Pella 80YV0102 User's Manual
Contents
1. A Mullion plate k Mullion plate Vv 4 Mullion p Yv v WwW gt 3 Wide Combination Vent amp Fixed Casement gt Large Awning Mullion plate v v v v a E A A A 3 Way Combination Vent amp Fixed Casement Standard Awning Large Awning Mullion plate Mullion plate Mullion plate Re install Interior Frame Covers Note Discard all Quick Release Bands before re installing Interior Frame Covers AWNING CASEMENT Interior Frame Cover 3 Head cover on Casement Fixed and Compression Spring Large Awning and the jamb cover without roto cover cut out on location in Standard Awning units Cover 3 Starting on one end of the frame insert the cover barbs of Interior Frame Cover 3 into the frame kerfs Align the kerfs along the length of the cover and press until the cover clicks into place COVER 3 COVER 1 Note Interior Frame Covers 3 contains compression springs which allow the cover to be compressed when re installing Interior Frame Compression Spring Covers 1 in Step 4K COVER 2 J Interior Frame Cover 2 Sill cover on Casement Fixed and Large Awning and a jamb cover with roto cover cut out on Standard Awning units P2. 2009 Pella Corporation Part Number 80YV0102 WINDOW REPLACEMENT INSTRUCTIONS FOR SINGLE HUNG DOUBLE HUNG CASEMENT AWNING INTO EXISTING CASEMENT 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 frame stops and frame hardware from the existing window The original window frame will remain in place If the existing window frame shows signs of water infiltration or is damaged beyond repair this method should not be followed and the entire existing window should be removed Installation recommendations for other types of wall construction wall systems conditions multiple windows or bow bay windows 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 S TOOLS REQUIRED SSS e Cedar or Impervious shims spacers 12 to a D e Tape measure 38 e Closed cell foam backer rod sealant backer e Level MKOAN 12 to 30 ft _ e Sealant gun J i i gt e Prybar e Pella SmartFlash foil backed butyl window
3. above the window or in the space between the spacers at the bottom of the window DO NOT over shim Check the interior reveal Make sure the measurement from the interior face of the window to the interior face of the window to the interior face of the wall is equal at several points around the window S Fasten the window in the opening by driving the 2 1 2 long screws through each pre drilled hole in the window frame through the shims and into the rough opening Note Single hung Raise the lower sash to access lower installation holes Double hung Lower the top sash to access the upper installation holes and raise the lower sash to access the lower installation holes Tilt the lower sash to the interior to access the installation holes at the checkrail Assistance from the interior is recommended for this step 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 Apply insulating foam sealant From the interior insert the nozzle of the applicator approximately 1 deep into the space between the window and the rough opening and apply a 1 deep bead of foam This will allow room for expansion of the foam and will minimize squeeze out Apply sealant across interior surface of shims to
4. create a continuous seal For windows with jamb extensions installed ensure the foam is placed between the window frame and the rough opening not between the jamb extension and the rough opening Follow foam manufacturer s instructions Note It may be necessary to squeeze the end of the tube with pliers to be able to insert into the space between the window frame and the rough opening B Check the window operation vent units only by SINGLE Installation MUNG opening and closing the window Screw oat Note If the window does not operate correctly hole check to make sure it is still plumb level square and the jambs are not bowed If adjustments are required remove the foam with a serrated knife Adjust the shims and reapply the insulating foam Jamb plug sealant C Insert jamb hole plugs provided into each screw hole for single hung and double hung units Interior Finish or Trim The space between the new window and the existing window s frame will need to be covered with trim There are many ways to accomplish this and each case can be unique How this is done will be the decision of the homeowner or window installer A few possibilities include using cove quarter round or a stop moulding 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 t
5. 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 ll ll Part Number 80YV0102
6. E and door flashing tape or equivalent e Utility knife e Pella Window and Door Installation Sealant or e Putty knife a equivalent high quality multi purpose sealant e Hammer fame g 1 tube per window seaanr e Screwdrivers Flat amp Phillips e Low expansion low pressure polyurethane e Adjustable pliers 4 insulating window and door foam sealant e Side cutter lt x DO NOT use high pressure or latex foams e Roto tool reciprocating saw 8 x 2 1 2 Wood screws pe e Wood chisel m as 6 to 10 per window 1 8 drill bit Installation will require two or more persons e Drill for safety reasons FOAM 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 EXTERIOR EXTERIOR EXTERIOR EXTERIOR ma REMOVE EXISTING INSERT REPLACEMENT REPLACEMENT WINDOW PANGAI DON SASH and STOPS WINDOW INSTALLED LIMITED Always read the Vinyl Window and Door Limited Warranty before purchasing or installing H Vinyl Windows and Doors manufactured by Pella Corporation By installing this product you ar
7. cation where installation screws are optional SSS a 4 b 4 VW b 4 Vent amp Fixed Casement Large Awning Vent amp Fixed Casement Large Awning M a a lt lt 42 Frame Width gt 42 Frame Width At combination mullion joints Drill a 3 16 pilot hole through the mullion plates at the factory drilled anchor holes prior to inserting screws If Frame Width lt 42 top and bottom screws are optional 2 High Vent amp Fixed Casement Standard Awning Large Awning Mullion plate Mullion plate Mullion plate v xry 4 Way Combination Vent amp Fixed Casement Standard Awning Large Awning Mullion plate 2 Wide Vent amp Fixed Mullion plate Casement Large Awning Mullion plate Mullion pla D Number of factory drilled fastener locations may vary depending on size of unit s gt Indicates typical locations of factory drilled anchor holes where screws and shims are ired gt require Indicates location where installation screws are optional If Frame Width lt 42 top and bottom screws are optional 3 High Combination Vent amp Fixed Casement Standard Awning Large Awning
8. e 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 confirm it will fit into the opening prior to removing the existing window The window needs to be 3 8 smaller in both width and height than the pocket frame i e existing sash opening A Remove the existing sash This will vary per manufacturer of the existing window Removing the hinge and operator fasteners will generally allow the sash to be removed from the existing frame Note Two or more people may be required when handling existing sash B Remove operator hardware and all head jamb and sill stops This can usually be accomplished with a prybar 2 OPENING PREPARATION A Inspect the existing window frame and repair or replace any defective or rotted wood parts Remove or seat any nails B Clean the opening of any dirt debris or excess old paint before proceeding Chisel off any high spots C Apply one piece of sill flashing tape to the sill of the existing window frame Cut the tape 12 longer than the existing window sill width Apply the tape on the existing sill 6 up each jamb and press down firmly The tape will not cover the sill depth comp
9. e cover and snap into place 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 Crank Handle open window then close and lock window Operator Stud 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 interfering with the window treatments Pocket LOCK LEVER REMOVAL AND INSERTION E Note You may want to remove the lock lever if it needs to be replaced with a different finish A Unlock and open the window Interior B Place the lock lever in the locked position C From the exterior of the window look through the opening behind the lock lever to locate the point where the lock lever and lock cam meet D Insert an approximately 1 4 wide flat blade screwdriver straight into the opening and center the blade tip at the point the cam and lever meet E Push the screwdriver against the lock cam and rotate the bottom of the blade toward the lock lever This will push the lock cam away from the lock lever hook so the lever can be removed Stop rem
10. e location s 3 Remove the construction handle tool from the handle package Bend in Tool Ag Spline Hole Hook Construction Handle Tool REFERENCE DESCRIPTION Construction Handle Tool may be used as a lock handle or crank handle AWNING CASEMENT B Remove Interior Frame Cover 1 If an Interior Frame Cover has a Quick Release Band around the cover pull the band to help remove the cover The cover on vent units where the lock handle slot is located and the cover on the opposite frame side Note Interior Frame Covers 1 are jamb covers on Casement Fixed Awning Casement and Large Awning units On Standard Awning units Interior Frame Covers 1 are the head and sill covers 1 Approximately 1 from the Bz bottom end of the cover insert the hooked end of the tool D between the cover and the sash D 2 Rotate the tool toward the sash and continue to insert the tool past the spline hole up to the point where the bend in the tool is aligned with the edge of the cover Note When the tool is inserted with the bend aligned with the cover edge there will be a slight gap between the tool and the face of the sash Cross Section of Interior Frame Cover with Tool Placement Detail 3 Push the tool flat against xl the sash not a lot of force is Y Barb released needed to release the back from kerf cover barb from the frame N x kerf behind the cover While
11. g the window Note Each existing window frame and wall depth will vary in different applications therefore there is not a standard measurement for the overhang of the window frame to the exterior or for the distance from the interior face of the window to interior trim When performing Steps 4B thru 4D installing the frame screws be sure to keep the distance consistent all around the window Note On the exterior there must be enough room for backer rod and 3 8 sealant bead 2 1 2 Screw in the window jambs Keep shims back 1 2 opening at the top two anchor hole locations from interior face of window 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 If additional installation holes are needed drill a 5 32 installation hole through both the interior and exterior walls of the frame Counter drill a 3 8 hole through the interior wall only of the frame DO NOT penetrate the exterior wall with the 3 8 bit EXTERIOR EXTERIOR Double Hung 5 32 gt Single Hung ane Fasten the window near the top of the opening by driving 2 1 2 long wood screws through the top two holes at the jambs and into the opening sides Interior the window frame and the rough opening at the anchor hole locations in the window frame Keep shims back 1 2 from interior face of window Note DO NOT shim
12. he exterior face of the window LLL 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 LLLLLLL C Begin the sill sealant bead 1 2 from one jamb running it across the sill and stopping 1 2 from the opposite jamb This 1 2 sealant gap on each side of the sill allows for incidental water drainage D 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 Any exposed wood and flashing tape on the exterior 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 INSTALLING ROTO COVER AND CRANK ame A Place the cover over the operator stud and snap gt into place Pocket End B Apply pressure to the pocket end of th
13. he sash and cover using the same method of insertion used for Interior Frame Cover 1 Note Insert the tool under Interior Frame Cover 2 next to the FRAME CORNER C2 2 Pull the tool away from the frame to start releasing the cover barbs from the frame kerfs 3 When the cover begins to pull away from the frame relocate the tool near the end of the cover as shown and continue to pull up to release the barbs from the kerfs 4 When the cover has been released near the crank handle cut out reposition the tool with the hook under the front edge of the cover Slide the tool over while pulling up on the cover Continue along the length of the cover until it is removed Note Take note of the cover support bracket around the roto operator hardware on the sill of casement and large awning units and on the jamb of standard awning units as the cover support bracket will be referenced when re installing Interior Frame Cover 2 D Remove Interior Frame Cover 3 The cover on vent units on the opposite frame side from where the crank handle is located For Standard Awning greater than 42 in width single units greater than 42 in height and multiple window combinations 1 Start at one end of the cover and insert the tool between the frame and cover as shown 2 Pull the tool away from the frame to start releasing the cover barbs from the frame kerfs 3 When
14. indow Insert shims between the window frame and the rough opening at the anchor hole locations in the window frame Keep shims back 1 2 from interior face of window Note Install shims per Shim and Fastener Guide DO NOT over shim i E Check the interior reveal Make sure the measurement from the interior face of the window to the interior face of the window to the interior face of the wall is equal at several points around the window F If additional installation holes are needed drill a 3 16 installation hole through both the interior and exterior walls of the frame ac e ac Ww x W G Fasten the window in the opening by driving the 2 1 2 long screws through each pre drilled hole in the window frame through the shims and into the rough opening Note Drive screws per the Awning Casement Shim and Fastener Guide H Insert the construction handle into the lock lever location and unlock the window Remove the handle Place the construction crank handle over the roto operator stud Open and close each sash to verify the smooth operation and alignment of sash locks with sash strikes Check and adjust shims as needed Remove the construction handle SHIM and FASTENER PLACEMENT GUIDE Number of factory drilled fastener locations may vary depending on size of unit s Indicates typical locations of factory drilled anchor holes where screws and shims are required gt Indicates lo
15. keeping tension on the tool pull the tool away from the frame to start releasing the cover barbs from the frame kerfs 4 Rotate the cover end slightly toward the interior when the cover begins to pull away from the frame relocate the tool under the cover towards the interior as shown then pull the tool away from the frame to continue the release of the cover barbs from the frame 5 Reposition the tool with the hook under the front edge of the cover Slide the tool over while pulling the cover away from the frame This will release the flexible barbs on the interior side of the cover which will aid in cover removal Continue sliding along the length of the cover while pulling it away from the frame until it is removed 6 Repeat Steps B1 thru B5 to remove the other Interior Frame Cover 1 If installing a single Casement Large Awning or Fixed unit less than 42 in width go to Step E Lock handle slot If installing a Standard Awning multiple window combinations or units greater than 42 in width go to Step C C Remove Interior Frame Cover 2 The cover on vent units where the crank handle and roto cover will be located AWNING CASEMENT For Standard Awning single units greater than 42 in height and multiple window combinations 1 Starting at the cover end closest to where the crank handle will be located insert the tool between t
16. lace the cover support referenced in Step C4 inside the stop as shown While holding the support in place position the cover to align the cover barbs with the frame kerfs Press the cover barbs into f the roto operator Continue to hold the support in place to ensure proper placement of the support over the operator Press the cover until it clicks into place Note The cover support bracket may need to be repositioned over the roto operator The correct support position allows the cover barbs to be fully seated into the frame kerfs K Interior Frame Cover 1 Jamb covers on Casement Fixed and Large Awning and the head and sill covers on Standard Awning units Insert the cover barbs of the first Interior Frame Cover 1 into the frame kerfs near Interior Frame Cover 2 first Rotate the Interior Frame Cover 1 towards Interior Frame Cover 3 and align the kerfs along the frame then press the cover until it clicks into place Repeat on the other cover L Insert the roto cover crank handle and lock handle See steps at the end of the instructions SINGLE HUNG and DOUBLE HUNG SINGLE HUNG and DOUBLE HUNG M Insert shims between the window and the Plumb and square the window Insert shims between Insert the window and center it in the opening to allow clearance for shimming Note Use of a suction cup on the glass will assist in handlin
17. letely under the new window D Install and level sill shims Place 1 wide by 1 4 thick shims on the bottom of the window opening 1 2 from each side Keep shims back 1 2 from interior face of window Shims are required at points where windows are joined in multiple window applications Add shims as necessary to ensure the sill is level Once level attach spacers to prevent movement Note Improper placement of shims may result in bowing the bottom of the window HEAD STOP JAMB STOPS SILL STOP fi 3 WINDOW PREPARATION AWNING and CASEMENT ONLY The interior frame covers must be removed to provide access to the pre drilled frame screw installation holes AWNING CASEMENT Note The following interior frame cover removal steps are for Casement Standard Awning Fixed Awning Casement and Large Awning The steps are similar for each but the order in which covers are removed will vary depending on the window type The order of interior frame cover removal is indicated below Use reverse order for re installation of covers CASEMENT STANDARD AWNING FIXED AW CM LARGE AWNING COVER 3 COVER 1 COVER 2 A Prepare the Window 1 Remove the screen and set aside 2 Use pliers to remove the plug s from the lock handl
18. oved to show orientation of F Remove the lock lever by pulling it straight out toward screwdriver between the interior of the building the lever and cam Interior G To install a lock lever from the interior hold it in the locked position and insert into the slot until it snaps onto the cam Note The lock cam must be in the locked position before the lock lever can be inserted FINISH The interior and exterior frame and sash are protected by a powder coat 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 spirts 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 CARE AND MAINTENANCE Care and maintenance information is available by contacting your local Pella retailer This information is also available at www pellaimpervia 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
19. the cover begins to pull away from the frame grasp the cover and continue to pull to release the barbs from the kerfs removing the cover TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS 4 SETTING AND FASTENING THE WINDOW Fans AWNING CASEMENT CASEMENT A Insert the window and center it in the opening to allow clearance for shimming Note Use of a suction cup on the glass will assist in handling the window Note Each existing window frame and wall depth will vary in different applications therefore there is not a standard measurement for the overhang of the window frame to the exterior or for the distance from the interior face of the window to interior trim When performing Steps 4B thru 4D installing the frame screws be sure to keep the distance consistent all around the window Note On the exterior there must be enough room for backer rod and 3 8 sealant bead B Insert shims between the window and the opening at the top two anchor hole locations in the window jambs Keep shims back 1 2 from interior face of window 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 C Fasten the window near the top of the opening by driving 2 1 2 long wood screws through the top two holes at the jambs and into the opening sides D Plumb and square the w
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