ceiling fan with light

Hunter ceiling fan with light kit. Operates from one wall switch (one power source). It's been working fine for 3 years. There is a Hunter fan/ light control module installed in the box above the fan and a corresponding wall switch that lets you control/ dim the lights and control the fan speed all from the wall switch. The module in the fan acts as a type of receiver for the signal sent from the wall switch and basically varies the voltage to control light level or fan speed.

Last night I turned on the light at the wall switch and one bulb popped really loudly and the other 3 glowed barely and then had no light. I tried new bulbs and got nothing. Today I started pulling things apart and measured 148 volts at the light output of the fan control module! No wonder the bulbs popped. Not sure how this module could produce 148 volts when I'm getting between 119 and 120 at the wall.

I pulled the module out of the fan electrical box and wired both the fan an light supply wires to the 120 line coming in at the box. The fan works just fine. I measure 120 after the fan switch and at the center contact on the light sockets. When I turn the switch off, I get nothing at the sockets. The switch seems to work properly. With power off, I get continuity from the side tab of the sockets back to the neutral wire (white wire) in the electrical box. However, as soon as I install a light bulb (that I know works), I get no power at the sockets and the bulb doesn't work. I even broke a bulb open and pulled off the filament. I then installed the bulb in a socket and measured across the 2 wires and got 120 volts. As soon as a working bulb goes in.... NOTHING! I guess any load is keeping it from working. Any ideas? I even pulled the chain switch out and hardwired it. Still the same thing.
   


Reference:

• http://www.baapoffers.com/forum/viewtopic.php?f=4&t=5434
• http://forum.homeone.com.au/viewtopic.php?f=20&t=66852
• http://artcastle.prophpbb.com/post16016.html