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, frame stops and frame hardware must be removed. If 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.

Always read the Vinyl Window and Door Limited Warranty before purchasing or installing Vinyl Windows and Doors manufactured by Pella Corporation. 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.

INSTALLATION INSTRUCTION - INSTRUCCIONES DE INSTALACION350 SERIES WINDOW INTO EXISTING WOOD FRAME WINDOW

Part Number: V984245© 2011 Pella Corporation

Vinyl Windows and Doors

Lea las instrucciones en español en el reverso.

TOOLS REQUIRED:

•Tapemeasure

•Level

•Sealantgun

•Prybar

•Utilityknife

•Hammer

•Screwdrivers(Flat&Phillips)

•Roto-tool,reciprocatingsaw

•Woodchisel

•5/32",3/8"and1/4"drillbit

•Drill

•Phillipsdriverbit

YOU WILL NEED TO SUPPLY:•CedarorImperviousshims/spacers(12to20)

•Closedcellfoambackerrod/sealantbacker (12to30ft.)

•Pella® SmartFlash™ foil backed butyl window

and door flashing tape or equivalent

•Highqualityexteriorgradepolyurethaneorsiliconesealant(1tubeperwindow)

•GreatStuff™ Window and Door Insulating Foam Sealant by the Dow Chemical Company or equivalent low pressure polyurethane window and door foam - DO NOT use high pressure or latex foams.

•#6x1/2"sheetmetalscrews(forheadexpander)

Installation will require two or more persons for safety reasons.

SEALANTSEALANT

Sill Adapter Flashing Tape

EXTERIORInterior

Drywall

Existing wall construction

Existing window frame

InsulationFraming

Checkrail

INSTALLING INTO EXISTING DOUBLE-HUNG OR CASEMENT FRAME FROM THE INTERIOR

INSTALLING INTO EXISTING DOUBLE-HUNG FRAME FROM THE EXTERIOR

B. Cut the balance cords on the bottom sash and lift out the sash. Allow weights to fall to the bottom of the weight pocket.

C. Remove the parting stops. There may be a small wedge of wood at the bottom of the upper sash that is next to the parting stops. To make it easier to remove the parting stop, use a chisel to knock off the wedge.

D. Lower the top sash and cut the balance cords allowing the balance weights to fall intotheweightpocket.Removethetopsash.Be careful not to damage the exterior blind stop.

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. Use appropriate personal protective equipment.

A. Score paint or varnish along interior sash stops with a sharp utility knife. Carefully removeinteriorsashstopsatjambs(sides)andhead(top)usingputtyknifeandprybar.Set aside to reuse.

A. Inspect the existing window frame and repair or replace any defective or rotted wood parts. Make sure the exterior blind stops are sound.

Interiorsash stop

Exteriorblind stop

Partingstop

Bottomsash

Top sashBottomsash weight

Top balancecord

Balancecord pulleys

Top sashweight

Bottombalancecords

INTERIOR

Interior sash stop

Parting stop

Exterior blind stop

IF INSTALLING WINDOW FROM EXTERIOR, OR REMOVING EXISTING CASEMENT SASH, REFER TO OPTIONAL SASH REMOVAL AT THE END OF THESE INSTRUCTIONS.

E. Remove the balance cord pulleys. Unscrewandremove balance cord pulleys. If they cannot be removed easily, drive them into the jamb using a hammer.

E. 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.

EXTERIOR

2C

EXTERIOR

2C

B. Insulate the weight pocket with loose fill insulation.

Note: Use of expanding/aerosol foam insulation is not recommended.

C. If applicable, install pre-finished metal flashing or trim to cover existing frame sill and the exterior trim at the head and jambs.

D. Clean the opening of any dirt, debris, or excess old paint before proceeding.

Note: Many windows in older homes are painted with lead-based paint. See caution note in Step 1. 2E

1REMOVING EXISTING SASH

2OPENING PREPARATION

A. Remove packing materials from the window. Note: Check product for any cracks or penetrations in the frame. DO NOT install damaged windows.

B. Install the sill adapter in the sill accessory groove.

Note: Use a rubber mallet to drive the sill adapter into the sill accessory groove. The vertical leg of the sill adapter may be cut to accommodate different sill angles.

G. Confirm that the installation jamb screws will fasten into solid wood. If not, insert solid filler at screw locations.

Note: Open the sash to access all pre-drilled installation holes.

Sill accessory groove

Sill adapter

3B

Sill accessory groove

Sill adapter

Continuous shim

If using a CLIP INSTALLION, refer to the installation instructions included with the install clip accessory package.

SLIDING WINDOW ONLY

C. Remove the venting sash.Unlockthewindowandslidetheventingsashopenuntilit clears the anti-lift clip. Lift up on the sash until the bottom of the sash will clear the bottom track. And remove the sash towards the interior.

E. Drill 5/32" installation screw holes throughtheframejambs,head,&sillperthe spacing shown in the graphic. The holes should be located in the center of the vent pocket.

3D

Fixe

d

Mee

ting

Rai

l

6" 6"4" 4"

6"

6"

16"

MA

X.

16" MAX.

3E

HEADJAMB/HEAD

INTERIOR

EXTERIOR

1-1/4"

5/32" drill

3/8" drill with drill guide placed 1/4" from end of bit. INTERIOR

EXTERIOR

1-1/4"

5/32" drill

3/8" drill with drill guide placed 1/4" from end of bit.

F. Head/Jamb Only: Counter Drillusinga3/8"drillbitwith a drill guide placed ¼"fromtheendofthebit.Drill through the first wall only of the frame. DO NOT penetrate the outer wall withthe3/8"drillbit.

D. Remove the vent track from the vent pocket sill. Usingasmallflat-headscrewdriver,prytheventtrack out of the sill pocket, being careful not to damage it. Keep this part, to be reinstalled later.

F. Ensure existing sill is level.

Note: If shimming of the sill is necessary, use a continuous shim that extends across the entire width of the sill.

Windows Installed From Interior

3PREPARE THE WINDOW FOR INSTALLATION

DOUBLE HUNG AND SINGLE HUNG WINDOWS Ifthesillriserhasa"QuickReleaseBand"aroundtheriser;openthesashandpullthebandtohelp remove the riser.

Then InsertScrewdriverHere

First Press Here3G

4D

1“

1“

A. Test fit the window in the opening. With the window closed and locked, set the bottom of the window into the opening, then tilt the top into position.

B. Ensure the window is resting against the interior surface of the blind stops and the sill adapter meets the original sill.

Note: The height of the window frame can be increased by as much as 3/8" by applying the head expander (included) to the window frame. If more than 3/8" height adjustment is required, install a continuous shim at the sill.

DO NOT use the head expander in High Performance installations.

C. Apply the head expander (if required). For installation using the head expander, go to INSTALLATIONINSTRUCTIONSHEADEXPANDERlaterinthisbooklet.

D. Drill two 1/4" weep holes in the sill adapter. Locate theholes1"fromeachend.Thebottomoftheweephole must be at the bottom of the vertical leg of the sill adapter.

E. Apply a 3/8" continuous bead of sealant to the interior face of the existing blind stops at the head and both jambs.

3A

Jamb blind stop

Head blind stop

4E

4SEALING AND FASTENING THE WINDOW

G.Remove the sill riser by opening the sash and using a flat headed screw-driver to pry the sill riser from the sill. Starting at one end, push on the top of the sill riser so that a small flat-bladed screwdriver can be inserted as shown. Pry sill riser up to remove.

3C

F. Place a bead of sealant where the existing stool meets the existing frame sill and jambs.

G. Place a bead of sealant where the jamb and sill meet.

Sill

Stool

3B4F

4G

Interior

4G

H. Insert the replacement window(fromtheinterior)in the opening by setting the bottom of the window in first, then tilting the top into place. Make sure the window rests against the interior surface of the blind stops and the sill adapter will contact the existing sill.

I. Place a shim near the top of one jamb, in line with the top pre-drilled hole in the window frame. Trim all shims sotheyarerecessedback1/4"-1/2"fromtheinteriorfaceofthewindowframe.Partiallyinserta#8x2"panheadscrew(provided).Repeatprocessforotherjamb. Interior

Shim

2" screw

4H

4H

4I

J. Continue placing shims at each pre-drilled installation screw holes in jambs as needed to plumb and square the window. Check window for squareness by making sure diagonal measurement from corner to corner is within1/8"inbothdirections.

K. Drill 5/32" pilot holes in the head and jamb shims to prevent the shims from splitting when driving screws.

Note: Raise the lower sash to access the bottom installation screw holes.

L. Fasten the window in the opening by driving #8 x 2"Phillips pan head corrosion resistant screws (provided)throughtheinstallationholesandtheshims and into the wall members. Place a dab of sealant in all installation screw holes in the sill prior to installing the sill screws. Sealant is required to prevent leakage at these screw holes. DO NOT over tighten. Over tightening will distort the frame and may interfere with the performance of the window.

M. Insert a plastic screw cover (provided)intoeachinstallationscrewholeintheframe.Useaflatbladescrewdriver to insert the covers into tight spaces in the frame.

Note: If window components were removed to access sill anchors; replace them now. The sill riser and sash track snap in by pressing them down.

N. Check window operation. Lock and unlock sash. Open and close all sash.

Note: If there are any problems with the operation of the window, recheck shim locations and adjust for plumb and square.

CASEMENTS: If additional adjustment is needed, use the adjustment tool and accompanying instructions.

4K

Screw Cover

InstallationScrewHole

Interior

4I4J

4M

A. Apply insulating foam sealant. From the interior, insert the nozzle of the applicator approximately 1"deep into the space between the window and theroughopeningandapplya1"deepbeadof foam. This will allow room for expansion of the foam and will minimize squeeze out. Apply sealant across interior surface of shims to create continuous seal. 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 new and existing window frame. DO NOT completely fill the space from the back of the blind stops to the interior face of the opening.

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.

B. Check window operation by opening and closing the window.

Note: If the window does not operate correctly, check to make sure it is still plumb, level, square and that the sides are not bowed. If adjustments are required, remove the foam with a serrated knife. Adjust the shims and reapply the insulating foam sealant.

Interior

5A

A. Reinstall existing interior sash stops or new trim as desired.

WINDOWS INSTALLED FROM INTERIOR:

A. If space between the new window frameandtheexistingwindowframeis≤1/4".GotoStep7B.Ifthespaceis>1/4”proceedto7C.

EXTERIOR

EXTERIOR

Corner beed

EXTERIOR

EXTERIOR

If>1/4"firstinstall backer rod and then sealant as shown in Steps 7C&7D

Addsealantif≤1/4"

5INTERIOR SEAL

6INTERIOR TRIM

7EXTERIOR SEAL

C. Insert backer rod into the space around the window at the head and jambs. This should provideatleast3/8"clearancebetweenthe backer rod and the exterior face of the window.

Note: Backer rod adds shape and depth for the sealant line.

D. Seal the window to the exterior stops. Place a corner bead of sealant around the perimeter of the window frame where the new frame contacts the original window frame. Also place a bead of sealant between the sill adapter and the bottom of the existing window sill. This bead should connect to the jamb sealant beads. Tool the sealant beads.

Note: When corner beading sealant around the perimeter of the window frame, be careful not to cover the weep holes at the sill.

E. 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.

Any exposed wood on the exterior stop needs to be covered/protected. There are many ways to accomplish this, and each case can be unique.

Note: The contractor/installer will determine when and how to finish the exterior.

EXTERIOR FINISH OF EXISTING FRAME

EXTERIOR OF WINDOWWITH FRAME EXPANDER

EXTERIOR

6A

6B

7C

7D

WINDOWS INSTALLED FROM EXTERIOR (STEP 10):

B. Seal the window to the exterior stops. Place a corner bead of sealant around the perimeter of the window frame where the new frame contacts the original window frame. Also place a bead of sealant between the sill adapter and the bottom of the existing window sill. This bead should connect to the jamb sealant beads. Tool the sealant beads. Proceed to Step 7E.

Note: When corner beading sealant around the perimeter of the window frame, be careful not to cover the weep holes at the sill.

Exterior

4K7B

OTHER EXISTING SASH REMOVAL INSTRUCTIONS

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 1/2" smaller in both width and height than the existing window frame.

A. Remove the existing sash. This will vary per manufacturer oftheexistingwindow.Removingthehingeandoperatorfasteners 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. SILL STOP

HEAD STOP

JAMB STOPS

1B

A. Inspect the existing window frame and repair or replace anydefectiveorrottedwoodparts.Removeorseatanynails.

B. Clean the opening of any dirt, debris, or excess old paint before proceeding. Chisel off any high spots.

C. Apply one piece of flashing tape to the sill of the existing windowframe.Cutthetape12"longerthantheexistingwindowsillwidth.Applythetapeapproximately1"fromtheexteriorontheexistingsilland6"upeachjambandpress down firmly. The tape will not cover the sill depth completely under the new window.

D. Ensure existing sill is level.Place1"wideby1/4"thickshimsonthebottomofthewindowopening,1/2"fromeachsideandbeneathmeetingrail.Placeadditional1"by1/4"thickshims,ensuringthedistancebetweentheshimsisnotmorethan18"oncenter.Adjustshimsasnecessaryto ensure the sill is level.

Note: Improper placement of shims or spacers may result in bowing the bottom of the window. The sill adapter will not be needed in this installation.

2B

2C 6“

8B

9B

9C

Return to Step 3.

8INSTALLING IN EXISTING CASEMENT FRAME

9OPENING PREPARATION

OTHER EXISTING SASH REMOVAL INSTRUCTIONS

A. Unlock the window. Raisethelowersashandlowertheupper 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 jamb and head parting stop.Removeanyhead 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 flush with the existing window jamb. Caution: Take care to prevent existing sashes from falling out when removing stops.

D. Remove the upper and lower sash. This will vary per manufacturer of existing windows. Somewillsimplypullout,whileothersmayneedtobecuttoberemoved.Graspthesashand 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

JAMB

STOP

1C

Head Stop

Jamb Stops

1D

Remove Sashes

Jamb Liner1E

10A

10B 10C

10C

10D 10E

10 INSTALLING IN EXISTING DOUBLE-HUNG FRAME FROM EXTERIOR

INSTALLATION INSTRUCTIONS (HEAD EXPANDER)

A. Make a pencil mark3/8"fromthetopofthewindow on the room side edge of each jamb.

B. Install the head expander on the top of the window frame. Slide the expander down onto the head as far as it will go.

Note: To determine if the Head Expander is required refer to Step 4B.

3/8"

Interior frame edge

A

Head expander

Top window frame

(Side View)

B

C. Test fit the window into the opening. Slide the head expander up until the top of the head expander is within 1/4"ofthetopoftheexistingopening.Ensure the pencil marks are not visible. If the pencil mark is visible, the expander is extended too far. Note: If the expander extends past the pencil mark it may be necessary to shim the original sill or to order a larger window.

Note: The void between the window frame and head expander can be filled with loose-fill insulation.

D. Drill two 1/16" pilot holes through the room side leg of head expander into the frame. Theseholesaretobe2"fromeachendoftheheadexpander.Inserta#6x1/2"panheadsheetmetalscrew(notprovided)intoeach hole.

Proceed to Step 4D.

Interior frame edge

Pencil mark

Head expander

1/4"

C

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.

EXTERIOR

2C

EXTERIOR

2C

Return to Step 3.

11C

11 OPENING PREPARATION

IMPORTANT NOTICEBecause 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 forclaimsordamagescausedbyanticipatedandunanticipatedwaterinfiltration;deficienciesinbuildingdesign,constructionandmaintenance;failuretoinstallPellaproductsinaccordancewithPella’sinstallationinstructions;ortheuseofPellaproductsinwallsystemswhichdonotallowforproper 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 flashingandsealingsystemsaretheresponsibilityoftheBuyerorUser,thearchitect,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)(alsoknownassyntheticstucco)orothernon-watermanagedsystems.ExceptinthestatesofCalifornia,NewMexico,Arizona,Nevada,Utah,andColorado,Pella makes no warranty of any kind on 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’s installation instructions.

Product modifications that are not approved by Pella Corporation will void the Limited Warranty.

CLEANING INSTRUCTIONSRemovelabelsandcleantheglass,usingasoft,clean,grit-freeclothandmildsoapordetergent.Be sure to remove all liquid by wiping dry or use a clean squeegee. The vinyl frame may be cleanedasdescribedabove.Forstubborndirt,a“non-abrasive"cleanersuchasBon-Ami® or Soft scrub® may be used. Do not use solvents such as mineral spirits, toluene, xylene, naphtha or muriatic acid as they can dull the finish, soften the vinyl and/or cause failure of the insulated unit seal. Keep door tracks clear of dirt and debris. Keep weep holes open and clear of obstructions.