Carefree DIRECT RESPONSE User manual

052567-001r5 Printed in USA September, 2016
C AREFREE
TRAVEL'R DIRECT RESPONSE
AUTO-RETRACT SYSTEM
The Travel'r Direct Response Auto-Retract System may be installed as part of the original Travel'r awning
installation or as an upgrade to an existing awning installation.
TABLE OF CONTENTS
Prior to Installing the Kit................................................................................................................................3
Installing the Sensor.....................................................................................................................4
Switch Installation.........................................................................................................................7
Wiring an Additional Extend/Retract Switch.................................................................................................8
Attach the Label ............................................................................................................................8
Read this manual before installing or using this product. Failure to follow the instructions
and safety precautions in this manual can result in personal injury and/or cause the
product to not operate properly.
Carefree of Colorado 2145 W. 6
th
Avenue Broomfield, CO 80020 a Scott Fetzer company

T RAVEL ' R D IRECT R ESPONSE I NSTALLATION M ANUAL C AREFREE OF C OLORADO
2 052567-001r5
P ROPRIETARY S TATEMENT
The Travel'r Direct Response 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.
S AFETY I NFORMATION
This is the safety alert symbol. It is used to alert individuals to potential
personal injury hazards. Obey all safety messages that follow this symbol to
avoid possible personal injury or death.
WARNING
Indicates a hazardous situation, which if not avoided, could result in death or
serious bodily injury.
CAUTION
Indicates a hazardous situation, which if not avoided, may result in minor or
moderate bodily injury.
NOTICE
Indicates a situation that may result in equipment-related damage.
General Safety:
WARNING Shock Hazard. Always disconnect battery or power source before
working on or around the electrical system.
WARNING Always wear appropriate safety equipment (i.e. goggles).
CAUTION Always use appropriate lifting devices and/or helpers when lifting or
holding heavy objects.
NOTICE When using fasteners, do not over tighten. Soft materials such as fiberglass and
aluminum can be "stripped out" and lose the ability to grip and hold.
CALIFORNIA PROPOSITION 65
WARNING This product contains chemicals known to the state of California to cause
cancer or birth defects or other reproductive harm. California’s Proposition 65 requires this
warning to be given to customers in the state of California.
Reference Publications available on-line at www.carefreeofcolorado.com:'
052540-002 Fixed Pitch Travel'r Installation Manual
052540-021 Adjustable Travel'r Installation Manual
052540-221 Travel'r Owner's Manual
052540-301 Travel'r Service Manual
Carefree of Colorado 2145 W. 6
th
Avenue Broomfield, CO 80020 a Scott Fetzer company

CAREFREE OF COLORADO INSTALLATION MANUAL TRAVEL'R DIRECT RESPONSE
052567-001r5 3
ITEM DESCRIPTION QTY NOTE
1 Sensor Module 1
2 Switch Kit 1
3 Covered Bezel, 2 Switch 1 1
4 Cable 205" 1
5 Terminal, Female, .187 18-22 awg 3
6 Terminal, Female, .187 14-16 awg 2
7 Terminal, Female, .25 14-16 awg 3
8 Terminal, Male, .25 14-16 awg 3
9 Cord Retainer 1
10 Label, Direct Response 1
Note: 1. The covered bezel (item 3) is optional and ordered separately. Refer to page 7 for information about
NFPA 1192 RV Standard, Section 6.4.9 (Switch Installation Requirements).
PRIOR TO INSTALLING THE KIT
For New Installations – These instructions assume that the awning and arms have been mounted and that the
motor cable from the arm has been routed through the exterior wall as described in the awning installation
instructions. These instructions replace the switch and wiring directions included with the awning.
For Existing Installations – The installer must locate and remove any existing switches. Access to the motor cable
and the 12VDC/Ground wires is required.
1. Determine the location of the switches:
1.1 Do not mount the switches near heat producing elements such as LP appliances or engine
exhaust components.
1.2 The dimensions for the switch plate are shown on page 7.
WARNING TO AVOID SHOCK HAZARD AND/OR ACCIDENTAL SYSTEM SHORTING,ALWAYS DISCONNECT
THE VEHICLE BATTERY AND ELECTRICAL SOURCES BEFORE WORKING WITH ELECTRICAL WIRING AND
COMPONENTS.
When the Direct Response installation is complete return to the original awning instructions for any final
assembly required.
LCDR002
1
2
4
5 876 10
9
RETRACT
ON
EXTEND
OFF
Awning Control
RETRACT
ON
EXTEND
AwningControl
OFF
3

TRAVEL'R DIRECT RESPONSE INSTALLATION MANUAL CAREFREE OF COLORADO
4 052567-001r5
INSTALLING THE SENSOR
This section is for fitting the motion sensor and wiring into the motor arm and head.
1. Open the awning completely.
2. Disconnect power to the awning.
3. (Detail A) Remove the front cover. There are six (6)
small screws through the back cover. Set parts aside.
4. Examine the rear cover.
4.1. For rear covers with emergency terminals:
Disconnect the wires from the emergency terminals
(Detail B). Do not remove the wires from the motor
at this time.
4.2. For rear covers without emergency terminals:
Separate the quick connect terminals in the arm.
4.3. Remove the rear cover. Set parts aside.
4.4. For rear covers with emergency terminals: Remove
the emergency terminals from the rear cover and
discard. Use care to not damage the rear cover.
5. Remove the two (2) screws holding the roller tube in
the endcap. Pull the roller tube out of the end cap
while holding the arm. Support the roller tube
NOTICE Do not allow the roller tube to drop
toward the ground. The twisting motion can
cause serious damage to the idler arm.
NOTE: The arm will extend out slightly when the
roller tube is detached.
6. Detach the motor assembly from the arm.
7. For units that had the emergency terminals on the
rear cover (refer to Detail C):
(for units without the emergency terminals go to step 8)
7.1. Partially pull the motor cable from the rear of the
arm (approximately 9"-10")
7.2. Cut the cable approximately 7" from the top of
the channel. Remove but DO NOT discard the
cable that was cut.
7.3. On the cable remaining in the arm: Strip
approximately 2" of the outer insulation to expose
the wires.
7.4. Strip and terminate the two wires in the cable with
.24, 14-16awg insulated female spade connectors.
7.5. Press the cable back into the channel groove leaving the connectors exposed.
7.6. For the cable that was removed: From the cut end, strip approximately 5" of the outer insulation to
expose the wires.
7.7. Strip and terminate the two wires in the cable with .24, 14-16awg insulated male spade connectors.
7.8. On the motor, replace the red and black wires with the newly made motor patch cable. Match the wire
colors (replace the red wire with the cable's red wire and the black wire with the cable's black wire).
Motor
Cable
Emergency
Terminals
Emergency
Terminals
RH Motor Head
7" .25, 14-16awg
Female Spade
Terminals (x2)
Motor
Patch Cable
.25, 14-16awg
Male Spade
Terminals (x2)
5"
DETAIL A
Rear
Cover
Motor
Assy
Motor
Cable
Front
Cover
DETAIL B
DETAIL C
LCDR001b
No
Terminals
Quick
Connects
Roller Tube Endcap

CAREFREE OF COLORADO INSTALLATION MANUAL TRAVEL'R DIRECT RESPONSE
052567-001r5 5
Match Colors
Red to Red
Black to Black
Motor Patch
Cable
Route module wires
down and behind motor,
connect to
motor patch cable
Connect switch wires
to module wires
(match colors)
Rear
Cover
Motor
Assy
Motor
Cable
Press New Cable
into Open Groove
of Front Channel
Press New Cable into
Open Groove of Channel #2
Clean this surface
Cutoff Tab from
Bottom of Front Cover
DETAIL A
12V Direct Response
Control Module
060686-001 Rev 1.0
DETAIL C
DETAIL D
DETAIL E
To Switch
DETAIL F
Front
Channel
Channel #2
Alternate
Switch
Routing
LCDR001a
Double Sided
Tape
Switch
Cable
3.5"
DETAIL
B
Cord
Retainer
Motor
Patch Cable Route long red & black
module wires inside arm
to motor cable
Front
Cover
Ø 5/16" Hole
Switch Cable
Top of Channel Routing
Bottom of Channel Routing
Ø 5/16" Hole
Switch Cable
Alternate
Routing

TRAVEL'R DIRECT RESPONSE INSTALLATION MANUAL CAREFREE OF COLORADO
6 052567-001r5
8. (Detail B) Clean the inner face of the motor frame.
9. Remove the release paper from the double-sided tape on the module. Position the module with the label out
and the two wires at the top and the 5 wires at the bottom. Firmly press the module against the inside face of
the motor frame. Ensure that the sensor does not touch the gears and that it is far enough inside to allow the
front cover to be installed.
10. Route the short red and black wires from the top of the module behind the motor and attach to the motor patch
cable.
11. Hold the motor assembly at the top of the arm channel.
12. (Details A & C) From inside the front channel, route the new module cable into the motor frame. The
cable must extend above the front channel 3.5".
13. Route the long red and black wires from the bottom of the channel down around the motor frame and
inside the front channel.
14. Attach the motor assembly to the front channel.
15. Lift and align the roller assembly with the end cap on the motor assembly. Rotate the end cap until the
slot in the cap aligns with the empty slot in the roller assembly, and then press the roller tube fully into
the cap. The end cap must seat squarely over the end of the roller tube when complete.
16. (Detail C) Connect the 5 colored short wires of the module to the wires from the cables. Match the
colors of the wires. The wiring diagram is on page 7.
17. In the front channel, attach the red and black wires from the module to the motor cable inside the
channel.
18. Secure the red and black wires into the groove of the front channel using a 2" piece of cord retainer.
19. Attach the rear cover.
20. (Detail D) Cut or break off the tab on the bottom of the front cover. Attach the front cover.
21. (Detail E) Route the new cable down the front channel pressing the cable into the open groove.
22. (Detail E) At the pivot joint, slip the cable into channel #2 under the shock mount.
23. Route the cable up channel #2 pressing the cable into the open groove.
24. Slip the cable through the open hole in the knuckle at the top of channel #2.
25. (Detail F) Route the new harness through the vehicle wall:
26. For top routing (cables enter the vehicle at the top of the arm): In the area shown, drill a 5/16” hole into
the vehicle. Route the cable to the switch location.
27. For bottom routing (cables enter the vehicle at the bottom of the arm):
27.1. Remove the fascia.
27.2. Loosen the attaching screws for the arm. If moly rivets have been used, it will be necessary to
drill off the head of the rivet use care to not enlarge the hole.
27.3. Slip the cable through the access hole at the top of the mounting channel and pull down. Lightly
pull the cable out of the bottom access hole and align cable with the rear channel groove.
27.4. Tighten the attaching screws for the arm. Replace any moly rivets that were removed.
27.5. Drill a 5/16" hole in area shown. Route the cable to the switch position.
27.6. Seal the hole and cable with a quality silicone sealant.
27.7. Reinstall the fascia.

CAREFREE OF COLORADO INSTALLATION MANUAL TRAVEL'R DIRECT RESPONSE
052567-001r5 7
SWITCH INSTALLATION
WARNING TO AVOID SHOCK HAZARD AND/OR ACCIDENTAL SYSTEM SHORTING,ALWAYS DISCONNECT THE
VEHICLE BATTERY AND ELECTRICAL SOURCES BEFORE WORKING WITH ELECTRICAL WIRING AND COMPONENTS.
Important Note: To comply with 2015 NFPA 1192 RV Standard, Section 6.4.9, switches must be
mounted as follows:
a) Installed in a dedicated switch cabinet with a latching door; or,
b) Installed with the optional covered bezel available from Carefree; or,
c) Installed in a cabinet with a latching door where the switch is protected and CANNOT be
activated by any items or cargo that may move or shift during transit; or,
d) Installed with an interrupt circuit that disables awning extension when the vehicle is in motion (i.e.
a relay tied into the parking brake or ignition that disconnects the BROWN extend wire).
1. At the switch location cut a 2 5/16" [5.9cm) x 1 1/2" [3.8cm] hole.
2. Route the cables from the arm through the hole.
3. Terminate the three (3) 20awg wires (Brown,
Yellow, Gray) with .187, 18-20 awg female
terminals. Attach to the EXTEND/RETRACT switch
as shown in the wiring diagram.
4. Terminate the RED wire from the motor cable with a
.187, 14-16 awg female terminal. Attach to one
terminal of the ON/OFF switch.
5. Terminate the BLACK wire from the motor cable with a
.25, 14-16 awg male terminal.
6. Run a minimum 14 awg wire to chassis ground.
Suitable ground would be the vehicle chassis or
conductive structure connected to the chassis.
Terminate the wire with .25, 14-16 awg female
terminal and connect to the black wire from the cable.
7. Run a minimum 14 awg wire from the power distribution panel (auxiliary battery circuit) or equivalent. The
circuit should be protected by a 15-amp fuse. Terminate the wire with a .187, 14-16 awg female terminal.
Attach to one terminal of the ON/OFF switch.
NOTE: If the wire run is 30 feet or longer, use 12awg wire to prevent voltage drop. Use the
appropriate wire terminals for the wire size.
8. Push the wires and switches into the hole then attach the switch frame using four (4) #6 x 1/2" screws.
9. Snap the switch bezel over the switch frame.
LCDR003c
On/Off
Extend/Retract
Rear View of
Switch Assy
Control Module
(mounted in
motor head)
Gray
Yellow
Brown
Red
Black
Awning
(Extend)
(Common)
(Retract)
(+12Vdc switched)
(Ground)
FM
FM
MF
MF
MF
FM
Chassis Ground
.25, 14-16awg
Spade Terminals
1 Male, 1 Female
To +12VDC
.187, 14-16awg Female
Spade Terminals (qty: 2)
.187, 18-20awg
Female Spade
Terminals (qty: 3)
Motor Cable
Switch Cable
M
F
M
F
Red
Black
Motor
Patch Cable
F
F
1" [2.5cm]
LCDR004
2.32" [5.9cm]
1.5"
[3.8cm]
#6 x 1/2" Screw (x4)
RETRACT
ON
EXTEND
OFF
Awning Control
RETRACT
ON
EXTEND
Awning Control
OFF
Optional
Covered Bezel

TRAVEL'R DIRECT RESPONSE INSTALLATION MANUAL CAREFREE OF COLORADO
8 052567-001r5
WIRING AN ADDITIONAL EXTEND/RETRACT SWITCH
This section is for wiring an additional EXTEND/RETRACT switch.
The switch must be momentary on, single
pole, double throw, center OFF
(Momentary ON – OFF – Momentary ON).
1. Route wires for the second switch to the
main switch location. Wires should be a
minimum 18awg.
2. Splice the wires in parallel with the
EXTEND/RETRACT switch wires from the
switch cable. Pin 1 of the additional
switch should go to pin 1 of the main
patio switch etc.
ATTACH THE LABEL
After completing and testing the system, attach the Direct Response identification label to the bottom of the
motor arm.
1. Thoroughly clean and dry the area at the bottom of the RH (motor) arm.
2. Remove the release paper and attach the "DR" label in the area shown
between the Carefree logo and the top of the plate.
Gray
Yellow
Brown
On/Off
Extend/Retract
Switch Cable
Rear View of
Switch Assy
LCDR003b
Gray
Yellow
Brown
Additional
Extend/Retract
Switch
LCDR006
Place DR Label
In This Area