NEWMAR SERVICE SCHOOL TRAINING INFORMATION GUIDELINE FOR FEBRUARY 2013
OUR PRODUCTS: NOVA DUAL PITCH AWNING G-2000/ G-1500 2 P a g e
G-2085 G-5000 3 P a g e
G-LINKS 4 P a g e
NOVA/ G-2000/ G-1500 BASIC ADJUSTMENTS A. ADJUSTING MOTOR LIMIT SWITCHES NOTE: The motor limit switches have been adjusted to the correct position at the factory prior to shipment. The awning motor is set to stop the exact moment the awning box closes. The fabric should be taut, the arms should be slightly bent, exposing a 1/4 gap at the elbows. Always check the motor limits after installation to ensure that the awning opens and closes correctly. Awning fabric can stretch over time, this will require an adjustment of the OUT limit switch. IMPORTANT: EXTREME CARE SHOULD BE TAKEN TO ENSURE THAT THE MOTOR LIMIT TURNS OFF AT THE EXACT MOMENT THE AWNING BOX CLOSES. FAILURE TO DO SO WILL CAUSE THE MOTOR TO RUN WHEN THE AWNING IS CLOSED. THIS CAN SUBSTANTIALLY REDUCE THE LIFE OF THE MOTOR. 1. The AC motors used in Girard Systems awnings are reversible. Any reference made to the motor limit switches in these instructions are based on the right-hand placement of the motor. For left hand placement, simply reverse the instructions. (Figure 8) 2. The motor has limit settings for both OUT (extension) and IN (retraction). 3. Adjust the limit switches with the black key provided with the awning, or you may use a 4mm (5/32 ) allen wrench. 4. Extend the awning a few feet to gain access to the motor. Locate the motor (standard installation is on the right hand side of the awning). The limit adjustment holes are located on the head of the motor. Using the symbols printed next to the adjustment holes, turn the black key (or 4mm allen wrench) to make the necessary adjustments. Typically, the motors are labeled with a (+) or a (-). (Figure 9) 5 P a g e
1. (Figure 9) 5. Approximately ¼ turn of the adjustment screws represents about 1 of awning movement. NEVER set outward limits so that the fabric is slack with full arm extension. For proper adjustment set limit switch to stop the motor just before the arms lock. This will expose about an 1/4 gap at the elbow. B. ADJUSTING PITCH and ARM (Elbow) HEIGHTH NOTE: This adjustment is usually required after an arm replacement. Also, when the elbow of the arm hits the bottom of the casing as the lead rail closes. Tools Required 19mm (3/4 ) open-end wrench 6 P a g e
10mm (3/8 ) open-end wrench A. ELBOW HEIGHTH 1. Extend the awning about 18 2. On the selected arm, loosen the two(2) nylon nuts on the side of the upper arm connection (shoulder), using a 19mm open-end wrench. 3. Locate the smaller adjustment bolt located directly below the rear lock nut loosened in step #2. (Figure 10) Using a 10mm open-end wrench rotate the bolt clockwise to TIGHTEN and raise the arm location inside the cassette. Rotate the bolt counter-clockwise to LOOSEN or lower the arm location inside the cassette. 4. NOTE: After retightening the nylon nuts, the arms will raise slightly higher. 5. Tighten the two(2) nylon nuts located on the side of the upper arm connection. 6. Close the awning completely to ensure a proper fit. Loosen front bolt Pivot bolt Adjustment bolt Arm elevator screw (Figure 10) B. ADJUSTING PITCH NOTE: Your NOVA Awning will have the pitch adjusted to its highest point. DO NOT TRY TO RAISE THE PITCH, this could result in damaging the awning. 1. Extend the awning about 18. 7 P a g e
2. On the arm selected, loosen the two(2) nylon nuts on the upper side of the arm connection using a 19mm open-end wrench. 3. Locate the larger adjustment bolt located on the bottom of the upper arm connection (shoulder). (Figure 11) Using a 19mm open-end wrench rotate the bolt counter-clockwise to LOOSEN or lower the pitch. If the pitch is lowered too far you may turn the bolt clockwise or TIGHTEN to raise the pitch. DO NOT OVERTIGHTEN. 4. Tighten the two(2) nylon nuts located on the side of the upper arm connection. 5. Close the awning completely to ensure a proper fit. Adjustment bolt (Figure 11) C. TESTING THE ANEMOMETER (Wind Sensor) 1. Partially extend the awning. 8 P a g e
2. Manually employ the anemometer by blowing on the cups or by spinning them. 3. At this point the awning should retract; if not, check motor connection for proper polarity. NOTE: The Anemometer will send a retract signal to all of the awnings installed on the RV. The power system of the vehicle must be able to withstand the resulting surge of current. The surge will be the greatest when the awnings are fully extended. When testing the system verify all of the awnings will close when fully extended. If the system does not operate correctly under these conditions you may: A. Provide sufficient power from your panel. B. Replace the anemometer in the electronics system with a Motion Sensor. D. ADJUSTING THE LEAD RAIL 1. The lead rail on your awning has been preset from the factory at +/- 3 degrees. This allows the lead rail to rest firmly into the cassette and also creates a weather resistant seal for travel. To increase or decrease the pitch angle insert a 5mm allen wrench into the top pitch-angle screw. Turn clockwise to increase the pitch and turn counterclockwise to decrease the pitch. (Figure 12) Lead rail Pitch-angle screw Tension plate Horizontal lead rail adjustment screw (Figure 12) 9 P a g e
G-5000 BASIC ADJUSTMENTS SPRING TENSION ADJUSTMENT The tension of the Torsion Spring is preset at the factory between 7 and 8 full turns. 1. To adjust the tension, facing the G5000, gently remove the left end (LH) plastic cap. 2. Attach Girard Tension Tool to 3/8 rachet. Insert tension tool in to square tube. Maintain tension on spring. Proceed to remove two center screws. 3. NOTE: Use caution when removing the two (2) center screws (#22) on the slide plate: The spring is under tension and may cause the ratchet to turn violently inflicting injury. 4. Hold the ratchet handle tight as you remove part the two center screws from the spring support and carefully release all tension. Use channel locks on the special tool to maintain the tension while repositioning the ratchet handle. 5. Now you are ready for tensioning. Take up fabric slack. Apply 7 full turns, or 14 half turns (follow arrows on end plate to tension). 6. Awnings of widths greater than 244 inches (G5000 Super-slide) are equipped with two (2) springs (one at each end). In this case, you will also need to adjust the tension of the second spring (right hand) (in this case clockwise more tension, counter-clockwise less tension). 7. Replace the screws and plastic end cap. SPRING REPLACEMENT 1. Facing the G5000, take care and remove the plastic end cap. 2. Attach Girard Tension Tool to 3/8 ratchet. Insert tension tool in to square tube. Maintain tension on spring. Proceed to remove two center screws. 10 P a g e
3. NOTE: Use caution when removing the two (2) center screws (on slide plate. The spring is under tension and will cause ratchet to turn violently. 4. Hold the ratchet handle tight as you remove the two center screws from the spring support, and carefully release all tension. Use channel locks on the tension tool to maintain the tension while repositioning the ratchet handle. 5. Remove the three remaining screws from the metal side plate. 6. Pull defective spring assembly out of roller tube and insert replacement spring with the drive (stationary fitting) first. 7. Once spring is reinserted reinstall the retaining screws into the cassette. 8. Now we are ready for tensioning. Take up fabric slack. Apply 7 full turns, or 14 half turns (follow arrows on end plate to tension). 9. Re-attach center screws into spring support while maintaining tension. 10. Replace the end cap. G-2085 BASIC REPAIRS AND ADJUSTMENTS SETTING MOTOR LIMITS 1. Adjust the limit switches with the black plastic key (provided) or a 4mm Allen wrench. 2. Extend the awning a few feet and locate the cylindrical awning motor mounted inside the awning roller tube, standard installation is at the right/front end of the awning). The limit switches are mounted on the black casing at the exposed end of the motor. The limit switches are two directional arrows, each with a plus (+) sign and a minus (-) sign. The actual limit switch is the recessed hole next to the corresponding arrow. 11 P a g e
3. Adjust limits according to the directional arrows). A 1/4 turn represents approximately 1" of awning movement. Never set outward limits so that fabric is slack after full arm extension. Adjust limit switches until the motor stops at the exact time that the arms reach a 90 ANGLE with the coach wall. FABRIC CHANGE 1. Relieve the tension from fabric by (+) the out limit until the roller tube is exposed and fabric hangs straight down. 2. Remove lead rail end caps (both sides)and housing end cap opposite of motor and fabric screws on both sides of the lead rail. 3. Remove old fabric and insert new fabric. This operation is completed much easier with two people. 4. Close awning making sure fabric is rolling up straight evenly spaced on both sides of tube. Apply gentle pressure to both sides of the fabric as it rolls up. 5. Open awning about 1/2 way, then (-) the out limit to set the awning back to its original 90 degree position. 6. Re-attach fabric screws and lead rail caps and the housing cap. G-LINK SYSTEM OVERVIEW AND PROGRAMMING GC-136 PROGRAMMING NOTE: Before starting this procedure the Receiver must be without power (OFF) for at least 10 seconds. During the programming function the interval between each step required must be less than 10 seconds. A. Programming the GC136 to a Remote 1. Turn on the power to the GC136. 12 P a g e
2. Press the PROGRAM button using a paper clip or other small tool: the Green LED will start blinking. 3. Press STOP The Green LED will stop blinking and stay on solid. 4. Press the UP button on the REMOTE (Control or Unit): The Green LED will turn off. B. Cancel one Remote from the GC136 1. Turn on the power to the GC136. 2. Press the PROGRAM button (Fig. 2) using a paper clip or other small tool: the Green LED will start blinking. 3. Press STOP (Fig. 1): The Green LED will stop blinking and stay on solid. 4. Press the DOWN button on the REMOTE (Unit): The Green LED will turn off. C. Delete all of the Remotes from the GC136 1 1. Turn on power to GC136. 2. Verify which Button of the GC136 functions as DOWN button (Opens the Awning). 3. Press simultaneously the STOP and DOWN button of the GC136 for at least 6 seconds: The Green LED will first turn on solid and then blink a few times. When the Green LED turns off the operation is completed. D. Program Continuous or Step mode of operation 1. Turn on power to GC136. 2. Verify which Button of the GC136 functions as UP button (Closes the Awning). 3. Press simultaneously the STOP and UP button of the GC136 for at least 6 seconds: The Green LED will first turn on solid and then blink a few times. When the Green LED turns off the operation is completed. 12V MOTION SENSOR PROGRAMMING A. Programming the GC779G to the (GC136) 1. Power the GC779G to a 12volt DC circuit. 2. Set the Adjustment Dial to level 5. 13 P a g e
3. Press the PROGRAM button on the GC136 (The green LED will start blinking). 4. Press the STOP button on the GC136 (The green LED will stay solid). 5. Place the unit on the base (attached to the Lead Rail) so that the Reed Switch (see Picture 2) is in close proximity with the magnet on the base (the purple LED will light). 6. Press the PROGRAM button on the GC779G. 7. Test if the code was accepted by pressing again the push button on the GC779G (The Awning should retract). 8. If the Awning does not retract start over again. 9. Bring back the Black Dial to the desired sensitivity number (level 3 is the factory setting. ANEMOMETER PROGRAMMING A. Programming the GC116I to a GC-136 Receiver 1. Turn on the GC-136 and the GC116I (Leave them on if already on). 2. Press the PROGRAM button on the GC-136 (the LED will start blinking). 3. Press the STOP button on the GC-136 (The LED will be on solid). 4. Press the UP button on the GC116I. 5. Extend awing using a Manual Remote Control and press again the UP button on the GC116I to verify that the unit is working properly (the awning should Retract). GC 104 AND 105A PROGRAMMING A. PROGRAMMING THE REMOTE CONTROLS TO A RECEIVER 1. Select on the GC105A the desired Channel, GC104 is single channel. 2. Make sure that the Receiver (GC136) is powered on. 3. Press the PROGRAM button on the Receiver: the Green LED of the Receiver will start blinking. 4. Press STOP on the Receiver: The Green LED will stop blinking and stay on solid. 5. Press the UP button on the GC106: The Green LED will turn off. 14 P a g e
GC 229 AND 230 PROGRAMMING A. To Program GC229 OR GC230 to a GC-136 Receiver 1. Turn on the GC-136 (Leave it on if already on). 2. Press the PROGRAM button on the GC-136 (the LED will start blinking). 3. Press the STOP button on the GC-136 (The LED will be on solid). 4. Press the desired UP button on the GC229 OR GC230. 5. Extend or Retract the awning to verify that the unit is working properly. THIS CONCLUDES THE BRIEF OVERVIEW OF SOME OF GIRARD SYSTEMS PRODUCTS. PLEASE CONSULT THE CD COPY OF THE MANUALS FOR ANY INFORMATION NOT COVERED IN THIS HANDOUT. FOR ANY OTHER TECHNICAL SERVICE QUESTIONS PLEASE FEEL FREE TO CALL GIRARD SYSTEMS SERVICE LINE MONDAY THROUGH FRIDAY 7AM TO 5PM PST. THE TOLL FREE NUMBER IS (800)382-8442. 15 P a g e
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