Pella 80Wx0101 Users Manual
80WX0101 80WX
80WX0101 to the manual 26a1d1c3-928d-4198-a0d2-ff0dbd15e8ce
2015-02-06
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©2012 Pella Corporation Part Number: 80WX0101 WINDOW REPLACEMENT INSTRUCTIONS FOR CASEMENT, DOUBLE-HUNG AND CLAD FRAME WINDOWS INTO EXISTING DOUBLE-HUNG FRAME USING FRAME SCREWS These instructions were tested and developed for replacing windows in wood-frame wall construction systems designed to manage moisture. This method of installation involves removing the sash only of the existing window. The original window frame will remain in place and only the existing sash, exterior stops and frame hardware must be removed. Installation recommendations for other types of wall construction, wall systems or conditions may be obtained from Pella Corporation or a local Pella retailer. Building designs, construction methods, building materials, and site conditions unique to your project may require an installation method different from these instructions and additional care on your part. Determining the appropriate installation method is the responsibility of you, your architect, or other construction professional. YOU WILL NEED TO SUPPLY: • Cedar or Impervious shims/spacers (12 to 20) TOOLS REQUIRED: • Tape measure • Closed cell foam backer rod/sealant backer (12 to 30 ft.) • Level • Pella® SmartFlash™ foil backed butyl window and door flashing tape or equivalent • Prybar • Pella Window and Door Installation Sealant or equivalent high quality, multi-purpose sealant (1 tube per window) SEALANT SEALANT • Putty knife • Low expansion, low pressure polyurethane insulating window and door foam sealant - DO NOT use high pressure or latex foams • #8 x 3-1/4" Finish head screws (6 to 10 per window) • Sealant gun • Utility knife • Hammer • Screwdrivers (Flat & Phillips) • Adjustable pliers • Side Cuts • Roto-tool, reciprocating saw • Pella replacement window sill adapter Installation will require two or more persons for safety reasons. • Wood chisel • 1/8" drill bit • Drill REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT EX TE RIO R CAUTION: Many windows in older homes are painted with lead-based paint. Removal of old windows may disturb this paint. Proper precautions must be taken to minimize exposure to dust and debris. Consult state or local authorities for more information. Sill Adapter Flashing Tape Always read the Pella® Limited Warranty before purchasing or installing Pella products. By installing this product, you are acknowledging that this Limited Warranty is part of the terms of the sale. Failure to comply with all Pella installation and maintenance instructions may void your Pella product warranty. See Limited Warranty for complete details at http://warranty.pella.com. 1 REMOVE THE EXISTING SASH Note: Remove the new window from its packaging. Inspect and measure the new window to ensure it will fit into the opening prior to removing the existing window. The window needs to be 3/4" smaller in both width and height than the pocket frame. 1A A. Unlock the window. Raise the lower sash and lower the upper sash so both are in the approximate middle of the frame. Note: Most of the following steps may be completed from the exterior of the house. OP HEAD ST J A M B Head Parting Stop S T O P 1B 1C B. Remove the head parting stop. Remove any head parting stop by pulling the stop down from the frame. In some cases, the stops are nailed on and can simply be pulled off. In other situations the stops may need to be pried or cut out of the frame. Head Stop Remove Sashes 1D Jamb Liner 1E 1C Jamb Stops C. Remove the exterior jamb and head stops. This can be accomplished with a wood chisel, circular saw, reciprocating saw, roto-tool, or equivalent. Ensure the stop is removed flush with the existing window jamb. D. Remove the upper and lower sash. This will vary per manufacturer of existing windows. Some will simply pull out, while others may need to be cut to be removed. Grasp the sash and pull out of the frame. The jamb liner material may come out of the frame when pulling the sash out. E. Remove any and all jamb liner material. Some liners may have frame attachment fasteners that will need to be removed before the liners can be removed. Caution: Spring loaded balances can cause injury; use care when removing balances from existing windows. 2 OPENING PREPARATION A. Inspect the existing window frame and repair or replace any defective or rotted wood parts. EX TE B. Clean the opening of any dirt, debris, or excess old paint before proceeding. RIO R 2C C. Apply one piece of sill flashing tape to the sill of the existing window. Cut the tape the same length as the width of the existing window sill. Place one side of the tape against the vertical leg of the stool, and work the tape into the corner before applying to the sill. Press down firmly. The tape will not cover the sill depth completely under the new window. 2C 2C Note: If needed, blocking/shims may need to be placed where the existing balances were located. TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS. 3 WINDOW PREPARATION Note: For Double-hung, proceed to Step B. A. Casement: On the room side of the window, drill 1/8" diameter clearance holes through the head, jambs and sill of the frame. Space the holes a maximum of 6" from each end and a maximum of 16" on center. Note: On vent casements, place the holes so they do not interfere with the roto operator and the latch points on the lock side of the window. Designer Series® and ProLine® Architect Series® Double-Hung Double-Hung Head Drill 1/8" clearance hole Double-Hung Head 1/2" 3A 3A Casement Sill 3D 3B 6" EVERY 16" 6" EVERY 16" Drill 1/8" clearance hole Double-Hung Jamb Drill 1/8" clearance hole 3D 3B 6" 1" Drill 1/8" clearance hole 6" Single Window Clad Frame Head Double-Hung Jamb EVERY 16" 1/4" Drill 1/8" clearance hole 3D 3B Drill 1/8" clearance hole Drill 1/8" clearance hole 3D 3B 3D 3B 1" Drill 1/8" clearance hole 1/2" 6" Drill 1/8" clearance hole Clad Frame Sill 6" Double-Hung Sill Double-Hung Sill B. Double-Hung and Clad Frame: On the room side of the window, drill 1/8" diameter clearance holes through the frame at the locations shown. Space the holes a maximum of 6" from each end and a maximum of 16" on center. Note: The lower sash must be raised to drill the holes in the sill of the double-hung window. 4 SETTING AND FASTENING THE WINDOW A. If the existing double-hung has a sloped sill the sill of the new window will need to be supported by using the Pella replacement sill adapter accessory or by using wood blocking as needed. B. If using the Pella replacement sill adapter accessory the sill adapter will need to be cut to the same length as the sill of the window and slid into the sill fin groove. This adapter may be adjusted to accommodate different sill angles by breaking off the grooved leg at the desired dimension. Dry fit the window to ensure the window will fit in the opening and that the sill adapter is trimmed properly. Casement Sill Double-Hung Sill 4B 4B Sill Adapter Sill Adapter (SILL CUTAWAY VIEW) EX TE RIO R (SILL CUTAWAY VIEW) C. Apply a 3/8" bead of sealant at the point where the existing stool meets the existing window sill. Additionally, place sealant at the ends of the flashing tape, making sure to connect with the stool sealant. 4D 4C D. Apply a continuous 3/8" diameter bead of sealant at the exterior surface of the interior head and jamb stops. Connect this bead of sealant to the sealant line on the stool. TWO OR MORE PERSONS ARE REQUIRED FOR THE FOLLOWING STEPS. E. Insert the replacement window in the opening. Check to make sure the window rests against the interior blind stops and is making contact with the sealant. F. From the exterior, place shims near the top of one jamb, in line with the top predrilled hole in the window frame. Partially insert one 3-1/4" finish wood screw. Repeat the process for the other jamb. Note: Position shims to ensure they allow at least 1/2" from the exterior surface of the window to allow for placement of backer rod and sealant. G. Continue placing shims at each pre-drilled hole as needed to plumb and square the window. Check window for squareness by making sure the diagonal measurement from corner to corner of the replacement window is within 1/8" in both directions. Insert a 3-1/4" finish wood screw into each pre-drilled hole in the frame. Finish inserting the top screw in each jamb. Note: DO NOT shim above the window. DO NOT over shim! H. Check operation before applying the insulating foam sealant in case adjustments need to be made. 5 INTERIOR SEAL CAUTION: Ensure use of low pressure polyurethane window and door insulating foams and strictly follow the foam manufacturer’s recommendations for application. Use of high pressure foams or improper application of the foam may cause the window frame to bow and hinder operation. EXTERIOR A. Insulate between new frame and the existing frame with low expansion insulating foam. FROM THE EXTERIOR insert the nozzle of the applicator approximately 1" from the interior stop and apply a 1" deep bead of foam. This will allow room for the expansion of the foam and will minimize squeeze out. Follow foam manufacturer's instructions. Note: Masking between the window and the existing interior stop will help alleviate possible squeeze out of the expandable foam to the interior. 5A B. Check the window operation by opening and closing the window. If bowed, remove foam with a serrated knife, then check operation. If still bowed, adjust shims as needed, then insulate as instructed in previous step. C. Inspect the interior and carefully trim all excess foam sealant if needed. 6 EXTERIOR SEAL A. Insert backer rod into the space around the window at the head and jambs. This should provide at least 3/8" clearance between the backer rod and the exterior face of the window. EX TE 6A RIO R Note: Backer rod adds shape and depth for the sealant line. B. Place a bead of sealant at the jambs and head between the existing window frame and the replacement window frame. Caution: DO NOT seal the bottom exterior to allow for incidental water to weep. 6B C. Shape, tool, and clean excess sealant. When finished, the sealant should be the shape of an hourglass. Note: This method creates a more flexible sealant line capable of expanding and contracting. EXTERIOR FINISH OF EXISTING FRAME The exposed wood on the exterior stop needs to be covered/ protected. There are many ways to accomplish this, and each case can be unique. A few possibilities include: a) Covering the existing trim with aluminum coil wrap/ frame expander. b) Sanding, priming and painting to match existing trim. c) Covering the exposed wood with a high quality exterior grade sealant. Note: The contractor/installer will determine how to finish the exterior. EXTERIOR OF WINDOW WITH FRAME EXPANDER EXTERIOR FINISH OF ALUMINUM CLAD WINDOWS The exterior frame and sash are protected by aluminum cladding with our tough EnduraClad® or EnduraClad Plus baked-on factory finish that requires no painting. Clean this surface with mild soap and water. Stubborn stains and deposits may be removed with mineral spirits. DO NOT use abrasives. DO NOT scrape or use tools that might damage the surface. Use of inappropriate solvents, brickwash or cleaning chemicals will cause adverse reactions with window and door materials and voids the Limited Warranty. INTERIOR FINISH If products cannot be finished immediately, cover with clear plastic to protect from dirt, damage and moisture. Remove any construction residue before finishing. Sand all wood surfaces lightly with 180 grit or finer sandpaper. DO NOT use steel wool. BE CAREFUL NOT TO SCRATCH THE GLASS. Remove sanding dust. Pella products must be finished per the below instructions; failure to follow these instructions voids the Limited Warranty. • On casement and awnings, it is optional to paint, stain or finish the vertical and horizontal sash edges. • On single-hungs and double-hungs, do not paint, stain or finish the vertical sash edges, any finish on the vertical sash edges may cause the sash to stick; it is optional to paint, stain or finish the horizontal sash edges. • On patio doors, it is optional to paint, stain or finish the vertical and horizontal panel edges. Note: To maintain proper product performance do not paint, finish or remove the weatherstripping, mohair dust pads, gaskets or vinyl parts. Air and water leakage will result if these parts are removed. After finishing, allow venting windows and doors to dry completely before closing them. Pella Corporation is not responsible for interior paint and stain finish imperfections for any product that is not factory-applied by Pella Corporation. Use of inappropriate finishes, solvents, brickwash, or cleaning chemicals will cause adverse reactions with window and door materials and voids the Limited Warranty. For additional information on finishing see the Pella Owner’s Manual or go to www.pella.com. CARE AND MAINTENANCE Care and maintenance information is available by contacting your local Pella retailer. This information is also available at www.pella.com. IMPORTANT NOTICE Because all construction must anticipate some water infiltration, it is important that the wall system be designed and constructed to properly manage moisture. Pella Corporation is not responsible for claims or damages caused by anticipated and unanticipated water infiltration; deficiencies in building design, construction and maintenance; failure to install Pella® products in accordance with Pella installation instructions; or the use of Pella products in wall systems which do not allow for proper management of moisture within the wall systems. The determination of the suitability of all building components, including the use of Pella products, as well as the design and installation of flashing and sealing systems are the responsibility of the Buyer or User, the architect, contractor, installer, or other construction professional and are not the responsibility of Pella. Pella products should not be used in barrier wall systems which do not allow for proper management of moisture within the wall systems, such as barrier Exterior Insulation and Finish Systems, (EIFS) (also known as synthetic stucco) or other non-water managed systems. Except in the states of California, New Mexico, Arizona, Nevada, Utah, and Colorado, Pella makes no warranty of any kind and assumes no responsibility for Pella windows and doors installed in barrier wall systems. In the states listed above, the installation of Pella products in barrier wall or similar systems must be in accordance with Pella installation instructions. Product modifications that are not approved by Pella Corporation will void the Limited Warranty. INSTALLING ROTO COVER AND CRANK Note: Finish the interior of the window and allow the window to dry before proceeding with these instructions. (To open the window for finishing, partially insert the lock handle into the jamb, unlock the unit, temporarily attach the crank handle and turn to open.) A. Place the cover over the operator stud and snap into place. Position the pocket end of the cover into place. Pocket End Note: If the cover does not have the screw hole, apply pressure on the pocket end of the cover to snap the cover into place and proceed to step C. B. Insert the provided screw into the hole in the bottom of the pocket. Use a # 1 Phillips screwdriver to secure the pocket screw snug against the bottom of the pocket to avoid scratching the crank handle knob. DO NOT over tighten. C. Use a medium size flat-blade screwdriver to loosen the set screw in the crank handle. D. Slide the crank handle onto the stud. Unlock, open window, then close and lock window. Screw Hole Operator Stud A B Crank Handle D Operator Stud Set Screw E. Fold the crank handle down and check alignment of knob with the pocket. C Knob E Note: You may need to adjust the crank position on the stud until the correct alignment is achieved. F. Open the crank and tighten the set screw. G. After the final installation, fold the crank over and snap the knob into the pocket. Note: Even with the window open the crank can be folded to avoid interferring with the window treatments. Pocket LOCK LEVER REMOVAL AND INSERTION Note: You may want to remove the lock lever prior to finishing the window, or if it needs to be replaced with a lock lever in a different finish. A. Unlock and open the window. B. Place the lock lever in the locked position. B Interior Exterior C C. From the exterior of the window, insert a small flat-blade screwdriver between the cam and lock lever near the bottom of the opening between the stop and frame gasket. D. Push the screwdriver inwards with a small amount of pressure; then turn the blade slightly clockwise for a left hand unit, counter-clockwise for a right hand units. DO NOT over-twist the screwdriver, this can damage the lock driver. Note: This will release the hook in the lever from the cam hook. E. Remove the lock lever by pulling it toward the interior of the building. F. To install a lock lever, hold it in the lock position and insert it, from the interior, into the slot until it snaps into the cam. Exterior F E D Interior
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