Hunter Douglas Palm Beach User Manual

Installation • Operation • Care

Palm Beach™ Polysatin™ Shutters

CONTENTS

Getting Started

Installation Overview ..................................................... 1

Unpacking .................................................................... 1

Tools and Materials Needed ........................................... 1

Fasteners ..................................................................... 2

Frame Assembly

Assemble the Frame – Panel Systems ............................ 3

Assemble the Frame – Track Systems ............................ 7

Installation

Framed Standard Panel Systems .................................... 8

Standard Panel Systems with Hang Strip ...................... 11

Unframed Standard Panel Systems .............................. 13

Bi-Fold Track Systems ................................................. 15

Bypass Track Systems ................................................. 20

French Door Shutters .................................................. 29

Corner Windows.......................................................... 31

Bay Windows .............................................................. 33

Framed Stand-Alone Specialty Shapes ......................... 36

Framed Specialty Shapes Over Standard Shutter ........... 37

Unframed Specialty Shapes ......................................... 38

Decorative Sill Cover ................................................... 39

Finish Work ................................................................. 40

Operation and Care

Operation ................................................................... 43

Care ........................................................................... 43

Troubleshooting ........................................................ 44

If you have any questions about installation, application, operation, or care and cleaning, Hunter Douglas Customer Service Shutter Specialists are available at 1-888-727-5230 toll-free. Shutter Specialists are available from 6:00 a.m. to 5:00 p.m. Mountain Standard Time, Monday through Friday.

GETTING STARTED

Hunter Douglas Palm Beach™ Polysatin™ shutters are built using the highest quality materials. When properly installed, these shutters will provide a lifetime of beauty and performance.

IMPORTANT: These installation instructions are intended for professional installers who have been certiﬁed after attending Hunter Douglas shutter training.

Installation Overview

Panel shutters come in many conﬁgurations — individually hinged, bi-fold panels, with and without T-posts, track systems comprised of from one to many panels, and with a variety of frames for inside or outside mounting.

Whatever the conﬁguration, installation procedures are basically the same. The frame is assembled and fastened to the window at two points. Then the shutter panels are individually installed and racked, during which time frame attachment is completed. Duracatch adjustment or magnet mounting, caulking and other ﬁnish work complete the installation.

™

lock

Unpacking

Carefully unpack the shutters. The package will include:

■ Shutter panels

■ Disassembled frames (frames for specialty shapes are typically assembled)

■ Miscellaneous hardware (hinge pins, button covers, etc.)

Tools and Materials Needed

Tools

■ Flat blade, Phillips, and Robertson #1 and #2screwdrivers

■ Power drill anddrill bits, including a 2" drill bit

■ Rubber mallet

■ Miscellaneous tools for non-typical installations (jig saw, hack saw, Dremmeltool,etc.)

Materials

■ Canvas drop cloth large enough for unpacking and frame assembly

■ Clean fabric cloth and a mild cleaning spray solution

■ Shim materials

■ Finishing supplies (caulk, sealant, etc.)

■ Instant adhesive for frame miters

■ Silcone adhesive or doubled-sided tape for Decorative Sill Cover installation

■ Measuring tape

■ Level

■ Awl

GETTING STARTED

Fasteners

Screws of varying lengths and types are required to install shutters. The chart below shows the standard fasteners, what each is used for, and the tool or driver needed to secure them. Other types of fasteners may be needed if mounting into concrete, metal, or similar surfaces.

#8 x 3" Panel Assembly Screw

#8 x 2" Pan Head Screw

#8 x 1½" Pan Head Screw

#8 x 1" Pan Head Screw

#8 x ¾" Pan Head Screw

#8 x 2" Bugle Head Screw

#8 x ¾" Flat Head Screw

#6 x 1¾" Round Head Screw

Attaches stiles to rails; also used as an installation screw

#2 Robertson drive

Installation screw #1 Robertson drive

Attaches Bi-fold or Bypass bracket to wall #2 Phillips drive

Installation screw #1 Robertson drive

Attaches Bi-fold and Bypass carrier hardware to panels

#2 Phillips drive

Attaches Bi-fold and Bypass track to frame or opening, as well as track system brackets to frame

#2 Phillips drive

Attaches T-post to frame #2 Phillips drive

Attaches Bi-fold pivot bracket to frame #2 Phillips drive

Attaches T-post block to frame #1 Robertson drive

#6 x ¾" Round Head Screw

#6 x ½" Pan Head Screw

#6 x 3/8" Pan Head Screw

#6 x 5/8" Flat Head Screw

#6 x 3/8" Flat Head Screw

Attaches magnets #2 Phillips drive

Attaches Bi-fold bottom track pivot bracket to bottom track

#2 Phillips drive

Attaches L-bracket to Bi-fold or Bypass frame and valance

#2 Phillips drive

Attaches hinges to frames and T-posts, as well as magnet strike plates to panels

#1 Robertson drive

Attaches metal corner key to frame #1 Robertson drive

Panel Systems

Bottom

FRAME ASSEMBLY

Assemble the Frame – Panel Systems

Prepare the work area. Lay the shutter panels on your drop cloth face up as they will appear in the window. Then follow the procedure below.

1. Lay the side frames beside the panels, so that the panel hinges are above the frame hinges. If one or more T-posts are used, lay them in the proper position, as well.

Top

Corner Key

Position hinge leaf on frame below hinge leaf on panel

Corner Key

2. Insert the plastic corner keys into the ends of the top and bottom frames.

➤ The Deluxe Casing frame, Colonial Z-frame, Classic Z-frame and Standard Z-frame

receive both the corner keys and metal brackets.

➤ Insert the side frame pieces onto the corner keys (and metal brackets, if applicable) of

the top frame.

IMPORTANT: With outside mount L-frames that have no T-posts, glue the corner keys in position as described in Step 3 on the following page.

FRAME ASSEMBLY

Panel Systems

3. Outside mount L-frames with no T-posts: Glue the corner keys in position as illustrated. This prevents the frame from bowing.

➤ First remove the tabs off the corner key with a ﬂat blade screwdriver.

➤ Then apply a small amount of instant adhesive or contact cement to the inside of

the frame.

➤ Insert the corner key into the end of the frame and hold ﬁrmly until set.

IMPORTANT: Be sure the frames match before gluing. The corners cannot be detached after the adhesive has set.

Outside Mount L-Frame with No T-Posts Only

Apply

Tab

Adhesive

Inside

Frame

4. With the Deluxe Casing frame, Colonial Z-frame, Classic Z-frame and Standard Z-frame, secure the top frame metal brackets to the side frames using the provided screws.

Tabs

Removed

Panel Systems

FRAME ASSEMBLY

5. Frames with T-posts: Attach the T-post to the top frame.

➤ T-post blocks will be pre-attached to the

#8 x 2"

Bugle Head

Screw

top and bottom frame pieces.

➤ Slide the T-post onto the T-post block on

the top frame piece and secure the T-post to the block using a #2 Phillips bit to drive the provided bugle head screw.

IMPORTANT: A long driver bit is required to get enough access to drive the screw.

T-Post Block

NOTE: See Step 8 on page 6 if T-post blocks were not provided, or for three-sided frames or inside mounts with no frames.

6. Attach the bottom frame to the side frames and T-post, repeating the methods described

T-Post

in Steps 2 through 5.

7. Deluxe Casing frame and outside mount L-frame only: If build-out is needed for additional clearance, install the build-out onto the back of the frame.

➤ The build-out snaps onto the back of the frame.

➤ The Deluxe Casing frame build-out is also screwed into the back of the frame.

Top

Frame

L-Frame Build-Out

½"

Deluxe Casing Frame Build-Out

FRAME ASSEMBLY

Panel Systems

8. With 3-sided frames or inside mounts with no frame, T-post brackets are used to attach the T-post to the sill or casement after the frame has been installed. Refer to the illustration below.

➤ Attach the brackets to the sill or casement using the slotted hole on the bracket to allow

for side-to-side adjustment.

➤ Be sure to square the T-post before tightening the brackets.

➤ T-post brackets can also be used to attach T-posts to frames when T-post blocks are

not provided.

IMPORTANT: When a Decorative Sill Cover is used, it must be placed between the window sill and T-post before attaching the T-post.

T-Post

Bracket

Sill

Track Systems

¾"

Build-Out

FRAME ASSEMBLY

Assemble the Frame – Track Systems

Prepare the work area. Lay the frame pieces on your drop cloth in their proper orientation. Thenfollow the procedures below.

1. Use four screws to attach the top frame to the side frames.

➤ With four-sided systems, attach the bottom frame to the side frames in the same way.

2. If build-out is needed for additional clearance, secure the build-out onto the back of the frame with screws, as shown below.

3" Screws

Track System

(Bi-Fold Shown)

Build-Out

¾"

Pre-Drilled

Outside Mount

Installation

Screw Holes

Pre-Drilled

Inside Mount

Installation

Screw Holes

INSTALLATION

Framed Standard Panel Systems

Optional

Cover Strip

Standard L-Frame

(IM)

Framed Standard Panel Systems

Standard

Z-Frame

(IM)

Standard L-Frame

(OM)

Deluxe Casing Frame

NOTE: If a Decorative Sill Cover was ordered, refer to page 39.

Step A. Install the Frame

1. Position the frame for mounting.

➤ Outside (OM) Mount. Center the frame over the opening. There should be a ¼" reveal

on all four sides (or an equal reveal if a larger or smaller reveal was speciﬁed on the original order).

➤ Inside (IM) Mount. Center the frame

in the opening. Insert temporary shims between the shutter frame and the window to hold the frame centered.

2. Attach the side frames at the top corners through the pre-drilled holes.

IMPORTANT: Tighten the screws snugly, but do not overtighten.

(OM)

Framed Standard Panel Systems

Step B. Mount the Panels

INSTALLATION

1. First, retract the Duracatch™ locks on the top and bottom of the panels.

Duracatch Lock

➤ The Duracatch lock system is designed

to help level the panels within the frame. Retracting the locks makes it possible to rack the shutter.

➤ Using a ﬂat blade screwdriver, push down

on the Duracatch lock and tighten the screw a quarter-turn.

Recessed Lock

Push Down and

Tighten ¼ Turn

2. Align the panel and frame hinges, and insert the hinge pins.

3. Close the panels and check for proper alignment.

➤ If panels are misaligned, rack the shutter by grasping the frame at the bottom corners

and moving it from side to side until proper alignment is achieved.

NOTE: In the following procedures, after each fastener is placed, close the panels and check the alignment. If the alignment is lost, remove the fastener, re-align the panels, and then re-install thefastener.

IMPORTANT: For installations with multiple T-posts, it is recommended that you begin your racking at the center most section and work your way out to each end.

Incorrect

Correct

INSTALLATION

Framed Standard Panel Systems

4. Hold the frame in the aligned position.

➤ Outside (OM) Mount. Use a fastener to secure the center of the bottom frame. Check

alignment, and then secure the side frames at the bottom corners.

➤ Inside (IM) Mount. Use fasteners to

secure the side frames at the bottom corners.

5. Insert screws into the remaining holes and check that the panels are still aligned after each screw has been tightened. Re-adjust if necessary.

6. Release all Duracatch

™

panel lock assemblies by loosening the lock screws a quarter-turn.

7. Close the panels and, if needed, adjust the Duracatch locks with a ﬂat blade screwdriver so that all doors close easily yet stay ﬁrmly shut.

➤ If necessary, install panel lock ramps on the sill or casement (see page 40).

➤ If necessary, install magnets and plates (see page 41).

8. Perform any other necessary ﬁnish work to complete the installation (see page 42).

NOTE: If necessary to drill more installation holes in the frame, drill

/8" holes through the ﬁrst

layer of vinyl only. Drill through the light block for both inside and outside mounts. (For sample

drilling locations, see the illustrations at the top of page 8.)

Hang Strip Behind Panels

Hang Strip to Side of Panels

Standard Panel Systems with Hang Strip

INSTALLATION

Hang Strip

Bent Leaf Hinge

/8" Holes for

Installation Screws

Hang Strip

Standard Hinge

/8" Holes for

Installation Screws

NOTE: If a Decorative Sill Cover was ordered, refer to page 39.

Step A. Install the Hang Strips

1. Attach the side hang strips inside or outside the opening.

➤ With outside mounts, be sure the hang strips are positioned the correct width apart and

at the correct height.

➤ Insert a Robertson screw into the top and bottom holes only, then set the screws into the

mounting surface.

➤ Tighten the screws snugly, but do not overtighten.

Step B. Mount the Panels

1. Hang the panels by ﬁtting the pin end of the hinges into the hinge barrels.

2. Square and align the panels to the opening.

➤ Hang Strip Behind Panels. If

necessary, adjust the bent-leaf hinges by loosening the hinge screws and moving the hinge left or right.

➤ Hang Strip to Side of Panels. If

necessary, place hinge shims between the hinge and hang strip.

➤ Re-tighten the hinge screws once the

panels are square and aligned.

Incorrect

Correct

INSTALLATION

Standard Panel Systems with Hang Strip

3. Insert screws into the remaining holes and check that the panels are still level after each screw has been tightened. Re-adjust if necessary.

4. With inside mounts, install Duracatch

™

panel lock ramps (see page 40).

5. With outside mounts, install magnets and plates (see page 41).

6. Perform any other necessary ﬁnish work to complete the installation (see page 42).

Unframed Standard Panel Systems

INSTALLATION

Unframed Standard Panel Systems

Unframed inside-mounted shutters may be installed ﬂush with the opening or projected out from the opening using extended leaf hinges, which are

NOTE: If a Decorative Sill Cover was ordered, refer to page 39.

/8" wider.

Step A. Install the Bottom Leaf of the Top Hinge

1. Position the left panel in the opening so that it has equal clearance at the top and bottom.

Mark where the bottom of the top hinge is located.

2. Align the top of the bottom leaf with the mark and attach it using one screw.

3. To check for accurate placement, install the panel by its top hinge, inserting a hinge pin to

hold the panel in place. Adjust placement of the hinge, if necessary.

➤ If placement is accurate, remove the panel and install the second screw into the bottom

leaf of the top hinge.

Step B. Install the Bottom Leaf of the Bottom Hinge

1. With the panel placed in the top hinge, mark where the bottom of the bottom panel hinge is

located.

2. Align the top of the bottom leaf of the hinge with the mark and attach it using one screw.

3. To check for accurate placement, install the panel into the two hinges. Adjust placement of

the bottom hinge, if necessary.

➤ If placement is accurate, install the second screw into the bottom hinge.

4. Repeat steps A and B for the right panel, if applicable. Be sure to align the right panel to the left panel.

Glass

Inside Mount

Flush with Opening

Top Leaf Attached

to Shutter

Bottom Leaf

Attaches to Opening

INSTALLATION

Unframed Standard Panel Systems

Step C. Install the Remaining Bottom Leafs of the Hinges

1. Once the panels are level and square in the opening, install the remaining bottom leafs while

the panels are hanging.

➤ Open the panels and install the bottom leafs onto the top leafs using the hinge pins.

➤ Screw the bottom leafs in place.

➤ If necessary, shim using the provided hinge shims.

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2. Install Duracatch

➤ When the Duracatch panel lock system is used, turn the adjustable plunger if minor

support or leveling is required.

3. Perform any other necessary ﬁnish work to complete the installation (see page 42).

panel lock ramps (see page 40) or magnets and plates (see page 41).

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