Fixed Upper Sash Replacement Guide for Andersen 400 Series Woodwright Springline Single-Hung Windows

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1 Fixed Upper Sash Replacement Guide for Andersen 400 Series Woodwright Springline Single-Hung Windows Manufactured Between September 2005 and October 2006 Read all instructions carefully before attempting this procedure. If you have any questions about your ability to complete this procedure, call Andersen at for further direction. Andersen WindowCare service center hours are Monday through Friday, 7 a.m. to 7 p.m. Central Time and Saturday 8 a.m. to 4 p.m. Central Time. Thank you for choosing Andersen products. Using ladders and/or scaffolding and working at elevated levels may be hazardous. Follow equipment manufacturer's instructions for safe operation. Use extreme caution when working around window and door openings. Falling from opening may result in injury or death. Improper use of hand/power tools could result in injury and/or product damage. Follow manufacturer's instructions for safe operation of equipment. Always wear safety glasses. Weight of window/door unit(s) and accessories will vary. Use a reasonable number of people with sufficient strength to lift, carry, and install window and door unit(s) and accessories. Always use appropriate lifting techniques. Parts Included (1) Instruction Guide (1) Sash (1) Wood Sash (1) Sash Stop (1) Upper Sash Interlock (1) Grille Bar (optional) (2) Foam Weatherseal (12) #8 x 1-1/2" Screws (6) #8 x 3/8" Screws Sash Stop Wood Sash Tools and Supplies Safety Glasses Silicone Sealant 1/8" Hex Wrench Phillips Screwdriver Small Pry Bar 1/16" Dowels Filament or Duct Tape Gloves Caulk Gun Putty Knife Hammer Utility Knife Painter s Tape Sash Upper Sash Interlock Andersen is a registered trademark of Andersen Corporation. All other marks where denoted are marks of Andersen Corporation Andersen Corporation. All rights reserved. 1 Instruction Guide F Revised 06/29/07

2 Glass Tempered safety glass is not standard and must be special ordered. Check local building codes for required safety glass locations. Do not remove product performance label before final inspection. Peeling off protective film may result in a static charge that could cause a shock or spark. Static charge and spark can pass through to the OTHER SIDE of glass. Solvents, cleaners and foam insulation must be dry and all flammables must be properly stored before removing protective film. Misting glass with water may reduce static charge and spark. For best results, protective film should be removed within 9 months of installation in temperatures above 32 F. REMOVE FROM AREA: Thinners Cleaners Mineral spirits Foam Insulation can Solvent soaked rags Protective Film Seam Suction Cup If suction cups are used while moving or installing unit, make sure that cups are not applied on the seam of the protective film. If suction cup is applied on the seam, the suction cup will lose adhesion, causing unit to slip or drop and potentially causing damage or injury. Do not allow sealants to contact exterior glass surface. Glass surface or exterior coating damage will result. If protective film is present, leave in place until unit is installed and job site construction is completed to protect glass surface. 1. Position Lower Sash Support Sash during removal and reinstallation. Failure to support Sash may result in injury, product, and/or property damage. Filament or Duct Tape Wash Assist Remove insect screen if present. Tape broken glass with filament or duct tape to reduce glass fragmentation. Remove interior removable grille bars if present. Position Lower Sash about 4" from sill. Slide Wash Assists down both side jambs to release Tilt Latches. Tilt Lower Sash in, toward interior to 90 and support on chair or object. 4" Lower Sash at 90 2

3 2. Lock Balance Cord Locks and Remove Balance Cord Clips Balance Cord Lock must be engaged (locked) before disengaging Sash from frame and/or before detaching Balance Cord Clips from jambs. Balance Cords must remain locked when Sash is not engaged with frame and/or Balance Cord Clips are not attached to jambs. Failure to keep Balance Cord locked in these situations may cause sudden release of Balance Cord which could potentially cause injury and/or product damage. Support bottom of Sash while detaching balance Cord Clips to prevent it from falling onto sill. Failure to do so may result in injury and/or product damage. Engage (lock) Balance Cord Lock in Balance on both sides of Lower Sash by turning hex screw 1/2 turn clockwise using 1/8" hex wrench. Positive stop will be felt. Remove hex head screws securing Balance Cord Clips to frame using 1/8" hex wrench. Retain screws for reuse. Sash will move freely in Jamb Liner after screws are removed. Balance 1/8" Hex Wrench Balance Cord Lock (hex screw) Balance Cord Clip Lower Sash Support on a chair/object 3. Remove Lower Sash Brake Lever Use extreme care when working around window opening. Never leave a window opening unattended, especially when children are present. Falling from window opening may result in injury or death. Hold Lower Sash at 90, lift one side until Brake Levers are clear of frame, and remove. Set Sash aside in a safe location. 3

4 4. Remove Permanently Applied Grille Bars from Upper Sash Wear gloves, safety glasses, goggles, or eye shields when handling glass. Failure to do so may result in injury. If there are no permanently applied Grille Bars proceed to Step 5. Remove permanently applied interior Grille Bars from Upper Sash by forcing thin putty knife between glass and Grille Bars to cut tape. Pry up to lift bars. Work putty knife along the Grille Bar removing the entire Grille Bar. Remove all interior Grille Bars from Upper Sash. Be careful while working around broken glass. Putty Knife Grille Bars 5. Remove Upper Sash Interlock Insert small pry bar between Upper Sash Interlock and interior of Upper Sash at one end. Push Upper Sash Interlock down and work small pry bar between Sash and Interlock. Work small pry bar along bottom of Sash, loosening Interlock. Be careful not to damage Jamb Liner. Discard old Upper Sash Interlock. Small Pry Bar Upper Sash Upper Sash Interlock Jamb Liner 4

5 6. Remove Sash Stop Insert a putty knife between head jamb and Sash Stop. Pry Sash Stop away from head jamb. Work putty knife around head jamb removing Sash Stop. Discard old Sash Stop if damaged. Head Jamb Wood Sash Stop Putty Knife Putty Knife 7. Remove Wood Sash Remove Lock Keeper(s) from Upper Sash using Phillips screwdriver. Keep Lock Keeper(s) and screws for new Upper Sash. Phillips Screwdriver Putty Knife Insert a putty knife between glass and Wood Sash. Pry Wood Sash away from glass. Discard old Wood Sash. Lock Keeper Wood Sash 8. Remove Sash Support Sash while removing screws to prevent it from falling out. Failure to do so may result in injury and/or product damage. Jamb Liner #8 x 1-1/2" Screw From interior, remove #8 x 1-1/2" screws from perimeter of Sash using a Phillips screwdriver. Support Sash at all times. Pull Sash down 1" to 2" then pull bottom towards interior and remove from frame. Discard old Sash. Outer Frame Member Sash 5

6 9. Install New Sash Examine weatherseal on head jamb. Replace if necessary. Match existing weatherseal length and location. Head Jamb Weight of Sash will vary. Use a reasonable number of people with sufficient strength to lift, carry and install Sash. Always use appropriate lifting techniques. Weatherseal Lift Sash into position. Place top of Sash against top inside of Outer Frame Member. Hold bottom of Sash away from Outer Frame Member. Slowly push bottom of Sash against Outer Frame Member and up, against head jamb. Hold Sash tight against Outer Frame Member and top frame and center between side Jamb Liners. Install #8 x 1-1/2" screw in bottom corner of Sash in predrilled hole on 45 angle, while holding Sash in position. Fasten other bottom corner of Sash. Keep Sash centered within the frame. Fasten top of Sash though predrilled holes on 45 angle. Install remaining #8 x 1-1/2" screws around perimeter of Sash in remaining predrilled holes. Sash Outer Frame Member Jamb Liner #8 x 1-1/2" Screw 45 Outer Frame Member Sash Sash Predrilled Holes #8 x 1-1/2" Screws 6

7 10. Prepare Wood Sash Remove red tape backer from VHB tape on interior side of Sash. Place 1/16" dowel across the VHB tape and hold in place by taping the dowel to glass with painter s tape. Place dowels every 12" around Sash. Apply two 1/4" beads of silicone sealant around perimeter of Wood Sash. See drawing for locations of silicone sealant beads. Tape Backer VHB Tape Follow silicone sealant manufacturer s instructions regarding surface cleaning and preparation, application, and temperature when applying silicone sealant. Failure to do so may result in water infiltration. Sash Glass Painter s Tape 1/16" Dowel VHB Tape 1/16" Dowel VHB Tape Caulk Gun 1/4" Bead Silicone Sealant Wood Sash Side Down Wood Sash Profile 7

8 11. Install Wood Sash Place Wood Sash over Sash aligning all edges. While holding Wood Sash in place, start at bottom corner, remove painter s tape from dowel and slide dowel out from under Wood Sash. Make sure Wood Sash stays aligned with Sash. Push corner of Wood Sash against Sash until it contacts VHB tape. Follow the same procedure removing remaining dowels working around the Sash. Push Wood Sash firmly against Sash, contacting VHB tape. Install Sash Stop around inside of curved head jamb against Sash. Attach with 1-1/4" finish nails, 2" from each end of Sash Stop and every 6" between. Install previously removed Lock Keeper onto Wood Sash using a Phillips screwdriver. Use predrilled holes. Wood Sash Dowel Wood Sash Wood Sash Sash Wood Sash Dowel VHB Tape Curved Head Jamb 1-1/4" Finish Nail Sash Stop 6" 2" 1-1/4" Finish Nail Phillips Screwdriver Lock Keeper Screw Wood Sash Lock Keeper 8

9 12. Install Upper Sash Interlock Follow silicone sealant manufacturer s instructions regarding surface cleaning and preparation, application, and temperature when applying silicone sealant. Failure to do so may result in water infiltration. Apply two 1/4" beads of silicone sealant to new Upper Sash Interlock in locations shown. Push Upper Sash Interlock into position on bottom of Upper Sash. Make sure Upper Sash Interlock is tight to bottom of Sash. Install #8 x 3/8" screws into predrilled holes in Upper Sash Interlock. 1/4" Bead Silicone Sealant Upper Sash Interlock Profile Upper Sash Interlock Upper Sash Silicone Sealant Upper Sash Interlock #8 x 3/8" Screw Cross Section Detail 13. Reapply Grille Bars to Glass If there are no permanently applied Grille Bars proceed to Step 14. Tape Backer Start to remove tape backer from VHB tape on back of Grille Bars approximately 2" from each end. Pull backer past edge of Grille Bar. Start all ends of tape backers. Place Grille Bar onto interior Upper Sash glass. Align Grille Bar with Grille Bar. Grille Bar VHB Tape Use position of Grille Bar for orientation and location of Grille Bar. While applying just enough force to keep Grille Bar from moving, start slowly pulling an end of tape backer away from tape. Pull backer perpendicular to grille bar. Push Grille Bar against glass about 4" behind tape backer as it is being removed from tape. Pull tape backers away from remaining tape following same procedure. Push Grille Bar firmly against glass to adhere tape to glass. Grille Bar Tape Backer 9

10 14. Prepare Balance Cord for Lower Sash Reinstallation If Balance Cords is wrapped around Brake Lever, Sash will not operate properly and may result in injury and/or product damage. Balance Cords are under high tension. Sudden release of Balance Cord may cause injury and/or product damage. Make sure Brake Levers are locked. Balance Cord (6" Minimum) Balance Cord must be extended at least 6" from Balance before reinstalling sash. Check that each Balance Cord is extended at least 6" from each Balance on lower Sash. Balance Cords must be extended at least 6" from Balance before reinstalling Sash. If Balance Cords are extended at least 6", proceed to Step 15. If Balance Cord is not extended at least 6", grasp Balance Cord firmly and disengage (unlock) by turning hex screw 1/2 turn counterclockwise with 1/8" hex wrench and turning Brake Lever parallel to Balance over the top of pulley. Balance is loaded at this point. Maintain a firm grasp on Balance Cord and pull out at least 6" from balance. Then, immediately lock Balance Cord by turning Brake Lever toward exterior side of Sash, perpendicular to exterior surface of Sash, and by turning hex screw 1/2 turn clockwise with 1/8" hex wrench. Balance Cord is not loaded at this point. Repeat for opposite Balance Cord if not extended at least 6" from Balance. Brake Lever (perpendicular to sash/locked) Brake Lever (parallel to sash/unlocked) Side Up 10

11 15. Reinstall Lower Sash Place Lower Sash on work surface exterior side up. Check that Brake Levers are positioned perpendicular to Sash, pointing to the exterior side of the Sash, in the locked position. Reposition if necessary. If Balance Cords are not extended at least 6", follow instructions in Step 14. Lay Balance Cords on exterior surface of Sash. Side Up Brake Lever (perpendicular to sash/locked) Check that Wash Assists are at top of frame. Lift Sash into opening at 90 and place Brake Levers into inner channel on Side Jamb. Wash Assist Brake Lever Side Jamb Inner Channel Wash Assist Balance Cord Clip Fasten Balance Cord Clips at original locations in inner frame channel on Side Jamb using previously removed screws. Keep Sash supported perpendicular to opening while fastening Balance Cord Clips. Disengage (unlock) Balance Cord Lock on each Balance (both sides of sash) by using 1/8" hex wrench to turn hex screw 1/2 turn counterclockwise, while supporting Sash. Slide Tilt Latches to open position and return Lower Sash to closed position. Check Tilt Latch engagement in Jamb Channel by gently pushing Sash back and forth. Push Lower Sash down into closed position. Side Jamb Tilt Latch 1/8" Hex Wrench Lower Sash Support on a chair/object Balance Cord Lock (hex screw) 11

12 Finishing, Cleaning, and Maintenance Instructions DO NOT expose unfinished wood to high moisture conditions, excessive heat or humidity. Finish wood surfaces immediately after installation. Unfinished wood surfaces will discolor, deteriorate, and/or may bow and split. DO NOT stain or paint weatherstrip, silicone beads, vinyl, glass, or hardware. Acid solutions used to wash masonry/concrete will damage glass, fasteners, hardware, and metal flashing. Follow the acid solution manufacturer s instructions carefully. Protect and/or cover Andersen products during the cleaning process to prevent acid contact. If acid does come in contact with unit, immediately wash all surfaces with clean water. Finish interior wood surfaces, including hidden surface (as shown by arrow) at check rail immediately after installation. Lower Check Rail FINISHING Read and follow finishing manufacturer s instructions and warnings on each container of finishing material for priming, painting, staining, and varnishing. CLEANING Clean exterior frame and door panel using a mild detergentand-water solution and a soft cloth or brush. DO NOT use abrasive cleaners or solutions containing corrosive solvents. For persistent dirt or grime, use a nonabrasive cleanser or a mixture of water and alcohol or ammonia. MAINTENANCE Immediately sand and refinish any wood that becomes stained or mildewed to prevent further discoloration and/or damage. For further information, contact your local Andersen Dealer. Dealers can be found in the Yellow Pages under Windows. 12

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