Albatros/Albatros Plus

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1 Albatros/Albatros Plus Albatros SINGLE MODULE Albatros DUAL MODULE Albatros PLUS Assembly manual

2

3 Assembly manual Albatros/Albatros Plus SUMMARY 1 Introduction Symbols used in the manual Requirements on the staff Required equipment Before initiating the assembling Safety General safety information Requirements to work safely Work environment... 3 Technical tables for assembly Guide support feet distance diagram (Albatros) and column position (Albatros Plus) Individual module cutting measurements Double module or multimodular cutting measurements Preloaded springs Min./ max dimensions based on the springs with Screen-Soltis fabric Spring tension with Screen-Soltis fabric Min./ max dimensions based on the springs with Acrylic fabric Spring tension with Acrylic fabric Albatros e Albatros Plus components Exploded view Albatros Exploded Albatros Plus Components...10 Fabric assembly on the winder pipe Pulley assembly Assemble the box plugs Insert the motor Spring assembly Preload the springs with the Screen-Soltis fabric Preload the springs with the Acrylic fabric Inserting the cord Select and fasten the feet Albatros Plus column assembly Double Module or Multimodular Assembly Central joint assembly with small plates with a pin Central joint assembly with small plates with a pin and motor Assemble the central joint with two motors Assembly of the motor Table choice of engines Packing...22 rev.06 2/07/11 3

4 Albatros/Albatros Plus Assembly manual 1 Introduction This awning manual was prepared by the Manufacturer to provide those authorized to assemble the components that make up the product with the necessary information. It is prohibited to remove, rewrite or in any way modify the pages of the manual and their content. Assembly must be carried out by personnel with the technical and professional skills required by current applicable national laws or standards (see chap. 1.2 Personnel requirements ). This manual should be kept intact in all its parts and in an easily accessible place. The manufacturer reserves the right to update the manufacturing and manuals, with no obligation to update previous manufacturing and manuals. The manufacturer reserves all rights on this manual. no complete or partial reproduction is permitted without writtenconsent thereto. 1.1 Symbols used in the manual The symbols used in the manual are shown below. Useful suggestions and instructions to ensure proper assembly of the awning. Failure to observe these messages may compromise the integrity and/or the resistance of the product. Danger to the operator! Instructions to be evaluated and followed carefully. Failure to comply with these messages may compromise individual safety. 1.2 Requirements on the staff The team dedicated to this operation must be in possession of a technical knowledge of product, with at least two years of experience or an appropriate course within the technical training. 1.3 Required equipment To ensure proper assembly of the mechanical part and of the fabric part, and as a result the proper operation of the finished product, you will need the following equipment: fabric rewinder frame; awning assembly frame with vertically mobile positioning bar; screwdriver; a level; complete tool kit; equipment for working at high levels (jolts, ladders, scaffolding, working platforms, etc.) that comply with existing safety regulations for persons on job. All of the screws used on aluminium components must be tightened with a maximum force of 20Nm (=2Kgm). Maximum force by tightening the screws can cause rupture of mergers and damage to the screw steel. It is recommended to use torque wrenches and screwdrivers. 1.4 Before initiating the assembling Before starting the assembly, the technician must have already done the cutting guides, profiles and roller tube depending on the size of the extendable awning that is desired (see Chapter 3.2 and 3.3 Size cutting table ). 2 Safety 2.1 General safety information Do not set objects on the canvas of the awning. It is prohibited to stand on or hang from the awning: This would create the risk of severe personal injury, as well as damaging the awning. 4 rev.06 2/07/11

5 Assembly manual Albatros/Albatros Plus Wear protective clothing and equipment required by the applicable standards of safety in workplaces. Assembly of components must be carried out only by skilled, specialized personnel. 2.2 Requirements to work safely Installation should be done in full compliance with the DPR Legislative Decree 164/6 and 494/96 for everything that concerns the safety of persons. Before use, check that all temporary structures (scaffolding, ladders, etc.) and all individual safety gear (harnesses, belts, etc.) are compliant with standards and in good condition. Always use appropriate personal protective equipment. If the installers are more than one, you must coordinate the work. Operators must conduct themselves in accordance with received safety instructions. If the extendable awning is to be mounted to a plane higher than the earth, it is necessary to demarcate and patrol the area during the climb to the floor of the extendable awning so that no one is under any suspended load. Firmly tie the ropes or straps around the arm supports so that it does not slip and risk falling. 2.3 Work environment Assembly of components must be carried out in a place that is sufficiently illuminated (based on specific standards) by either natural or artificial lighting. The operator must in fact have good visibility for the work involved, and must also prevent any third person being near to the extendable awning working area. 3 technical tables for assembly 3.1 Guide support feet distance diagram (Albatros) and column position (Albatros Plus) Albatros The guide support feet adjust the awning position. For protrusions exceeding 300 cm, a third foot is added. See Fig. 1 (measurement in cm). Albatros PLUS Position the column bar about 20cm from the guide cap. max protrusion 400 for protrusions > min 260 max 360 B/2 B/2 B min 100 max 00 fig. 1 fig. 1a rev.06 2/07/11

6 Albatros/Albatros Plus Assembly manual 3.2 Individual module cutting measurements TABLE WITH THE SIZES OF THE INDIVIDUAL MODULE (measurements in mm) L indicates the total awning size, H=height, SP=projection Albatros Albatros PLUS UPPER AND LOWER BOX SOMFY MOTOR A-110 A-110 GUIDING RAIL SOMFY MOTOR SP-18 SP-18 TERMINAL SOMFY MOTOR A-13 A-13 COVER SOMFY MOTOR A-13 A-13 REWINDER TUBE SOMFY MOTOR A-7 A-7 WINDBREAKER SOMFY MOTOR A-12 A-12 SOMFY MOTOR A-14 A-14 FABRIC THE FABRIC IS ATTACHED 3 MM FROM THE EDGE OF THE ROLLER TUBE FROM THE MOTOR SIDE COLUMN MOTORE SOMFY - H-36 COLUMN S CROSSBAR PROFIL MOTORE SOMFY - A-13 An awing L in length equal to A. is produced with these measurements. 3.3 Double module or multimodular cutting measurements A B C D box cap box cap central joint central joint front view motor motor motor bird's eye view fig. 2 6 rev.06 2/07/11

7 Assembly manual Albatros/Albatros Plus TABLE WITH THE SIZES OF THE DOUBLE OR POLYMODULARMODULE Albatros AND Albatros PLUS (measurements in mm) MOTOR MODULE B MODULE C MODULE D GARBAGE BIN UPPER AND LOWER SOMFY MOTOR B-108 C-106 D-108 GUIDING RAIL SOMFY MOTOR SP-18 SP-18 SP-18 TERMINAL SOMFY MOTOR B-133 C-130 D-133 COVER SOMFY MOTOR B-133 C-130 D-133 REWINDER TUBE SOMFY MOTOR B-6 C-4 D-6 WINDBREAKER SOMFY MOTOR B-120 C-90 D-120 FABRIC SOMFY MOTOR B-143 C-140 D-143 THE FABRIC IS BLOCKED 3MM FROM THE MOTOR SIDE. COLUMN SOMFY MOTOR H-36 H-36 H-36 COLUMN S CROSSBAR PROFIL MOTORE SOMFY B-104 C-73 D-104 To read the table, refer to fig. 2, page 6. An awing L in length equal to A. is produced with these measurements. 3.4 Preloaded springs The springs are preloaded as described on page 13. The following tables explain how to open the awning to obtain the right preload. The measurements are indicative Min./ max dimensions based on the springs with Screen-Soltis fabric SPRING AWNING SIZE (measurements in m) SPRING 4MOL_ SPRING 9MOL MINIMUM MEASUREMENTS MAXIMUM MEASUREMENTS Minimum WIDTH PROTRUSION WIDTH PROTRUSION maximum minimum maximum rev.06 2/07/11 7

8 Albatros/Albatros Plus Assembly manual Spring tension with Screen-Soltis fabric The minimum preload of the springs with Screen-Soltis fabric is about 20/30mm when the awning is closed. This measurement is valid for all the awnings of realizable dimensions. (see table , p. 7). For the type of springs to use based on the dimensions, refer to table MOL TYPE SPRING Resting length = 364 (measurements in mm) Maximum length = 700 (measurements in mm) 4MOL TYPE SPRING Resting length = 40 (measurements in mm) Maximum length = 870 (measurements in mm) Min./ max dimensions based on the springs with Acrylic fabric SPRING AWNING SIZE (measurements in m) SPRING 4MOL SPRING 9MOL MINIMUM MEASUREMENTS WIDTH minimum PROTRUSION maximum MAXIMUM MEASUREMENTS WIDTH minimum PROTRUSION maximum Spring tension with Acrylic fabric TIGHTENING THE ACRYLIC Albatros AWNING FABRIC WIDTH in m PROTUSION in m TOTAL LENGTH OF THE SPRINGS WHEN THE AWNING IS HALF OPEN 9MOL TYPE SPRING 4MOL TYPE SPRING Resting length = 364 (measurements in mm) Resting length = 40 (measurements in mm) Maximum length = 700 (measurements in mm) Maximum length = 870 (measurements in mm) 8 rev.06 2/07/11

9 Assembly/installation manual Albatros/Albatros Plus 4 Albatros and Albatros PLUS Components Key 4.1 Exploded View of Components 1 Cassette end cap and guide end cap 2 Ø80mm Rollerbat 3 Ø80mm cap with Ø14mm hole and bearing 3/1 Ø80mm cap with Ø14mm hole 4 Albatros profile set Tightening kit and front bar caps 13 6 Ø19mm spring Guide profile Ø 60mm windbreaker profile 9 Ø60mm cap with threaded pin 10 Supports for windbreaker Middle cassette end caps and middle guide end caps Middle guide profile 13 H30 plate with sliding round pin 14 Gasket 1 Ø3mm polyester rope 16 Brush for cassette Albatros 17 Adjustable guide support on the side 17/1 Inclinable and adjustable guide support 17/2 Adjustable guide support 17/3 Internal niche supports Profile for guide supports Albatros PLUS 19 Cassette wall brackets 20 Cassette ceiling brackets Universal profile 22 Perimeter support for guide 23 T shaped joint /2 17/3 24 Foot 2 Angular support 26 26mm over-roof bracket /1 fig. 1 rev.06 2/07/11 9

10 Albatros/Albatros Plus Assembly/installation manual 4.2 Exploded Albatros Plus Components fig rev.06 2/07/11

11 Assembly manual Albatros/Albatros Plus Fabric assembly on the winder pipe The instructions which follow are of a general nature and must therefore be adapted to the model of awning being assembled. E To make this easier, it is advisable to temporarily fasten the rewinder tube to the canvas rewinder frame. A B C fig. 3 Apply two rivets on both sides of the tube (E). Be careful when attaching these rivets: they should be slightly inclined (between the fabric and the groove) in order to guarantee correct blockage. 6 Pulley assembly Instructions for installation are described in the "Installation Manual". fig. 3 1 On the control side of the roller tube, insert the cap with the square pin (A). 2 On the opposite side, insert the round pin cap (B) or, alternatively, the one with the hole (C). fig. 6 6 Insert the brush and the seal in the lower box. fig. 4 3 Place the previously packaged fabric in the nose cone of the winder pipe and slide to the opposite side. 4 Rotate the roller tube in the right direction taking care on the command side rev.06 2/07/11 11

12 Albatros/Albatros Plus Assembly manual G 11 With the awning wound, wrap the cord around the pulley once or twice (L). 12 From the cap side, position the roller tube in the lower corner of the container (I). 6.1 Assemble the box plugs F N M fig. 7 7 Position the winding pulley from the lateral engine without locking it with the beads (G). 8 Position the winding pulley so it is in contact with the cap and locking it with the beads (F). fig Assemble the box plus with the small plate with the pin (M). 14 Attach the box cap to the engine (N). 26mm >30mm H collar O P washers fig. 8 9 Calculating the cord length to use: Cord length = (awning width + awning protrusions) x 4 10 Insert the cord inside hole (H) of the pulley, knotting it on both sides of the tube. (see fig. 8) Insert the cord in the hole on the side of the collar. fig Check that the size of the engine head allows the pulley to be positioned at about 26 mm from the box cap (O). If the engine size is greater than 30 mm, add two or more washers next to the diverter pulleys (P) to compensate the difference and block its stroke. I L fig rev.06 2/07/11

13 Assembly manual Albatros/Albatros Plus Insert the motor Inserting the motor can be done in two ways: MODULE A 1st hole 2nd hole S T fig Once the engine is hooked to the box cap, insert it in the roller tube. 17 Block the pulley by using the beads. fig Create two 8 mm holes (S) about half a meter from one another along the terminal to drain the water. MODULE B Q 21 Attach the blocking clamp on the terminal (T). fig Enter the engine in the roller tube and attached the box cap to the box (Q). fig Roll up the canvas and insert the lower edge in the terminal ferrule. R fig Pass the cord through the box cap in both sides of the roller tube, checking that it goes above the small pulley (R). U fig Fasten the canvas onto the terminal using one screw (U) per side. The screws should be slightly inclined (between fabric and frame) to ensure proper locking. rev.06 2/07/11 13

14 Albatros/Albatros Plus Assembly manual 6.2 Spring assembly fig Insert the springs in the sheaths. The springs can be inserted later. Nevertheless, we suggest assembling them with the caps before attaching them to the terminal Preload the springs with the Screen-Soltis fabric 26 With the awning closed, after having blocked the cords inside the terminal, preload the springs by pulling the cords separately until both lengthen the minimum value indicated on page Ensure that the dual pulley is half the length of the terminall 28 Check that when the awning is completely open, the springs do not touch The spring preload value can change based on the elasticity of the fabric, respecting the minimum prescribed value Each preloaded cm increases the the length of the completely open awning springs. To improve the fabric tightness, increase the preload, keeping the maximum length allowed in mind. 29 When the awning is completely open, ensure that the length does not exceed the maximum values indicated in paragraph on page Preload the springs with the Acrylic fabric fig Position the springs above the terminal and attach the caps to the screws (lubricate the springs with silicon grease). To tighten the springs, refer to the tables on page 7-8 and carefully follow the instructions. 30 After blocking the cords inside the terminal, open the awning for up to half of its protrusion 31 Pull the cords separately so both springs reach their determined length 32 Ensure that the pulley is half the length of the terminal 33 Check that the cord is taut when the awning is closed 34 Check that when the awning is completely open, the springs do not touch 3 The preload spring measurements are indicative and can vary based on the elasticity of the fabric 36 Each preloaded cm increases the the length of the completely open awning springs. To improve the fabric tightness, increase the preload, keeping the maximum measurements allowed in mind. When the awning is completely open, you must ensure that the length does not exceed the maximum values indicated in awning tightening table on page 8. The springs are preloaded in two different ways based on the awning fabric. 14 rev.06 2/07/11

15 Assembly manual Albatros/Albatros Plus 6.3 Inserting the cord fig Place the small plates in the guide section bars (V). (For each guide section bar, include: 2 small plates for the cassette cap, 1 for the guide cap and 2 for each foot; if you want to add a windbreaker, include another small plate). V fig Pass the cord through the terminal cap pulley and through the hole. To assemble Albatros Plus, include 2 small plates for each rail to attach the angular joint. fig Assemble the rails by keeping the cord taut so that it does not come out of the pulleys. fig Pass the cord under the rail cap pulley. fig Pass the cord exiting the terminal cap through the dual compensation pulley. rev.06 2/07/11 1

16 Albatros/Albatros Plus Assembly manual 6.4 Select and fasten the feet blocking clamp fig Thread the sheath and pass the second cord through the dual pulley. Before blocking it, make a knot in the cords. 43 Block the cords with the blocking clamp fig. 28 Four types of feet can be used: (1): foot for horizontal-lateral adjustments; (2): foot for vertical adjustments; (3): variable height foot (this is foot (2) with an aluminium bar that helps increase the distance from the porch). (4): variable height foot and 90 incline 1) 7 90 K 27 Z Y 64 fig Insert the brush in the upper box (Z). 4 Attach to the plastic covers to the box cap (V). 46 Place the cover bar on the terminal (K). 6 fig. 29 Foot clearances for horizontal-lateral adjustments. 2) mm 20 mm A B fig Use the extra screws to attach the box caps to the rails Foot clearance for vertical adjustments: minimum height (A); maximum height (B) fig rev.06 2/07/11

17 Assembly manual Albatros/Albatros Plus 3) C , fig. 31 Variable height foot. Advised rail height, see (C). For the minimum and maximum foot measurements, refer to fig. 33, page 17. fig Assemble the supports selected to install the awning. 4) D fig. 32 Variable height foot. For the minimum and maximum foot measurements, refer to fig. 33, page 17 A fig For sizes exceeding 4x4m, we suggest assembling the windbreaker roller (D) to have more fabric tension. 7 Albatros plus column assembly E F G L I H 41 A min 70 max 200 fig Insert the small plates (G) in the column rail (H) that are used to attach the perimeter support. 1 Insert the other two small plates in one side of the column rail (H) only to attach the perimeter support. fig. 33 Albatros interaxial feet, single module. A = awning width, (measurements in mm). Insert two small plates in the slot (I) on the universal rail to fasten the angular support. 2 Attach the small plate (F) with four screws (E) to the universal rail (H). rev.06 2/07/11 17

18 Albatros/Albatros Plus Assembly manual 8.1 Central joint assembly with small plates with a pin M fig Attach the foot to the universal rail/column using screws (M). N fig. 40 Left central joint with small plate with a pin for the multimodular Albatros with the motor on the opposite side. 9 Attach the small plate with the pin on the central joint using the appropriate screws. P O J fig Insert two small plates (J) in the universal rail (O) to fasten the angular support. Attach the perimenter support (N) to the universal rail (O) using four screws (P). 8 Double Module or Multimodular Assembly fig Assemble the left central joint to the lower box. Before attaching the joint to the box, check that the tube pulley is aligned with the small central joint pulley. To fasten the joint to the box, make holes for the screws with a Ø2.8/3.0 bit (3. mm screws) in positions 1 and 2 indicated in figure 42 and 43. fig. 39 The assembly procedure is similar to the one for the single Albatros. There are 3 configurations for the central joint: 6. central with two small plates with a pin 7. central with one small plate with a pin and motor 8. central with two motors 18 rev.06 2/07/11

19 Assembly manual Albatros/Albatros Plus fig. 42 fig Repeat the assembly operation for the right central joint and attach it to the left central joint using the appropriate screws 1, 2 and 3. R fig Fasten the joint with the box using self-threading screws. fig Insert the upper box in both sides; make the hole in the position indicated in figure 3 (hole no. 3) and attach it with screws (R). 8mm Q fig Assemble the central rail to the central joint and attach it using the appropriate screws (Q) To transfer the cord, follow the same procedure for the single Albatros module. fig Assemble the canopy and make a hole with a Ø3.8/4mm bit (screws from 4.8mm), 8mm from the outside edge. 66 Attach it to the central joint with a self-threading screw. rev.06 2/07/11 19

20 Albatros/Albatros Plus Assembly manual When large awnings have to be assembled and they cannot be assembled in the workshop, assemble the left part, then the right part and then test them separately. To support the central rail when the right part is assembled, make a hole near the central joint tab (see Fig. 48 (S)). fig Assemble the central joint with the lower box and attach it with the appropriate screws (to position the screws, see fig. 42 and fig. 43, page 19). 8.3 Assemble the central joint with two motors S fig Central joint assembly with small plates with a pin and motor To assemble the awning with two motors, see the instructions in section 7.2. Repeat the operation on the opposite side of the awning. 9 Assembly of the motor The following instructions are general in nature and must therefore be adapted to the model of the engine that is being assembled. Follow the instructions in the manual as supplied with the requested motor. U Z T W fig To assemble the left part, follow the instructions in section 8.1 Central Joint Assembly with Small Plates with Pin. 68 For the right part of the awning, insert the roller tube (T) motor and attach the motor plate to the central joint using the appropriate screws. 69 Check that the tube pulley is aligned with the small central joint pulley. Z fig.1 71 Insert the crown (Z) into the tube from the motor side. 72 Rotate the crown until complete match up of their locations of interlocking crown-engine (W) until it clicks. 20 rev.06 2/07/11

21 Assembly manual Albatros/Albatros Plus U V fig Insert the adapter (U) in the other side, ensuring that there is a proper joint. Insert the appropriate fixed engine staple (V). Having assembled the awning and the engine, adjust the limit switches by following the instructions in the "Engine Manual" attached. 9.1 Table choice of engines Albatros AWNING MOTOR TABLE WIDTH in m PROTRUSION in m Nm 0Nm 4 rev.06 2/07/11 21

22 Albatros/Albatros Plus Assembly manual 10 PACKING bubble wrap be careful when moving the awning. If necessary, use suitable lifting and moving equipment. Also make sure that there are no people in the work area. extendible film fig Package the rails with extendible film. fig Close the awning completely. 7 Remove the caps from the rails on both sides of the awning. 76 Remove the cover rail from the terminal. To package the double module, wrap the central joint first with bubble warp; position the previously packaged side rails externally and package everything with extendible film (see fig. 4). cover rail terminal fig. 7 fig Individually package the rail caps with bubble wrap and place it above the terminal, leaving the cord attached. 78 Attach them to the box with extendible film. fig. 79 Remove the box cap rails and package them individually. fig.8 81 Package the box with the terminal cover bar with bubble wrap, being careful to keep the two bars separate to avoid dragging them. 22 rev.06 2/07/11

23 KE PROTEZIONI SOLARI srl Via Calnova, 160/a Noventa di Piave (VE) Italy tel fax Via Mateotti, 21/ Rancio Valculvia (VA) Italy tel fax

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