Vertical Slider. Technical Manual. Issue E September 2006 Part No

Transcription

1 Vertical Slider Technical Manual Issue E September 006 Part No

2 Issue E Ammendments Page No. Ammendment & fringe seals added & bottom seals replaced with & VSR4S replaced with VSR44S & VSR5..4 Rail lift hook drawing inverted VSR4S replaced with VSR44S & VSR5 and & bottom seals replaced with & as appropriate. 4.7 Vertical section V3 without bottom rail added. 6.1 VSR4S replaced with VSR44S & VSR5. 6. VSR4S replaced with VSR44S & VSR Screw drawing changed & bottom seals replaced with & and & fringe seals added VSR4S replaced with VSR44S & VSR5 and screw drawings changed as appropriate VSR4S replaced with VSR44S.

3 TERMINOLOGY The following terminology is used throughout this manual : Pile Seal Groove Profile Height Restrictor Channel Balance Chamber Profile Depth Ovolo Detail Bead Location Detail Reinforcement Chamber Sash Fitting Channel Standard Configuration : Windows of this configuration provide an equal glass sight line by using the VS03 small sash for the top vent, and VS04 for the bottom vent. Heavy Duty Configuration : For windows of larger overall dimensions, the standard sash (VS04) may be used to produce both the bottom and top sash. The aluminium interlock is required to give additional rigidity. (see section 4) PART NUMBERS All part numbers for ancillary components shown throughout this manual are for white items where relevant. Refer to the product guide for alternatives e.g. foil options.

4 INTRODUCTION. This manual contains information of a technical nature and consequently is only intended for use in the course of a business by persons who are skilled in the subject matter covered. Although reasonable care has been taken in the preparation of this manual. Spectus does not accept any liability for damage resulting (whether directly or indirectly) from the use of the information contained in this manual. Accordingly this manual is supplied on the basis that the user accepts all risks associated with the use of the information contained within it. Description Page No. Section 1. Safety 1.1 Section. Section 3. Section 4. Section 5. Section 6. Section 7. Section 8. Section 9. Section 10. Section 11. Section 1. Section 13. Section 14. Section 15. Section 16. Product Guide Size Limitations Detail Sheets Cutting Calculations Reinforcement Drainage Hardware Preparation Mechanical Joints Hardware Selection Weatherseals Hardware Fitting Glazing & Georgian Bars Installation Woodgrain Details Fire Egress Details Section 17. Bay Details 17.1 A limited quantity of special fixtures and fittings are required, these include welding fixtures, cutter stacks, drill jigs and glazing bead support blocks. Details and supply of these items can be obtained by application to the Spectus Field Technician.

5 SAFETY It is important to emphasize to the fabricators and fitters of this window, that the balances are supplied pre-tensioned, therefore care should be taken when : - working with unglazed windows, - working with windows where the weight of the sash is not held by the balance (i.e. when the window is on its side or lay flat). The following precaution should be taken to ensure the safety of the fitter during fabrication : A length of VS10 Sash stop should be clipped into the top balance channel to restrict the lower sash movement to a minimum. 1.1

6 PRODUCT GUIDE Main & Bead Profiles VS01 - Outer frame VS0 - Cill VS14 - Cill 18 VS03 - Top Sash VS04 - Standard Sash VS05 - Bottom Rail VS06 Square Bead 4mm 18 VS07 Ovolo Bead 4mm.1

7 PRODUCT GUIDE Ancillary & Reinforcement Profiles VS09 - Interlock VS10 - Sash Stop VS11 Narrow Georgian Bar VS1 Wide Georgian Bar VS13 Woodgrain Trim Glazing Gasket (White) (Black) Bottom Sash Bubble Seal (Brown) (Tan) Fringe Seal Pile Seal mm Packer mm Packer Coupling VSR1 Outerframe Aluminium Reinforcement VSR44s Sash Steel Reinforcement 58.5 VSR5 Bottom Rail Aluminium Mechanical Joint Reinforcement VSR3s Sash Steel Reinforcement 4. VSR9 Aluminium Interlock.

8 PRODUCT GUIDE Ancillary Mouldings. VSM01 Decorative Horn VSM0 Sash Stop End Cap VSM14 10mm Cill End Cap VSM04 150mm Cill End Cap VSM05 Sash Block VSM06 Mechanical Corner Joint.3

9 PRODUCT GUIDE Decorative Hardware. Sash Handle. Rail Lift Hook. Sash Lift. Tilt Latch Button. Top Sash Button. Lock. i) Night Vent Keep. ii) Standard Keep. Functional Hardware. Horn Pivot Bar Pivot Bar Housing Restrictor Channel Sash Tilt Latch Tilt Restrictor Arm Balance Standard Pivot Bar Balance Shoe.4

10 PRODUCT GUIDE Drill Jigs & Tooling VSJ01 Balance Fixing Drill Jig VSJ0 Cill Drill Jig VSJ03 Brass Access Drill Jig VSJ04 White Access Drill Jig VSJ05 Bottom Rail Joint Drill Jig VSJ06 Lock & Standard Keep Drill Jig Riv Nut Gun (Balance Fixing) VSJ07 Lock & Night Vent Keep Drill Jig Gun Adaptor Balance Fixing.5

11 Maximum Sash Weight : 50kg Maximum Sash Weight for tilt applications : 35kg SIZE LIMITATIONS Maximum Window sizes for given wind loads : The two graphs below show the maximum overall dimensions of windows with given wind loadings. 1. For normal / standard applications, use the 100 Pascals curve.. For more critical / heavy duty applications, the specific wind pressure can be determined using CP3 : Chapter V : Part, or BS 6375: Part 1, and used with the relevant curve below. Standard Configuration : Heavy Duty Configuration : Minimum Window Heights: Based on Caldwell Spiral Balance 03mm. Window Height = 700mm Sash Height = 310mm Minimum Window Heights: Based on Caldwell Ultralift Balance 317mm. Window Height = 880mm Sash Height = 400mm Minimum Sash Weight = 6kg 3.1

12 DETAIL SHEETS Section Through Standard Configuration. VSR1 - Aluminium Reinforcement VS01 - Outerframe VS03 - Top Sash with VSR3s Reinforcement VS06 - Square Bead VS10 - Sash Stop Lock Keep Lock VS09 - Interlock VS04 - Standard Sash with VSR44s Reinforcement VS09 - Interlock VS07 - Ovolo Bead VS05 - Bottom Rail with VSR5 Reinforcement Lift Hook VS10 - Sash Stop VS0 - Cill Bubble Seal 4.1

13 DETAIL SHEETS Section Through Heavy Duty Configuration. VSR1 - Aluminium Reinforcement VS01 - Outerframe VS04 - Standard Sash with VSR44s Reinforcement VS06 - Square Bead VS10 - Sash Stop Lock Keep Lock VS09 - Interlock VS04 - Standard Sash with VSR44s Reinforcement VSR9 - Aluminium Interlock VS07 - Ovolo Bead VS05 - Bottom Rail with VSR5 Reinforcement Lift Hook VS10 - Sash Stop VS14 - Cill Bubble Seal 4.

14 DETAIL SHEETS Vertical Section - V1. (Standard Configuration) VSR1 - Aluminium Reinforcement VS01 Outerframe VSR3s - Steel Reinforcement VS10 Sash Stop VS03 Top Sash VS07 - Ovolo Bead V1 V1 (window viewed from outside). 4.3

15 DETAIL SHEETS Vertical Section - V1. (Heavy Duty Configuration) VSR1 - Aluminium Reinforcement VS01 Outerframe VSR44s - Steel Reinforcement VS10 Sash Stop VS04 Standard Sash V1 VS07 - Ovolo Bead V1 (window viewed from outside). 4.4

16 DETAIL SHEETS Vertical Section - V. (Standard Configuration) VS03 - Top Sash VS06 - Square Bead VSR44s - Steel Reinforcement VS09 Interlock VSR3s - Steel Reinforcement VS09 - Interlock VS04 - Standard Sash VS07 - Ovolo Bead V (window viewed from outside). V 4.5

17 DETAIL SHEETS Vertical Section - V. (Heavy Duty Configuration) VS04 - Standard Sash VS06 - Square Bead VSR44s - Steel Reinforcement VS09 Interlock VSR44s - Steel Reinforcement VSR9 - Interlock VS07 - Ovolo Bead VS04 - Standard Sash V (window viewed from outside). V 4.6

18 DETAIL SHEETS Vertical Section - V3. VS05 - Bottom Rail VS07 Ovolo Bead VSR5 - Aluminium Reinforcement VS14 - Cill VSR5 - Aluminium Reinforcement Bubble Seal (window viewed from outside). V3 V3 4.7

19 DETAIL SHEETS Vertical Section - V3. (Without Bottom Rail) VS04 - Standard Sash VS07 Ovolo Bead VS0 - Cill VSR44s - Steel Reinforcement Bubble Seal 60.0 (window viewed from outside). V3 V3 4.8

20 DETAIL SHEETS Horizontal Section - H1. (Standard Configuration) VS01 Outerframe VSR3S Steel Reinforcement VS07 Ovolo Bead VSR1 Aluminium Reinforcement VS03 Top Sash H1 H1 (window viewed from outside). 4.9

21 DETAIL SHEETS Horizontal Section - H1. (Heavy Duty Configuration) VS01 Outerframe VSR44s Sash Steel Reinforcement VS07 Ovolo Bead VSR1 Aluminium Reinforcement VS04 Standard Sash H1 H1 (window viewed from outside). 4.10

22 DETAIL SHEETS Horizontal Section - H VS07 Ovolo Bead VS01 Outerframe VS04 Standard Sash VSR1 Aluminium Reinforcement VSR44s - Steel Reinforcement VS10 - Sash Stop 69.0 (window viewed from outside). H H 4.11

23 DETAIL SHEETS Horizontal Section - H Coupling mm Coupling (Modified) (window viewed from outside). H3 H3 4.1

24 CUTTING CALCULATIONS PROFILES. The tables and calculated examples on the following pages cover vertical sliding windows with the following characteristics: VS01 Outer frame VS0 150mm Cill VS14 10mm Cill VS03 Small Sash VS04 Standard Sash VS05 Sash Bottom Rail VS09 Interlock VS10 Sash Stop VS14 10mm Cill Glass Clearance = 6mm Internally Glazed Only. REINFORCEMENT. Reinforcement requirements and calculations for cutting sizes are shown in Section 6. SASH STOP. Bottom sash stop lengths for unequal sash splits the following applies: For every 5mm that the top sash is smaller than equal split, 50mm must be added to the bottom sash stop length. This is to compensate for the 5mm shorter balance length and the loss of 50mm of travel. CRITERIA. Basic dimensions for manufacturing calculations are: - Overall outer frame. CILLS AND PACKERS. Survey dimensions include cill and stacking packers. Allow for these when deriving basic dimensions for manufacturing. WELD BURN-OFF. All PVC-u cutting dimensions for welded construction include a burn-off allowance of.5mm per end, per weld i.e. 5mm per bar. MECHANICAL JOINTS. Cutting dimensions for mechanical joints are to suit Spectus recommended cutters for end milling. DEDUCTIONS. The tables on the following pages show the amounts to be added to or subtracted from the basic dimensions to give correct bar lengths for fabrication and the correct glass sizes allowing clearance for spacers and packing blocks. Note: All cutting sizes calculated from the following tables are to the longest points of the bars. ie. VS01 jambs are measured from the end of the mitre to the point of the 5deg end. 5.1

25 CUTTING CALCULATIONS i) Bottom Rail with Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W Height : H x SPLIT Bottom Glass Panel : Width : W Height : H x SPLIT DECORATIVE HORNS WINDOW HEIGHT (H) BOTTOM RAIL PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS03 Top Sash (width) VS03 Top Sash (height) VS04 Bottom Sash (Width) VS04 Bottom Sash (height) VS05 Bottom Rail VS09 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 35 W - 86 H x SPLIT - 0 W W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Square / Mitre Mill / Mill Square/Square Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off 5.

26 CUTTING CALCULATIONS ii) Without Bottom Rail, with Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W Height : H x SPLIT Bottom Glass Panel : Width : W Height : H x SPLIT DECORATIVE HORNS WINDOW HEIGHT (H) PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS03 Top Sash (width) VS03 Top Sash (height) VS04 Bottom Sash (width) VS04 Bottom Sash (height) VS09 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 35 W - 86 H x SPLIT-6.5 W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Mitre / Mitre Square/Square Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off off 5.3

27 CUTTING CALCULATIONS iii) Bottom Rail without Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W Height : H x SPLIT Bottom Glass Panel : Width : W Height : H x SPLIT WINDOW HEIGHT (H) BOTTOM RAIL PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS03 Top Sash (width) VS03 Top Sash (height) VS04 Bottom Sash (width) VS04 Bottom Sash (height) VS05 Bottom Rail VS09 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 35 W - 86 H x SPLIT - 0 W W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Square / Mitre Mill / Mill Notch / Notch Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off 5.4

28 CUTTING CALCULATIONS iv) Without Bottom Rail, without Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W Height : H x SPLIT Bottom Glass Panel : Width : W Height : H x SPLIT WINDOW HEIGHT (H) PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS03 Top Sash (width) VS03 Top Sash (height) VS04 Bottom Sash (width) VS04 Bottom Sash (height) VS09 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 35 W - 86 H x SPLIT-6.5 W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Mitre / Mitre Notch / Notch Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off off 5.5

29 CUTTING CALCULATIONS v) Heavy Duty - Bottom Rail without Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W - 07 Height : H x SPLIT - 10 Bottom Glass Panel : Width : W Height : H x SPLIT WINDOW HEIGHT (H) BOTTOM RAIL PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS04 Top Sash (width) VS04 Top Sash (height) VS04 Bottom Sash (width) VS04 Bottom Sash (height) VS05 Bottom Rail VSR9 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 3 W - 86 H x SPLIT - 0 W W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Square / Mitre Mill / Mill Notch / Notch Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off 5.6

30 CUTTING CALCULATIONS vi) Heavy Duty - Without Bottom Rail, without Horns. WINDOW WIDTH (W) Top Glass Panel : Width : W - 07 Height : H x SPLIT - 10 Bottom Glass Panel : Width : W Height : H x SPLIT WINDOW HEIGHT (H) PROFILE CUTTING CALCULATIONS. Profile Cutting Calc. End Prep. No. per Window VS01 Outer frame (width) VS01 Outer frame (height) VS0 Cill (or VS14 Cill) VS04 Top Sash (width) VS04 Top Sash (height) VS04 Bottom Sash (width) VS04 Bottom Sash (height) VSR9 Interlock Top Sash VS09 Interlock Bottom Sash VS10 Sash Stop Top (vert.) VS10 Sash Stop Top (horiz.) VS10 Sash Stop Bottom W + 5 H W W H x SPLIT - 3 W - 86 H x SPLIT-6.5 W W mm W mm Mitre / Mitre Mitre / 5deg. Square/Square Mitre / Mitre Mitre / Mitre Mitre / Mitre Mitre / Mitre Notch / Notch Notch / Notch Square / Mitre Mitre / Mitre Square/5deg. off off off off off off off 5.7

31 Reinforcement Requirements. REINFORCEMENT Spectus aluminium / steel reinforcement must be used where applicable. In all cases, reinforcement should be continuous and unbroken, otherwise the Spectus warranty will be invalidated. Spectus recommended minimum reinforcement requirements are as follows: WHITE PROFILE In the head and side jambs of the outerframe. In all members of both the top and bottom sashes. Where trickle vents are to be fit to the head section, reinforcement should be broken around routed area to allow ventilation. FOILED PROFILE As white profile. REINFORCEMENT CUTTING SIZES Outer Frame Reinforcement Deduction:- 1 No. VSR1 Overall Width - 80mm No. VSR1 Overall Height - 80mm Top Sash Reinforcement Deduction:- No. VSR3s Sash Width - 80mm No. VSR3s Sash Height - 80mm Bottom Sash Reinforcement Deduction Without Bottom Rail:- No. VSR44s Sash Width - 100mm No. VSR44s Sash Height - 100mm Bottom Sash Reinforcement Deduction With Bottom Rail:- 1 No. VSR44s Sash Width - 100mm (Top rail) No. VSR44s Sash Height - 61mm (Jambs) No. VSR5 Sash Width - 90mm (Bottom rail) 6.1

32 REINFORCEMENT Reinforcement Location & Fixing Points. Reinforcement should be secured to the PVC-U profile at a maximum of 100mm from the ends of the reinforcement and then at a maximum of 400mm centres (300mm when using foiled profiles). The recommended screws are self drilling, M4 flat faceted head, TEKS point screws. VSR1 Aluminium Reinforcement with VS01 Outerframe. Self drill / tap screw M4 x 16mm Countersunk Facet Head VSR3s Steel Reinforcement with VS03 Top Sash. VSR4s Steel Reinforcement with VS04 Standard Sash. VSR4s Steel Reinforcement with VS05 Bottom Rail. 6.

33 DRAINAGE Drainage slots can be machined using a preset drainage machine or by a hand router. All horizontal member, except the heads of frames and vents, require water slots - 5mm wide x 30mm long. Drainage slots should be cut in the outside chamber of the profile, never in the reinforcement chamber. Drainage slots should be staggered to avoid blow back. Spectus recommend that cill / concealed drainage is the normal practice. However a situation where face drainage is required, drainage slots should be positioned appropriately for aesthetics. They can then be concealed using a face drain cover cap. Cross sectional positions and horizontal drainage locations are shown below. Cross section drainage positions. Face Drain Face Drain Top Sash Drainage VS03 with VS09 Bottom Sash Drainage VS04 Bottom Rail Drainage VS05 Horizontal drainage locations. Denotes drainage slot in. Denotes drainage slot out. up to 1m = = over 1m = = = =

34 DRAINAGE Pressure Equalisation. After fabrication of internally glazed windows, 5mm diameter pressure equalisation holes should be drilled into the head to aid drainage by preventing partial vacuum. Woodgrain Ventilation Holes. All woodgrain and dark surfaced profiles must have ventilation holes into any chambers which are sealed due to welding. The holes should be positioned in non visible areas. Cross section pressure hole locations. Pressure equalisation holes are only required in the bottom sash when there is NO Bottom rail. Top Sash Pressure VS03 Bottom Sash Pressure VS04 Pressure hole locations

35 HARDWARE PREPARATION Insert Hole Location. Holes are required in the outerframe for the balance inserts to be located in. They are of diameter 7mm. They are located centrally in the balance chamber, and vertically as indicated in the diagram below. A jig (VSJ01) is available to assist in the drilling of the outerframe. The hole should be drilled through the whole section of the profile. Diagram showing jig VSJ01 location Diagram showing insert hole location 45deg. 5 5 Insert Part No The inserts are applied to the outerframe using the appropriate tooling. Note : The compression force of the insert applicator should be tested and tuned before it is used to apply the insert to the window. This is to ensure that it does not distort or damage the profile. 8.1

36 HARDWARE PREPARATION Sash Preparation for Pivot bars. A hole is required in the bottom corners of each of the sashes side members to provide clearance for the plastic split pin that is used to secure the pivot bars in the housing units. An 8mm hole is required to give sufficient clearance for the split pin. The hole position is as shown. The hole needs only to go through one wall of the plastic extrusion. 8mm dia. The pivot bar channel may be used to locate the position of the hole. The channel should be located in the corner of the balance channel Sash Preparation for Restrictor Quick Release. 8mm dia. x 1.0 A slot is required on each side member of the sashes. They are required to give clearance when the restrictor quick release device is used. Dependant on the length of the tilt restrictor arm, the distance x is derived. - x for short restrictor arm = 380mm - x for long restrictor arm = 510mm If transom height or drop is 649 or less, use the short restrictor arm. If transom height or drop is 650 or over use the long restrictor arm. The slot passes through one wall of the extrusion, and is has overall size of 8mm x 0mm as shown. Note: When horns are fitted dim x is measured from the bottom of the horn. Alternatively deduct 70mm from dim x and measure from the bottom of the sash. 8.

37 HARDWARE PREPARATION Bottom Sash VS09 Interlock Milling Details. Top Sash VS09 Interlock Milling Details dia. 6.5 dia i) 7mm x 1mm notch gives clearance from outerframe on assembly. ii) 6.5mm diameter slot is clearance for the latch button when assembled with the sash. i) 8mm x 0mm notch gives clearance around the pivot bar to enable the sash to be removed without removing the interlock. 8.3

38 HARDWARE PREPARATION Routing Details for Trickle Vents Trickle vents can be fitted through the head of the top sash. The VS03 sash will accomodate vent slots up to 10mm only. If wider slots are required ie. to achieve 8000mm sq free area then the top sash must be made using the VS04 sash profile. Alternatively there are many glazed in vents available to suit any air flow specification that can be used with any sash profile. Where trickle vents are to be fit to the head section, reinforcement should be broken around routed area to allow ventilation. Note: Glazed in vents will affect the glass size and may affect the sash weight. Consult the balance supplier for advise. For Vent Slots up to 10mm For Vent Slots up to 18mm mm offset VS03 Vent 18.0 VS04 Vent Section showing Typical Glazed in Vent system 8.4

39 MECHANICAL JOINTS Bottom Rail End Preparation : The bottom rail should be end milled with the detail shown below. This ensures a flush joint with the side members of the sash. 0.5 R Bottom Rail Assembly Bottom Rail & Sash Assembly : The VSM06 mouldings (left & right handed) are required when assembling the bottom rail with the side members. 1) Insert the moulding into the bottom of the sash side member. The screws pass through the clearance holes in the moulding and into the screw ports in the side members profile. Drilling Details : The two side members of the bottom sash must be prepared before the bottom rail is fixed to it. The bubble seal should be cut back 60mm (as shown), and then the profile should be predrilled using the VSJ05. The jig (VSJ05) is located as shown. Two 5mm diameter holes are then drilled through the section, these are to provide clearance for the two screws used to mechanically join the bottom rail. Self drill / tap screw 3.9 x 38mm Countersunk ) Locate the moulding in the bottom rail using the location lugs. Then using two screws, secure the side member to the bottom rail. The screws pass through the clearance holes in the side members and into the screw ports in the bottom rail reinforcement (VSR4S). 60mm Self tap screw 5.5 x 55mm Countersunk 9.1

40 MECHANICAL JOINTS Cill Assembly with Outerframe Side Jambs. Cill Drilling Details : The cill (VS0 or VS14) is to be drilled at both ends. The drill jig (VSJ0) is positioned as shown. The arrows show the direction of the force required to locate the jig. Four holes are to be drilled through the cill section. The holes are required for mechanically joining the outer frames vertical members to the cill. A 5mm diameter drill should be used to give clearance holes for the screws used to secure the outer frame. Fastening Side Jambs : Drill Jig Drill Jig VS0 Cill VS14 Cill Each of the side jambs is attached to the cill using four screws. The screws pass up through the cill (through the clearance holes), they are then screwed into the screw ports in the outerframe profile. This ensures that the side jambs are located correctly. Note: The cill jig is designed for use with cills cut to the overall width of the window. If the cill size has been adjusted to allow for the end caps then they must be fitted prior to positioning the jig. When fixing the cill, ensure the following has been done : 1) The pile seal has been put in both the cill and the outerframe. ) That all of the necessary slide gearing has been put into the relevant chambers. 3) The bottom of each of the side jambs has been cut at 5 degrees (in the correct direction). Self tap screw 5.0 x 60mm Countersunk - A silicone seal is required around the joint where the side jamb meets the cill. 9.

41 HARDWARE SELECTION Decorative Hardware Selection : The following four options are for the selection of the decorative / viewable hardware. The selection is dependant on (i) preference towards either brass or white access, (ii) whether or not the window has a bottom rail, (iii) the window width and (iv) the selection of either a night vent keep or a standard keep. Brass Access & Bottom Rail Sash Handle Rail Lift Hook Tilt Latch Button Top Sash Button Lock i) Night Vent Keep ii)standard Keep < 800mm 1 * * * White Access & Bottom Rail Sash Lift Rail lift Hook Tilt Latch Button Top Sash Button Lock i) Night Vent Keep ii)standard Keep < 800mm 1 * * * Brass Access & No Rail Sash Handle Tilt Latch Button Top Sash Button Lock i) Night Vent Keep ii)standard Keep < 800mm * * * > 800mm > 800mm > 800mm 4 Functional Hardware Selection : The following two options are dependant on whether the window is to be fabricated with or without the decorative horns. The selection of the pivot bars required is the only factor to be considered, and that is dependant on the horn option. The balance selection (i.e. balance resistance), is calculated from the sizes of the sashs they are to support. The hardware supplier will advise on the selection of these. Basic with Horns Standard Pivot Bar Horn Pivot Bar Balance Balance Shoe Pivot Bar Housing Tilt Restrictor Arm Restrictor Channel Sash Tilt Latch Basic with No Horns Standard Pivot Bar Balance Balance Shoe Pivot Bar Housing Tilt Restrictor Arm Restrictor Channel Sash Tilt Latch White Access & No Rail Sash Lift Tilt Latch Button Top Sash Button Lock i) Night Vent Keep ii)standard Keep < 800mm * * * > 800mm 4 * Note : Different quantities of hardware are required dependant on the window width. For windows less than 800mm wide, only one lock and keep is necessary, but having this will obstruct any georgian bars being used, so two can be used for aesthetics. 10.1

42 BALANCE DETAILS TILT TYPE WINDOW - PROBLEM CHECK SHEET If for some reason the balances do not perform as required - the following checks should be made : OBSERVED FAULT Rods pulling out of bottom of balance on bottom sash. Rods pulling out of bottom of balance on top sash. Evidence of damage to bottom of balance tube and in the extreme a bent tube. Noisy operation of the balance. CAUSE Balance too short. a. Balance too short. b. Cill stops too short or not fixed. a. Balance too long on top and bottom sashes. b. In the case of the bottom sash, no head stop. Bent rod. REMEDY Replace with correct balance. Replace with correct balance. Check if head stop is fitted and of correct dimensions. Replace with the correct balance. Check if the head stop fitted and is of correct dimensions. Replace balance. Balance takes tension then suddenly loses tension. Rotation often accompanied by clicking noise. Reverse turns have been applied somewhere down the line. Replace balance, but if this fault becomes common, supplier should be contacted as a basic error is occurring in fixing. Sash not holding up. Insufficient Tension. Apply more turns equally to each balance. Sash jumping up. Too much tension. Reduce number of turns equally on each balance. Sash will not hold even after the application of more turns. Balance totally jams on applications of too many turns. Rod will not move at all. Sash drops at top position but jumps from cills. a. Balance broken probably. See (E). b. Balance is not strong enough for the sash weight. Balance has been tensioned and spring has collapsed gripping the rod. Too strong a balance for this application. Check sash weight against the limitations of the sash. Balance broken. Check weight of sash and ensure correct balance has been incorporated. Use balance of lower capacity. Pivot bars bending. a. Window is bowed as a result of installation. b. Jamb section too small. c. Pivot bars inserted too far. Adjust window fixing. Consult profile supplier. Adjust pivot bars. N.B. TORSO BALANCES ARE NON ADJUSTABLE If you require any further clarification of the balance information shown, contact the Technical Department at the address shown below: Caldwell Hardware (UK) Limited, Herald Way, Binley Industrial Estate, Coventry. CV3 RQ England. Telephone - (0476) Facsimile - (0476)

43 WEATHERSEALS The location of all weather seals can be found in Section 4 - Details Sheets Replacement Glazing Gasket (part no ) - All profiles are supplied with glazing gasket where neccesary. In the event of the gasket becomming damaged, this replacement gasket may be used. 9.0 Bottom Sash Bubble Seal (part no white, black) - A bubble seal is required along the bottom of the bottom sash. It is available in both white and black Pile Seal (part no ) The pile seal is required in : - the jambs of both sashes, - in the head and interlock of the top sash, - in the cill and interlock of the bottom sash. - in the cill section - in the head and jambs of the outerframe Fringe Seal (part no Brown, Tan) - A fringe seal is required on foiled on white windows (see woodgrain section). It is available in both brown and tan. Interlock Pile Seal Detail The pile seal should be cut past the end of the interlock and tucked behind it to form a seal at the interlock ends (as shown below). 11.1

44 HARDWARE FITTING Balances & Balance Shoes. Outerframe (VS01) i) Balance selection. Four balances are required per window. The balance supplier will supply the correct tension and length of balance to suit the size and weight of the window. Stainless steel screw M5 x 30mm Countersunk ii) Balance location. The balances for the top and the bottom sashs are different lengths. The shorter pair of the balances are to be used with the top sash. They are located in the channel towards the outside of the window, one in each jamb. The two longer ones are located towards the inside of the window, one in each jamb. iii) Fastening balances to outerframe. The balances are fastened to inserts that are located at the top of each jamb, in both the inside and outside channel. iv) Adjusting the tension. Tension adjusting tools are available to both adjust the tension of the balance, and align the balance shoe fixing pin on assembly. Refer to diagrams. Detail showing balance to balance shoe fixing. Note: The horn pivot bar and tilt restrictor arm must be fitted at this stage prior to fitting the cill. 1.1

45 HARDWARE FITTING Bottom Sash Tilt Latch. Tilt Latch Button Screws The diagram below is of the bottom sashs tilt catch and interlock assembly. The diagram shows the right hand latch only, the left hand latch fits in the rebate at the opposite end of the sash. VS09 - Interlock Milled as shown i) Tilt latch location and fixing. The tilt latches are left and right handed. The appropriate tilt latch is positioned in the rebate so that the casing sits flush with the edge of the sash. It is then secured using the two self tapping screws. ii) Interlock orientation and location. The interlock (VS09) is prepared as shown in Section 8. The interlock is positioned so that the slots are in line with the slots in the latch, and the removed corner section is towards the inside of the vent. iii) Tilt Latch Button location. The tilt latch button thread is Right Hand Tilt Latch fastened into the tilt latch through the slot in the interlock. Self drill / tap screw 3.9 x 19mm Countersunk Bottom Sash Tilt Latch & Interlock Assembly. Vent viewed from inside 1.

46 HARDWARE FITTING Top Sash Tilt Latch. Top Button The diagram below is of the top sashs tilt catch assembly. The diagram shows the right hand latch only, the left hand latch fits in the rebate at the opposite end of the sash. Right Hand Tilt Latch i) Tilt latch location and fixing. The tilt latches are left and right handed. The appropriate tilt latch is positioned in the rebate so that the casing sits flush with the edge of the sash. It is then secured using the two self drilling screws. The tilt latch button screws directly into the tilt latch. Vent viewed from inside Top Sash Tilt Latch Assembly. Self drill / tap screw 3.9 x 19mm Countersunk Non-Tilt Sashes. For applications of the window where there is no tilting of the sashes required, or where the weight of the sashes exceeds 35kg, the tilt latches can be locked in position. This can be achieved by locking of the tilt latches in their closed position. This is done by drilling a 4mm hole through the tilt bar, insuring that the hole is in line with the countersink in the casing. A screw can then be fastened through this hole and into the sash. This prevents the movement of the tilt latch. 4mm Drill in line with the countersink Self drill / tap screw 3.9 x 19mm Countersunk 1.3

47 HARDWARE FITTING Pivot bar housing & Pivot bar. Pivot bar housing location & fitting : A pivot bar housing unit is fastened to the bottom corner of each sash, in the rebate. They are then secured in that position using three screws. Self drill / tap screw 3.9 x 19mm Countersunk Vent viewed from inside Pivot bar housing Pivot bar location & fitting : A pivot bar is located in each of the housing units. The pivot bar is slid into the housing unit up to the stop, so that the holes in both the pivot bar and housing are aligned. The plastic split pin is then used to fasten the pivot bar to the housing. This operation is performed when the pivot bars are located in the outerframe, and the sashes are being installed. 1.4

48 HARDWARE FITTING Quick Release Tilt Restrictor Fixing. Vent viewed from inside Tilt Catch Flat head Oval head x A restrictor channel is fastened to each of the side members of the sash. The distance x is dependant on which of the two tilt restrictor arms is used. - x for short restrictor arm = 300mm - x for long restrictor arm = 430mm. The left and right hand channels should be level with each other, to ensure an even tilt. Note: When horns are fitted, distance x is measured from the bottom of the horns. If transom height or drop is 649 or less, use the short restrictor arm. If transom height or drop is 650 or over use the long restrictor arm. Self drill / tap screw 3.9 x 19mm Countersunk Flat Head Self drill / tap screw 4.8 x 16mm Countersunk Oval Head Restrictor arm assembly The Tilt Restrictor Arm assemblies are slid into the outer frame channels as shown above in both jambs of the outer frame. They must be inserted before the pivot bars are attached to the balance shoes and before the cill is fitted to the outer frame. Should there be any need to remove the tilt restrictors or balance shoes after the window has been installed, a slot can be routed behind the sash stops to make this possible. The slot will then be covered by the stops when replaced. (See Section. Balance Shoe Replacement) 1.5

49 Hardware Location : Rail Lift Hook Sash Drilling Details : HARDWARE FITTING Window without Bottom Rail Sash Handle Pilot holes should be drilled to position the access hardware. The VSJ03 drill jig is available for the Brass Access drilling positioning. The location of the screw guide holes provided by the jig allow the handles etc. to be positioned so that they do not collide with the outerframe or cill, and provide both ergonomic and aesthetic positioning. Brass Access Drilling & Fitting. The table below indicates the location of hardware when the overall dimensions and style of the window are known. Window with Bottom Rail Window width < 800mm Window width > 800mm Sash Handle 1 Required for Top Sash Required for Top Sash Positioned centrally max. of 300mm from corners Required for Bottom Sash max. of 300mm from corners 1 Required for Top Sash 1 Required for Bottom Sash Positioned centrally Required for Bottom Sash max. of 300mm from corners Required for Top Sash Required for Bottom Sash max. of 300mm from corners Sash Handles : The jig should be positioned as shown below. The V notch in the jig should be aligned with the horizontal location (as detailed in the table above). The.5mm diameter holes are then drilled through one wall of the plastic and reinforcement to provide the screw with a guide. The handles are fixed using four screws, shown bottom. Rail Lift Hooks : The jig should be positioned as shown below. The V notch in the jig should be aligned with the horizontal location (as detailed in the table above). The.5mm diameter holes are then drilled through one wall of the plastic and reinforcement to provide the screw with a guide. The handles are fixed using two screws, shown bottom. Self drill / tap screw 3.9 x 19mm C sunk Self drill / tap screw 3.9 x 19mm C sunk 1.6

50 Hardware Location : Rail Lift Hook Sash Drilling Details : HARDWARE FITTING Window without Bottom Rail Sash Lift Pilot holes should be drilled to position the access hardware. The VSJ04 drill jig is available for the White Access drilling positioning. The location of the screw guide holes provided by the jig allow the sash lifts etc. to be positioned so that they do not collide with the outerframe or cill, and provide both ergonomic and aesthetic positioning. White Access Drilling & Fitting. The table below indicates the location of hardware when the overall dimensions and style of the window are known. Window with Bottom Rail Window width < 800mm Window width > 800mm Sash Lift 1 Required for Top Sash Required for Top Sash Positioned centrally max. of 300mm from corners Required for Bottom Sash max. of 300mm from corners 1 Required for Top Sash 1 Required for Bottom Sash Positioned centrally Required for Bottom Sash max. of 300mm from corners Required for Top Sash Required for Bottom Sash max. of 300mm from corners Sash Lift : The jig should be positioned as shown below. The V notch in the jig should be aligned with the horizontal location (as detailed in the table above). The.5mm diameter holes are then drilled through one wall of the plastic and reinforcement to provide the screw with a guide. The handles are fixed using two screws, shown bottom. Rail Lift Hooks : The jig should be positioned as shown below. The V notch in the jig should be aligned with the horizontal location (as detailed in the table above). The.5mm diameter holes are then drilled through one wall of the plastic and reinforcement to provide the screw with a guide. The handles are fixed using two screws, shown bottom. Self drill / tap screw 3.9 x 19mm C sunk Self drill / tap screw 3.9 x 19mm C sunk 1.7

51 Drilling Details : HARDWARE FITTING Cam Lock & Standard Keep Drilling & Fitting. Pilot holes should be drilled to position the lock and keep hardware. The VSJ06 drill jig is available for the lock / standard keep drilling positioning. The jig is located when the window is fully assembled, and is in the closed position (refer to safety notes in Section 1). A.5mm drill is then used through the drill guides, these holes act as screw guides to locate both the lock and keep. The location of the screw guide holes provided by the jig allow the lock and keep to be positioned correctly, thus giving the necessary clamping action. Diagram showing the VSJ06 drill jig in position. Standard Keep : The V notch in the jig should be aligned with the horizontal location. The.5mm diameter holes are then drilled through the bead and into the sash, to provide the screw with a guide. The keeps are fixed after the sash is glazed using two screws as shown below. Self drill / tap screw 3.9 x 45mm Countersunk Cam Lock : The V notch in the jig should be aligned with the horizontal location, as with the keep location. The.5mm diameter holes are then drilled through the interlock and into the sash and reinforcement, to provide the screw with a guide. The locks are fixed after the sash is glazed using two screws as shown below. Self drill / tap screw 3.9 x 38mm Countersunk 1.8

52 Drilling Details : HARDWARE FITTING Cam Lock & Night Keep Drilling & Fitting. Pilot holes should be drilled to position the lock and keep hardware. The VSJ07 drill jig is available for the lock / night keep drilling positioning. The jig is located when the window is fully assembled, and is in the closed position (refer to safety notes in Section 1). A.5mm drill is then used through the drill guides, these holes act as screw guides to locate both the lock and keep. The location of the screw guide holes provided by the jig allow the lock and keep to be positioned correctly, thus giving the necessary clamping action. Diagram showing the VSJ07 drill jig in position. Night Keep : The V notch in the jig should be aligned with the horizontal location. The.5mm diameter holes are then drilled through the bead and into the sash, to provide the screw with a guide. The keeps are fixed after the sash is glazed using two screws as shown below. When the keep is positioned, two additional holes should be drilled (see below), using the keep to locate them. An extra two screws are then used to secure the keep. Cam Lock : The V notch in the jig should be aligned with the horizontal location, as with the keep location. The.5mm diameter holes are then drilled through the interlock and into the sash and reinforcement, to provide the screw with a guide. The locks are fixed after the sash is glazed using two screws as shown below. Self drill / tap screw 3.9 x 38mm Countersunk Self drill / tap screw 3.9 x 19mm Countersunk 1.9

53 HARDWARE FITTING Horn Fitting and Removal details The Horns are fitted to the top sash after the sash has been installed in the outer frame. Ensure the correct pivot bar has been used before assembling. (See below). (1). The horn is positioned on the sash so the legs locate in the pile seal groove. (). Hold the horn against the sash in the vertical plane (1) and slide it horizontally () until it clicks into position. (3). The horn is then secured using a 3.9 x 19mm countersunk screw through the hole provided in the pile seal groove. The pile seal can then be slid over the screw head, it may be necessary to slide the seal past the end of the horn in order to fit the other horn. Standard Pivot Bar Horn Pivot Bar Self drill / tap screw 3.9 x 19mm C sunk Horn Removal If it becomes necessary to remove the horns this can be achieved by removing the retaining screw from behind the pile seal. The horn can then be released by inserting a small flat screwdriver through the 6mm hole in the back of the horn, locating the tip on the angled ledge adjacent to the retaining pip on the horn. (See diag.). The horn is then removed by applying light pressure to the screwdriver to release the pip and then reversing the fitting action described above. 1.10

54 HARDWARE FITTING Sash Block Location & Fixing. Sash Block (VSM05) Top Sash Location : The sash block in the top sash locates in the chamber in the top jamb when the window is closed, this helps to prevent deflection. The sash block should be located midway along the top of the sash. They are fixed as shown below, and secured with a screw into the reinforcement. Sash Block (VSM05) Top Sash Self drill / tap screw 4.9 x 5mm Countersunk Bottom Sash Location : The sash block in the bottom sash locates onto the cill when the window is closed, this provides a definite stop for the window. The sash block should be located midway along the bottom of the sash. They are fixed as shown (right), and secured with a screw into the reinforcement. Bottom Sash Self drill / tap screw 4.9 x 5mm Countersunk Sash Block (VSM05) 1.11

55 HARDWARE FITTING Balance Shoe replacement The Balance shoes are fitted to the window prior to assembly and installation and cannot be removed in the same way as they were fitted. If it becomes necessary to replace the balance shoes or tilt restrictor arms this can be done by routing cut outs in the jambs as shown below. Once the shoes/ tilt restrictors have been replaced the cut outs are covered by the re-installation of the VS10 sash stops. Balance Shoe VS10 Sash Stop 1.1

56 GLAZING Glazing Options The glazing beads VS06 & VS07 are to suit 4mm Double Glazed units only. Glass Packing : All glazing should be in accordance with BS66, and all current codes of practice. Position the glazing packers as illustrated below. Bead Cutting : Glazing beads can be either scribed or mitred. Mitred beads require suitable supports when cutting at 45deg. to mimic their position when glazed. REBATE SIZE - 18mm REBATE SIZE Suggested Bead Configuration For Top Sash REBATE SIZE - 18mm REBATE SIZE REBATE SIZE REBATE SIZE Suggested Bead Configuration For Bottom Sash REBATE SIZE REBATE SIZE Spacer Glazing Packer The configuration of the beads in the top sash is only effected by the requirement of having the square bead (VS06) at the bottom of the sash. The bottom sash bead configuration is not effected by any of the hardware. This means that either the above option may be used, or any combination of the above two, e.g. the configuration shown below. REBATE SIZE REBATE SIZE - 3mm REBATE SIZE - 3mm REBATE SIZE 13.1

57 Georgian Bar Profiles. The stick on georgian bars both carry the windows unique ovolo detail. It is available in two widths (mm and 30mm), to provide maximum design flexibility. GEORGIAN BARS Stick on Georgian Bars Application. The georgian bar is supplied with the tape already bonded to it. To stick the bar to the glass, the following steps should be taken : 1) Using an applicator pad, clean the glass with VHB surface cleaner ) Remove the tapes protective liner and bond the bar to the glass. Adhesive Tape VS11 - Narrow Georgian Bar 30 3) Rub down with a roller to ensure good contact. Please note : Correct application temperature is 3C. Bars should not be applied at temperatures below 15C. The bars should be cut 1mm shorter than the opening that it is to be fit into Adhesive Tape VS1 - Wide Georgian Bar End Preparation. The georgian bar requires end milling where it butts up to another georgian bar or the ovolo bead. Refer to end preparation diagram below. 9.0 R VS End Preparation. 1.5 R VS1 8.0 End Preparation. 13.

58 Tape supplier recommendations. Clean all application surfaces. All surfaces should be clean and free of dust, moisture and oil residues. Normally a clean paper towel should be sufficient to remove most surface contaminants, but the use of a Isopropanol wipe may be benificial. Apply pressure for secure adhesion. These are pressure sensitive adhesive products and require good overall pressure to secure the adhesive to the first surface, and the same pressure again for the second surface. Allow time to achieve full bonding capability. These adhesives should perform well in many difficult enviromental conditions, but will activate more redily if applied at normal room temperature. The bond strength will then continue to increase after the initial application. Many of the adhesives will reach their full bond strength within an hour, but the PURE Acrylic adhesives may take longer depending on application temperature conditions. Apply in correct temperature conditions. If the surface, or the tape, are too cold this will affect the bonding ability of the adhesive. This will tend to make the adhesive dryer to the touch, and could therefore, take longer to achieve its full bonding potential. Preferred applying temperature : no less than 10C, and ideally between 0C and 5C. Allow for atmospheric changes. Be aware of atmospheric changes, such as taking a glazed unit from the stores into a warm work area. This may cause surfaces to be coated with an invisible layer of condensation. Correct storage conditions. These adhesive products should be stored upright, in the original cartons, in dry conditions, away from direct heat sources. Stock should be rotated and used within 1 months. GEORGIAN BARS Stick on Georgian Bars 13.3

59 GEORGIAN BARS Clip on Georgian Bars The Geo Fast System. The Geo Fast system is available from THE GEORGIAN BAR CO. LTD, Princess House, Arkwright Way, Scunthorpe. DN16 1AD Tel: The Geo Fast system comprises of a 4mm bar clip, a cruciiform clip, a bridge piece clip and a featured georgian bar which matches the ovolo design on our Vetical Sliding Window.The system has been designed to achieve a quick and efficient application time and can be fitted on site. The bar does not rely on adhesive tape, thus greatly reducing the possibility of it being dislodged after installation. The 1mm featured bar is available in white with foiled options also available to order. Assembly 1 Fit the edge clips around the sealed unit to suit the required positions or internal spacer bar (if used) and glaze into the frame in the normal manner Note: Ensure the clips are in the correct position prior to final beading. Glass packers may be used at edge clip locations if required. 1 Product Identification 1mm Feature Bar GB VS (White) GB WG VS (Mahogany) GB LO VS (Light Oak) Cut and end mill shortest full span Georgian Bar to the precise length using the Sash Form set-up. Fit the cruciform clip(s) (if required), and clip the bar into position. 3 Cut and end mill the remaining Georgian Bars. At cruciform joints use the Bar Form set-up. Where the bar meets the sash use the Sash Form set-up. Note: Ensure that bar lengths are cut and milled accurately prior to fitting. 3 Cruciform Clip GCC VS 4mm Bar Clip GC 4 VS Bridging Piece GBBT VS 4 Repeat procedure on the reverse side of the glass. Note: For longer spans the bridging piece can be used and 0.5mm double sided tape used to eliminate movement. 13.4