Carefree Mirage 2-Stage Service Manual Download Page 32

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IRAGE

2-S

TAGE

Service

Manual

Carefree of Colorado

052588-301r4

ART

UMBER

ISTING

ART

UMBER

ERIAL

UMBER

OCATION

LLUSTRATED

ARTS

IST

M2501

HS Configuration

Canopy construction with

horizontal seams (current)

VS Configuration

Canopy construction with
vertical seams (previous)

There are two configurations of the
Mirage 2-Stage based on the canopy
construction as shown above.

Original Motor Configuration

(Silver Body)

Detail

(VS Configuration)

(HS Configuration)

M2017

Serial# / Part# Located
Inside Case on Motor Side

Summary of Contents for Mirage 2-Stage

Page 1: ...onal injury and or cause the product to not operate properly For LED replacement parts and service procedures refer to 070013 301 LED Service Manual for Box Awnings available on line at www carefreeofcolorado com IMPORTANT NOTICE The adjustments and repairs described in this book should be performed by trained technicians at Authorized Carefree Dealerships Work performed by non authorized persons ...

Page 2: ...Operation Items 11 Diagnostic Tests Direct Response for Single Awning 12 Testing the System Single Awnings 12 Diagnostic Tests Direct Response for Multiple Awnings 15 Testing the System Multiple Awnings 15 Electronics 19 Wiring Diagram Single Awning 20 Wiring Diagram 2 Awnings 21 Wiring Diagram 4 Awnings 23 Connection Flex w 110VDR Control Boxes 25 Optional Manual Bypass Switch 25 Sensor Replaceme...

Page 3: ...ssages 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 Al...

Page 4: ......

Page 5: ...rations Power 120V 60Hz 2 5A Torque 60nm Speed 14 RPM CONTROLS Carefree Direct Response COLOR Hardware Black Fabric Woven Acrylic refer to sales literature for colors Optional factory installed 12V LED lighting mounted in the lead rail is available for the Mirage 2 Stage awning LED lighting requires a separate 12V control switch There are two configurations of the Mirage 2 Stage based on the canop...

Page 6: ... the time the motor runs 3 3 Extend to confirm that the adjustment is correct 3 4 Repeat the procedure until the awning extends correctly 4 If the arms do not extend completely 4 1 Retract the awning approximately 10 12 4 2 Using a 4mm Allen wrench turn the OUT limit switch to increase the time the motor runs 4 3 Extend to confirm that the adjustment is correct 4 4 Repeat the procedure until the a...

Page 7: ...ce allowances based on the minimum distance from the top of a projection i e open door or slide out to the bottom of the mounting plate B This provides clearance for the travel path of the lead rail Wall 0 0 A Projection Door Slideout 0 12 24 36 48 60 72 B Min Mounting Height min pitch 3 5 5 8 25 12 16 21 26 B Min Mounting Height max pitch 3 8 14 20 5 28 36 5 45 The minimum mounting height B is me...

Page 8: ... with the coach wall 10 When the lead rail adjustments are completed tighten the 3 4 nut on the side of the knuckles MANUAL OVERRIDE If 110V power is not available to the vehicle the awning can still be safely retracted using the manual override The bypass may be accessed from inside the case on the motor housing or from the top of the case above the motor housing To use the inside bottom access T...

Page 9: ...signal CAUTION When the receiver learns the transmitter signal the system will perform the operation of the button pressed Example Pressing an Extend button during the learning phase will cause the awning to extend when the receiver learns the signal Use caution to avoid unexpected movement by the awning 6 Repeat for each additional remote OPERATIONAL NOTES The transmitter and receiver operate on ...

Page 10: ... slots in the roller tube 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 10 Slide the new canopy into the lead rail and roller tube 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 roller tube The hem sh...

Page 11: ...pposite end plate If this occurs reinsert the idler into the endplate before continuing NOTICE When pulling the motor out of the case the servicing technician must use care to not break or damage the sensor and LED cables routed through the end plate NOTE When pulling the motor it will be necessary to firmly support the roller tube to keep it from coming out of the case Do not let the roller tube ...

Page 12: ...wn are properly seated inside the roller tube NOTICE For the HS configuration When the crown is seated in the roller tube the canopy edge with the polyrod must be in the fabric groove of the crown 11 Attach the end plate to the motor the using the new screws and nuts provided Make sure to match the orientation from the old motor 12 Route the new motor cable through the end plate 13 Press the motor...

Page 13: ...de the lead rail Have a second person hold or otherwise support the unattached end 9 Detail C 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 10 Slightly loosen the 6mm locking screw 11 Firmly grasp the spring arm and slide the case arm knuckle out of the arm support Set the arm ...

Page 14: ... and ramp block 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 7 Return to step 14 on the previous page Replacing the Case Arm Support 1 C...

Page 15: ... function LEDs extend retract and stop perform a dual function When the button is pressed the LED illuminates The LED stays illuminated during the selected operation and after the awning has fully extended or retracted This provides an indicator of the awning position When the stop button is pressed the LED will illuminate and stay on until a function is pressed If on it indicates that the awning ...

Page 16: ... POWER ON OFF button disables all functions including Auto Retract and the optional RF remote if installed It does not disconnect the 110VAC power 3 Press the POWER ON Press the EXTEND button the LED should illuminate while the awning extends and stay on after the awning auto stops Observe the awning it should fully extend The system performs an auto tension action when the awning is fully extende...

Page 17: ... system 1 or control box 1 2 Connect awning motor directly to 110VAC power source Motor White to Neutral White of AC cord Motor Green to Ground Green of AC cord Motor Red Black are Motor Direction Control connect Red to AC Hot Black 1 3 While observing awning briefly apply power 1 4 Disconnect power and attach other motor direction control wire Black to AC Hot Black 1 5 While observing awning brie...

Page 18: ...re ends between the Common and Retract terminals Does the awning move YES Control Board is good Touch pad is defective replace NO Control Board is defective replace control box D02 THE AWNING OPERATES DIFFERENTLY THAN THE SWITCH MARKINGS This condition generally occurs during new installations or when major components have been replaced A Does Awning operate in reverse of the switch plate labeling...

Page 19: ... Awning 1 EXTEND button The awning should extend 3 3 Press the extend button again The awning should stop 3 4 Press the extend button a third time Observe the awning it should fully extend The system performs an auto tension action when the awning is fully extended The awning rolls in reverse to tension the fabric The auto tension feature works only with the extend function when the awning is full...

Page 20: ...erate refer to D03 A Confirm 110VAC power to control box 5 Shut off power source 6 Open control box 7 On some early units a fuse is installed on the circuit board Check that fuses on circuit boards are intact 8 Check that 110VAC connections and splices to both boards are correct and secure Refer to system schematic 9 While observing the circuit boards have power restored The LEDs on the boards sho...

Page 21: ...Response auto retract system operates by gauging the motion of the awning s leading edge not by the direct wind speed Refer to the description in the operations section of the manual NOTE The awnings have independent sensors and may not retract concurrently A Press the power on button then press the auto retract button Do the auto retract LED flash YES The flashing LED indicate that the sensor s h...

Page 22: ...goes to pin 3 and pin 4 goes to pin 4 Cable must be plugged into the BUS port of controller 1 YES Cable is OK Confirm that cable is securely plugged in go to step 4 NO Repair or Replace cable as required 4 Confirm that the Receiver is programmed for the Remote Refer to Programming the Receiver on page 5 and retest If system does not work go to step 5 5 Program a second remote and test YES 2nd remo...

Page 23: ...reater than 10 feet the installer must provide a terminated jumper cable from the box location to the cable end Terminated cable is a 4 wire RJ11 terminated phone cord straight no twist The 110V electronic control system provides the user with simple pushbutton controls for the awnings installed Three configurations are available 1 Direct Response for Single Awning Installations System includes Co...

Page 24: ...D DR012a Ignition Switched 12VDC 12VDC Ground Ignition Lockout Sensor Optional Splitter Sensor Key Pad Awning 1 3 5 4 2 Conductor 14AWG NM Wire w Gnd To 110VAC AMD SUN AUX EYE DSK BLK WHT RED GRN grn wht blk 1 7 6 5 4 3 2 1 7 6 5 4 3 2 3 Conductor 14AWG NM Wire w Gnd Sensor Remote Red Black White Green Ground 1 Wire Legend 2 For RH Motor Configurations Motor Red goes to Pin 1 Motor Black goes to P...

Page 25: ...12VDC Ground Ignition Lockout Sensor Optional Sensor 1 Key Pad Sensor 2 Awning 1 3 5 RED WHT BLK GRN BLK WHT RED GRN Wht Blk Grn Wht Blk Grn 2 Conductor 14AWG NM Wire w Gnd To 110VAC AMD SUN AUX EYE DSK AMD SUN AUX EYE DSK 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 3 Conductor 14AWG NM Wire w Gnd Sensor GRN BLK WHT RED Awning 2 Sensor Remote 3 3 Conductor 14AWG NM Wire w Gnd DETAIL A 110VAC Power L...

Page 26: ...to any open EYE port Wires for Ignition Lock Out Sensor are not pin specific For screw type terminals After testing connections use Loctite 29005 or equivalent to secure screws in terminal block Cables are 4 wire RJ11 terminated phone cord straight no twist Terminal block designations are for reference only Actual boards may not be marked TO CONTROL BOARD FROM MOTOR 1 MOTOR 2 AC Power Source White...

Page 27: ...N AMD SUN AUX EYE DSK AMD SUN AUX EYE DSK AMD SUN AUX EYE DSK AMD SUN AUX EYE DSK 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 To 110VAC 3 Conductor 14AWG NM Wire w Gnd To 110VAC Sensor GRN BLK WHT RED Awning 2 Sensor Remote 3 3 Conductor 14AWG NM Wire w Gnd GRN BLK WHT RED Sensor 3 Sensor 4 Awning 3 3 3 Conductor 14AWG NM Wire w Gnd Sensor GRN BLK WHT RED Awning 4 Sensor ...

Page 28: ...minals After testing connections use Loctite 29005 or equivalent to secure screws in terminal block Cables are 4 wire RJ11 terminated phone cord straight no twist Terminal block designations are for reference only Actual boards may not be marked TO CONTROL BOARD FROM MOTOR 1 MOTOR 2 MOTOR 3 MOTOR 4 AC Power Source White 4 4 4 4 Black 5 5 5 5 Ground 7 7 7 7 Awning 1 Motor Black Refer to Flag Note 2...

Page 29: ...l boxes are compatible with integrator interfaces Contact Carefree engineering for information and system requirements OPTIONAL MANUAL BYPASS SWITCH Installers may elect to install a manual bypass switch for testing or emergency operation of the awning The simple switch allows the operator to extend or retract the awning without using the keypad control panel For multiple awning installations a se...

Page 30: ...ensor case 3 6 Test the continuity of the installed cable Several cable testers are commercially available If the cable is faulty go to Replacing a Sensor and Cable If the cable is OK go Installing a Sensor Only REPLACING A SENSOR AND CABLE 1 Remove the existing cable Pay particular attention to the routing and attachment points of the existing cable 2 Slide the new sensor into the vertical mounti...

Page 31: ...ldew will not appear However in areas where high temperature and humidity are common mildew can be a problem and required the material to be washed more frequently Thoroughly rinse the fabric with clean water and allow to air dry completely before rolling up the awning Pooling When water collects on the top of the fabric this is known as pooling This can occur during inclement weather or if a runn...

Page 32: ...27 27 27 28 HS Configuration Canopy construction with horizontal seams current VS Configuration Canopy construction with vertical seams previous There are two configurations of the Mirage 2 Stage based on the canopy construction as shown above 10 12 13 14 15 17 15 Original Motor Configuration Silver Body Detail A VS Configuration HS Configuration 11 25 16 15 M2017 Serial Part Located Inside Case o...

Page 33: ...5 Spring Arm Assy LH and Center Mill R012598 JVL115 Spring Arm Assy LH and Center Black 20 R019366 23L Lead Rail Connector LH 21 019260 001 Case Connector RH Mill 019260 JVR Case Connector RH Black 22 R012598 JVR115 Spring Arm Assy RH Mill R012598 JVR115 Spring Arm Assy RH Black 23 R019366 23R Lead Rail Connector RH 24 R001769xxx Middle Rail Assy 25 R036609 00X End Plate Lead Rail 26 R001770XXX xx...

Page 34: ...60596 001 Coupler Cable 14 R060532 001 Ignition Lockout Sensor R060532 002 Ignition Lockout Sensor RTL 15 R060589 001 Splitter 16 R060538 002 Motion Sensor w cable 17 R001355 Bracket Kit Vertical Sensor Mount 18 R040616 206 Cable Channel Notes 1 Control boxes switches and remotes are NOT interchangeable between systems For LED replacement parts and service procedures refer to 070013 301 LED Servic...

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