The Maxxfan Deluxe series of roof-mounted ventilation fans are designed for installation in recreational vehicles (RVs) and campervans. These fans offer temperature regulation, humidity control, and improved air quality within the vehicle. Installation requires a specific roof opening size and adherence to safety precautions, particularly regarding electrical connections and sealant compatibility. This article details the installation process, operational considerations, and model-specific information based on available documentation.
Roof Opening and Fan Placement
The Maxxfan Deluxe series requires a roof opening measuring 355mm x 355mm for KI models and 400mm x 400mm for KI40 models. Prior to installation, it is necessary to verify the existing roof opening size if replacing a previous vent. The interior ceiling garnish trim ring should be removed to accurately measure the opening or confirm compatibility by attempting to slide the Maxxfan interior garnish trim ring into place.
The documentation emphasizes the importance of unobstructed roof space around the fan. The exhaust/intake louvers, which face the rear of the vehicle, require a clear area free from obstructions such as air conditioners or storage boxes. The fan is designed for roof thicknesses ranging from 25mm to 90mm; additional support may be needed for roofs thinner than 25mm.
Installation Procedure
The installation process involves several steps, beginning with preparation of the roof opening. Any existing roof sealant must be removed for a minimum of 50mm around the perimeter of the opening. The Maxxfan should be positioned in the opening with the hinge facing the front of the vehicle and centered within the opening. A pencil line should be traced around the fan to verify the seal area.
Before securing the fan, a continuous strip of butyl tape or equivalent caulking must be applied to the underside of the flange, ensuring coverage of all screw holes. Disconnecting the vehicle’s main power supply is a critical safety precaution before making any electrical connections.
Electrical connections are made using insulated 16-gauge connectors to connect the vehicle’s 12-volt power to the two Maxxfan power wires located on the driver’s side of the unit. The black wire, identified with a (+) tag, must be connected to the vehicle’s 12-volt positive supply. Connecting the fan to an incorrect voltage or with reversed polarity can cause damage to the unit, personal injury, or property damage and will void the warranty.
Once the electrical connections are complete, the fan is secured to the roof using sixteen screws provided. These screws should be inserted into the raised ring dimples along the flange, avoiding overtightening to prevent cracking. After installation, excess caulk should be removed, and a daub of sealant, such as Dicor self-leveling lap sealant, should be applied over each exposed screw head. A bead of sealant, approximately 5mm wide, should also be applied along the entire perimeter of the flange.
Garnish Ring Installation
The interior garnish trim ring requires adjustment to fit the specific roof thickness. The distance from the vehicle ceiling to each corner of the Maxxfan control plate must be measured, accounting for any roof slope. The garnish ring should be cut 6mm to 12.5mm longer than the measured dimensions at each corner. The documentation provides an example measurement of 90mm, to which 12mm was added, resulting in a cut line at 102mm. Care should be taken to avoid probing or tampering with the thermostat or IR sensors during this process.
The final step involves positioning the garnish ring and securing it with four flat-head screws. Remote control models include a cradle that can be attached to the wall using two #6 screws.
Sealant and Material Considerations
The documentation specifically cautions against using sealants containing solvents such as Xylene, Toluene, Methyl Ethyl Ketone, Acetate, or Acetone, as these can damage the flange. Polysulfide (Thiokol) type sealants should also be avoided. Compatibility with the flange material and the roof surface is essential. Dicor self-leveling lap sealant is recommended.
When preparing the roof surface for installation, it is recommended to deburr the edges of any holes created and smooth them with 220-grit sanding paper to promote paint adhesion. Applying painter’s tape around the perimeter of the flange and de-glossing the mating surface with a Scotch-Brite pad are also recommended preparatory steps. Cleaning the surfaces with isopropyl alcohol before applying adhesives is crucial.
Additional Installation Steps (Campervan Specific)
For campervan installations, additional steps may be necessary to ensure a secure and watertight seal. These include applying butyl tape around the entire flange perimeter and using Sikaflex 221 adhesive to the surface of the adapter mating with the roof. The adapter is installed first, followed by the fan flange. Screws and washers are inserted from the top, and nyloc nuts are secured from the bottom, ensuring uniform tightening without overtightening to prevent flange cracking.
Model Variations
The Maxxfan Deluxe series includes several models, including the 5100KI, 6200KI, 6200KIT, 7000KI, 7500KI, 7500KIT, 5100KI40, 6200KI40, 6200KI40T, 7000KI40, 7500KI40, and 7500KI40T. These models vary in lid color (white or smoke) and opening mechanism (manual or automatic). The documentation refers to a specific part number, 11D90001KI, for Deluxe models as of August 2017.
Safety Precautions
Several safety precautions are highlighted in the documentation. Disconnecting the vehicle’s main power before making electrical connections is paramount. The fan is designed for use with a nominal 12-volt DC system and should not be connected to other voltages. The documentation warns against modifying the fan in any way not intended by AIRXCEL, INC., and advises contacting an authorized distributor with any questions.
Warranty Information
The Maxxfan Deluxe series is covered by a one-year limited warranty.
Conclusion
The Maxxfan Deluxe series provides a ventilation solution for RVs and campervans. Proper installation, adhering to the provided instructions and safety precautions, is crucial for optimal performance and longevity. Careful attention to sealant compatibility, roof opening dimensions, and electrical connections will ensure a reliable and effective ventilation system.