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ORANGEBOX Air 3 Installation Document

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CAUTION
CRUSH HAZARD!
FAILURE TO PROPERLY SECURE PRODUCT TO
BUILDING COULD RESULT IN PERSONAL INJURY.
For commercial use only. Read all instructions before using the Air3 pod.
Save these instructions for future reference.
DANGER – To reduce the risk of electric shock, always unplug this
furnishing from the electrical outlet before cleaning or servicing.
WARNING – To reduce the risk of burns, fire, electric shock, or injury to
persons:
• Unplug from the outlet(s) before putting on or taking of parts.
• Use this furnishing only for its intend use as described in these
instructions. Do not use attachments not recommended by the
manufacturer
• Never operate this furnishing if it has a damaged cord or plug, or if it is
not working properly. Contact the dealer for examination and repair.
• Keep Cords away from heated surfaces
• Do not operate where aerosol (spray) products are being used or
where oxygen is being administered.
• To disconnect from power, turn all controls to the off position, then
remove plug(s) from outlet
• Mount only approved work surfaces and secondary surfaces (Shelves)
in accordance with instructions. Failure to do so may cause instability ,
collapse, or failure of electrical components
Installation Instructions Air
3
Pods
Revision 15
September 2023
Doc # 165750 Rev A

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Summary of Contents for ORANGEBOX Air 3

  • Page 1 Installation Instructions Air Pods CAUTION CRUSH HAZARD! FAILURE TO PROPERLY SECURE PRODUCT TO BUILDING COULD RESULT IN PERSONAL INJURY. For commercial use only. Read all instructions before using the Air3 pod. Save these instructions for future reference. DANGER – To reduce the risk of electric shock, always unplug this furnishing from the electrical outlet before cleaning or servicing.
  • Page 2 Contents page 1) Suppor ng documents ……………………………………………………………………………………………………………………………………………………………..1.1 PPE Informa on……………………………………………………………………………………………………………………………1.5 Pod range overview……………………………………………………………………………………………………………1.6 – 1.10 2) Service hoop assembly ……………………………………………………………………………………………………………………………………………………………..2.1 Se ng out oor jigs……………………………………………………………………………………………………..……2.2 – 2.6 posi on of pod Se ng out hoop…………………………………………………………………………………………………………………………2.8 Opening hoop covers…………………………………………………………………………………………………………………2.9 Connec ng cables in switch side hoop ver cal……………………………………………………......2.11 A aching the actuators……………………………………………………………………………………………………...
  • Page 3 ... Sign posi of pod 6) Upholstery panels assembly ……………………………………………………………………………………………………………………………………………………. .1 ) Front and back glass ……………………………………………………………………………………………………..............1 7.1. Rear Glass ..7.7 ....7.8 ..7.9 Front glass ………………………………………………………………………………………………………………………………… .10 7.11 7.12 7.13 7.14 7.16 7.17 7.18 ) Glass door I ..........................
  • Page 4 WARNING...
  • Page 5 TOOLS / EQUIPMENT REQUIRED FOR INSTALL Gla ss Items Quan ty Descrip on Vacuum Suc n Cups - 8" or 9" Safety Glasses (1 pair per installer) Safety Gloves (1 Pair per installer) Plas c Gasket Roller (Tool to seal glass) - Sold Separately Sold Separately Pack...
  • Page 6 Tools/Equipment 12" Wonder Nar Pry Bar (or similar) NM Gauge Hoop Leaver T-Handle Flat Screw Driver Small Driver Small Crossbar Roller Spirit Level Trigger Clamps 12mm VHB TPE / Electrical Tape Pack Isoproponal (IPA) Wipes No 13 Amored Corner Protectors Floor Slide Guides 10mm Steamer...
  • Page 8 For Commercial Use Only Solo Para Uso Comercial À Usage Commercial Uniquement Conforms to UL Std 962 E332997 Certified to CSA C22.2 #68...
  • Page 9 AIR-23 OPENING ROOF HALF SQUARE POD SECTION 8 SECTION 5 SECTION 4 SECTION 3 SECTION 2 SECTION 6 SECTION 8...
  • Page 10 AIR-25 OPENING ROOF SQUARE POD SECTION 7 SECTION 5 SECTION 7 SECTION 3 SECTION 2 SECTION 8 SECTION 6...
  • Page 11 AIR-27 OPENING ROOF RECTANGULAR POD SECTION 7 SECTION 5 SECTION 4 SECTION 3 SECTION 7 SECTION 2 SECTION 8...
  • Page 12 AIR-29 ROOF 3X3 SQUARE POD SECTION 4 SECTION 7 SECTION 5 SECTION 3 SECTION 2 SECTION 6 SECTION 8...
  • Page 13 Assembly sequence...
  • Page 14 ASSEMBLE THE JIGS AS REQUIRED USING THE LAYOUT SHEETS PROVIDED - LAY OUT JIGS TO SET POSITION OF POD - ENSURE AREA IS FLAT AND FREE OF DEBRIS - ENSURE THAT THERE IS ADEQUATE HEIGHT FOR POD ENSURE FIRM CONNECTION - USE AS SIGN OFF POSITION FROM CLIENT BETWEEN COMPONENTS - USE TO CHECK FLOOR BOX POSITIONS...
  • Page 16 2753...
  • Page 17 4222...
  • Page 18 4 X AIR-JIG-001 4222 BUILD THE STRAIGHT CONNECTOR CONNECT THE STRAIGHT FRONT/ PARTS AROUND THE TWO HOOP JIGS REAR ALIGNMENT JIGS (NUMBERED 3 & 12). (NUMBERED 2).
  • Page 26 RE-ASSEMBLE THE BODY OF THE FAN TO THE BASE AND RE-STRAP ENSURE THAT THE END WITH BLUE LABEL AND WHITE ARROW IS FACING THE AIR INLET SLOTS IN THE HOOP HORIZONTAL DO NOT PLUG FAN IN UNTIL PAGE 3.6 2.20...
  • Page 27 AMERICAS HEAT DETECTOR MOUNTING...
  • Page 28 AMERICAS HEAT DETECTOR INSTALLATION...
  • Page 29 AMERICAS CONNECTIONS...
  • Page 30 AMERICAS CONNECTIONS Grounded Outlet Grounded Outlet Box Fig. 1 Grounding Methods Note: *Grounding, Cord-connection This product is for use on a nominal 120-volt circuit and has a grounding plug that looks like the plug illustrated in (Fig. 1) Make sure that the product is connected to an outlet having the same configuration as the plug.
  • Page 31 OPENING ROOFS AMERICAS POWER AND DATA...
  • Page 33 WARNING...
  • Page 34 Assembly sequence section...
  • Page 40 Assembly sequence...
  • Page 53 Connect the rear glass frame to the hoop on the back of an Air 23 using the contents from box labeled “half pod kit” Hoop & a ached fan motor Half Pod kit contents: • longer bolts regular longer • special corner caps •...

  • Page 54: Assembly Sequence

    Assembly sequence...
  • Page 70 Opening Roofs -...
  • Page 72 5.29...
  • Page 73 5.30...
  • Page 74 5.31...
  • Page 75 5.32...
  • Page 76 5.33...
  • Page 77 5.34...
  • Page 78 5.35...

  • Page 79: Assembly Sequence

    Assembly sequence...
  • Page 82 WHENEVER POD SHIPS WITH THESE MOULDINGS THEY SHOULD BE REMOVED AS PART OF INSTALL PROCESS...
  • Page 88 Assembly sequence...
  • Page 89 Glass Door: 1160w x 2189h Glass 1: 675w x 2167h Glass 2: 875w x 2167h Glass 4: 875w x 2167h Glass 5: 875w x 2167h Glass 6: 875w x 2167h Glass 4 Glass 5 Glass 6 Graphic Application Notes: Dimensions provided are taken from the full glass panel size.
  • Page 90 Glass Door: 1160w x 2189h Glass 1: 680w x 2167h Glass 2: 875w x 2167h Glass 5: 875w x 2167h Glass 6: 875w x 2167h Glass 5 Glass 6 Glass 7 Glass 7: 875w x 2167h Graphic Application Notes: Dimensions provided are taken from the full glass panel size.
  • Page 91 Glass Door: 1160w x 2189h Glass 1: 680w x 2167h Glass 2: 875w x 2167h Glass 6 Glass 7 Glass 8 Glass 6: 875w x 2167h Glass 7: 875w x 2167h Glass 8: 875w x 2167h Graphic Application Notes: Dimensions provided are taken from the full glass panel size.
  • Page 92 Glass Door: 1160w x 2189h Glass 1: 1035w x 2170h Glass 2: 930w x 2170h Glass 7 Glass 8 Glass 9 Glass 10 Glass 3: 930w x 2170h Glass 7: 930w x 2170h Glass 8: 1035w x 2170h Glass 9: 1035w x 2170h Glass 10: 930w x 2170h Graphic Application Notes: Dimensions provided are taken...
  • Page 95 CAUTION:...
  • Page 96 Using Vacuum Suction Cups, push/pull the two outside pieces of glass as far into the corner vertical upright as possible BACK OF in order to provide enough room to place piece C in the middle without damaging it...
  • Page 97 IF THE GLASS WILL NOT ALIGN, FLIP THE GLASS ON LONG EDGE (TO KEEP GLASS CERTIFICATION MARKING ON BOTTOM) TO CREATE MORE FAVORABLE CONDITIONS FOR ALIGNMENT...
  • Page 101 7.10...
  • Page 102 6.11 7.11...
  • Page 103 CAUTION: 6.12 7.12...
  • Page 104 USE 2-3 GLASS JOINING STRIPS PROVIDED 6.13 7.13...
  • Page 105 6.14 7.14...
  • Page 106 6.15 7.15...
  • Page 107 6.16 7.16...
  • Page 108 THREE PERSONS MINIMUM 6.17 7.17...
  • Page 109 6.18 7.18...

  • Page 110: Assembly Sequence

    Assembly sequence wrench...
  • Page 111 M8 X 25 X3 TORQUE 14NM {10.32 FT-LBF) ENSURE THAT ALL WHEELS ARE ADJUSTED TO SAME LEVEL BEFORE LIFTING ONTO TRACK NOTE: HAND TIGHTEN FIXINGS EVENLY TO AVOID PINCH POINTS 14NM TORQ UE SETT I NG NOTE WHERE DOOR HANDLE HOLE POSITIONS ARE WHEN INSTALLING RUNNERS.
  • Page 114 WRENCH...
  • Page 117 ENSURE NYLON SPACERS ARE USED BETWEEN ALL 4 BOLTS/FIXINGS AND GLASS PUSH BOLTS/FIXINGS TROUGH NYLON SPACES (ON INSIDE) BEFORE PUSHING INTO HOLES & SECURING INTO PLACE. DO NOT OVERTIGHTEN - RISK OF THREADING! USE FIRST BOLT/FIXING TO ALIGN HEIGHT OF HANDLES...
  • Page 119 8.10...
  • Page 120 8.11...
  • Page 121 8.12...
  • Page 122 8.13...

  • Page 123: Assembly Sequence

    Assembly sequence...
  • Page 128 CAUTION:...
  • Page 133 CAUTION: DO NOT EXCEED 55” OR 25KG (55LBS) ON ANY SCREEN...
  • Page 139 SMALL TABLE AIR-30 US...
  • Page 143 ADA DOOR EXPANSION/NIB Step 1: The support frame is installed into the slots of the current extrusion. See Detail A. M8x40 screws fix the support frame to the amended upright of the pod. Both M8 variants hold the panel bracket in place.
  • Page 144 Assembly sequence...
  • Page 145 Contents page Plas�c / Rubber seals………………………………………………………………………………………………………..10.2 Pod Alignment template jigs……………………………………………………………………………………………..10.3 Screen hook posi�ons Upholstery Screen crossbar………………………………………………………………………………………………10.4 Upholstery screen to hoop alignment 1 Upholstery screen to hoop alignment 2…………………………………………………………………………….10.5 Upholstery screen to front/rear glass frame alignment Bo�om door track to upright…………………………………………………………………………………………….10.6 Door track to screen block Glass edge cleaner…………………………………………………………………………………………………………….10.7 Sealing the glass panels...
  • Page 146 Plas�c/Rubber Seals. Check all plas�c and rubber seals are assembled correctly prior to any assembly. If a seal is no�ced to be pulled out and not engaging correctly late on in the build, the pod will need to be dismantled to put right.
  • Page 147 Pod Alignment Template Jigs. To be assembled in posi on before the build. To guarantee Pods will be built to accurate dimensions and angles, otherwise problems will occur throughout the build. Also to con rm the posi on with the client prior to building. 2623mm or 103.3 Inches >2623mm or 103.3 Inches 90°...
  • Page 148 Screen Hook Posi�ons . Check the hook posi�ons on each screen before hooking them onto the hoop. The height will be misaligned causing gaps throughout and covers will fit poorly. The screw must be located over the detail in extrusion. Upholstery Screen Crossbar.
  • Page 149 Upholstery Screen to Hoop Alignment. Ensure the screen height aligns accurately with the hoop cas�ng when hooking into the hoop. Use a so� mallet if necessary. The top covers and upholstery panels will be misaligned and cause gaps throughout. Tap down with a so� mallet if necessary. Upholstery Screen to Hoop Alignment 2.
  • Page 150 Upholstery Screen to Front/Rear Glass Frame Alignment. Ensure the screens align accurately with the front/rear frames, when bol�ng the frame uprights onto the screens. The pod will be misaligned and cause gaps throughout. Bo�om Door Track to Upright. When assembling the front/ rear glass frame always sit the upright onto the door track completely parallel.
  • Page 151 Door Track to Screen Block. Ensure the block is inserted before the door track is bolted on . Gaps will appear in each corner Place the block into posi�on when the upright is being a�ached to the screen. Glass Edge Cleaner. The glass edges must be cleaned using the Isopropanol wipes prior to any plas�c extrusion being bonded on.
  • Page 153 Roof Panel Alignment. When moun the roof panels ensure that the roof panel edge sits in the middle of the hoop cas each side. The roof panels will be misaligned causing the opening/ closing movement to be poor. Securing the Opening Roof. A er loca g all the roof panels, apply an even force around each to secure.
  • Page 154 Adjus�ng the Opening Roof. Once opera�onal, loosen the actuator bracket and push towards the middle of the pod un�l all roof blades are firmly closed, then re-�ghten. Gaps may be visible between the roof blades when fully closed Push into the center of the Pod to reduce the roof blade gaps.
  • Page 155 Door Adjustment- Tips Before moun�ng the door. These are crucial �ps on how to mount the door successfully. Without following these �ps, the door will be mounted incorrectly or poorly. 1. Set the runner wheels to the neutral posi�ons as shown below. 2.
  • Page 156 3. Close the door to inspect the level, ensuring there is an even gap against the door upright. Recommended door force: Max: 4. If you are happy with the door movement/ alignment, adjust the inner wheels down to match the outside wheels, but do not over �ghten 5.
  • Page 157 Door Handle Alignment. When moun�ng the door handle onto the glass door, ensure the extrusions are parallel and at 90° to the glass. The door handle can easily be mounted at an incorrect angle, pu�ng stress on the glass fixing holes. 90°...
  • Page 158 Star�ng off the Glass Seal. Use the spatula tool/ Hoop opening tool to create enough space in the extrusion for the post fix glass seal to be inserted. The post fix glass seal can be very difficult to push in, especially on the curved glass frames.
  • Page 159 Moun�ng the Front/ Rear Covers. Ensure the covers are located into the clips correctly, to hide/ protect the door runners and glass clamps. The covers will not be fully clipped on otherwise and may come loose/ fall off. 2. Apply force diagonally down to clip the cover on.
  • Page 160 Corner Trim Caps Before the outside upholstery panels and front/rear track covers are mounted. The corner trim moulding will not fit into place with these parts mounted before. Push the moulding un�l it Align the corner trim up to its Using a T-bar and mallet, meets the screen cover.
  • Page 161 Moun�ng the Upholstery Panels Push down firmly in the areas highlighted to properly engage the panel clips into the screens. If any of these clips are not engaged correctly the upholstery panel become loose. Apply force to the 4 areas highlighted to engage the clips into the screen extrusions.

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