Casablanca Malibu Star User manual

1
Ma l i b u St a r ®
INTRODUCTION
Before You Start 2
Safe Use 2
MOUNTING RECOMMENDATIONS
General Guidelines ......................................................................................................................................................... 3
Sloped Ceiling Installations ............................................................................................................................................ 3
FAN INSTALLATION
Perma®Lock Hardware ................................................................................................................................................... 4
Fan Preparation ............................................................................................................................................................... 4
Ceiling Hardware ........................................................................................................................................................... 4
Getting StartedCanopy Installation ................................................................................................................................ 4
Crossbar Mounting Bracket Installation ......................................................................................................................... 5
Canopy & Blade Hardware............................................................................................................................................. 5
Canopy Installation ........................................................................................................................................................ 5
Hanging the Fan ............................................................................................................................................................. 6
Canopy Electrical Connections....................................................................................................................................... 6
Canopy Hatch Installation .............................................................................................................................................. 6
Blade Orientation............................................................................................................................................................ 7
Blade Installation............................................................................................................................................................. 7
Blade Adjustment Angle................................................................................................................................................. 7
WALL CONTROL
W-80 or W-81 Wall Control for Fan and Lights............................................................................................................ 8
W-80 or W-81 Wall Control Operation ......................................................................................................................... 8
TROUBLESHOOTING TIPS............................................................................................................................................ 9
CARE RECOMMENDATIONS...................................................................................................................................... 10
PRODUCT SPECIFICATIONS....................................................................................................................................... 10
READ AND SAVE THESE INSTRUCTIONS!
SAFETY FIRST: Safety and the proper operation of your Casablanca fan both require a thorough knowledge of the product
and proper installation. erefore, before attempting to install and operate your Casablanca fan, read this Owner’s Manual
completely and carefully. Retain the manual for future reference
CAUTION: To avoid possible electrical shock, make certain that electricity is turned off at the circuit breaker or fuse box
before attempting any installation procedure.
PN 2343010 AT0109
CONTENTS
Ma l i b u St a r ® Ow n e r ’SMa n u a l

2
CIRCUIT BREAKER
Trip the breaker for
the circuit you will
be working on
FUSE BOX
Remove the fuse for
the circuit you will
be working on
SAFE USE
• Inspectthecontentsofyourcartonforpossibleshipping
or handling damage and report any such damage directly
to your authorized Casablanca dealer.
• Itisalwaysagoodideatohaveanassistanttohelpwith
the installation.
• eblades in eachpack arematchedfor equal weight
to assure smooth fan operation. If more than one fan is
being installed, be careful not to mix blades from different
cartons.
• Neverinstallafanoverapoolorspa.
• Forsafetyreasons,thefanbladesmustbeaminimumof
7 feet above the floor.
• Inanyinstallation,thetipsofthebladesmustbeatleast18
inches from the wall in order to provide sufficient clearance
for the blades.
• Neverinsertanythingintothepathofthefanbladeswhile
the fan is in operation.
• When cleaning, painting, orworkingnearyour fan, be
very careful of the fan and blades. Always turn the power
OFF to the ceiling fan before servicing it, working on it,
or replacing lightbulbs.
• Neveroperateafanthathasbeendamagedinanyway.
For assistance in obtaining service, call Casablanca Fan
Company toll-free at 1-888-227-2178 or contact your
local Casablanca Authorized Dealer.
BEFOREYOU START
INTRODUCTION
18″
84″
• CAUTION:RISKOFELECTRICALSHOCK!InstallationistobeinaccordancewiththeNationalElectricalCode,
ANSI/NFPA 70-1999 and local codes. If you are unfamiliar with the wiring codes, you should use a qualified electrician.
To avoid overheating and possible damage to other equipment,do not install control to a receptacle,fluorescent light fixture,
motor operated appliance, or transformer-supplied appliance.
• isfanisdesignedtobeinstalledonanexistingelectricaloutletbox.eoutletboxmustbeULListedforceilingfan
installations, if it is not, a new box must be installed. Casablanca extension poles are available for sloped or high ceiling
installations.
• is ceiling fan requires a grounded electrical supply of 120 VAC, 60 Hz and a minimum 15 amp circuit. e maximum
current requirement for the fan with light fixture is 3.0 amps. e fan uses about 1 amp or 100 watts. Maximum light
current is 2.0 amps or 240 watts of lighting.
•Where wire nuts are employed, be sure all bare wires are within the connectors. When installing the canopy hatch, make
sure all wires are within the canopy and that no wires are being pinched.
• WARNING:Donotbendthebladebracketswheninstallingthebrackets,balancingthebladesorcleaningthefan.Do
not insert foreign objects in between the rotating fan blades.
• WARNING:Toreducetheriskofreorelectricshock,donotusethisfanwithanysolidstatespeedcontroldevice.Use
only the control provided with or recommended for this fan..
Unpacking
Before assembling and installing your ceiling fan,remove all parts from the shipping cartons and check them against the parts
listed here. Before discarding packaging material, be certain that all parts have been removed.
NOTE: For best performance and for your warranty to be valid, use only genuine Casablanca Fan Company blades, light
fixtures, and accessories.

3
Ma l i b u St a r ®
Ceiling Height Pole Length
8′ 0” standard
8′6” standard
9′ 0” 6”
9′6” 12”
10′0” 12”
11′0”18”
12′0”24”
13′ 0” 36”
14′ 0” 48”
Before mounting your Casablanca fan, read the following helpful recommendations. e location of the fan, air circulation,
and fan size are all important factors to consider before installation.
Location
Ceiling fans have practical uses in almost every room in your home.We suggest
you follow these mounting recommendations as you decide where to install
your Casablanca fan.
• isfanrequiresaminimumceilingheightof9feet.
• Donotlocatethefaninadoorwayoraboveaswingingdoor.
• Inbedrooms,fansworkbestwhenmountedabovethefootofthebed.
• Overpooltables,besuretoprovideplentyofclearancetoavoiddamagefrom
pool cues.
• In kitchens, be sure to allow for open cupboard doors to clear the fan
blades.
• Donotinstallafancloseto,orover,apoolorspa.Highhumiditycombined
with corrosive gases will destroy the finish and warp the blades.
FanSize
Variable fan speed capability permits the use of a full-size 54-inch fan even in smaller rooms. For very large rooms, two fans
may be needed.
7’ minimum
SUGGESTED EXTENSION POLE LENGTHS
WhentoUseExtensionPoles
For best performance and appearance, an extension pole
should be used with your Casablanca fan when installing on
high (cathedral) ceilings or sloped ceilings.Casablanca offers
standard poles in increments of 6 inches up to 5 feet.Custom
poles are available in lengths up to 9 feet 9 inches. See your
Authorized Casablanca Dealer for details.
NOTE: e fan may wobble or vibrate if the pole length
is not long enough and the inside blade is too close to the
downslope or side wall. Extending the pole length usually
will solve the problem.
Calculationof32Degrees
Use the tear-off Ceiling Angle Template card inserted in
this manual. It provides you with a simple “go”or “no go”for
installing your fan on a sloped ceiling.
Blades must be a
minimum of 7′
above the oor
Extension
Pole
Maximum Angle 32º
This slope is less than 32 degrees.
It is okay to install your fan.
SLOPED CEILING INSTALLATIONS
MOUNTING RECOMMENDATIONS
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
This slope is more than 32 degrees.Your
fan will not hang straight down;an adaptor
is necessary.Contact your localAuthorized
Casablanca Dealer to purchase a “Sloped
Ceiling Adaptor.”
This slope is 32 degrees,the maximum
slope that will allow the fan to hang
straight down. It is okay to install
your fan.
GENERAL GUIDELINES

4
Step1b. Using the provided Allen wrench, loosen the set
screw several turns to allow installation of the downrod.
read the downrod into the motor coupling until it stops
turning. is will take at least four and a half full turns.
Step1c. Tighten the set screw securely with the provided
Allen wrench to ensure safe operation of your fan.
IMPORTANTSAFETYINFORMATION!
Beforestartingtheinstallationofyourceilingfan,installthethreaded
downrodintothemotorcouplingandlocktheassembly
Prepareforfaninstallationasfollows:
Step1a. Route the wires from the motor through the
Perma•Lock™ downrod and ball assembly.
Tip:edownrodhasataperedthreadthatisdesigned
tolockcompletelywhencorrectlyinstalled.
CAUTION: Failure to fully lock in the downrod
before securely tightening the Allen set screw may
cause the fan to separate from the downrod during
normaloperation!
FAN INSTALLATION
FAN PREPARATION
CEILING HARDWARE
GETTING STARTED
Unpacking: Before assembling and installing your ceiling fan, remove all parts from the shipping cartons and check them against
the parts listed here. Before discarding packaging material, be certain that all parts have been removed.
PERMA*LOCK HARDWARE
AllenSetScrew
1/4-20x1/4”
(pre-installed) 3mm
AllenWrench
Downrod&Ball
Assembly
MotorWires
GroundWire
Downrod
&BallAssembly
Motor
Coupling
Allen
SetScrew
Tapered
read
InstallingaNewCeilingFixtureOutletBox
If you do not have an existing fixture located where you wish
to place your Casablanca fan,an approved ceiling fixture outlet
box must be installed and wired.
Warning:To reduce the risk of fire, electrical
shock,orpersonalinjury,mounttooutletbox
markedacceptableforceilingfansupportusingthe
mountinghardwareprovidedwiththeoutletbox.
WireNut(4)
Crossbar
Mounting
Bracket
UsingExistingCeilingFixtureOutletBox
After turning the power OFF at its source (either circuit breaker
or fuse box), lower the old fixture and disconnect the wiring.
Check the ceiling fixture outlet box to be sure that it is marked
‘Approved for ceiling fan mounting’. If it is not, a new box must
be installed.
2-1/4x8-32Rounded
HeadScrew(2)
ADDITIONALHARDWARE
1x8-32rounded
headscrew(2) FlatWasher(2)
IMPORTANTNOTE-CEILINGHEIGHT
isfanisdesignedforinstallationonceilingswithaminimumheightof10feetfromtheoor.
elargebladesrequiretheuseofthe12”extensionpoletoallowforproperairowandventilation.

5
Ma l i b u St a r ®
CROSSBAR MOUNTING BRACKET INSTALLATION
CANOPY & BLADE HARDWARE
CANOPY INSTALLATION
CAUTION:Toreducetheriskofpersonalinjury,
useonlythemountinghardwareprovidedwiththe
approvedoutletboxtoinstallthecrossbarmounting
bracket.
Proceedwithinstallationasfollows:
Step 2. Route the wires from the ceiling outlet box through the
crossbar mounting bracket center hole.Attach the bracket,with
ground wire and ridges down, to the ceiling fixture outlet box
with the mounting hardware included with the outlet box.
Tighten the screws firmly by hand only, being careful not to
bend the bracket by over tightening.
CeilingFan
Approved
OutletBox
Ceiling
Wiring
Crossbar
Mounting
Bracket
Flat
Washer
OutletBox
Mounting
Hardware
Green
Ground
Wire
Ridge
Side
Down
Canopy
Hatch Canopy
CanopyScrew(4)
Canopy
LockWasher(4)
Wire
Nut(3)
W-80or
W-81
Control
AllenHex
Key
CrossbarMounting
BracketInstalled
Canopy
CanopyLock
Washers
Canopy
Screws
Step3. Attach the canopy to the crossbar mounting bracket
with three of the 8-32 x 2-½long canopy screws and canopy
lock washers.
Tighten the screw firmly by hand only.
NOTE:Onslopedceilings,alignthecanopyopeningtowards
thetoporroompeak.

6
HANGING THE FAN
CANOPY ELECTRICAL CONNECTIONS
DONOTattempttoattachthebladesuntilafterthefanbodyis
attachedtotheceilingandSteps5,6,7and8arecompleted.
Step4. To hang the fan body in the canopy, hold
the fan body firmly and insert the ball into the
canopy opening.Check that no wires were pinched.
Rotate the fan body until the slot in the ball fits
into the pin opposite the canopy opening.
Note:Independentcontrolofthelightxture
usingaW-80orW-81requiresanadditional
independentpowerwirerunfromthewallswitch
tothefan.SeePage7forwiring.
Capped
Blue
D-1Option
Wireon
3-SpeedOnly
forIndependent
W-81Light
Control
Ball
Slot
Pin
CANOPY HATCH INSTALLATION
Step5. Attach the fan wires to the ceiling fixture outlet box
wiring by twisting the bare ends of the wires together and then
securing with a wire nut. Test that the connection is secure by
pulling on the wire nut. Connect in this order:
Step6a.W-80orW-81WiringConnections-NOlight
xture
•GREENleadsfrommountingplateandfantoGROUND
conductor of power source. Secure with wire nut.
•WHITEwirefromfantowhiteNEUTRALwireinceiling
fixture outlet box. Secure with wire nut.
•BLACKpowerwirefromfantoREDwirefromW-80in
ceiling outlet box. Secure with wire nut.
•CapBLUED-1Optionwirewithwirenut.
Step6b.W-80orW-81WiringConnections-WITHlight
xture
• GREENleadsfrommountingplateandfantoGROUND
conductor of power source. Secure with wire nut.
• WHITEwirefromfantowhiteNEUTRALwireinceiling
fixture outlet box. Secure with wire nut.
• BLACKpowerwirefromfantoREDwirefromW-80in
ceiling outlet box. Secure with wire nut.
• BLUEwirefromfantoYELLOWwirefromW-80inceiling
outlet box. Secure with wire nut.
NOTE:Seepage7foradditionalwiringinformation.
W-81Connections
NoLightFixture
W-81Connections
WithLightFixture
WireNut
Capped
D1-OptionWire
Black&Red
Wires
2WhiteWires
3GreenWires
Black&Red
Wires
2WhiteWires
3GreenWires
Blue&Yellow
Wires
Canopy
Hatch
Canopy
Washer
Canopy
Screw
Tiltthe
Fanto
Install
Last
Canopy
Screw
Step7. Tuck the wires into the canopy with the
wire nuts pointed upwards, so that the WHITE
andBLACKwires areonopposite sidesof the
canopy and all wires are clear of the canopy
opening.
Step8. Install canopy hatch with the last canopy
screw and lock washer.To insert canopy screw, tilt
the fan body away from the hatch opening.
Step9. Straighten the fan, then check to ensure
that there is no movement between the canopy and
ceiling or Hang-Tru ball and 12” extension tube.

7
Ma l i b u St a r ®
BLADE ANGLE ADJUSTMENT
BLADE ORIENTATION
BLADE INSTALLATION
Step10. Orientation of fan blades. Note that the Malibu Star
fan only rotates in the clockwise direction (when looking up
at the fan on the ceiling). As you face the motor a fan blade
extending from the motor to you will have its leading edge on
your right.
Leading
Edge
Blade
Holder
Clamp
LoosenedReady
forBlade
Installation
AllenHexHead
BladeHolder
ClampScrew
(4PerBlade)
Blade
Holder
Blade
Shaft
Allen
Key
Upper
Chainwheel
Lower
Chainwheel Switch
Housing
Step11. Use the allen wrench provided
to loosen the four (4) allen screws on
each of the blade clamps but do not
remove completely. Insert each blade
with the proper orientation (as described
in previous Step 9).
NOTE:Beforesecuringthefanblade
adjustthe‘pitch’orangleoftheblade
foreitherupwardordownwardairow,
asdescribedbelowinStep11.
Step12.e pitch angle should be no more than 15° upward
or downward. Each blade must be adjusted to the same pitch
angle, otherwise the rotating fan will wobble.Tighten the four
(4) allen screws on each blade clamp. Check after tightening
to be sure they are all tight.
CAUTION!DONOTattempt to
adjustthetensiononwireholdingthe
silkclothintheblade.esehaveall
beenfactoryadjusted.
15°
Maximum
Angle
±15°
INCHE S
1
2
7/8 = 15°
Max Lower
Chainwheel
Upper
Chainwheel
Switch
Housing
BladeAngleAdjustment
BladeHolder BladeShaft
BladeArm
Airow
Direction
LeadingEdge
LeadingEdge
UpwardAirow
DownwardAirow
Measure
BetweenUpper
Chainwheel
andEndof
BladeArm

8
Wall Control
W-80 or W-81 WALL CONTROL FOR FAN & LIGHTS
• efanmaybeturnedONandOFF
by the W-80 or W-81 wall control.
• elightsmaybeturnedONand
OFF by the W-80 or W-81 and
the intensity adjusted from low to
high.
• efanmustbesuppliedwithtwo
independent 120V AC supply wires.
You may have to contact a qualified
electrician to have an additional
120V AC supply wire installed.
• eW-80orW-81allowsthechoice
of four different speed settings.
W-80 or W-81 WALL CONTROL OPERATION
e W-80 or W-81 wall control provides separate control of fan and light with two separate
knobs from a convenient wall location.e W-80 or W-81 is designed to replace a standard
wall switch and wall boxes with a depth of 2" or greater. Requires two hot leads from wall
box to ceiling wiring box. To install a W-80 or W-81 wall control in place of an existing
wall switch, follow the instructions on the W-80 or W-81 package.
Operation of the fan from the wall switch is simple:
1. Turn the upper knob to the desired fan speed.
2. Turn the lower knob to the desired light setting.
OFF
LO
MED
MED
HI
HI
OFF MAX
OFF
LO
MED
MED
HI
HI
OFF MAX
W-80 or W-81
W-80 OR
W-81 WALL
CONTROL

9
Ma l i b u St a r ®
Please refer to this guide before requesting service or contacting your dealer for assistance.
TROUBLESHOOTING TIPS
PROBLEM POSSIBLE REMEDIES
Fanwillnotstart • Checkthemaincircuitfuses,circuitbreakers,andwallswitchposition.Checkall
wire connections. Make sure the power is turned off during this inspection.
Fanisnoisyduringoperation • Checkandtightenthelightxtureretainingscrews,glassshadescrews,and/or
lightbulb(s).
 • Tightenthebladetobladeholderscrews.
 • Tightenthecanopyscrewsandmountingplateassembly.
 • Checkandtightenbladeholderstoywheel(ordirectdrivemotor).
 • Makesureallscrewsinthemotorhousingaresnugbutnotoverlytight.
 • Checkthatthewirenutsinsidethecanopyandswitchhousingarenottouching
the metal parts or have fallen off the wire splices. Tighten or adjust as necessary.
Fanrunsslowlyineitherdirection • Defectivereverseswitch,defectivecapacitor,oropenmotorwinding.Replace
ifrotationisstartedbyhand;willnot reverse switch assembly, replace PCB assembly, or replace motor unit.
reverse
Fanwillnotoperateatproperspeeds • Defectivethree-speedpull-chainswitchassemblyordefectivecapacitor.Replace
orwillnotoperateatanyspeed three-speed pull-chain switch assembly or replace PCB assembly.
Fanwobblesorshakesexcessively • Checkthatallbladesaresettoexactlythesameanglebyrepeatingthe"Blade
Angle Adjustment" instructions on page 7.
 • Checkthatallbladesareinstalledcorrectlyinthebladeholderassemblysothat
their leading edge is facing the correct direction. See "Blade Orientation" section,
Step 10, on page 7.
Allbladesap • Bladeorientationhasmaterialasleadingedge.Orientbladescorrectly,thenset
blade angle by repeating Steps 10 through 12 on page 7 starting with "Blade
Orientation."
Onebladeaps • Bladewiretensionisincorrect.Returnbladesettofactoryforservice
refurbishment and repair.
 • Bladematerialistorn.Returnbladesettofactoryforservicerefurbishmentand
repair.
Noairowfromfan • Bladeangleissetat.Orientbladescorrectly.
 • Bladeangleissettoolow.Orientbladescorrectly.
 • Bladeangleissetforupwardairow.Orientbladescorrectly.

10
ForquestionsortolocatethenearestCasablancaAuthorizedServiceCenter,
call1-888-2272178toll-free,orvisitusontheWebatwww.casablancafanco.com.
is device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
1. is device may not cause harmful interference.
2.This device must accept any interference received, including interference that may cause undesired operation.
is equipment has been tested and found to comply with the limits for a class B digital device, pursuant to Part 15 of the
FCC rules.ese limits are designed to provide reasonable protection against harmful interference in a residental installation.
is equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communication. However, there is no guarantee that the interference
will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by
one or more of the following measures:
• Reorientorrelocatethereceivingantenna.
• Increasetheseparationbetweentheequipmentandreceiver.
• Connecttheequipmentintoanoutletonacircuitdierentfromthattowhichthereceiverisconnected.
• Consultthedealeroranexperiencedradio/TVtechnicianforhelp.
NOTE:AnychangesormodicationstothetransmitterorreceivernotexpresslyapprovedbyCasablancaFanCompany
mayvoidone’sauthoritytooperatethisremotecontrol.
CARE RECOMMENDATIONS
FanFinishes
• Forcleaning,asoftbrushorlint-freeclothshouldbeusedtopreventscratchingthenish.
• Avacuumcleanerbrushnozzlecanremoveheavierdust.
• Surfacesmudgesoranaccumulationofdirtanddustcanberemovedeasilybyusingamilddetergentandslightlydampened
soft cloth. An antistatic agent may be used, but never use abrasive cleaning agents as these will damage the finish.
Blades
• Dustregularly.Ifbladesbecomedirty,removefromfan.SoakinbathtublledwithwarmwaterandWoolitefor10to15
minutes. Rinse. Air dry. Reattach to fan.
NoNeedforLubrication
• Never lubricate this fan! e precision motor at the heart of your Casablanca fan features sealed bearings that are lubricated
for life.
• Donotattempttooilthemotor.
ChangingLightbulbs
• BesuretoturnthepowertoOFFatthewallswitchorcircuitbreakerbeforechanginglightbulbs.
• Replacebulbswiththesametypeasyouremovedfromthelightxture.
• emaximumwattageratingforcompatiblelightkitsis240watts.
Modelname: Malibu Star®
Modelnumber: 23B002
Dimensions: A = 21"
B = 23"
C = 3"
D = 6.25"
E = 5.60"
Weight: 19 lbs.
PRODUCT SPECIFICATIONS
Motor: XLP-2000TM
Bladespan: 84 inches
Bladeironpitch: 15°
No.ofblades: 5
Technology: 4-Speed/W-80 or W-81
Airow: 5,170 cfm
ElectricUse*: 109 watts
AirowEciency*: 47.7 cfm/watts
* Performance data is for fan only. No lighting wattage is included.
NOTE: Dimension
B includes light
fixture and glass.