Difficulty

Moderate

Steps

6

Time Required

Suggest a time??

Sections

1

  • Thermal cutout
  • 6 steps

Flags

2

In Progress

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  • BackVornado Zippi Fan

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Introduction

What you need

Step 1

              Locate and remove side screws
  • There are two obvious screws on the sides of the fan. These are of the “Phillips” variety and need to be removed.
  • Remove the wire base by simply pulling each side out of the plastic housing. They are only held in place by the springiness of the wire base.

There are two obvious screws on the sides of the fan. These are of the “Phillips” variety and need to be removed.

Remove the wire base by simply pulling each side out of the plastic housing. They are only held in place by the springiness of the wire base.

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Step 2

              Remove the hidden screw in the base
  • All of the screws are of the “Phillips” variety. It takes a bit of fiddling to get the screwdriver blade to engage with the screw but then it backs right out. Just leave the screw behind the rubber bit as it would be a nightmare to get it out and we will need it there for reassembly anyway.

All of the screws are of the “Phillips” variety. It takes a bit of fiddling to get the screwdriver blade to engage with the screw but then it backs right out. Just leave the screw behind the rubber bit as it would be a nightmare to get it out and we will need it there for reassembly anyway.

Step 3

              Carefully pry off the power knob and the front propeller
  • Be careful not to ding up the plastics. I had to use quite a bit of force to get the propeller off.

Be careful not to ding up the plastics. I had to use quite a bit of force to get the propeller off.

Step 4

              Remove the remaining 4 screws holding the case together
  • After pulling away both sides of the plastic case, remove the black plastic housing by removing the two screws that hold it in place.

After pulling away both sides of the plastic case, remove the black plastic housing by removing the two screws that hold it in place.

Step 5

              Cut away the insulation around the thermal cutout

Use a razor knife and carefully cut away the silicon insulation around the thermal cutout.

Clip the old unit out and melt a blob of solder on the wires that stick out. Then clip short the leads of the new thermal cutout so that they just reach the exposed wires.

Hold the thermal cutout as far away from the device as possible with needle-nose pliers as a heatsink so that the soldering iron doesn’t blow the fuse and quickly solder the fuse in place.

Now thread a bit of electrical insulation around the cutout to cover the exposed wires. Do not use more than a layer or the cutout may not operate when it is needed.

Step 6

              Reassemble in the reverse order
  • Now simply put all of the pieces back together in the reverse order that you took them apart. Here is my Zippi, good as new and ready for the hot summer.

Now simply put all of the pieces back together in the reverse order that you took them apart. Here is my Zippi, good as new and ready for the hot summer.

To reassemble your device, follow these instructions in reverse order.

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                                                                                      4 other people completed this guide.

Author

                                      with 2 other contributors 


                    Albert Straub

Member since: 05/06/2013

269 Reputation

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Jonathan Bell - Jul 19, 2017

Reply

Thank you, my thermal was fine but my zippi was making an annoying clicking sound - just the disassembly, lubrication of the motor shaft with PTFE and putting it back together fixed it and it’s running at a nice white noise hum right now better than ever.

Idmi - Nov 30, 2021

Reply

Thank you very much! I thought the motor had burnt out!