I went back and noted that you only posted this last night, please don?t take offense!
From what I read, if the circuit of fan is the only thing that is tripping the AFCI than you need to bring a test circuit to the fan and see if the fan is faulting the AFCI!
If the fan works with this test then the fan is OK, it?s backwards from that point. That is not my only suggestion.
All of the following are good suggestions:
# 3
# 4
# 5 You did State you did this - tried a regular breaker.
# 6
# 7 Sounds like the real problem based on your description of the job from your post # 15 & some of # 16
IE You only tighten up the circuit joints, You didn?t qualify a truly ?individual? circuit.
# 8 The mother of all tests? The meggar. One megger the wires not the AFCI.
# 9 You stated it?s not its not a MWBC
# 11 - #12 (also referencing #7) a real key to why a AFCI will not work on multi circuits/ shared circuit neutrals (two circuits sharing a neutral), or wires touching in some fashion. Now since it?s not a MWBC or a Rated Dual Breaker, it can stay in for ?Cause of Fault??
# 13 - it?s the Junk Fan - if could have been damaged, it has improper internal wiring or damaged after install of fan! An example is nicked neutral wire in the throat of the raceway inside the fan.
# 14 - Testing with POWER OFF an Ohm Meter, and the wire off the circuit breaker. almost the same as using a megger, just depends on where the wire nicked in # 7 it, on how the fault reading would show up!
(for the purist I realize their completely two different types of tests)
#15 - #16 JOB DRAMA that don?t fix the issue(?s) at hand, but it really sounds like you need to ID and totally understand every circuit and it distribution. It is a hatchet job and several types of hatchets where used to put it together, which is reflective of what was said in # 17
The following is a list that just frankly need to be done.
# 7, # 8, # 11, # 12, # 13, # 14 and One could probably do everything except # 8 and find the problem, it will be just about the same amount of work but if you don?t have the meggar, well you don?t?
Or what was said in #19 and also said in other posts?
My thoughts on it; AFCI = ARC Fault Circuit Interrupt; We should remember it as ARC Fault Circuit INDIVIDUAL !
It takes an individual circuit (one), IE a complete circuit, nothing shared to the equipment and or devices for the AFCI not to trip.
Hope that helps!