40684 Talbot Line, St. Thomas, Ont., N5P 3T2 Phone: (519) 637-7899

Toll Free: (800) 265-5701 Fax: (519) 637-3403

Web Site: www.northstarwindows.com

I:\PDAssembly\2Panel\CovPg.doc - 12/7/06

NORTH STAR

2-PANEL PATIO DOOR

ASSEMBLY INSTRUCTIONS

TWO PANEL PATIO DOOR HARDWARE LIST

645.2090ROLLER ASSEMBLY

645.3010ROLLER SHIMS

645.3030HEAD GASKET (LH & RH)

645.3020SILL GASKET (LH & RH)

645.3000OPERATING PANEL SEAL

645.5435 INTERLOCK END CAP L

950.1090HOLE PLUG

645.5430INTERLOCK END CAP R

645. 5640SILL INTERLOCK DUST PLUG 1" x 3"

575.1036HEAD INTERLOCK DUST PLUG 1/2" x 1-1/2"

645.2085HEAD DUST PLUG

645.5200INTERIOR HANDLE, SCREWS & LEVER

645.5220EXTERIOR HANDLE

645.5260SINGLE POINT LOCK & KEEPER

2 580.6145 #10 x 2-1/2" P. H. ZINC

16 580.1386 #8 x 2-1/2" R. H. W. ZINC

2 580.6115 #10 x 3/4" F. H. ZINC

5 580.1090 #6 x 3/4" F. H. WHITE

1 580.1310 #8 x 1/2" P. H CAMTAP ZINC

1 580.0930 #5 x 1/2" F. H. ZINC

QTY. DESCRIPTION

QTY. DESCRIPTION

QTY. DESCRIPTION

1

1

1

2

4

2

2

1

1

1

4

1

1

1

1 645.5460 SASH BUMPER (HEAD)

12/21/04

1 645. 5550 SASH BUMPER (SILL)

DETAIL A

DETAIL A

DETAIL B

DETAIL B

A

B

STEP 1SLIDE FIXED SASH SUPPORT

INTO SILL AS INDICATED

STEP 3REMOVE PROTECTIVE FILM FROM

SILL GASKETS AND APPLY TO BOTH

SIDE JAMBS AND FASTEN SIDE JAMB

TO SILL USING #8 x 2-1/2” R. S. W .

SCREWS.

P. 1

2-PANEL PATIO DOOR ASSEMBLY INSTRUCTIONS

STEP 2REMOVE PROTECTIVE FILM FROM HEAD

GASKETS AND APPLY TO BOTH SIDE JAMBS.

APPLY SILICONE TO THE LEG LOCATION

SHOWN ON EACH SIDE JAMB AND FASTEN

USING #8 x 2-1/2” R. S. W . SCREWS.

11/01/04

DETAIL B

DETAIL B DETAIL A

DETAIL A

B

A

IF ASSEMBLED AT JOB SITE, TEMPORARILY

PIN FRAME IN OPENING.

STEP 4DETERMINE OPERATION OF DOOR (XO OR OX). IF OPPOSITE OPERATION IS REQUIRED SLIDE FIXED PANEL SUPPORT TO OPPOSITE SIDE.FOR PANEL ORIENTATION READ LABEL ON

EDGE OF PANEL, ENSURING GLASS STOPS

ARE TO UNIT INTERIOR.

INSERT FIXED PANEL AS INDICATED AND PLACE IT ON FIXED PANEL SUPPORT AND SLIDE INTO SIDE JAMB POCKET

P. 2

PANEL ORIENTATION LABEL

FIXED PANEL INSTALLATION

11/01/04

STEP 5APPLY SILICONE ON BOTTOM AND SIDES OF 1" x 3" DUST PLUG PLATE AND PLACE ON SILL FLUSH WITH FIXED PANEL SUPPORT AS INDICATED IN DETAIL A. FASTEN WITH #6 x 3/4 F. H. SCREW THRU CENTER OF PLUG USING RUBBER MALLET INSTALL INTERLOCK BEFORE SECURING FIXED PANEL WITH 4 - #6 x 3/4" F. H. SCREWS THRU FRAME WEATHER STRIPGROOVE AS INDICATED.MAKE SURE HEAD JAMB IS TIGHT AGAINST THE TOP

OF THE INTERLOCK, THAT THE FIXED PANEL AND

FRAME ARE SQUARE BEFORE FASTENING.

COMPLETE ANCHORING OF UNIT FRAME ENSURING

UNIT IS SQUARE, PLUMB AND LEVEL.

DETAIL C

DETAIL C

DETAIL B

DETAIL B

C

B

STEP 7AFTER FRAME IS INSTALLED IN

OPENING, INSTALL LATCH KEEPER

USING 2 #10 x 2-1/2" P. H. SCREWS

AT MARKED LOCATIONS INTO STUD.

IF USING MULTI-POINT HARDWARE

FASTEN KEEPER WITH 2 #10 x 3/4"

AND 2 #10 x 2-1/2" P. H. SCREWS.

STEP 8INSTALL SCREEN LATCH KEEPER

USING 2 #5 x 3/4" P. H. SCREWS

ON MARKED LOCATIONS.

STEP 9APPLY OPERATING

PANEL FOAM SEAL

STEP 6APPLY 1/2" x 1-1/2" INTERLOCK SEAL

ON UNDERSIDE OF HEAD JAMB

AS INDICATED.

P. 312/21/04

DETAIL A

DETAIL A

DETAIL B

DETAIL B

A

B

STEP 12INSERT LOCK WITH LATCH ENGAGEMENT UPWARD AND FASTEN WITH 2 #10 x 3/4" F. H. SCREWS. INSERT THUMB LEVER AS INDICATED, AND INSTALL HANDLES ENSURING SCREWS AREON THE INTERIOR OF DOOR PANEL.(STANDARD SINGLE POINT HARDWARE SHOWN)

STEP 10PEEL AND STICK ROLLER SUPPORT FOAM PADS INSIDE OF BOTTOM RAIL AND INSERT ROLLER ASSEMBLIES (NO SCREWS REQUIRED). APPLY BEAD OF SILICONE FULL LENGTH TO UNDERSIDE EXTERIOR EDGE WHERE WEATHER-STRIP ADAPTOR SNAP IN LEG CONTACTS SASH. SILICONEBOTTOM RAIL ACROSS ENDS TO COMPLETELY SEAL OFF EACH END BETWEEN SASH AND WEATHER-STRIP ADAPTER. NEXT SNAP SASH WEATHER STRIP ADAPTOR INTO PLACE TO SECURE ROLLER ASSEMBLIES AND FASTEN WITH #5 x 1/2" F. H. SCREW AT MIDPOINT OUTSIDE EDGEON 45 DEGREE ANGLE AS SHOWN.(NOT IN ROLLER TRACK PATH)

LATCH ADJUSTMENTSCREW

STEP 11INSTALL OPERATING PANEL INTO FRAME.

P. 412/21/04

#5 x 1/2" F. H. SCREW

SILICONE

DETAIL A

DETAIL A

A

P. 5

STEP 14PLACE SMALL BEAD OF SILICONE IN BOTTOM INTERLOCK OPENING. INSERT END CAP AS SHOWN. INSTALL INTERLOCK ON OPERATINGPANEL AS INDICATED. ENSURE INTERLOCK IS FLUSH WITH BOTTOM OF WEATHERSTRIP ADAPTOR.(1 RIGHT AND 1 LEFT END CAP IS PROVIDED FOR REVERSIBILITY OF DOOR)

STEP 13SLIDE OPERATING PANEL TO THE CLOSED POSITION.INSERT DUST PLUG INTO HEAD JAMB POCKET WITH SCREW HOLE TOWARDS INTERIOR AND SLIDEINTO POSITION SO WOOL PILE IS FLUSH WITH EDGE.OF DOOR PANEL. FASTEN WITH #8 x 1/2" P. H. SCREW.

STEP 15ADJUST ROLLERS, ENSURING PANEL IS SQUARE TO JAMB AND CLEAR OF TRACK, PRIOR TO INSERTING HOLE PLUGS. AFTER LOCK AND KEEPER ARE ALIGNED, IN AND OUT ADJUSTMENT MAY BE MADE BY TURNING LATCH SCREW AS SHOWN IN STEP 13.

11/01/04

DUST PLUG

DETAIL A

DETAIL A

A

P. 6

STEP 16INSERT SCREEN PANEL INTO HEAD TRACK, AND BOTTOM ONTO SCREENSILL TRACK.

STEP 17SECURE SCREEN BY ADJUSTING TOP ANDBOTTOM ROLLERS WITH ADJUSTMENT SCREWS FOR SMOOTH OPERATION.

11/01/04

DETAIL A

DETAIL A

A

P. 7

INTERIOR AND EXTERIOR TRIM

STEP 20INSERT HEAD JAMB POCKET COVER AND THEN SIDE JAMB POCKET COVER AS INDICATED.(OPTIONAL ON WHITE DOORS)

STEP 19INSERT POCKET COVER IN SIDE JAMB AS INDICATED. (OPTIONAL ON WHITE DOORS)

STEP 18INSTALL OPERATING PANEL STOP

06/28/05

EXTERIOR VIEW

INTERIOR VIEW

STEP 21 INSERT SASH BUMPER (SILL)AS SHOWN.

DETAIL A

DETAIL A

DETAIL B

DETAIL B

AB

PRIOR TO INSTALLING NAILING FIN

APPLY 1/8" BEAD OF SILICONE AT

THIS LOCATION. FULL LENGTH OF

HEAD & SIDE JAMBS

APPLY SILICONE TO END JOINT

ON EACH NAILING FIN.

NAILING FIN INSTALLATION INSTRUCTIONS

APPLY SILICONE ON JOINT

11/11/04

P. 1

PATIO DOOR INSTALLATION INSTRUCTIONS

STEP 1A LEVEL BASE AND SQUARE OPENING IS CRITICAL FOR THE PERFORMANCE OF THE DOOR. APPLY TWO BEADS OF SILICONE ON BASE, 1" IN FROM INTERIOR AND EXTERIOR EDGE OF SILL BEFORE INSTALLING DOOR.

STEP 2PLACE DOOR FRAME INTO OPENING AS SHOWN, ENSURING SILICONE FORMS A GOOD SEAL BETWEEN FLOOR AND DOOR SILL. (DOOR MAY ALSO BE INSTALLED FULLY ASSEMBLED)

11/11/04

DETAIL A

DETAIL A

DETAIL B

DETAIL B

A

B

P. 2

STEP 3SHIM SIDE JAMBS IN THREE PLACES AS SHOWN AND FASTEN TOP AND BOTTOM WITH #10 x 2-1/2" P. H. SCREWS IN V GROOVE AS SHOWN IN DETAIL "B". PLACE MIDDLE SHIM IN LINE WITH MARKED LOCATIONS FOR LOCK KEEPER. FASTEN SIDE JAMB AND KEEPER USING #10 x 2-1/2" P. H. SCREWS AS SHOWN IN DETAIL "A". FASTEN HEAD JAMB AFTER FIXED PANEL AND INTERLOCK ARE INSTALLED. (REFERTO DOOR ASSEMBLY INSTRUCTIONS FOR DETAILS)

STEP 4TRIM EXCESS WOOD SHIMS AND LOOSELY FILL CAVITY BETWEEN JAMBS AND OPENING WITH FIBER INSULATION. APPLY A QUALITY EXTERIOR GRADE CAULKING TO THE EXTERIOR FRAME CAVITY BETWEEN DOOR FRAME AND OPENING

SINGLE POINT LOCK KEEPER

11/11/04