Carefree of Colorado APEX User manual

052522-301 Printed in USA April, 2006
SERVICE MANUAL
APEX
RV With Direct Response Electronics
Table of Contents

PROPRIETARY STATEMENT
The Apex Awning is a product of Carefree of Colorado, located in Broomfield, Colorado, USA. The
information contained in or disclosed in this document is considered proprietary to Carefree of Colorado.
Every effort has been made to ensure that the information presented in the document is accurate and
complete. However, Carefree of Colorado assumes no liability for errors or for any damages that result
from the use of this document.
The information contained in this manual pertains to the current configuration of the models listed on the
title page. Earlier model configurations may differ from the information given. Carefree of Colorado
reserves the right to cancel, change, alter or add any parts and assemblies, described in this manual,
without prior notice.
Carefree of Colorado agrees to allow the reproduction of this document for use with Carefree of Colorado
products only. Any other reproduction or translation of this document in whole or part is strictly prohibited
without prior written approval from Carefree of Colorado.
SAFETY INFORMATION
WARNING
AWARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,IF NOT AVOIDED,COULD RESULT IN
DEATH OR SERIOUS INJURY AND/OR MAJOR PROPERTY DAMAGE.
CAUTION
ACAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT MAY CAUSE MINOR TO MODERATE
PERSONAL INJURY AND/OR PROPERTY DAMAGE.IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.
NOTE: A note indicates further information about a product, part, or step.
Tip: A tip provides helpful suggestions.
Safety Notes:
•Always disconnect battery or power source before working on or around the electrical system.
•Always wear appropriate safety equipment (i.e. goggles).
•Always use appropriate lifting devices and/or helpers when lifting or holding heavy objects.
•When using fasteners, use care to not over tighten. Soft materials such as fiberglass and aluminum
can be "stripped out" and lose the ability to grip.
Reference Publications located @ www.carefreeofcolorado.com:'
052522-001 Apex, Single Awning Installation Manual
052532-001 Apex, 2-Awning Installation Manual
052546-001 Apex, 4 Awning Installation Manual
052522-201 Apex Owner's Manual
052522-301 Apex Service Manual
Carefree of Colorado 2145 W. 6
th
Avenue Broomfield, CO 80020
aScott Fetzer company 303-469-3324 ♦www.carefreeofcolorado.com
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Carefree of Colorado Service Manual APEX
052522-301 1
TABLE OF CONTENTS
Product Overview..........................................................................................................................2
Apex Patio Awning Specifications.......................................................................................................2
Canopy Replacement....................................................................................................................3
Spring Arm Replacement..............................................................................................................5
Motor Replacement.......................................................................................................................7
Diagnostics/Troubleshooting.......................................................................................................9
Common Operation Items...................................................................................................................9
Diagnostic Tests – Direct Response for Single Awning........................................................................10
Testing the System – Single Awnings ..................................................................................................10
Diagnostic Tests – Direct Response for Multiple Awnings ...................................................................13
Testing the System – Multiple Awnings................................................................................................13
Electrical ......................................................................................................................................17
Wiring Diagram – Single Awning..........................................................................................................18
Wiring Diagram – Dual Awnings...........................................................................................................19
Wiring Diagram – 4 Awnings ................................................................................................................21
Standard Service Procedures ....................................................................................................23
Adjusting the Pitch................................................................................................................................23
Setting the Motor Limits........................................................................................................................24
Adjusting the OUT Limit Switch.........................................................................................................24
Adjusting the IN Limit Switch.............................................................................................................24
Programming the RR24 for the Remote...............................................................................................25
Manual Override...................................................................................................................................26
Standard Maintenance................................................................................................................27
Fabric Care...........................................................................................................................................27
Mildew...............................................................................................................................................27
Pooling..............................................................................................................................................27
Arm Care ..............................................................................................................................................27
Motor Maintenance...............................................................................................................................27
Illustrated Parts List....................................................................................................................28
Part Number Configuration...................................................................................................................30

APEX Service Manual Carefree of Colorado
2 052522-301
PRODUCT OVERVIEW
The Apex Patio Awning offers the coach owner an awning system that provides as much or as little shade
as required. The canopies are housed in an aluminum case that easily blends in with the coach roof. The
awning extends to a maximum of 10 feet from the side wall. The canopy is made from Sunbrella® Acrylic
fabric.
Each unit is equipped with lateral support arms that are the strongest available on the market. No vertical
arms interfere with coach sidewalls or equipment that may be mounted on the roof. These arms can also
be adjusted to vary the canopy pitch up to 3 feet (it is strongly recommended that service and adjustments
be performed by trained technicians).
The unique and innovative 110V electronic control system provides Carefree’s Direct Response system with
interior touch pad controls for standard extend/retract functions. At the master control panel the auto-retract
system can be engaged to automatically retract the awnings in windy conditions with sensitivity, set by the user, to
respond to a variety of wind speed conditions. An optional RF remote is available with the Direct Response
system.
Apex Patio Awning Specifications
The following information is for reference only. Specific information is detailed in the installation instructions.
LENGTHS: 15’ – 22’ (in 1 foot increments)
EXTENSIONS: 10’ Drop: 12" @ Minimum Pitch 36" @ Maximum Pitch
COLORS AVAILABLE: Case: Standard: White; Optional: Black, Champagne, Pewter
Fabric: Sunbrella Acrylic Fabric refer to order form for available colors
MOTOR SPECIFICATIONS:Available in LH or RH configurations
Type: Tubular Motor
Power: 120V, 60HZ, 2.5A
Torque: 60 nm
Speed: 14 RPM
Cycle: 40 Sec ON / 1 Min OFF
APPROXIMATE WEIGHT (LBS.)
Awning Length (ft.) Weight Awning Length (ft.) Weight Awning Length (ft.) Weight
12 155 16 192 20 227
13 162 17 198 21 234
14 169 18 205 22 240
15 185 19 216
Notes: 1. The Apex awning measurement is end of case to end of case including the two standard end caps.
2. The awning uses 4 mounting brackets that are 7” wide and 24" long.
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CANOPY REPLACEMENT
During the following instructions, use the manual override procedure on page 26 to open and close the awning.
CAUTION
WHEN MOVING AN AWNING OR LIFTING THE ROLLBAR AND MOTOR OUT OF THE CASE,THE SERVICING TECHNICIAN
MUST USE CARE TO NOT BREAK OR DAMAGE THE MOTOR AND SENSOR CABLES.
Mounting
Bracket (ref)
Retaining
Bolt
Idler
Canopy
DETAIL E
RTA017a
DETAIL B
Canopy
Motor
Roll Bar
Lead Rail
Motor Attach
Screws
Outer Spring Arms
Firmly Tie
Elbows Together
DETAIL A
End Cap
Top Cover
Remove Screw
DETAIL C
DETAIL D
Lead Rail Retainer Screw
DETAIL F
1. Disconnect power to the awnings.
2. For multiple awning installations where the awnings are mounted end to end it will be necessary to move the
unaffected awning. (refer to Detail A) To move an adjacent unaffected awning:
2.1 Close the awning if open.
2.2 Loosen the retaining bolts in the back of the mounting plates.
2.3 Slide the awning away from the other awning, allow a minimum of 6" to 8" between awnings. See
Caution above.
2.4 Temporarily tighten at least one of the retaining screws.
3. Open the awning to be serviced several inches to expose the arm elbows.
4. (refer to Detail B) Using a minimum 1/2" rope, firmly tie the elbows of the outer spring arms together, do not
use bungee cords. When tying the rope, use a non-slip knot such as a square knot or equivalent.
CAUTION
FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY
EXTEND OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING.
5. (refer to Detail C) Remove the two fabric retainer screws on both sides of the lead rail and set aside.
6. (refer to Detail D) Remove the 3 screws holding the end cap of the motor end (if installed) and remove
from the case.
7. Remove the top screws holding the top cover. Rotate the top cover back and out of the way. If rotated
back without obstructions, the top cover will disengage from the pivot rail and can be set aside.
8. Use the manual override to unroll the canopy until the roll bar slot holding the canopy and polyrod is exposed.
9. (refer to Detail E) Remove the screws and nuts holding the motor.
10. Carefully lift the motor and rollbar up then pull out until the idler shaft clears the frame on the other end.
Rest the motor and roll bar on the case or a flat surface. See the Caution above about motor cables.
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11. (refer to Detail F) From the idler end of the rollbar, simultaneously slide the old canopy out of the roller
tube and lead rail.
12. Slide the new canopy into the lead rail and roller. Both edges must be done at the same time.
13. Roll up excess fabric on the roll bar. The material rolls over the top of the roll bar.
14. Lift rollbar and canopy up and insert the idler shaft into the end plate of the awning frame.
15. Position the motor end of the rollbar into the awning frame and secure using the nuts and screws
removed previously.
16. Center the canopy into the slots of the rollbar and lead rail.
17. Use the manual override to roll the canopy onto the rollbar. Ensure the fabric rolls evenly onto the rollbar.
18. Once the fabric is snugly rolled up, remove the rope used in step 4.
19. Restore power to the awning.
20. Extend and retract the awning several times. This will allow the canopy to self-center.
NOTE: It may be necessary to adjust the motor limits. Refer to page 23.
21. Install the fabric retainer screws in the lead rail.
22. Install the top cover and end caps if installed.
23. Reposition the adjacent awning if it has been moved. Ensure that all the retaining bolts are properly
tightened.
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SPRING ARM REPLACEMENT CAUTION
THE SPRING ARM IS UNDER TENSION TO OPEN.USE EXTREME CARE TO FIRMLY HOLD THE SPRING ARMS DURING
ASSEMBLY AND DISASSEMBLY TO AVOID ANY SUDDEN OR UNEXPECTED MOVEMENT BY THE ARM.SERIOUS
PERSONAL INJURY AND/OR PROPERTY DAMAGE COULD OCCUR.
The following procedure requires two people.
1. Open the awning to the maximum extension or as
wide as possible. This is to minimize the spring
tension in the arms during this procedure.
2. Disconnect power to the awning.
3. Use a scaffold, ladder or other means to firmly
support the lead rail.
4. (refer to Detail A) At the lead rail, remove the
M12-1.25 x 90 bolt, lock washer and nut from the
arm and lead rail connector.
5. Slightly loosen the 6mm adjustment screw. DO
NOT loosen the outer set screw.
6. Firmly grasp the spring arm and slide the lead rail
arm knuckle out of the lead rail connector. Allow
the arm to extend to its maximum length outside
the lead rail. Have a second person hold or
otherwise support the unattached end.
7. (refer to Detail B) Inside the case, remove the
M12-1.25 x 25 bolt and washer from the side of
the arm support. Remove the M12-1.25 x 40 bolt,
washer and saddle from the front of the support.
8. Slightly loosen the 6mm locking screw.
9. Firmly grasp the spring arm and slide the case
arm knuckle out of the arm support. Set the old
arm aside.
NOTE: On replacement arms, the lead rail
connector and the arm support are
included for instances when additional
damage (i.e. lead rail) has occurred.
10. On the replacement arm assembly, remove the lead rail connector and arm support bracket from the
arm knuckles.
11. Using two people firmly hold the new arm assembly and remove the shipping ties. Allow the arm to
slowly open to its maximum extension. CAUTION
WHEN THE ARM IS CLOSED,IT CAN OPEN WITH SIGNIFICANT FORCE.USE CARE WHEN OPENING THE ARM.
Tip: Use a floor or ground cover and place one knuckle and arm half on the ground. Have one person
firmly hold the arm half on the ground while the second person carefully opens the other arm half.
12. Lift the arm assembly into position.
13. (refer to Detail B) Slide the case arm knuckle into the support inside the case and secure with 1 each
M12-1.25 x 25 bolt and washer and 1 each M12-1.25 x 40 bolt, washer and saddle. Do not tighten at
this time.
A
Detail A (Lead Rail)
Detail
B (Case)
B
M12-1.25 x 25
Bolt & Washer
Saddle
M12-1.25 x 40
Bolt & Washer
Arm Support
6mm Locking Screw
6mm Adjustment Screw
M12-1.25 x 90
Bolt, Washer &
Nut
RTA029
Lead Rail Connector
Lead Rail
Arm Knuckle
Case Arm Knuckle
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14. (refer to Detail A) insert the lead rail arm knuckle into the lead rail connector and secure with 1 each
M12-1.25 bolt, washer and nut. Do not tighten at this time.
15. Adjust the arm pitch as required. Follow the procedure for pitch adjustment on page 23.
16. Restore power to the awning
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MOTOR REPLACEMENT
During the following instructions, use the manual override procedure on page 26 to open and close the awning.
For multiple awning installations where the awnings are mounted end to end it will be necessary to move the
unaffected awning. CAUTION
WHEN MOVING AN AWNING OR LIFTING THE ROLLBAR AND MOTOR OUT OF THE CASE,THE SERVICING TECHNICIAN
MUST USE CARE TO NOT BREAK OR DAMAGE THE MOTOR AND SENSOR CABLES.
Mounting
Bracket (ref)
Retaining
Bolt
DETAIL D
RTA030
DETAIL B
Canopy
Motor
Roll Bar
Lead Rail
Motor Attach
Screws
Outer Spring Arms
Firmly Tie
Elbows Together
DETAIL A
End Cap
Top Cover
Remove Screw
DETAIL C
1. Disconnect power to the awnings.
2. (refer to Detail A) To move an adjacent unaffected awning:
2.1 Close the awning if open.
2.2 Loosen the retaining bolts in the back of the mounting plates.
2.3 Slide the awning away from the other awning; allow a minimum of 6" to 8" between awnings. See
Caution above.
2.4 Temporarily tighten at least one of the retaining screws.
3. Open the awning to be serviced several inches to expose the arm elbows.
4. (refer to Detail B) Using a minimum 1/2" rope, firmly tie the elbows of the outer spring arms together, do not
use bungee cords. When tying the rope, use a non-slip knot such as a square knot or equivalent.
CAUTION
FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY
EXTEND OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING.
5. (refer to Detail C) Remove the 3 screws holding the end cap of the motor end (if installed) and remove
from the case.
6. Remove the top screws holding the top cover. Rotate the top cover back and out of the way. If rotated
back without obstructions, the top cover will disengage from the pivot rail and can be set aside.
7. Use the manual override to partially unroll the canopy to provide slack in the fabric.
8. (refer to Detail D) Remove the screws and nuts holding the motor.
9. Carefully lift the motor and rollbar up then pull out until the idler shaft clears the frame on the other end.
Rest the motor and roll bar on the case or a flat surface. See the Caution above about motor cables.
10. Disconnect the motor wires from inside the coach and pull out or clip the motor wires. If cutting the
motor wires be sure to leave enough wire that can be stripped and spliced.
11. Note the orientation of the motor then pull the motor assembly out of the roll bar.
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12. Remove the drive gear and crown from the existing motor and install on the new motor
13. Slide the new motor assembly into the roll bar. Ensure that the motor drive gear and crown are
properly seated inside the roll bar.
14. Route the new motor wire into the coach and attach (refer to wiring diagrams on page 17 for the
appropriate control system) or if the wires were cut, splice the new wires to the existing wires. Ensure
that the wire colors match (i.e. red to red and black to black). All wiring must conform to NEC
(National Electrical Code) and local codes.
15. Roll up excess fabric on the roll bar. The material rolls over the top of the roll bar.
16. Lift rollbar and canopy up and insert the idler shaft into the end plate of the awning frame.
17. Position the motor end of the rollbar into the awning frame and secure using the nuts and screws
removed previously.
18. Use the manual override to roll the canopy onto the rollbar. Ensure the fabric rolls evenly onto the rollbar.
19. Once the fabric is snugly rolled up, remove the rope used in step 4.
20. Restore power to the awning.
21. Extend and retract the awning several times. This will allow the canopy to self-center.
22. It will be necessary to adjust the motor limits. Refer to page 24.
23. Install the top cover and end caps if installed.
24. Reposition the adjacent awning if it has been moved. Ensure that all the retaining bolts are properly
tightened.
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