Pella 80Wx0101 Users Manual

80WX0101 80WX

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Part Number: 80WX0101©2012 Pella Corporation

WINDOW REPLACEMENT INSTRUCTIONS FOR CASEMENT,

DOUBLE-HUNG AND CLAD FRAME WINDOWS INTO EXISTING

DOUBLE-HUNG FRAME USING FRAME SCREWS

EXTERIOR

Flashing Tape

Sill Adapter

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.

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.

REMEMBER TO USE APPROPRIATE

PERSONAL PROTECTIVE EQUIPMENT

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.

YOU WILL NEED TO SUPPLY:

•CedarorImperviousshims/spacers(12to20)

•Closedcellfoambackerrod/sealantbacker

(12to30ft.)

•Pella®SmartFlash™foilbackedbutylwindow

and door flashing tape or equivalent

•PellaWindowandDoorInstallationSealantor

equivalent high quality, multi-purpose sealant

(1tubeperwindow)

•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)

•Pellareplacementwindowsilladapter

TOOLS REQUIRED:

•Tapemeasure

•Level

•Sealantgun

•Prybar

•Utilityknife

•Puttyknife

•Hammer

•Screwdrivers(Flat&Phillips)

•Adjustablepliers

•SideCuts

•Roto-tool,reciprocatingsaw

•Woodchisel

•1/8"drillbit

•Drill

Installation will require two or

more persons for safety reasons.

SEALANT

SEALANT

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.

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.

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.

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ush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.

1A

1B

Head Parting Stop

1C

HEAD STOP

J

A

M

B

S

T

O

P

1C

Head Stop

Jamb Stops

1D

Remove Sashes

Jamb Liner 1E

2 OPENING PREPARATION

A. Inspect the existing window frame and repair or replace

any defective or rotted wood parts.

B. Clean the openingofanydirt,debris,orexcessold

paint before proceeding.

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.

Note: If needed, blocking/shims may need to be placed

where the existing balances were located.

Note: For Double-hung, proceed to Step B.

3 WINDOW PREPARATION

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.

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.

TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS.

Casement Sill

Drill 1/8"

clearance hole

3A

Single

Window

6"

6"

6"

EVERY

16"

6"

6"

EVERY

16"

6"16"

EVERY

Drill 1/8"

clearance hole

Double-Hung Jamb

1/4"

Double-Hung Head

Drill 1/8"

clearance hole

1/2"

Double-Hung Sill

Drill 1/8"

clearance hole

1/2" Clad Frame Sill

Drill 1/8"

clearance hole

1"

Clad Frame Head

Drill 1/8"

clearance hole

1"

3D

3D

3D

Double-Hung Sill

Double-Hung Head

Drill 1/8"

clearance hole

Drill 1/8"

clearance hole

Double-Hung Jamb

Drill 1/8"

clearance hole

3D

3D

Designer Series®

and ProLine®

Architect Series®

Double-Hung

3B

3B

3B

3B

3A

3B

EXTERIOR

2C

EXTERIOR

2C

2C

EXTERIOR

4D

4C

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.

4 SETTING AND FASTENING THE WINDOW

Sill

Adapter

(SILL CUTAWAY VIEW)

Double-Hung Sill

Sill

Adapter

(SILL CUTAWAY VIEW)

Casement Sill

4B 4B

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.

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.

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.

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.

TWO OR MORE PERSONS ARE REQUIRED FOR THE FOLLOWING STEPS.

F. From the exterior, place shims near the top of one jamb, in line with the top pre-

drilled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"nish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.

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.

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.

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.

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

6A

6B

EXTERIOR

5A

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.

EXTERIOR FINISH OF EXISTING FRAME

EXTERIOR OF WINDOW

WITH FRAME EXPANDER

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.

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.

EXTERIOR FINISH OF ALUMINUM CLAD WINDOWS

If products cannot be finished immediately, cover with clear plastic to protect from dirt, damage

andmoisture.Removeanyconstructionresiduebeforenishing.Sandallwoodsurfaceslightly

with180gritorner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nishtheverticalandhorizontal

sash edges.

•Onsingle-hungsanddouble-hungs,donotpaint,stainornish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nishtheverticalandhorizontalpaneledges.

Note: To maintain proper product performance do not paint, finish or remove the weather-

stripping, 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nishes,solvents,

brickwash, or cleaning chemicals will cause adverse reactions with window and door materials

and voids the Limited Warranty.

ForadditionalinformationonnishingseethePellaOwner’sManualorgotowww.pella.com.

INTERIOR FINISH

Care and maintenance information is available by contacting your local Pella

retailer. This information is also available at www.pella.com.

CARE AND MAINTENANCE

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ashing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.

IMPORTANT NOTICE

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.

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.

Pocket End

Operator Stud

Screw Hole

A

B

Crank Handle

Operator Stud

Set Screw C

D

Knob

Pocket

E

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.

E. Fold the crank handle down and check

alignment of knob with the pocket.

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.

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.

Interior

BExterior C

Interior

F

Exterior

D

E

A. Unlock and open the window.

B. Place the lock lever in the locked

position.

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.