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Installation Instructions - Alu Star
"surface mountig" Installation
Please
read these instructions entirely before attempting to
install your order!!!
A.
Unpack your shutter components and inspect for
correctness and damage. Report any discrepancies
immediately to Alutech United.
B.
Remove all protective plastic covering from shutter
housing.
C.
When measuring for the shutter you should have
determined if you needed to build out ("pack
out") the shutter so that the shutter clears any
protrusions, handles or knobs.
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NOTE:
If you are installing a shutter with a motor and gear
override
you should follow the same instructions as the
gear crank along
with the electrical and motor limit
installation procedure
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1. Pre-drill your guiderails as shown - 6" from the
top and bottom, and every 12" in between. Drilling
on 6" center from the ends and 12" centers .
Start by drilling a 1/4" hole through both the
exterior wall and interior wall of the hollow part of
the guiderail. Next drill a 1/2" hole using the
1/4" hole as a pilot through the exterior wall of
the guiderail only. Special "step-down" drill
bits are available for this process. Contact Alutech
United for details.
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2.
You
must now determine where your operator will be
mounted and drill through the wall to get the
operator to the inside of the structure. If your
shutter has outside operation you need only to
mount the shutter at this point.
Now mark on the wall where your operating
mechanism must come through for drilling. Remove
the shutter and drill a ¾" hole where you
just marked (some customers like to insert a small
piece of tubing through this hole for weather
protection).
Insert the endcap pins into the guiderails as
shown in figure (3). Now lift the entire shutter
unit into place being very careful not to break
the endcap pins at this stage.
From the inside now bring the operator through the
wall into the operation mechanism of the shutter.
Secure the shutter in place by screwing through
your pre-drilled holes into the post/wood pack out
you previously installed.
If you are installing a Motorized shutter go to
Step#3. |
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For
Strap Operated Shutters:
First lace the strap through
the wall strap guide (1), then insert the strap through
the wall. On the outside, attach the strap to the pulley
(2) by making a small slit in the center of the strap
pulley and loop it over the strap holder knob (3). Turn
the axle in the "curtain down" direction
filling the strap pulley until it is ¾ full.
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For
Crank Box Shutters:
Lace the strap or cord through the
wall guides (1), then insert the strap or cord through
the wall. On the outside attach the strap or cord to the
pulley (2). Turn the axle in the "curtain
down" direction filling the pulley until it is ¾
full. |
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For
Gear Crank Shutters:
When drilling the ¾" hole
angle your hole slightly up (1). This slight angle will
keep any weather from leaking down toward your home.
Insert the universal through the wall and into the gear
(2). If the universal is too long mark and cut to
length. The rod should come through the gear and just
out the other side (3) .
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Attach the Universal Bullet
device to the interior wall. Using the crank handle turn
the axle in the "curtain down" direction until
the gear stops turning. |
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3.
For Motorized shutters consult your electrician for
local electric codes and electrical placement.
4.
Once your shutter is mounted and secure and all
operators have been attached, fasten the sheet metal
safety plates to the interior of both endcaps. Lay a
blanket or old sheet over the axle to keep the curtain
from getting scratched in the following steps.
5.
Starting with the endslat, place the curtain over the
axle and down in the guiderails. Make sure that the
concave slat profile is facing the shutter housing. Next
attach the T-straps to the axle. Note: If this is a
motorized shutter be sure to used the small painted
screw on the motor side!!
6.
Place T-straps on the top slat of your curtain spaced
about every 15"-18"
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7.
Install the conical stoppers in the endslat as shown.
Motorized shutters do not have stoppers for you to
install they are stopped by the motor limits. |
8.
Now you must go inside and make fast all the operators.
For strap and crank box operators, attach them to the
wall where convenient for the customer. For Gear
shutters, attach the handle and install the holder clip
to the wall and store the handle in its receiver.
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For
Motorized shutters, you can now set the limits.
First pop out both the yellow and white limit
buttons. With a tester switch connect like color
wires to operate the shutter. Run the shutter up
and push in the "up limit" when the
endslat is the only slat hanging out of the
housing. Now run the shutter down and push the
"down limit" button when the shutter
fully closes being careful to not allow the axle
to overturn the T-straps past their locking
position.
*** When the motor is mounted on the right (from the
outside) the yellow button is the down limit and the
white button is the up limit. For motors installed on
the left (from the outside), the yellow button is the up
limit and the white button is the down limit. |
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9.
Put the housing cover on making sure that it locks in
the "interlocking" configuration on the
housing back. Attach the hood by drilling small self-tappers
through the cover into the endcaps. Use 2 screws for the
face and 2 on the bottom for each side.
10.
Weatherproof the shutter by caulking along the edges of
the entire shutter as pictured below.
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