Carefree of Colorado APEX User manual

S ERVICE M ANUAL
APEX
RV With Direct Response Electronics
052522-301r5 Printed in USA November, 2010

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:'
052522-002: Apex Installation Manual
052522-201 Apex Owner's Manual, Single Awning, Switch Button Controls
052522-220 Apex Owner's Manual, Multiple Awning, Full Time Direct Response
052522-230 Apex Owner's Manual, Multiple Awning, Key Pad Controls
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

Carefree of Colorado Service Manual APEX
052522-301r5 1
TABLE OF CONTENTS
Product Overview..........................................................................................................................2
Apex Patio Awning Specifications.......................................................................................................2
Canopy Replacement....................................................................................................................3
Spring Arm Replacement..............................................................................................................5
Replacing the Arm ..................................................................................................................................5
Replacing the Lead Rail Connector: ...................................................................................................6
Replacing the Case Arm Support........................................................................................................6
Motor Replacement.......................................................................................................................7
Removing the Awning...................................................................................................................9
Diagnostics/Troubleshooting.....................................................................................................10
Common Operation Items .................................................................................................................10
Diagnostic Tests – Direct Response for Single Awning........................................................................11
Testing the System – Single Awnings ..................................................................................................11
Diagnostic Tests – Direct Response for Multiple Awnings ...................................................................14
Testing the System – Multiple Awnings................................................................................................14
Electrical ......................................................................................................................................18
Wiring Diagram – Single Awning ..........................................................................................................19
Wiring Diagram – 2-Awnings ................................................................................................................20
Wiring Diagram – 4 Awnings ................................................................................................................22
Connection Flex w/ "110VDR" Control Boxes ......................................................................................24
Optional Manual Bypass Switch ...........................................................................................................24
Control Board Replacement - Direct Response....................................................................................25
Sensor Replacement for Direct Response ...........................................................................................26
Installing the Vertical Mount Bracket.................................................................................................26
Installing a New Sensor ....................................................................................................................26
Replacing the Touch-Pad with a Key Pad ............................................................................................28
Remove the Existing Control Pad .....................................................................................................28
Installing the New Key Pad ...............................................................................................................28
Standard Service Procedures ....................................................................................................29
Adjusting the Pitch................................................................................................................................29
Setting the Motor Limits........................................................................................................................30
Adjusting the OUT Limit Switch.........................................................................................................30
Adjusting the IN Limit Switch.............................................................................................................30
Programming the Remote Receiver .....................................................................................................31
Operational Notes: ............................................................................................................................31
Key FOB Batteries ............................................................................................................................32
Manual Override ...................................................................................................................................32
Standard Maintenance................................................................................................................33
Fabric Care...........................................................................................................................................33
Arm Care ..............................................................................................................................................33
Motor Maintenance...............................................................................................................................33
Illustrated Parts Listings.............................................................................................................34
Part Number Configuration...................................................................................................................34
Awning Components.............................................................................................................................35
Electronics Components.......................................................................................................................36
Component Identification......................................................................................................................38
Control Panel and Remotes Identification.........................................................................................38
Control Box Enclosure Identification .................................................................................................39

APEX Service Manual Carefree of Colorado
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 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 RF remote is furnished with the Direct Response system.
Apex Patio Awning Specifications
The following information is for reference only. Specific information is detailed in the installation instructions.
Length
RTA003
6.13"
[15.6cm]
8.75"
[22cm]
Direct Mount Slide & Lock Plates
LENGTH 12’ [3.7m] – 21’ [6.4m] (in 1 foot [.305m] increments)
EXTENSION: 10' [3m] DROP: 12" [30.5cm] @ Minimum Pitch; 36" [91.4cm] @ Maximum Pitch
Values are approximate, actual dimensions may vary with specific installations.
Tubular Available in LH or RH configurations
MOTOR: Power: 120V, 60Hz, 2.5A Torque: 60nm Speed: 14 RPM
CONTROLS: Direct Response with a single master control and single remote for all awnings.
COLOR: Hardware: Black
Fabric: Woven Acrylic (refer to sales literature for colors)
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
15 185 19 216
Notes: 1. The Apex awning measurement is end of case to end of case.
2. The awning uses 4 mounting brackets that are 7” wide and 24" long.
2 052522-301r5

Carefree of Colorado Service Manual APEX
CANOPY REPLACEMENT
During the following instructions, use the manual override procedure on page 31 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.
RTA017a
DETAIL B
Outer Spring Arms
Firmly Tie
Elbows Together
DETAIL A
End Cap
Top Cover
Remove Screw
DETAIL C
DETAIL D
Lead Rail
Retainer Screw
Canopy
End Plate
Glide Bearing
1. Disconnect power to the awnings.
2. (refer to Detail A)If installed, remove the 3 screws holding the end cap on the idler end and remove cap
from the case.
3. 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.
NOTE: On early units, the attach screws for the cover went through the end plates, under the end
caps. If this is an older unit, it will be necessary to remove both end caps to access the
cover screws.
4. Open the awning to be serviced several inches to expose the arm elbows.
5. (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 ARMS AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY EXTEND
OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING.
6. (refer to Detail C) Remove the two fabric retainer screws on both sides of the lead rail and set aside.
7. Use the manual override to unroll the canopy until the roll bar slot holding the canopy and polyrod is exposed.
8. (refer to Detail D) Remove the screws holding the idler end plate and remove plate from case and set
aside.
9. (refer to Detail D) From the idler end of the rollbar, simultaneously slide the old canopy out of the roller
tube and lead rail.
NOTE: It will be necessary to support the roll bar do not allow the rollbar to pull off the motor.
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APEX Service Manual Carefree of Colorado
4 052522-301r5
10. Inspect the slots in the roll bar and lead rail. Clean and deburr as required. Lightly spraying the inside
of the slot with a dry silicone lubricant will aid in sliding the new fabric in.
11. Slide the new canopy into the lead rail and roller. Both edges must be done at the same time. Orient
the fabric so that the large polycord goes into the lead rail, the smaller polycord goes into the roll bar.
The hem should be on the down side.
12. Center the canopy into the slots of the rollbar and lead rail.
13. Reattach the end plate to the case with the roll bar idler seated into the glide bearing.
14. Use the manual override to roll the canopy onto the rollbar, the material rolls over the top of the roll bar.
Ensure the fabric rolls evenly onto the rollbar.
15. Once the fabric is snugly rolled up, remove the rope used to secure the arms previously.
16. Restore power to the awning.
17. 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 29.
18. Install the fabric retainer screws in the lead rail.
19. Install the top cover.

Carefree of Colorado Service Manual APEX
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.
NOTE: If replacing an original series arm, it will be necessary to also replace the lead rail connector (page
6)
REPLACING THE ARM
The following procedure requires two people.
Detail A (Lead Rail)
Detail B (Case)
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
Washer & Nut
RTA029
Lead Rail Connector
Rail Knuckle
Case Knuckle
B
A
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. For arms with the sensor cable mounted, carefully
remove the sensor cable from the wire channel on
top of the arm. Use care to not bend, break or
compromise the cable.
5. (refer to Detail A) At the lead rail, remove the M12-
1.25 lock washer and nut from the arm and lead rail
connector.
6. Slightly loosen the 6mm adjustment screw. DO NOT
loosen the outer set screw.
7. 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.
8. (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.
9. Slightly loosen the 6mm locking screw.
10. Firmly grasp the spring arm and slide the case arm
knuckle out of the arm support. Set the old arm aside.
11. If the arm has wire channel mounted for the sensor cable, carefully remove the channel from the arm to
reuse on the new arm.
12. On the replacement arm assembly, remove the lead rail connector and arm support bracket from the
arm knuckles.
NOTE: The lead rail connector and arm support bracket are included in case there is damage to the
existing brackets. If there is no damage, it is not necessary to replace them with the arm.
13. If replacing the lead rail connector or case arm support, go to page 6then return to step 14.
14.
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.
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APEX Service Manual Carefree of Colorado
6 052522-301r5
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.
15. Lift the arm assembly into position.
16. (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.
17. (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.
18. If the sensor cable is routed on the replacement arm:
Attach a piece of wire channel to the top of each section of the arm. If using new channel, cut
each piece slightly shorter than the arm extrusion. Attach the channel using double sided tape.
Route the cable through the wire channel. At the arm joints, arch the cable slightly to avoid
binding. Do not twist the cable.
Tip: Use a small tool, such as a flat bladed screwdriver to gently spread open the channel then insert
the cable. Do this for the entire length of the channel until the cable is fully inserted.
19. Adjust the arm pitch as required. Follow the procedure for pitch adjustment on page 29.
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 30.
Replacing the Lead Rail Connector:
1. Remove the lead rail end plate.
2. Carefully mark the location of the existing connector.
3. Loosen the 6mm securing screw and slide the existing connector from the lead rail.
4. Insert the new connector assembly into the lead rail and position at the marks made previously.
5. Tighten the outer 6mm securing screw.
6. Attach the lead rail end plate.
Replacing the Case Arm Support
1. Carefully mark the location of the existing support.
2. Open the upper cover of the case.
3. Remove the end cap if installed.
4. Remove the end plate. (Refer to details on page 3)
For the idler side, remove the end plate screws then slide the end plate off of the roll bar idler and
set aside.
For the motor side, remove the motor attach screws and set end plate aside.
5. Loosen the clamping screws on the support and slide the old support out of the case.
6. Insert the new support assembly into the case and position at the marks made previously.
7. Tighten the clamping screws.
8. Reinstall the end plate. Ensure that the idler pin of the roll bar is properly seated. If previously
detached, securely fasten the motor to the end plate.
9. Close and secure the top cover if open
10. Reinstall the end caps if previously installed.
11. Return to step 14 on the previous page.

Carefree of Colorado Service Manual APEX
MOTOR REPLACEMENT
During the following instructions, use the manual override procedure on page 31 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.
Drive
Crown Motor
Cover
(ref)
Roll Bar (ref)
RTA030a
Mounting
Bracket (ref)
Retaining
Bolt
DETAIL D
DETAIL B
Outer Spring Arms
Firmly Tie
Elbows Together
DETAIL
A
End Cap
Top Cover
Remove Screw
DETAIL
C
End Plate Assy
1. Disconnect power to the awnings.
2. Locate the junction box inside the coach and disconnect the motor wires.
3. (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.
4. Open the awning to be serviced several inches to expose the arm elbows.
5. (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 ARMS AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY EXTEND
OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING.
6. (refer to Detail C) For older units, 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.
NOTE: On early units, the attach screws for the cover went through the end plates, under the end
caps. If this is an older unit, it will be necessary to remove both end caps to access the
cover screws.
8. Use the manual override to partially unroll the canopy to provide slack in the fabric.
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APEX Service Manual Carefree of Colorado
8 052522-301r5
9. (refer to Detail D) Remove the screws holding the end plate.
10. Carefully lift up and pull out the end plate, motor and rollbar until the idler shaft clears the end plate on
the other end. Rest the motor and roll bar on the case or a flat surface. Use care to not stretch or
damage the canopy.
11. If not previously done, disconnect the motor wires from inside the coach and pull out.
12. Remove the screws and nuts holding the motor to the end plate. Set the end plate aside. Note the
orientation of the motor then pull the motor, crown and drive out of the roll bar.
13. Remove the drive gear and crown from the existing motor and install on the new motor
14. Attach the new motor assembly to the end plate using the screws and nuts removed previously.
15. Slide the new motor assembly into the roll bar. Ensure that the motor drive gear and crown are
properly seated inside the roll bar.
16. Lift rollbar and canopy up and insert the idler shaft into the idler end plate.
17. Position motor end plate on the case and attach using the screws removed previously.
18. Route the new motor wire into the coach and attach (refer to wiring diagrams on page 18 for the
appropriate control system). 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.
19. Use the manual override to roll the canopy onto the rollbar. Ensure the fabric rolls evenly onto the rollbar.
20. Once the fabric is snugly rolled up, remove the rope used to secure the arms.
21. Restore power to the awning.
22. Extend and retract the awning several times. This will allow the canopy to self-center.
23. It will be necessary to adjust the motor limits. Refer to page 30.
24. Install the top cover and end caps if installed previously.
25. Reposition the adjacent awning if it has been moved. Ensure that all the retaining bolts are properly
tightened.