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I opened it up. It was filthy. And it's pretty clear what part is causing the problem. How in the world did the ultrasonic vibrator unit get so rusted and corroded? I see it's also cracked. I'll try to clean off the corrosion and repair the crack, but it appears beyond repair. I wonder if they sell this part.Thanks very much for this Instructable post. I don't know why it never occurred to me to open up the humidifier to look inside. Duh!
Well, it was easy to separate the electronics from the casing, so I can aggressively clean the casing. There is a little bit of corrosion on the board, but I'll be able to clean that up with some 99% isopropyl alcohol and a chamois swab. The corroded casing is a bigger problem. I might be able to remove the rust with a vinegar soak - works with cast iron. I have some silicone I can use to seal the cracks. I guess that's what is causing the leaks and the corrosion. Fatal flaw in this humidifier, apparently - seems to happen a lot.
My AOS 7145 humidifier only produces mist if it's tipped sharply to the left side - 20-30 degree tip. If it's on a flat surface, the red light comes on even when the tank is full, and there's no mist. Any idea what problem could cause that? I'd really like to fix it. Thanks.