Englefield Sapphire Series User manual

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IMPORTANT READ ALL INSTRUCTIONS CAREFULLY BEFORE STARTING THE INSTALLATION
• Suitable for installation with Duracryl Wall lining.
INSTALLATION
INSTRUCTIONS
SHOWER WALL
RETURN RETAINER
RETURN PANEL
CORNER POST
INSTALLATION KIT
DOOR SILL
TOP RAIL
DOOR ASSEMBLY
SHOWER TRAY
INSTALLATION GUIDE
SAPPHIRE ANGLE CORNER SHOWER
Sika Silaflex NG
•To seal the WHITE shower door and returns to the shower tray.
Usage:
• 1 cartridge per wall shower
Sealant required to complete this
installation.

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Position the return wall
retainer profiles against show-
er wall, resting on the shower
base sill. The retainer should be
located plumb. Measure from the
Duracryl wall surface as shown.
TOOLS REQUIRED
• Tape Measure
• Soft pencil
• Drill
• Caulking gun
• Hole saw
• Drill bit 2.5mm
• Fine toothed saw
• Spirit level
• Jig saw (fine toothed blade)
• Box cutter
DRILLING AND CUTTING DURACRYL®
DRILLING: Small holes can be drilled with a twist drill, but
the cutting edge MUST be backed off with an oil stone (the
sharp edge dulled). Large holes must be drilled with a hole
saw.
Maximum drill size: 12 mm. Drill speeds:- 6 mm x 1800 RPM
- 12 mm x 900 RPM
CUTTING: If for any reason the acrylic requires cutting, use
a fine tooth hacksaw and proceed with caution. Edges
can be smoothed with a second-cut file and medium-fine
sandpaper. If the surface of the acrylic should happen to be
damaged, it can be restored by polishing with an abrasive
cleaner such as Meguiars Mirror glaze 28 all metal polish or
3M marine “one step” painted aluminium cleaner and wax.
PART ONE
CAUTION: BEFORE DRILLING
HOLES, ENSURE THERE ARE NO
ELECTRICAL CABLES OR WATER
PIPES BEHIND WALLS.
DOOR AND RETURN INSTALLATION
Ensure that the shower tray and
wall are installed according to the
instructions supplied.
1.
CAUTION: We recommend fixing
the wall retainers by screwing
through the backing board and
into studs. Other methods may
cause warping and may void
warranty.
Insert return panel into wall
retainer so that the black
mark aligns with the edge of
the wall retainer. NB: The mark-
ings on the top & bottom rails
should be on the outside of the
enclosure & the flexible side of
the PVC gasket on the inside.
3.
Fit both 45º corner profiles
to return panel assemblies
and push into place.
4.
A
A
DURACRYL
Dim ‘A’
900 865mm
1000 970mm
RETURN SIDE
Fix both wall retainers in
place using the 6 long
screws. Make sure the screws go
into studs.
2.

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Move 45º Corner Posts and
Return Panel Assemblies out
to allow Door Assembly to be
fitted.
5.
Fit Door Assembly into 45º
Corner Posts and push
together.
6.
Using a sharp knife, trim top
seal off door as shown.
9.
Centralise Door Assembly
between Wall Retainer and
Corner Post.
b.Position Return Panel between
Wall Retainer and Corner Post so
that the black lines at each corner
are not visible. DO NOT push the
PVC gasket into position at this
stage.
Ensure an even gap between
Door/Returns and edges of the
tray.
7a.
Check that the Door and
Return Panel Assemblies are
level with top of Wall Retainer and
45º Corner Profiles.
8.
IMPORTANT
TEST THE OPENING AND
CLOSING OPERATION OF THE
PIVOT DOOR
Using spirit level, plumb
Door, Return panels and
45O Corner Posts. Tape into posi-
tion as shown. Check Door opens
and shuts properly and the black
lines on the Return assembly top
and bottom rails remain hidden.
Readjust if necessary.
NOTE: This is an important part
of the installation procedure
and your careful attention at
this stage will ensure that you
will obtain the best possible
results.
10.
If door alignment is incorrect,
door will not function properly
and further adjustments are
necessary. Remove tape and re-
align until correct alignment is
achieved.

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Position Return Panel PVC
gasket by pushing outside
leg into both Wall Retainer and
Corner Post. It should ‘snap’ into
place. Now push the inside leg
into place.
13.
Drill 2.5mm holes ( NOTE:
DO NOT USE BIGGER DRILL
BIT) through punched holes at
top and bottom of each Wall Re-
tainer and Corner Post to secure
door and return. Make sure Door
and Return assemblies do not
move during this operation. Fit
screw, screw caps and remove
tape.
Remove screws from
corner of door at each 45O
post in turn and fit corner brack-
ets. Fit screw into top of Return
Panel as shown.
11.
12.
DO NOT PROCEED TO STEP 12 UNTIL
DOOR IS OPERATING CORRECTLY.
6g x 3/8"
screw
45O CORNER POST
Inside Shower
Outside Shower
Push ouside leg
Push inside leg
RETURN WALL RETAINER

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SEALANT APPLICATION
STEPS
Cut tip of silicone tube nozzle at
45O angle.
b. Hold the tube at 45O angle
and push forward as sealant fills
the joint.
c. The surface of the sealant can
be smoothed (before surface
dries) by using a finger dipped
in a small quantity of water with
one drop of washing liquid add-
ed.
d. Excess sealant should be
removed immediately with a
damp cloth.
PART TWO
SEALANT APPLICATION
Ensure all joints are clean and
dry before applying sealant.
CAUTION: Avoid contact with
skin, eyes and mouth and avoid
breathing vapour. If in eyes, im-
mediately flush with water.
If irritation persists, seek medi-
cal attention.
Keep out of reach of children.
Seal full height the joint
between the Walls and the
Wall Retainers.
b. Seal joint between the Door
Sill, the Return Panel and the
Shower tray.
IMPORTANT
SILAFLEX NG SEALANT SHOULD BE
APPLIED TO ALL OUTSIDE JOINTS.
DO NOT SEAL FROM INSIDE.
6mm
45°
1a.
Sealant
c. To a height of 100mm, seal
joints between Door Frame &
Corner Post and Door Frame &
Wall Retainer.
d. Seal up to the PVC gasket
joints between Return Panel &
Corner Post and Return Panel &
Wall Retainer.
IMPORTANT
ALLOW 24 HOURS FOR SEALANT
AND ADHESIVE TO CURE BEFORE US-
ING THE SHOWER.
2a.

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NEW ZEALAND
KOHLER NZ Ltd.
133 Diana Drive,
Glenfield,
Auckland.
Ph [phone]
Fax [phone]
[e-mail]
www.kohler.co.nz
CALL US FOR HELP
AUSTRALIA
KOHLER Co.
Unit 10, 70-99 St. Hilliers Road,
Auburn,
Sydney. NSW 2144.
Ph [phone]
Fax [phone]
[e-mail]
www.kohler.co.nz