Chapter 1 Rolling Shutter Installation Instructions

If you are protecting more than one opening, ensure that the shutter corresponds to the appropriate opening. To assist in identifying the items, each package will be labeled with the opening numbers from the Rolling Shutter Order Form. Most rolling shutters will be shipped in three separate cartons.

The first will contain the assembled shutter box;
in the second, the guide rails and storms bars;
and the third the shutter curtain, see Figure 1.1 below.

This information is presented to give installers the basic knowledge of rolling shutter installation. We recognize that field conditions and installation procedures may vary, depending on the type of shutter and location of the installation. As written in this procedure, installations may have to be modified, deleted or added to complete an installation, and satisfy your customer.

It is recommended that you read these instructions thoroughly, until you fully understand each step. If you have any questions, do not hesitate to call the A.C.C. Manufacturing Corporate Office at 1-877- 4-ACCMFG.

NOTE : Check the material in each box to ensure that you have received the items
necessary to complete the installation.

Section 1.1 Necessary Tools

Electric Drill
Drill Bits
Power Cords
Drop Clothes
Screwdrivers (Regular and Phillips)
Touch-up Spray Paint
Masking Tape

Level
Hammer
Caulking Gun and Caulk
Tape Measure
Rivet Gun and Rivets
Vacuum Cleaner
Ladders

You may have to keep various colors of touch up paint and caulk on hand depending on the color of the shutter you are installing. The drill bits for installing the operators through the walls should be no less than 12 inches long.

Section 1.2 Preparation of the Opening

1. Check the opening to determine if the window is square and level and measurement three places across the opening and three places up the opening. This must be accomplished before a rolling shutter is installed regardless whether it is a new or existing building.

2. Prepare the wall where the tracks and shutter box are attached to the wall, and the bottom of the opening for the shutter to close. It may require a build out for mounting side frames, mounting brackets, sidetracks and sill. The objective of the build out is to achieve a level surface for the roll shutter assembly. Make sure that the thickness of the build out is sufficient so that the shutter will clear all protrusions such as handles, hinges, doorknobs etc… It is important that the surface the tracks and box are to be mounted on is on level for the correct operation of the shutter.

Note: Prior to drilling any holes ensure the all of your drill bits are sharp to prevent the drill from binding and possible damaging the shutter material or the wall of the building. Spread out your drop clothes adjacent to the opening.

3. Place the shutter box on the drop cloth, paper, or cardboard.

4. Insert the tracks into the pins of the shutter box side frame. Measure the track-to-track (T-T) distance and check this against the cut sheet supplied with the shutter. If these dimensions agree, then proceed by placing the shutter into position, centered over the opening. Temporarily attach the system through the two pre-drilled holes in the top of each guide rail.

Note: Ensure that the front plate of the shutter box must be installed for this step. This will ensure that the side plates are parallel to each other.

5. Mark the location of the guide rails on the wall.

6. Mark the location of the operator 1 inch above the top of guide rail in line with existing pre-drilled mounting holes of guide rails.

7. Remove the box and the guide rails.

8. Install the build out against the lines marked in step 5.

Note: Do not place the shutter material directly on concrete or lawn or garden material.

Chapter 2 Operator Installation

These are many different types of operators designed to suit every individual preference.

Strap system
Gear with Crank inside or outside
Motorized

The different operators require different attention for drilling the operator hole. The track can be located on the inside or outside of the building. The operators can be located on the left or right side (looking from the outside to the inside) of the opening. All of these options must be determined before the shutters have been ordered. Refer to the Rolling Shutter Order Form to guarantee what type of operator you are installing and where it is to be located.

Click here to see larger figure

Note :Drilling the operator holes is one of the most important steps to a successful installation. Make sure that the strap or dive rod can operate the shutter freely without touching the wall or protection tube. Otherwise, noise and more unwanted friction will occur and make the shutter harder to operate, or possibly inoperable.

If the operator hole passes through a hollow wall section with loose insulation, place optional PVC protection tube through the hole. This is also recommended on block walls where hollow sections are possible. Caulk the inside and outside wall around the tube. With the strap-operated shutter, the straps should be fed through the operator hole before setting the box into the tracks.

As mentioned earlier, field conditions vary and this can change the procedure. For some installation, installers will secure the strap inside the box, install the box and then feed the strap through the operator hole.

Note : Before drilling through any wall, avoid any drapes, valances, cabinets and any other interior obstructions.

Section 2.1 Strap Operator Installation

The strap operator is comprised of a nylon strap that is fed from the pulley inside the shutter box, through the wall, over a pulley to a strap re-coiler attached to the wall.

1. Drill a ¼ inch pilot hole, and a ¾ inch hole for operating strap through the wall from outside of the house.

2. Clean the hole inside and out and remove any loose pieces of debris. Only if you are installing on a masonry structure, insert a plastic tube and spring coils to avoid fraying of the operating strap.

3. Cover the above-mentioned ¾ inch hole with pulley, see figure, after you have fed the operating strap through.

Note: The operator strap must not be twisted!

4. Feed operating strap into strap box. Attach the end of strap to lug on inner rim of wheel. Remove axle by loosing screws and feed through slot in wheel then affix a knot (see figure) replace the axle and affix screws.

5. Mount straps box approximately 3 feet above the floor, ensuring that the operating strap is vertical.

Section 2.2 Crank with Universal Operator Inside Installation.

Whether you are using a 90 or a 60 universal assembly, makes sure that is always at a 90 angle or less. Never elevate the handle assembly above 90. The gear setting can be set for any angle; it is typically pre-set for a 90 or 30 installation. Determine the path for the universal operator and ensure that any interior fixtures will not interfere with the operation of the shutter.

Note : Before drilling through any wall, avoid any drapes, valances, cabinets and any other interior obstructions.

1. Drill a pilot hole using a ¼ inch masonry drill bit.

2. Drill the finish hole ¾ inch in diameter.

3. Clear the hole of obstructions.

4. Insert the universal assembly into the gear making sure it is a straight path.

5. Secure the universal assembly securely and neatly with the appropriate fasteners.

Section 2.3 Crank with Universal Operator outside Installation

Prior to installing the hood over shutter assembly, make proper references points and measurements to ensure the proper location of the universal. All of the steps to install the shutter will be completed prior to installing the crank and universal on the outside of the shutter assembly

1. Drill a small pilot hole though the aforementioned reference holes.

2. Make a larger (no smaller than ½ inch and no longer than ¾ inch) hole for the universal operator.

3. Insert the universal through the hood and into the gear.

4. Fasten the universal assembly to the outside of the hood.

Section 2.4 Motorized Operator Installation

The electrical contractor should have already installed the wire or a junction box to the installation of the shutter system. Double-check the Rolling Order Form to ensure that the power locations are correct. Always check with the local building codes to make certain that the wiring is correct.

1. Locate and drill the hole in the back of the shutter box for the power cord.

2. Feed the wire through the back to the shutter box.

3. Connect the wires to the motor “pig tail”.

4. Fill the hole with caulk to maintain the integrity of the wall.

Click here to see a larger figure

Chapter 3 Track Final Installation

In most cases the track will be pre-drilled in the factory.

The following paragraphs will describe how to install the track to different mounting surfaces.

concrete surface

wood surface

The location of these holes will be dependent on the type of installation called out on the Rolling Shutter Order Form.

If the opening is restricted, the holes will be located within the slat groove on the guide rail.

Un-restricted openings will have the holes located on the face of the guide rail, see figure. In his case you will cover the holes with the provided plugs.

Section 3.1 Concrete Structure Installation

1. Drill using ¼ inch masonry bit approximately 2 ½ inches deep into the wall structure until you reach the 2 by 4 framing of the structure.

2. Deepen these holes with 1/8-inch wood drill bit until the overall depth is approximately 2 inches.

3. Align the guide rail over the holes and ensure the rail is level.

4. Fasten the rail to the wall through one of the middle holes using the appropriate TAPCON fastener.

5. Ensure that the rail is level, and install one of the bottom fasteners.

6. Install the fasteners in the remaining pre-drilled holes.

Section 3.2 Wood Structure Installation

1. Drill using a 1/8-inch wood bit approximately 1 inch deep into the wall structure through the pre-drilled holes in the track.

2. Align the guide rail over the holes and ensure the rail is lever.

3. Fasten the rail to the wall through one of the middle holes using the appropriate wood-screw.

4. Ensure that the rail is level, and install one of the bottom fasteners.

5. Install the fasteners in the remaining pre-drilled holes.

Repeat the drilling and fastening procedures through all of the remaining, pre-drilled holes. Do not tighten the fasteners at the top of the guide rails to leave enough room to install the shutter box.

Chapter 4 Shutter Box Installation

In most cases it will require two installers to properly set a shutter box assembly in to place. It is very important that the shutter box is properly placed in the tracks in order for the shutter for function properly.

1. Set the shutter box in place, by inserting the tabs into the guide rails. Making sure of fit in line with guide rails.

2. Ensure that the shutter end caps and the guide rails are in line and plumb.

3. Drill mounting holes using a ¼ inch, metal drill bit into the back panel.

Chapter 5 Curtain Installation

Care must be taken when handling the shutter slats to ensure that they are not damaged during the installation.

1. Insert the spring end of the strap in the key-way of the reel. Place the end straps 2 inches in from each end of the reel and evenly space the remaining straps taking care not to exceed 12 inches between the straps.

2. Make sure that all of the straps are hanging even and parallel to the reel assembly.

Shutter Slats

1. Insert the slats into the guide rails and lower the shutter to the bottom rail.

2. Hang the top slat from the security spring by inserting them into the “j- hook”.

3. Install the two “up stops” in the bottom slat and test shutter operation.

Chapter 6 Hurricane Bar Installation

If hurricane bars were specified on the Rolling Shutter Order Form they are included in the shipment with hurricane bars, brackets and hardware.

Shutter Header The shutter header will only be included with a rolling shutter that is to have hurricane bars installed.

Mount the header between the two vertical guide rails.

1. Secure the header to the shutter hood box.

2. Install the hurricane bar brackets to the header spaced to the requirements of the local municipality.

3. Install the hurricane bars on the brackets.

4. Mark the location of the bottom brackets by letting the hurricane bars hang from the header.

5. Install the bottom hurricane bar brackets.

Chapter 7 Caulking and clean up

The R-Value of A.C.C. Manufacturing products are tested and published. To achieve this important value it is important to caulk around the shutter box and tracks. Air infiltration behind the shutter must be kept to a minimum for maximum sound and thermal insulation.

1. Place a bead of caulk on both sides of the guide rail and/or build out.

Note To save time and caulking material, sue a backer rod to fill the large gaps between the track and or the build out prior to caulking.

2. Caulk around the perimeter of the shutter box.

3. Plug the outer holes with the plugs provided, or install the outer snap track piece. Waterproof the system by caulking the joints between the guide rails and the building.

Note :Do not allow the caulking to come in contact with the operator system.

Clean up. I

t is very important to leave the job site cleaner than it was upon your arrival. Take special care to remove any dust or filling that have been created installing the shutter system. Carefully remove any drop cloths to be shaken out back at the shop.