How to fix a MaxxAir Maxx Fan that won't turn on (easy $10 repair)

Step 1: Open the fan housing

• Remove the three screws that hold the cover.
• Pull the fan handle out. That's all it takes to open it.

Step 2: Remove the dead logic board

• Find the electronic logic board inside.
• Remove its screws, unplug it from its connector and take it out.
• These boards are a known failure. In the video it was likely a transistor, and the manufacturer said they knew about the flaw.

Step 3: Choose a replacement speed controller

• Option one: a bigger board with a separate potentiometer (speed) and a switch for direction, air in or air out.
• Option two: a small board with the potentiometer and switch built in. Turn one way for air in, the other for air out, middle is off.
• The video uses the small one. With the bigger one you may need to cut the ends to fit or extend the cables.

Step 4: Mount the new controller through a hole

• Pick a spot where you can reach the knob. The video uses a place that keeps the factory setup possible later.
• Remove the nut, make a small hole, push the control through and put the nut back on.
• Check that the nut fits. If not, trim the plastic a little.

Step 5: Cut away the plastic in the way

• Cut the plastic that is in the way so the board fits perfectly.
• Unplug the wires and run them through the hole, then reconnect on the other side.

Step 6: Measure for the knob and switch holes

• Measure the space before drilling. In the video it is about 20 mm (around 3/4 inch) on one side and about 1.5 cm (around half an inch) on the other.
• Make the holes and fit the controls.
• A rocker switch is another option instead of the board's own switch.

Step 7: Connect power in and motor out

• IN is the power going to the board. OUT goes to the motor.
• Use the motor cable taken from the old board connection.
• On this board power is on the left and the motor is on the right. The switch handles the direction.

Caution: Make sure the motor is on the out side and power on the in side.

Step 8: Prepare extension wires and heat shrink

• Add extension wire so the cables reach where you mounted the controller.
• Cut a piece of heat shrink in half and slide it onto the wire first so you don't forget it.
• Use red and black so the wires are easy to tell apart.

Step 9: Crimp the butt connectors

• Push the wire halfway into the butt connector and crimp it. The video uses 16-14 connectors.
• Put the U-shape of the crimper the right way, then do the other side.
• Repeat for every connection. It should be very firm and tight.

Caution: You could solder, but if you don't know how to solder it takes longer. A good crimp won't come apart.

Step 10: Seal the connections with heat shrink

• Slide the heat shrink over each crimped connector.
• Heat it with a heat gun (a Ryobi in the video) until it is firm, tight and sealed.

Step 11: Route the cables with plugs

• Run the cables from the motor and the power to the new controller location.
• Keep two plugs in the line, so you can unplug them right away for service.
• Reinstall the parts in the fan.

Step 12: Test direction and speed

• Push the switch one way for air coming in, middle is off, the other way spins the fan the opposite way.
• Turn the knob to change the speed. The LED light changes too.
• You lose the original control panel, so open and close the lid manually.