ORANGEBOX Air 3 pod Installation Instructions Manual Download Page 20

Page: 20 / 216

BUILD THE CURVED

CONNECTOR PARTS

(NUMBERED 4) AROUND

THE CENTRAL HOOP

ALIGNMENT JIG

1 OF EACH x

OPEN AND CORRECTLY POSITION

THE HOOP ALIGNMENT JIG

PARTS FIRST (NUMBERED 1)

COMPLETE THE OVERALL JIG

BY CONNECTING THE FRONT

ALIGNMENT PARTS (NUMBERED 5 &6)

FINALLY, USE THE AIR-JIG-008

HOOP SET SQUARE PARTS TO

CHECK THE VERTICAL ANGLE OF THE

HOOP UPRIGHTS

KIT CONTENTS:

2 X AIR-JIG-001

2 X AIR-JIG-004

1X AIR-JIG-005-01

1 X AIR-JIG-005-02

HALF ROUND ALIGNMENT JIG

REV0

2.3

Summary of Contents for Air 3 pod

Page 1: ...O N L YMO D E L SA I R 2 3 A I R 2 5 A I R 2 7 A I R 2 9A R EE T LL I S T E D R e v i s i o n 1 1 S e p t e mb e r 2 0 1 7...

Page 2: ...ckets and checking alignments 3 4 Attaching top screen covers to check alignments 3 5 Attaching fan cowls and plugging fan in 3 6 4 Front and back glass frame assemblies 4 1 Square frame assembly opti...

Page 3: ...oining the glass 6 20 Sealing the glass 6 20 6 22 7 Glass door Installation 7 1 Assembling door runners 7 2 Bottom door track glides into glass 7 3 Lifting door onto track 7 4 Levelling door 7 5 7 7 D...

Page 4: ...HORISED PERSONNEL PERMITTED TO PARTICIPATE IN ASSEMBLY ORANGEBOX CERTIFIED PERSONNEL ONLY APPROPRIATE PPE MUST BE WORN AT ALL TIMES DURING ASSEMBLY OF ORANGEBOX PRODUCTS PART ASSEMBLED PODS MAY NOT BE...

Page 5: ...e Mallet 1 Touch Up Paint Provided By Orangebox 2 Glazing Shovel Plastic Hoop Opener Provided by Orangebox 1 Straight Cut Aviation Snips or similar 1 Metric T Handle Hex Key 2 5mm 1 Metric T Handle He...

Page 6: ...Steamer 1 Circuit Tester Pen Plug Socket Tester Tools Equipment Alignment Jigs Jigs Pods Page Half Round Pod Alignment Jig Air 10 2 3 Air 11 Round Pod Alignment Jig Air 12 2 4 Air 13 Logenze Pod Alig...

Page 7: ...n n e c t i o nt ot h el i s t i n gf o r as p e c i f i i c p r o j e c t t h ec u s t o me r w i l l h a v et ow o r k d i r e c t l y w i t ht h eA H J a n dl o c a l c o d ec o n s u l t a n t t o...

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Page 19: ...T JIGS TO SET POSITION OF POD ENSURE AREA IS FLAT AND FREE OF DEBRIS ENSURETHAT THERE ISADEQUATE HEIGHT FOR POD USE AS SIGN OFF POSITION FROM CLIENT USE TO CHECK FLOOR BOX POSITIONS LiONE PERSON MINIM...

Page 20: ...THE HOOP ALIGNMENT JIG PARTS FIRST NUMBERED 1 COMPLETE THE OVERALL JIG BY CONNECTING THE FRONT ALIGNMENT PARTS NUMBERED 5 6 FINALLY USE THE AIR JIG 008 HOOP SET SQUARE PARTS TO CHECK THE VERTICAL ANGL...

Page 21: ...4 AROUND THE CENTRAL HOOP ALIGNMENT PART JIG 4 FINALLY USE THE AIR JIG 008 HOOP SET SQUARE PARTS TO CHECK THE VERTICAL ANGLE OF THE HOOP UPRIGHTS CONNECT THE FRONT REAR ALIGNMENT PARTS NUMBERED 5 6 KI...

Page 22: ...BUILD THE ROUND CONNECTOR PARTS AROUND THE TWO HOOP JIGS NUMBERED 4 5 CONNECT THE ROUND FRONT REAR ALIGNMENT PARTS NUMBERED 5 6 FINALLY USE THE AIR JIG 008 HOOP SET SQUARE PART TO CHECK THE VERTICAL A...

Page 23: ...STRAIGHT SCREEN CONNECTORS NUMBERES 13 7 4x FINALLY USE THE HOOP SET SQUARE PART TO CHECK THE VERTICAL ANGLE OF THE HOOP UPRIGHTS NUMBERED10 IDENTIFY THE POSITION OF THE CURVED DOOR FRAME AND POSITION...

Page 24: ...MINI POD JIG 3 CONNECT THE TWO HALFS TOGETHER TO COMPLETE THE OVERALL JIG LAYOUT 2 CONNECT PARTS 2 8 AND 7 TOGETHER TO CREATE THE SECOND HALF OF THE MINI PODJIG KIT CONTENTS 2 X AIR JIG 002 2 X AIR JI...

Page 25: ...AROUND THE CENTRAL HOOP ALIGNMENT PART JIG COMPLETE THE OVERALL JIG BY CONNECTING THE FRONT REAR ALIGNMENT PARTS NUMBERED 3 KIT CONTENTS 2 X AIR JIG 001 4 X AIR JIG 002 4 X AIR JIG 003 2 X AIR JIG 00...

Page 26: ...LY POSITION THE HOOP ALIGNMENT JIG PARTS FIRST NUMBERED 1 CONNECT THE TWO HOOP JIGS TOGETHER BY USING THE INTERMEDIATE CONNECTORS NUMBERED 9 FINALLY USE THE AIR JIG 008 HOOP SET SQUARE PART TO CHECK T...

Page 27: ...STRAIGHT CONNECTOR PARTS AROUND THE TWO HOOP JIGS NUMBERED 2 4 4x CONNECT THE STRAIGHT FRONT REAR ALIGNMENT JIGS NUMBERED 3 12 5 FINALLY USE THE HOOP SET SQUARE PART TO CHECK THE VERTICAL ANGLE OF THE...

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Page 38: ...UK SMOKE DETECTOR MOUNTING 2 21...

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Page 40: ...U S AH E A TD E T E C T O R MO U N T I N G 2 21 2...

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Page 42: ...F O RC O N N E C T I N GP O WE RI N T OP O DP L E A S ES E EP A G E S2 2 3 2 2 8F O RV A R I O U S O P T I O N SA V A I L A B L E...

Page 43: ...uit Board Switch Input Circuit Mains Out Fan Connection Actuator Outlet Lighting Vent Control Box Power Cut Off Circuit Male Female GST 18 Connector LED LED XIM Adaptor Ring LED C W Reflector Legend R...

Page 44: ...u p p l i e d d 7 8 I n c h d i a me t e r o p e n i n g T h e r e a r e s e v e r a l t y p e s o f c o n d u i t s a n d c a b l e s t h a t c o u l d b e u s e d i n a c c o r d a n c e w i t h C h...

Page 45: ...ower Cut off Male Female GST 18 Connector Mains Socket Outlet x 3 Supply in Mains Outlet x 3 P I R Presence Detector Membrane Switch Connected to Switch Input Circuit Board Lighting Vent Control Box N...

Page 46: ...1111 CII POWER CONNECTION REFERENCE FIXED ROOFS UK POWER ONLY FIXED ROOF UK POWER AND DATA 1111 DATA CABLES CABLE FROM LIGHTS TO POWER SOCKETS CABLE FROM CONTROLBOX TO POWER CABLE 2 26...

Page 47: ...NING ROOFS UK POWER ONLY OPENING ROOFS UK POWER AND DATA RJ45 CABLE FROM AUTOMATED ROOF BOX TO CONTROL BOX CABLE FROM LIGHTS TO POWER SOCKETS CABLE FROM CONTROL BOX TO SOCKETS RESET BOX TO CONTROL BOX...

Page 48: ...d d7 8I n c hd i a me t e r o p e n i n g T h e r ea r es e v e r a l t y p e s o f c o n d u i t s a n dc a b l e s t h a t c o u l db eu s e di n T h e r ea r es e v e r a l t y p e s o f c o n d u...

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Page 52: ...O ADJUST HOOK POSITION IF REQUIRED M6X20 GRUB SCREWS ENSURE HOOK IS LOCATED ON THE BOTTOM INDENTATION SEE THE KNACK SECTION 10 4 BACK OF POD t TWO PERSONS MINIMUM SEE PAGE 10 4 FRONT OF POD DOOR THESE...

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Page 54: ...FIT BRACKET AND REPLACE AND FULLY TIGHTEN FIXINGS BACK OF POD FRONT OF POD DOOR 0 SEE SECTIONS 10 4 10 7 USE CLAMPS AND SOFT MALLETS TO ADJUST SCREENS AS REQUIRED TOP OF BOTH SCREENS MUST BE IN LINE...

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Page 65: ...IGHTS BEFORE ATTACHING TO SCREENS DOOR FRONT OF POD OFFER FRAME UP TO SCREENS AND V ATTACH AS SHOW N 12M6X8 N04 T BAR M6X12 FOR HALFPODS TO RQUE 3NM 2 21 FT LBF QTY 3 M6 ROLL IN T NUTS PER UPRIGHT LOC...

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Page 110: ...x 2167h Glass 6 875w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to be cut do...

Page 111: ...ss 6 875w x 2167h Glass 7 875w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to...

Page 112: ...2167h Glass 7 875w x 2167h Glass 8 875w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics wil...

Page 113: ...7 875w x 2167h Glass 8 930w x 2167h Glass 9 1040w x 2167h Glass 10 1040w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustmen...

Page 114: ...167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to be cut down to the actual visual s...

Page 115: ...Glass 5 875w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to be cut down to the...

Page 116: ...Glass 5 1024w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to be cut down to t...

Page 117: ...w x 2167h Glass 6 1024w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphics will have to be cut...

Page 118: ...x 2167h Glass 6 1024w x 2167h Glass 10 1024w x 2167h Graphic Application Notes Dimensions provided are taken from the full glass panel size Due to the floor level adjustments of the glass the graphic...

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Page 199: ...ck to screen block Glass edge cleaner 10 7 Sealing the glass panels Door track packing adjustment 10 8 Roof panel alignment Securing the opening roof 10 9 Adjusting the opening roof 10 10 Door adjustm...

Page 200: ...s Check all plastic and rubber seals are assembled correctly prior to any assembly If a seal is noticed to be pulled out and not engaging correctly late on in the build the pod will need to be dismant...

Page 201: ...round the floor template jigs will guarantee all angles and dimensions are correct To be assembled in position before the build To guarantee Pods will be built to accurate dimensions and angles otherw...

Page 202: ...will fit poorly 4 Upholstery Screen Crossbar Check the crossbar is flush with the top of the upholstery screen ideally before hooking them onto the central hoop Covers will not align and gaps will app...

Page 203: ...oop with no gaps between when hooking into the central hoop Use a clamp across both screens if necessary Upholstery Screen to Hoop Alignment The top covers and upholstery panels will be misaligned and...

Page 204: ...front rear glass frame always sit the upright onto the door track completely parallel 8 7 Upholstery Screen to Front Rear Glass Frame Alignment The pod will be misaligned and cause gaps throughout Ens...

Page 205: ...is being attached to the screen Glass Edge Cleaner 10 The bonding tape will not fully stick to the glass edges as dust grime reduces its adhesion The glass edges must be cleaned using the Isopropanol...

Page 206: ...erial through 11 Tip place a sucker on each side of the join and use a clamp to squeeze the glass panels together 12 Door Track Packing Adjustment Stops door track sag loss of height due to the weight...

Page 207: ...ng the roof panels ensure that the roof panel edge sits in the middle of the hoop casting each side 13 Securing the Opening Roof 14 The opening roof movement will be disrupted if all roof panels are n...

Page 208: ...between the roof blades when fully closed Once operational loosen the actuator bracket and push towards the middle of the pod until all roof blades are firmly closed then re tighten Push into the cent...

Page 209: ...rews on each to 14Nm using a torque wrench and ensure the wheels are in their neutral positions 3 Adjust the outer wheels first to set the overall height of the door Ensure the door does not scrape on...

Page 210: ...t do not over tighten 5 Adjust the locking wheels up against the extrusion to secure the door but don t over tighten as this will mean the door is stiff This locking wheel is critical for the safety o...

Page 211: ...arallel and at 90 to the glass The door handle can easily be mounted at an incorrect angle putting stress on the glass fixing holes 90 Run the spatula tool glass packer between the glass face to relea...

Page 212: ...ough space in the extrusion for the post fix glass seal to be inserted Sealing the Glass Externally 20 Stretching the seal and pushing into position will mean over time the seal will shrink and leave...

Page 213: ...and glass clamps 1 Locate the cover details inside the clips 2 Apply force diagonally down to clip the cover on Add the pad onto the anti slip moulding to add more height Upholstery Panel Height Adjus...

Page 214: ...nnector and cable 3 Pull both cable ties tight and cut off tails Corner Trim Caps 24 The corner trim moulding will not fit into place with these parts mounted before Before the outside upholstery pane...

Page 215: ...panel become loose Push down firmly in the areas highlighted to properly engage the panel clips into the screens Apply force to the 4 areas highlighted to engage the clips into the screen extrusions O...

Page 216: ...Installation Guide User Manual REV Iss ECR Author Date 11 1 AE 2017 11 2 JT 2018 11 3 JT 2018...

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ORANGEBOX Air 3 pod, Installation Instructions Manual

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