How to Repair a Rechargeable Fan: Easy DIY Fixes for Battery and Charging Issues

It’s a familiar scene for almost all rechargeable fans after 1 or 2 years - the fan works when plugged in, but the battery can’t hold charge. The truth is, the battery is the weakest component of your rechargeable fan. It endures unusual voltage fluctuation. Even your surge protector circuit can fail during a heavy lightning strike, making your battery dead.

Well, a dead battery is not the only reason your fan becomes non-functional. In this complete guide, we’ll show you easy steps to identify the issues, correct solutions to fix them, and get your rechargeable fan functional (no engineering degree required.)
Let’s get started.

How Rechargeable Fan Works

Before we go into rechargeable fan repair, it's crucial to know how the rechargeable fans actually work. A rechargeable table fan includes a mini DC motor powered by an internal rechargeable battery. When you plug it in AC power, the adapter converts the power to DC and charges the battery through a control circuit, usually known as a PCB.

The major components are:

• Battery: This component stores electrical energy so you can use it to get airflow during power outage. It comes in lead-acid or lithium-ion type.
• Charging Circuit (PCB): It controls crucial things such as how long the battery should be charged, when the power should be cut off during an emergency, etc.
• Motor: This crucial component that spins the blades and creates airflow.
• Charging Port & Indicator Light: Allows you to charge your fan and the light notifies power status.
• Switch & Speed Control: Controls fan on/off and speed.

If any of these components fails to operate or lose their natural performance, the fan might not work properly.

How They Work

When you plug in the charger, electricity flows through the charging circuit to replenish the battery. Once charged, flipping the switch activates the motor, spinning the blades. Over time, wear and tear can affect these parts, leading to common failures.

Why They Fail

Common culprits include battery degradation from repeated cycles, dust buildup clogging the motor, loose wiring in the charging system, or physical damage from drops. Understanding these helps in targeted repairs, ensuring your fan lasts longer.

How Repair Rechargeable Fan : Common Symptoms and Fixes

Fully functional fans will deliver the best airflow at its rated capacity. If you see your fan is suddenly struggling to deliver airflow at its natural pace, you should check out the current voltage condition in your area. Lower the voltage means lower the speed.

If the electric supply is good, but your fan is spinning slowly, it’s an indication that something wrong is happening inside. Here are some common symptoms your fan can show-

Symptom 1: Fan is completely dead (no lights, no sound)

Plug your rechargeable fan to the electricity supply and turn on the switch. If it's not spinning at all and indicator lights are not responding as well, it might be your dead cable that causes interruption in power supply. Dead PCB could also be a reason, especially when the part of the circuit that deals with power delivery is damaged.

Steps to repair

• Check the power cable first: Try using the fan with a new cable. Typically damage or breakage of the line will produce a complete power down.
• Test the wall socket: If you plug another device (like your phone charger or a lamp) into the same outlet, and it works, then the problem isn’t your power source.
• Inspect the charging port: Inspect the port for dust, bent pins or signs of corrosion. Gently clean it with a soft brush or a can of compressed air.
• Check the internal fuse (if it has one): Some rechargeable fans even have a tiny in-line fuse. If it’s blown, swap it with a new one (with the same rating.)
• Unfold the fan and inspect the PCB: If you find any traces of burning, swelling parts or loose connections, any of the parts are damaged, you should just replace the PCB board.
• Check the battery voltage using a multimeter:Check if the voltage reading is below the rated value, which means that the battery may be dead and it needs replacement.
• Check the power switch:Things can get jammed or it can fail internally. You might want to clean it using contact cleaner or swap this out if needed.
• Reassemble and test again: After inspecting and replacing bad parts, re-assemble the fan, plug it in and see if it starts.

Probable Solution When PCB is dead

Look for burnt areas, broken traces, or swollen components on your PCB. You can also use magnifying glass for better inspection. Make sure the charging IC and other chips are properly seated. Loose parts can cause intermittent issues. If you find any physical cracks on your circuit or damaged copper tracks, note their location. These may need fixing or bridging with wires.

Symptom 2: Fan only works when plugged into the charger

This symptom shows mostly when your rechargeable fan battery is dead. When you plug it with the AC power supply, the battery can’t hold charge. But when you plug it in with the direct electric supply, the fan can run at full speed. Faulty PCB can also cause this issue. If your rechargeable fan brand includes a dedicated PCB for power supply, replacing it with a new one can fix this issue instantly.

Steps to repair

• First things first: Take a look at the battery connection. Gently pry open the fan housing and see if your battery terminals are making good contact. The battery may not be charging if connections are loose or corroded.
• Test the battery with a multimeter: If the reading is less than rated voltage (e.g. under 10V for a 12V battery), it indicates that the battery no longer can hold charge and needs to be replaced.
• Replace the battery if it is dead: Just remember to replace it with one of the same voltage (14.4 or 18 volts) and carrying capacity/rating as the old one.
• Check the charging circuit or PCB: Check for any burn marks, broken resistors or leaking capacitors. If you see any, replace the PCB or components.
• Check the charging port/cable: Nothing could be more evident, but always have your charging port checked. Dirt, rust or bent pins can prevent correct charging. Use a soft brush or contact cleaner to gently clean out the port.
• Fully charge the fan after repairs are made: Insert it into a live power outlet and charge for a couple of hours to see if it can work on battery.

Symptom 3: Fan runs for a very short time and dies

When your battery is dying (but not dead yet), this symptom will show up. It happens due to losing its capacity to store energy. If you see this sign, just replace the battery and plug in to recheck your fan. Switch it on, and your fan will be fully functional.

Steps to repair

• Fully charge the fan first: Before you blame the battery, let it charge for a few hours and check if the issue improves.
• Test the battery voltage: Check the battery voltage by following the method mentioned in “Symptom-2”.
• Replace the old battery: If the voltage test indicates that your battery is weak, purchase a replacement with the same voltage and an amp-hour rating equivalent to (or as close as possible) the original one. Never use the battery under Minimum rating.
• Inspect the battery terminals: Wipe away any dust, dirt, rust or corrosion that may disrupt the flow of electricity. For light cleaning, use a soft brush or sandpaper.
• Check for loose wiring: The wires connecting the battery to the PCB or motor are occasionally likely to loosen over time. Tighten any loose joints or re-solder ones which are broken.
• Examine the charging circuit: A bad charging circuit could prevent the battery from being fully charged even if the battery is good. If so, restore or fix the PCB.
• Test the fan after reassembly: While not plugged in, after you have connected the new/repaired battery, turn on the fan. If it runs well for an extended period of time then the issue is resolved.

Symptom 4: The charging indicator light doesn't turn on

Sometimes your charging indicator might expire. In that case your fan remains fully functional. You can change your LED indicator considering a nominal costing. If you want to leave it as it is, you can. It won’t create any impact on your rechargeable fan’s lifecycle.

Steps to repair

• Check if your fan is charging properly: Even if the green light does not turn on, you can still plug in the fan for a few hours and check to see if it runs. If it does, only the LED indicator is damaged.
• Inspect the charging indicator LED: Carefully open the fan housing and check the LED light. Look for burn marks or shattered legs on the LED. Replace it with a new one of the same color and voltage rating.
• Check the indicator wiring: Occasionally, a loose or disconnected wire is solely responsible for preventing the LED from turning on. Re-solder or reconnect any joints that are loose.
• Test the charging port and cord: If the LED and wires are good, test the charger with a multimeter. A faulty charger might not be able to send power to turn the indicator on.
• Check for damaged parts on the PCB: The LED circuit is generally the part of the PCB. If a resistor or transistor connected to the indicator is burned out or broken, replace it.
• Test the indicator after reassembly: Simply plug your rechargeable fan into the power source. If the LED lights up, you’re good to go.

Symptom 4: The charging indicator light doesn't turn on

Sometimes your charging indicator might expire. In that case your fan remains fully functional. You can change your LED indicator considering a nominal costing. If you want to leave it as it is, you can. It won’t create any impact on your rechargeable fans lifecycle.

Steps to repair

• Check if your fan is charging properly: Even if the green light does not turn on, you can still plug in the fan for a few hours and check to see if it runs. If it does, only the LED indicator is damaged.
• Inspect the charging indicator LED: Carefully open the fan housing and check the LED light. Look for burn marks or shattered legs on the LED. Replace it with a new one of the same color and voltage rating.
• Check the indicator wiring: Occasionally, a loose or disconnected wire is solely responsible for preventing the LED from turning on. Re-solder or reconnect any joints that are loose.
• Test the charging port and cord: If the LED and wires are good, test the charger with a multimeter. A faulty charger might not be able to send power to turn the indicator on.
• Check for damaged parts on the PCB: The LED circuit is generally the part of the PCB. If a resistor or transistor connected to the indicator is burned out or broken, replace it.
• Test the indicator after reassembly: Simply plug your rechargeable fan into the power source. If the LED lights up, you're good to go.

Symptom 5: Fan speed is very slow, even at the highest setting

In most cases this symptom shows up when your fan capacitor is dead, or dying. If this is the case, replacing the fan capacitor with a new one will instantly solve your problem. But there are some more reasons that cause your fan to spin slowly. Before buying a new one, don’t forget to read our complete guide on how to buy a fan capacitor.

Steps to repair

• Check the power supply first: Ensure that the fan is connected to a good power source. Lower voltage leads to slower fan speed.
• Inspect the fan blades: Debris or dust can create more resistance, reducing how fast the motor spins. Clean the blades and grill with a soft brush or cloth.
• Test the fan capacitor: Open the fan housing and find the capacitor, typically a small metallic cylinder adjacent to the motor. Use a multimeter with a capacitance function to check if it’s still within the rated range printed on it.
• Replace the bad capacitor: Get a new capacitor with the same voltage and microfarad (µF) rating as the old one. A lower or higher value will influence the performance.
• Inspect the motor bearings: If they look dry or stiff, put a few drops of light machine oil on them. Fan bearings can also wear out and slow the fan.
• Examine the speed control switch: Dust or wear within the control knob can result in fluctuating speeds. Clean contacts or replace the switch if necessary.
• Test the fan again: Turn the fan on after replacing or fixing parts you think could be the cause and see if it helps with speed at every setting.

Ending Note

Fixing a rechargeable fan can be confusing at first but with some patience and the right guidance, it is absolutely doable. Many of the common problems such as dead batteries, bad capacitors or weak PCBs can be repaired without too much difficulty by using some basic tools and a bit of scrutiny. It's not only a money saver, but it also keeps your fan last longer because you aren't wasting things you don't need.

Don't forget to unplug the fan before opening it and handle the internal parts carefully. If you are stuck anywhere, it’s better to seek professional help from an expert technician. If you found this guide helpful, feel free to share it with friends or family who might be going through similar fan troubles.

FAQ

Can I use any and all batteries in my rechargeable fan?

No, please replace the battery only with a new battery of the same type and specifications (voltage and capacity). An incompatible battery will damage the circuit and degrade performance.

How can I tell if it’s time to replace my fan’s battery?

If your fan works only when connected or dies shortly after charging, the battery is probably not repairable. You can test it with a multimeter to see if it’s still holding some charge.

Can I use any and all batteries in my rechargeable fan?

No, please replace the battery only with a new battery of the same type and specifications (voltage and capacity). An incompatible battery will damage the circuit and degrade performance.

Why is the fan slow on high?

The most usual cause is a faulty or burnt capacitor. Replacing it with a new one of the same rating usually gets everything spinning at normal speed again.

My fan’s charging light isn’t turning on. Is it serious?

Not necessarily. Or, it has the possibility that the LED indicator is burnt out because the fan still charges fine. You can fix it if it bothers you, but it doesn’t impact the overall functionality of the fan.