PRODUCT INFORMATION MANUAL SECTION: 2C ALUMINIUM SHUTTERS ALUMINIUM SHUTTERS

Transcription

1 ALUMINIUM SHUTTERS

2 Copyright 2016 Hunter Douglas Limited [ABN ] Registered Trade Marks of Hunter Douglas Limited. 04/2016

3 PAINTED PANELS MATERIAL Made from 6063-TS Grade Aluminium. The Shutter panel is fixed together with stainless steel screws. Supporting accessories are also made from stainless steel to ensure robustness in external environment. COLOURS The painted panel comes standard in 4 colours (White, Black, Pearl & Silver). Custom colours are available. Any colour chosen from the Dulux colour range will not require a sample; however, all other custom colour request require a high quality paint brush out. Custom colours may vary due to sheen levels. WRAPS Wrap are available to offer provide the look of timber but with the added robustness and versatility of aluminium. CONSTRUCTION Aluminium extrusions have a 1.4mm wall thickness for added stiffness and strength. Fasteners are stainless Steel. Frames are reinforced by angle sections. COATING SYSTEM All profiles are sanded and chemically cleaned using a pre-treatment to ensure maximum coating adhesive and increased resistance against corrosion. Components are then electrostatically powder coated. Components are then over cured. INSTALLATION METHODS Hinged Panel, Hinged in Frame, Bi-fold, Fixed, Track Bi-fold and Track Sliding. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 3 OF 28

4 SPECIFICATION CHART SPECIFICATION Blade Profile Elliptical Elliptical Elliptical Blade Size 64mm 89mm 114mm Blade Thickness 12mm 12mm 12mm Stile Sizes Beaded: 30mm x 60mm Rail Depth Top Rail: 78mm Mid Rail: 90mm Bottom Rail: 85mm Tilt Rod Left or Right hand, Front or back LIMITATIONS Height Max 3600mm Height Minimum 400mm Minimum Width 200mm Mid 2000mm Second Mid 3000mm MAXUMUM PANEL WIDTHS Hinged: All types 870mm Double Hinged: All types 600mm Fixed Chanel 1500mm 2 Track Sliding 1500mm Bi-Fold 700mm ACCESSORIES Frames L Frames / Z Frames, U channels, Fascia s, H sections Hinges Pivot and Bi-Fold Track Sliding YES Track Bi-fold YES Shaped Shutters YES T-Post YES Access Options Security Bold, Flush Bolt, Lockable Handle, Blade Stay Angles 25 x 10, 25 x 25 Post 50 x 50 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 4 OF 28

5 BLADES SIZES REVEAL CLEARANCE FOR BLADE OPERATION Install Method Clearance 64mm blade Clearance 89mm Blade Clearance114mm Blade Hinged No Frame N/A N/A N/A Hinged L Frame Hinged Z Frame Fixed In Channel Track Sliding Blade Closed Track Sliding Blade Open Bi-Fold *Minimum reveal depth-be sure to measure from the most protruding object in the reveal. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 5 OF 28

6 TILT RODS Clearview tilt rod is placed at the rear of the shutter and screwed to the ends of the blades on the hinged side of the shutter. The Tilt rod protrudes approximately 3mm from the blade. CRITICAL MID RAIL HOW TO MEASURE MID-RAIL HEIGHT When measuring the mid-rail height it is important to measure to the center point of where you would like the mid-rail to be placed. As the mid-rail is the same size as an individual blade, it will be placed approximately +/- 25mm for the specified height. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 6 OF 28

7 FRAME OPTIONS Flat 50mm L Frame Flush Mount Z Frame T-POST Standard Z Frame REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 7 OF 28

8 CHANNELS Top Channel Bottom Channel 25 x 25mm L Angle H Section REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 8 OF 28

9 TRACKS Top Track Double Sided Fasica Installation Option 1 Bottom Track Double Sided Fasica Installation Option 2 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 9 OF 28

10 ACCESS OPTIONS Method Image Security Bolt Flush Bolt Lockable Handle Blade Stay (Available August 2016) REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 10 OF 28

11 HOW TO MEASURE REVEAL (INSIDE) MOUNT Width Points of Measure: Top, Center and Bottom Height Points of Measure: Left, Center and Right For Reveal openings, enter the smallest width and height of the measurements taken. All standard deductions will be taken for the units to fit inside the opening. Measuring tip: Always measure your opening from left to right. FACE (OUTSIDE) MOUNT Width Points of Measure: From the left to the right of the opening Height Points of Measure: From the top to the bottom of the opening For Face Mount openings enter the width and height of the opening. No deductions will be taken. The measurements given will be from edge to edge including the frame. SUB-WIDTHS: HOW TO MEASURE REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 11 OF 28

12 PANEL CONFIGURATION: Hinged No Frame DRAWING PANEL CONFIGURATION CODE DRAWING PANEL CONFIGURATION CODE REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 12 OF 28

13 PANEL CONFIGURATION: Hinged In L or Z Frame DRAWING PANEL CONFIGURATION CODE DRAWING PANEL CONFIGURATION CODE REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 13 OF 28

14 PANEL CONFIGURATION: Fixed Channel DRAWING PANEL CONFIGURATION CODE FHFHFHFHF - 5 FHFHFHFHFHF - 6 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 14 OF 28

15 PANEL CONFIGURATION: Sliding DRAWING PANEL CONFIGURATION CODE DRAWING PANEL CONFIGURATION CODE BFBFBF - 6 (2 Tracks) BMFFMB - 6 (3 Tracks) FMBBMF - 6 (3 Tracks) REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 15 OF 28

16 PANEL CONFIGURATION: Bi-Fold STD Fold PANEL CONFIGURATION CODE DRAWING PANEL CONFIGURATION CODE DRAWING REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 16 OF 28

17 PANEL CONFIGURATION: Bi-Reverse Fold DRAWING PANEL CONFIGURATION CODE DRAWING PANEL CONFIGURATION CODE LLLLRR - 6 LLRRRR - 6 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 17 OF 28

18

19 MEASURING AND INSTALLING 1. FIXED IN PLACE USING TOP AND BOTTOM CHANNELS Figure 1 Aluminium Shutters in a fixed position will be supplied with 50 mm x 36 mm Top channel and a 25 mm x 36 mm Bottom channel, AS PER SIDE VIEW DIAGRAM, FIGURE 2. SIDE VIEW The side fixings can be a selection of either 50mm x 36mm, 25 mm x 36 mm, or 25 mm x 25 mm angles as show in diagram above, this will be your preference to suit the opening that the shutters are to be installed into. All deductions are taken by the factory in reference to the channels selected on the placed order. 1. Determine the exact position the shutters will be installed referring to your original quotation and measurements. 2. Locate your top 50 mm x 36 mm channel and pre drill fixing holes in a zig zag configuration approximately 200 mm apart along the full length of the set channel. 3. Repeat this procedure with the bottom channel. 4. Using the Top channel as a template place it in the position it will be attached, and mark the holes in preparation for predrilling pilot holes. 5. Repeat this with the bottom channel ensuring it is aligned perfectly with the top channel, as per figure Now pilot holes can be drilled according to your markings. 7. If you have requested side channels repeat the above procedures ensuring all channels align. 8. We highly recommend all external installations that stainless steel screws are used to secure the installation components. 9. Now all the channels are secured in place install the first panel by lifting the panel and inserting the top section of the shutter into the top channel until you have enough clearance above the bottom rail of the shutter to drop it into the bottom channel. 10. Once the panel is installed in both top and bottom channels slide the shutter across fully ensuring the shutter is inserted into the side channel. 11. If H section was required between the panels for extra stability, fit the section over the first panel before fitting the second panel, factory deductions are taken to accommodate the H section. Figure Repeat this process with the second panel; you may need to carry the shutter via the midtrial or a central blade as there will only be minimal clearance to install the second shutter. Figure 2 Figure 3 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 19 OF 28

20 FIXED IN PLACE USING TOP AND BOTTOM CHANNELS - CONTINUED This will prevent you from jamming your hands between the opening and the shutter. If handling the shutter via a central blade ensure you lift the panel under the blade up against the pivot point of the blade, as this is the strongest point, but it is still a fragile area so please take maximum care. As per figure 4. EXISTING STRUCTURE BOTTOM CHANNEL Figure Once the panels are both within the channels, determine the centre point of the opening and align the joining sections of the two panels to that mark. 14. As per figure 4 or have it determine the best position to secure the panels, choosing a position that your fixings will penetrate through both the channel and the shutters being secured. We recommend stainless steel, or aluminuim pop rivet fixing for the best result. In some cases you may need to purchase pre-coated rivots in a colour that best suit the ordered colour. Figure 5 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 20 OF 28

21 2. REVEAL FIT TO L. FRAME (APPLICABLE FOR Z-FRAME) Alumiuim frames are supplied with 50mm x 50mm angle sections for assembly the frame unit. These sections will be attached to the top and bottom frame section for easy identification and quick assembly. All frames and shutters will be supplied with pre-fitted hinges, unless this is not specified. A Figure 6 1. Firstly remove the four machine screws on either side or the top and bottom sections, as per Figure 6, Now assemble the frame by pushing the exposed angled section into the sleaved section as per the preassembled side, ensuring you have correctly placed the LHS and RHS. 2. Once the corners of the frames are joined tightly re-attach the machine screws through the frame into the angle section, we also recommend checking the pre-fitted screws in case they have become loose during freight / transit. Figure 7 3. Now the frame is fully assembled, pilot holes can be pre-drilled for easy installation. 4. Pilot holes are drilled on the inside 18 mm lip of the frame, as shown in the example below. This position also renders the screws invisible to the customer, when the shutter is closed, If you wish the screw head to be less visible when the panel is in the open position apply a small amount of touch up paint to it once the frame is secured. We recommend the most stable position for the fixing holes are in line with the hinge positions, and the centre of the top and bottom frame section. Figure 8 B Ensure you counter sink the holes so as the screw heads sit flush to the frame surface as per figure Place the frame inside the reveal with the front beaded section of the frame sitting flush with the outside face edge of the wall. The factory has taken a standard 2 mm clearance on all 4 sides for the frame to fit with adjustments into the reveal opening. 6. For accurate spacing around the frame place a packer / shim under both the LHS and RHS bottom of the frame. 7. Now mark the pilot holes you drilled into the frame onto the reveal. 8. Remove the frame and drill your pilot holes. 9. Now ready your stainless steel fixing screws and cordless screwdriver for the Installation, ensuring they are easily accessible as you may need to support the frame with one hand and drill the fixing screws in with the other hand. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 21 OF 28

22 REVEAL FIT TO L FRAME - CONTINUED 10. Now place the frame back into the reveal and secure the top screws only. This will give you the ability to make small adjustments to determine the correct position of the alignment of the shutters within the frame. 11. Now remove the pivot pins from large male section of the hinges, now insert you shutter into the frame guiding female section of the hinge between the male sections. 12. Once in position replace the pivot hinge pins. 13. With the shutter in place you can now adjust the frame by moving the bottom section from either one side or the other, this with raise or lower the panel heights. 14. Once you have found the correct position ensuring the panels align, open the panel and keeping the frame in the correct position and secure the bottom of the frame. 15. Some adjustments may still be required after this procedure; this can be done by simply by making small adjustments to the fixing screws. 16. If further adjustments are necessary loosen the screws in the oval section of the hinges and adjust the panel until level. 17. Once you are satisfied with the shutter positions tighten all the screws and fit the screws into the middle hinge holes. 3. SLIDING SHUTTER INSTALLATION In a sliding installation the shutters will be supplied with carrier saddles pre-attached to all panels. Each panel will also have a unique end stile cap that is designed to accommodate the spring loaded floor guides, these floor guides will be pre-attached to the shutters. All tracking will be supplied cut to the ordered opening size. The floor guides along with the carrier are supplied loose, along with the tracking and fascia. 1. Measure your tracking to ensure it has been cut to the desired length. 2. Check the area in which the tracking will be attached to, as you may need to remove objects that will prevent the tracking from securing level and flat. 3. As per your original quotation measure you should be aware if the opening is un-level, it is recommended that the top track is attached level and flush to ensure the panels operate as specified. 4. If the surface that the tracking is being attached to is un-level the tracking will require packing. 5. Place the top track upside down onto of a surface that supports the track evenly in preparation for drilling the pilot holes, ensure the surface can be drilled into if your drill pushes though the tracking. 6. Working with the measurement of the track evenly mark pilot hole positions approximately 200mm apart. 7. Drill your pilot holes. 8. We recommend to counter sink all holes to prevent any screws from impairing the action of the carrier system. 9. Hold the tracking in the required fixing position and drill through the tracking in one or two holes approximate to the middle. 10. Now insert the carriers supplied to support the shutters. 11. Carefully raise the tracking and using bugle head stainless steel screws attach the tracking to the opening through the middle holes. 12. Now the tracking is supported you can pre-drill the remaining pilot holes. 13. Once pre-drilled secure the tracking fully, following the steps below regarding Figure 9 the fascia. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 22 OF 28

23 3. SLIDING SHUTTER INSTALLATION - CONTINUED Figure 10 If the sliders are only seen on one side (face side) you will only need to attach one section of the 50 mm x 20 mm fascia. 14. Before fully tightening the fixing screws to the track, insert the fascia under the tracking, as seen in figure 10. Once the fascia is positioned correctly tighten fixing crews. 15. Now pre-drill pilot holes for the bottom track, ensuring all holes are counter sunk to eliminate the guide catching on the screw heads. 16. Once again ensure the surface the track is to be attached to is clean and level. 17. In order for the shutters to operate seamlessly the floor track centre point must align with the centre point of the top track. 18. Prior to attaching the floor track insert the floor guides into the track. Figure Now attach the floor track using stainless steel bugle head screws. 20. Now the shutters can be attached to the carriers. 19. Prior to attaching the shutters adjust all carrier bolts to the exact level, this will ensure the shutters are at a even height once the panels are hung. 20. Now attach your shutters to the carriers using the pre-attached saddles fixed to the tops of the panels. 21. Once the shutters are supported by the top tracking, compress the bottom spring loaded guide, and pop them into the floor track guide. Figure Adjustments can now be made to the panels by either removing the shutter back off the top saddle and adjusting the carrier bolts to the desired heights, or adjustments can be made by using an open ended spanner on the slotted section of the adjusting bolt. 23. Once you have achieved the required adjustment tighten the carrier bolts. Figure We recommend spraying all friction areas and hardware with a coat of silicone spray on completion of the installation. 25. It is also advised to give your customer a full run down of the product operation, and explain the cleaning and lubrication procedures. Figure 11 Figure 12 Figure 13 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 23 OF 28

24 4. BI-FOLD INSTALLATION Hardware supplied to suit the Bi-Fold Installation As this is a bi-fold only 1 track is supplied for the top and bottom, it is imperative for the correct operation that the top track is installed level. The bottom track can have some minor fall, but no more than 10 mm, if this amount is greater than 10 mm you will need to pack the bottom track. Panels are supplied with pre fitted hinges which are divided in two sections and connected via a removable pin, Figure 14 Figure 14 ELIVATED VEIW FACE VEIW 1. Follow steps 1 through to 10 section 3 Sliding. 2. Before securing the top track ensure the top pivot mount and carriers are inserted into the tracking. 3. Once the tracking has been secured the pivot mount can be set up in it s correct position. 4. It is recommended to set the centre point of the pivot block 35 mm out from the starting point of the track, by sliding the block into place and tightening the cap head bolts, this measurement will need to be transcribed on the floor pivot as shown in figure 15. The floor pivot mount inserts into the track and is supplied with two stainless steel screws which are secured though the mount into the track / floor. 5. Panel 1 will be fitted with a spring-loaded pivot to the top left hand side (LHS) of the shutter stile if the panels are bi-folding to the left, if they are bi-folding to the RHS it will be attached to the right hand side (RHS). Panel 1 will also be fitted with an adjustable pivot pins on the bottom of the same stile. Figure 19. Figure 15 REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 24 OF 28

25 4. BI-FOLD INSTALLATION - CONTINUED Figure 16 Figure Panel 2 will be fitted with a carrier plate on the top RHS of the stiles. Figure 16, the bot tom RHS are pre-fit ted with spring loaded floor guides. 5. Once the top pivot mount and floor mount are positioned and secured, the panels can be fitted. 6. On panel 1 insert the pre-fitted floor pivot into the floor track mount and then compress the top spring loaded guide popping it into the floor track mounted pivot. Figure Attach panel 2 against panel 1 using the re-fitted hinges once attached lift the RHS or panel 2 attaching the carrier saddle to the track carrier. 7. Now compress the spring-loaded floor guide and insert into the floor track guide, Figure Now adjust the heights of the carries using the spanner provided on panel 2 ensuring the gaps above the panels are equal and level. Figure Operate the panels using the full range of the track length to ensure the panels are running smoothly and level, If not make adjustments as required. Figure 18 Figure 19 Figure 20: Completed View REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 25 OF 28

26 SHAPED SHUTTERS Ordering Shape Shutters Shape shutters can only be ordered in fixed louvers using the 2.8mm stiles. Angle shapes only, no round shapes. Steps: 1. Nominate shape, example: Sloping right, sloping left. 2. Measure width, height and hieght Take height dimensions every 100mm or make a template. 4. Nominate the blade direction facing up or down viewed from inside. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 26 OF 28

27 ALUMINIUM SHUTTERS LEAD TIME AND DELIVERY Lead times will vary throughout the year however as a general guide, to custom make your order, we expect approximately 8 weeks lead time. Lead times commence from order entry. REMAKES Remakes will be prioritised and scheduled for immediate production; however they will be shipped by sea freight and therefore subject to the timing of the next container. Remakes for replacement louvers and panels must be provided on the louvre replacement/panel replacement form contained within the technical manual. This information is critical in ensuring we are able to correctly manufacture your requirements to avoid further delays. PRODUCT CARE Cleaning Aluminium Shutters Wipe over the shutters using a nonabrasive cloth or sponge with warm soapy water. A garden hose can be used applying the same principles. Concentrate on the areas where the stainless steel hardware is attached to the shutter. Remove any salt residue, tannin stains caused by trees and any other marks created. On completion of the cleaning process, spray a light film of silicone lubricant to any operational hardware such as the tracking system. Ensure these areas are fully dry prior to this application. We recommend cleaning your aluminium shutters on a routine basis every six months. For shutters installed in premises close to coastal or saltwater environments the following cleaning timeframes are recommended. COASTAL AREA RECOMMENDATIONS Proximity Cleaning Time Frame Direct Beach Front Weekly 1 km Radius Monthly 10 km radius Quarterly REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 27 OF 28

28 WARRANTY INFORMATION Aluminium Shutters are covered by a 10 year structural warranty and 5 years on finishing. Copies of the warranty are available on request and will be packed with each sutter order. The installer should pass this important document on to the customer and explain who to contact in case of a problem in the future. For proof of repair under warranty, photographic evidence is required. The following is not covered under warranty: Any condition caused by normal wear and tear. Abuse of the product such as alterations, accidents and misuse. Exposure to the elements (i.e Sun Damage), discolouration over time. Failure to follow instructions with respect to measurement, proper installation, cleaning or maintenance. Varying levels of light penetration will occur between the louvers. Aluminium shutters are neither intended, nor guaranteed to provide blackout conditions when closed. Your shutters will require some care in the future. Re-Finishing and repairs to the surface are not covered under the original warranty. *Refer to website for warranty details. REPLACES ISSUE DATE: APPROVED BY: R. BOKTOR PAGE 28 OF 28