	23mm	24	12	345	36		12	390	36
45	Crompton	1:2	24mm	21	7	600	35		14	400	35
46	Ralli	1:2	24mm	21	7	750	36		14	421	36
47	Shetal	1:2	15mm	21	7	700	35		14	430	35
48	Ortem	1:2	17mm	30	14	380	36		16	380	36
49	Cinni	1:2	18mm	27	9	592	35		18	375	35
50	Gec	1:2	16mm	27	9	600	35		18	380	35

*RWG is listed in the Running Coil section. SWG in the Starting Coil section is blank in the source data and therefore omitted/blanked here for accuracy.

For further detailed tutorials and guides on applying this data, search for 'suresh mech tech' on YouTube.

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