A blower fan is connected to the negative battery terminal (also called ground) on one end and to the positive battery terminal through a blower resistor on the other end. The blower resistor is connected in series with the blower fan. This means that the current running through the blower motor, and thus is speed is controlled by the resistor value. The user chooses a suitable fan speed by using a selector to connect one of the resistors in the blower resistor pack. Blower resistors are made of several resistors with different resistances. There are also two additional circuits used for the off state and the highest fan speed state. In the off state, the blower motor is disconnected from the power supply. In the highest speed state, the blower resistor is bypassed completely and the fan is connected directly to the car’s battery, which allows maximum current through the motor. The lower the resistance of the selected resistor in a pack, the higher the current that flows through the blower fan, and the faster the fan will turn.
The individual resistors inside the pack are usually wire wound and they may fail by burning out from use, and may also fail due to mechanical stresses and vibrations typically found in an automotive environment. When a blower resistor is faulty, the fan will usually operate at one speed only, usually the highest speed setting possible. Sometimes, only some of the speed settings will be faulty while others might work.
