Ø 100mm Extractor Fan Housing

Description

I have a custom built server rack positioned centrally in my home. In order to improve cooling airflow and reduce noise, I bought some cheap bathroom extractor fans, took out the motor & impeller assembly, and designed this housing to mount those in. Some usages I can think of with this design:

• Workshop fume extraction

• Bathroom ventilation

• Systems cooling

• General airflow circulation

Printing Instructions

You will need to print the following in the following recommended settings:

Recommended Hardware

Assembly Instructions

1. Remove any brim or printing artifacts from the printed pieces. Sand rough areas to ensure a as-smooth-as-possible surface everywhere you can reach.

2. Carefully insert the motor-impeller assembly into the fan housing. Make sure the motor wires go through each of the two wire holes.

3. Secure the motor to the housing with the appropriate screws. These usually come with the motor, especially if you salvaged the motor from a finished product.

4. Terminate the motor wires in the HE1WPR/02 terminal, ensuring you clamp the screw onto copper and not the insulation.

5. Put the intake part on top of the fan housing, making sure the wires sit nicely in the channels and the terminal is secured.

6. Insert the housing through the Ø 100mm hole you have (hopefully) prepared, and secure the entire assembly with your selected screws/bolts.

7. If environmentally required, seal the gap between the fan housing and the intake parts. I recommend something that is durable and water tight, but still easy to remove for future maintenance. Some silicone or tape can work depending on your needs.

Notes

Please read through the safety section before starting assembly or installation!

Compatibility List

This is a list of compatible parts/products that can be used in this design. This list is not comprehensive by any means, but if you find something that you've verified to be compatible, please let me know and I'll add it to the list.

Safety

I'm no electrician, engineer, or otherwise an expert on these things. I'm just a dad with a few hobbies.
With that said, here are some important safety rules to keep in mind when assembling/installing this:

• Do not expose this to areas with a risk of water entering the motor assembly. Take due caution to insulate and seal any gaps where water may enter through, especially the gap between the two main pieces.

• Remember to properly insulate any exposed wire contacts, joints, connections, terminals, etc. You do not want to touch live wires powered by mains!

• Do not do the final installation into electrical systems yourself unless you're competent with this and you're allowed to do so (different countries have different laws regarding electrical installations). Get an electricion to verify your work and do the final installation if you're unsure.

• Most, if not all, fans that fit this design do not have any electrical protections built in, such as fuses or grounding. Please, do not handle any wires or exposed metal parts while it is connected to electricity. both wires need to be disconnected before you can safely handle these motors.

• Make sure operating temperatures stay within specs of your motor/impeller. I have added motor cooling into this design to help keep temperatures within spec and prevent overheating or deformation from prolonged use, but these motors and plastics still have their limits.

• Connect these fans to an easily accessible switch and a 0.5A slow fuse for extra convenience and security.

  • You can use a compact 1-pole switch to toggle the fans, but do not rely on this for maintenance. Maintenance on the fans require you opening both live and neutral, as these fans are AC.

  • Use a 2-pole switch for maintenance/security.

  • Do not use fuses higher than 0.5A, as these will not trip easily enough to actually provide any meaningful protection. A 0.5A fuse is already way too strong of a fuse for these fans, but they are still worthwhile to include.

• Make sure that the intake is not restricted to the point where it reduces the output of the fan. Some fust filtering is fine, but make sure you leave enough empty space in front of the intake to sufficiently provide the fan with enough airflow. This airflow also cools the fan motor, so do not neglect it!