Service Manual - Boyd Aluminum
Contents
1. nh acini Place 1 6 3 4 x 1 1 4 1628 03 144 setting blocks at 1 4 points Quarter points are determined by taking the day light opening and dividing by 4 This dimension is CAL for the setting block After setting blocks have been installed the window is ready for glass Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 22 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 mportant Note Step 5 Orient glass for Low e tints special coatings and glass make up as the project requires Boyd will not be responsible for stickers on glass based on correct inside out orientation Boyd recommends that proper tools for detection of tints coating or laminates be supplied for field glazing and installation Step 5 Pull correct sized glass for opening orientate glass make up correctly to job requirements and set in opening Make sure that glass is pushed tight against exterior glazing leg and sitting flush on setting blocks Retrieve the previously supplied glass stops that were taken out and marked from Step Drive front leg into the race way and engage glass stop back in to framing Remember to reuse marked and correct glass stop in same locations as supplied See Step 6 and Step 6 1 R2. Proceed to the outside and apply a cap bead seal between the glass and exterior glazing leg of the frame While applying cap bead be sure to check for bubbles or holes in continuous seal Cap Bead must be applied by using either DOW 999 or a compatible sealant Sealant compatibilities are responsibility of glazing team or contractor See Step 7 and Figure 7 1 Cap Seal exterior with Dow 999 Black or compatible sealant Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 17 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Apply sealant properly so that cavity between glass butyl tape and exterior leg is filled and sealed completely Tool the sealant so that a clean and proper fillet cap bead is visible Cap Seal exterior with Dow 999 Black or compatible sealant Assembled Grid Glazing application 1 16 x 3 8 Schneed Moorehead Butyl Tape between grid and glazing leg 1 8 x 3 8 Schneed Moorehead Butyl Tape between glass and grid Figure 9 1 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 18 of 38
3. and many cleaning materials used to clean masonry and many other materials are very harmful to anodized and painted finishes and should not be allowed to come in contact with the window system In the event that any does come in contact it should be removed immediately with mild soap and water Start at the top of material and soak the entire location with water and mild soap solution to remove soil and large pieces of debris Start by wiping with a non abrasive brush in a horizontal manner and then a vertical top to bottom motion Rinse cleaning materials with clean water and dry with a clean non abrasive cloth 2 2 Removal of debris and oils Cleaning of anodized aluminum surfaces should be in accordance with AAMA 609 amp 610 02 Cleaning and Maintenance Guide for Architecturally finished Aluminum ATTENTION Use of duct tape masking tape and similar products to painted aluminum surfaces will produce permanent adhesion of tape to the finish This adhesion will promote adhesion failure of finish to aluminum surface upon removal of the tape If protective coatings are required these should be tested prior to application and removed prior to using field applied sealants during installation Always refer to protective coating manufacturer for compatibility of different finishes 3 Painted Aluminum Cleaning and Maintenance 3 1 General Cleaning Cleaning products for terrazzo cement plasters and many cleaning materials used
4. field applied sealants during installation Always refer to protective coating manufacturer for compatibility of different finishes 4 Maintenance Schedule for Windows and Sliding Doors 4 1 Quarterly Blow or vacuum out dust dirt and debris from sliding track and sills of windows Remove any debris within window system as it may cause deficiency in hardware operation Clean sand or debris from all working mechanisms hinges latches limit stops rollers and any specialty parts Polish external hardware to protect finish Non abrasive products can be purchased at most local retailers 4 2 Annually Blow or vacuum out dust dirt and debris from sliding track and sills of windows Remove any debris within window system as it may cause deficiency in hardware operation Clean sand or debris from all working mechanisms hinges latches limit stops rollers and any specialty parts Polish external hardware to protect finish Non abrasive products can be purchased at most local retailers Check exterior perimeter caulking and interior seals and repair as needed Adjust hardware to allow for proper engagement operation and performance 4 3 Frequently Wash exterior and interior windows and glass per the above mentioned methods Be aware not to scratch or damage material or glass Blow or vacuum out dust dirt and debris from sliding track and sills of windows Lubricate and oil all rollers hinges and moving hardware Lubrication s
5. foreign substances clean surface is ready for glazing Clean Inside portion of Glazing Leg with Alcohol Based Cleanser Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 13 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 After cleaning the glazing and removing any impurities apply the Schneed Moorehead Butyl Tape 1 8 below the day light opening D L O of framing Run the horizontals 2 past the D L O and butt the verticals into the horizontal tape See Step 3 and Figure 3 1 below for clarification For grid applications see Figure 9 1 Attach 1 8 x 3 8 Schneed Moorehead Butyl Tape to exterior glazing leg Make sure to run horizontals 1 2 past D L O and run verticals tight to horizontal tape to ensure a tight fit Attach at a min of 1 8 below D L O to allow for cap bead from outside ESR is h 3 fi ZL KIS y RIS 4 IZ 3 R o ROBO 6 RRM X ROO 1 ROR o ROKR Ks CUSLES BS ROR 64 PRO a EnEn Sa s S N BRRR PRS ORB ROIKROIIL RIKI KR OSS Figure 3 1 OIRO XR KOKORO LOS KI DOR Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities sh
6. glass manufacturers fabricators distnbutors and mstallers neither condones nor recommends widespread scraping of glass surfaces with metal blades or kmfes Such scrapme will permanently damage or scratch the glass surfaces When paint or other construction matenals cannot be removed with normal cleaning procedures a new l razor blade may need to be used only on non coated glass surfaces The razor blade should be used on small spots only Scrapmeg should be done im one direction only Never scrape m a back and forth motion as this could trap particles under the blade that could scratch the glass This prachee may cause halme concentrated scratches which are not normalh visible when lookme through the glass but may be visible under certain behing conditions Jobsite storage and construction conditions can lead to stams on the glass surface Cleanme and removal of such stams may require the use of a more aggressive cleamme solution and procedure If conditions are found that cannot be cleaned using the above procedures contact the glass suppler for pmidelines on stam removal Members of the Glass Associaton of North Amenca GANA publish imformmation relating to jobsite protection and cleamme of architectural glass products In order to ensure long term performance of the glass m a building GANA encourages glazing contractors general contractors buldimg management and owners to be aware of conditions that can damage glass and to follow the
7. handlme and cleamme suidelmes provided by their glass producer and fabricator Consult th GANA website arew glasswebsite com for additional mformation on glass and glazing appheations and links to members providing additional technical resources The Glass Association of North America GANA has produced this Glass Information Bulletin solely te provide general information as to basic proper procedures for cleaning architectural glass products The Bulletin does not purport to state that any one particular type of glass cleaning process or procedure should be used in all applications or even in any specific application Ihe user of this Bulletin has the responsibility to ensure the cleaning instructions from the glass supplier are followed GANA disclaims any responsibility for any specific resulis relating to the use of this Bulletin for any errors or omissions contained in the Bulletin and for any liability for loss or damage of any kind arising out of the nse of this Bulletin GANA 01 0300 2 Copyright GANA 2000 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 7 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Quick RKeference Guide to Cleaning Architectural Glass Products The following Do s and Do Not s are
8. informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 4 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Glass Care and Maintenance 1 1 General Cleaning Glass should be washed rinsed and dried during the different phases of construction This will help prevent the accumulation of foreign debris to adhere and distort glass from its original quality For most glass except specialty or coated glass use mild soap clean with soft and particle free cloths or sponges Use of a slightly acidic cleaning solution can be used on glass but immediate rinsing with clean water must be competed Use of a rubber squeegee for streak free viewing is acceptable Check with project glass manufacturer for specific cleaning instructions Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 5 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 AFGOR iat ion OF NORTH AM enic i Glass Informational Bulletin GANA 01 0300 Proper Procedures for Cleaning Architectural Glass Products Architectural glass products play a major role m the comfort of Ining and workmg environment of today s homes and c
9. l Use a 9 32 Allen wrench Hex Key to unscrew but do not remove tilt lock screw See Figure 2 Figure 2 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 33 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 After disengaging tilt sash screw move screw towards center of window Figure 3 This will disengage tilt sash lock from jamb and allow sash to tilt to mside Figure 3 Tilt sash to the interior of window to a full horizontal position Figure 4 Make sure that sash is secured and controlled as dropping sashes may cause damage or injury Figure 4 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 34 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Tilting the sash to horizontal position allows locks on balances shoes to engage From the horizontal position Figure 5 rotate either side up and remove sash from frame Figure 6 Figure 5 Remove sash from frame by removing tilt pin from the pivot shoe assembly Proceed with proper maintenance cleaning or reglazing as
10. needed If window unit is a double hung application repeat process for upper sash To reinstall sash repeat process in reverse order If you have any questions or items that need to be addressed contact your nearest Boyd Aluminum Representative prior to proceeding with any applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 35 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 10 Boyd Slider Sash Removal and Reinstall This process is a typical slider sash removal instruction Failure to follow these instructions correctly may lead to injury or damage due to falling sashes Read completely and follow for proper and correct sash removal and installation Once the window system has been properly shimmed anchored plumbed and sealed the next step is to remove the lock down screws on the fixed panel Figure 1 These are located on the fixed panels on an OX XO OXO at the jamb These screws are located at the sill on an XOX or XOO configuration Viewed from Interior Open sash to middle of frame See Figure 2 Figure 2 Viewed from Interior Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions proces
11. Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Setting blocks on casements must be crossed blocked Place setting blocks as noted in Figure 10 1 for proper distribution of weight Place setting block 6 six inches from the edge of locking rail at sill and jamb Place setting blocks at 6 from edge at hinge jamb and sill Place block at hinge jamb 6 from head rail Setting blocks marked with X must be tight for proper performance of hardware Hinge right shown hinge left opposite Figure 10 1 If any questions or items need to be addressed contact your nearest Boyd Representative prior to proceeding with any glazing applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 19 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 6 Boyd Reglazing Instructions Wet Glazing This Process is a typical glazing application for Boyd Products and should be followed but final field glazing may differ based on project specifics Fixed lite glazing is shown but operable sash glazing is similar Once the window system has been properly shimmed anchored plumbed and sealed the next step is to prep frame for glazing As you can see in the drawing Step 1 the first step is to remove the installed interior g
12. Tape Glazing Page 13 19 5 1 Removal Deglazing of defective or broken glass 5 2 Installation Glazing of replacement glass 6 Reglazing Instructions for Wet Glazing Page 20 24 6 1 Removal Deglazing of defective or broken glass 6 2 Installation Glazing of replacement glass 7 Boyd Marine Wrap Reglazing Instructions Page 25 28 7 1 Removal Deglazing of defective or broken glass 7 2 Installation Glazing of replacement glass Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 2 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Sash Removal and Reinstallation 8 Boyd Side Load Sash Remove and Reinstall Instructions Page 29 32 8 1 Removal of sash 8 2 Installation of sash 9 Boyd Tilt Load Sash Remove and Reinstall Instructions Page 33 35 9 1 Removal of sash 9 2 Installation of sash 10 Boyd Slider Sash Remove and Reinstall Instructions Page 36 38 10 1 Removal of sash 10 2 Installation of sash In the event of any conflict between the Boyd Aluminum Mfg Co Service Manual and the recommendations of the American Architectural Manufacturing Association AAMA the recommendations of AAMA shall control Service Manual Instructions are to be used for genera
13. ainst glass Service Manual 3825 968 Rev 08 08 San A j r NNN ns SS w SOS NS SSS eta SSNS UNNE SOSSE a V l NSN os SST SOSA SE N SN A X S RN NA a SEAT NT NANNE SERA SNS viata mentee yaa eon ares a N ne SV y RON S SS Se Apply a sufficient bead of Dow 995 Silicone or compatible sealant on glazing leg ta seal properly against glass Run continuous bead of Dow 995 silicone or compatible sealant around corner for proper glazing and proper seals against frame and glass Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 21 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 var After silicone application locate setting block location and attach to sill and jamb Setting blocks are located at industry standard 4 points but verify with appropriate glass manufacturer as shown in Step 4 and Step 4 1 Step 4 lt i Set 1 8 x 34 x 1 1 4 1626 03 144 setting blocks i 1 4 points Place two at jambs for side blocks for proper spacing g Step 4 1 a 40 NTS T 20 NTE 20 NTS NNS 10 NTS 10 NTS A RAAR LLL LLL LLL ALLELE A R Gn LEZ LED E SIO NX ee SSE
14. al Page 9 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Glass Care and Maintenance 1 3 Care During Installation Cleaning of glass and windows must be done and monitored during all stages of installation and construction Upon arrival to the jobsite and installation windows and glass should be wiped down and cleaned Cleaning during the construction phase of the glass and windows should be soaked with clean water then a mild soap solution to loosen any dirt dust and debris Use a non abrasive or cloth brush to apply a non abrasive cleanser to the glass Before the cleanser becomes dry use a squeegee and dry glass Make sure not to hit nick or scratch glass with any metal or sharp object After drying glass and window frame a blue max or similar protective film may be applied to protect from new construction debris dust paint welding spatter or contaminates provided that these must be tested prior to application to avoid damaging the finish Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 10 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Finish Care and General Maintenance 2 Anodized Aluminum Cleaning and Maintenance 2 1 General Cleaning Cleaning products for terrazzo cement plasters
15. be very noticeable when the sun 1s at a certain angle in the sky or when the sum 1s low in the sky 2945 SW Wanamaker Drive Suite A Topeka KS 66674 5271 785 277 0208 Fax 785 271 0166 wew olasswebsite com Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 6 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 The glass industry takes extreme care to avoid glass scratches by protecting all glass surfaces dumme glass manutactunne and fabrication as well as duming all shippme and handling required to deliver the glass to the end user A large percentage of damaged glass results from mon elass trades working near glass This will melode pamters spacklers momworkers landscapers carpenters and others who are part of the constuction process They may inadvertently lean tools against the glass splash materials onto the glass andor clean the glass meorectly any of which can permanently damage glass One of the common mistakes made by non glass trades people imcluding glass cleammeg contractors 15 them use of razor blades or other scrappers on a large portion of the glass surface Using 2 3 4 5 meh and larger blades to scrape a window clean cames a large probability for causing mreparable damage to glass The entire mdustry of
16. cate as in Step 5 mportant Orient glass for Low e tints special coatings and glass make up as the project requires Boyd will not and can not be responsible for stickers on glass based on correct inside out orientation Boyd recommends that proper tools for detection of tints coating or laminates be used for field glazing and installation Pull correct sized glass for opening orientate glass make up correctly to job requirements and set in opening Make sure that glass is pushed tight against exterior glazing leg and sitting flush on setting blocks Retrieve the previously supplied glass stops that were taken out and marked from Step 1 Drive front leg into the race way and engage glass stop by rotating back in to framing Remember to reuse marked T ri Ey ET SOOT AS onu l Pag Reinstall interior glass stop with installed bulb gasket Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 16 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Engage front leg of Glass Stop by rolling extrusion as shown in 6 1 Apply pressure from top to engage back leg of Glass Stop for proper compression Roll Glass Stop for front leg engagement Apply pressure to engage leg on Glass Stop Figure 6 1
17. duce the risk of leaving residue and cleanmg solutions on glass at the lower levels Cleamme procedures should also ensure that the wind 1s not blowing the cleamme solutron and residue onto already cleaned glass Cleaning durme constrection activities should begm with soaking the glass surfaces with clean water and soap solution to loosen dut or debris Using a mild non abrasive commercial window washing solution uniformly apply the solutton to the glass surfaces with a brush stump washer or other non abrasive applicator Immediately followme the application of the cleamme solution a squeegee should be used to remove all of the cleaning solubon from the glass surface Care should be taken to ensure that no metal parts of the cleamme equipment touch the glass surface and that no abrasive particles are trapped between the glass and the cleamme matenals All water and cleaning solution residue should be dred from window gaskets sealants and frames to avoid the potential for deterioration of these materials as the result of the cleanme process lt is strongly recommended that widow washer clean a small area or one window then stop and examine the surface for any damage to the glass and or reflective coatme The ability to detect certam surface damage 1e light scratches may vary greatly with the liehtme conditions Direct sunlight is needed to properly evaluate a glass surface for damage Scratches that are not easily seen with a dark or gray sky may
18. einstall interior glass stop Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 23 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Engage front leg of Glass Stop by rolling extrusion as shown in step 6 1 Apply pressure from top to engage back leg of Glass Stop for proper compression Step 6 1 If any questions or items need to be addressed contact your nearest Boyd Representative prior to proceeding with any glazing applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 24 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 7 Boyd Reglazing Instructions Marine Gasket Glazing This process is a typical glazing application for Boyd products and should be followed but final field glazing may differ based on project Sash glazing is shown but fixed glazing is similar Once the window system has been properly shimmed anchored plumbed and sealed the next step is to prep frame for glazing As you can see in Figure 1 the first step is to remove the sash from its frame slider single hung double hun
19. g Place sash panels in a protected area as not to damage material You will need this material to complete the glazing process Figure Take sash panels and remove corner assembly screws from the jambs Figure 2 ___ Corner Assembly Screws Figure 2 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 25 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 After removing assembly screws pull sash apart into 4 separate pieces Do not damage or lose members as you will need them to glaze and reglaze sash Figure 3 a Figure 3 I Take correct sized glass for sash panel and start applying correct depth marine gasket Start at top centerline of glass to apply marine gasket Figure 4 Make sure that edge is cut straight and clean Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 26 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Cut gasket square and straight but do not cut completely through Leave lower edge of gasket to run continuously around interior portion of the f
20. hould be applied after 1200 cycles per operating hardware set Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 12 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Boyd Reglazing Instructions 5 Boyd Reglazing Instructions Butyl Tape Glazing This Process is a typical glazing application for Boyd Products and should be followed but final field glazing may differ based on project specifics Fixed lite glazing is shown but projected glazing is similar Once the window system has been properly shimmed anchored plumbed and sealed the next step is to glaze the frame As you can see in the drawing below Step 1 the first step 1s to remove the installed interior glass stop from its frame Apply pressure on the interior side of the glass stop to disengage out of track Continue this process for the head and jambs while being careful not to damage material You will need this material to complete the glazing process Step 1 Remove Interior Glass Stop Place your glass stop in a safe place and label by either location or elevation so that you can reuse as shown in Step 6 Upon removing the glass stop wipe down the interior side of the exterior glazing leg as shown in Step 2 Be sure to remove any and all contaminates or
21. l Installation conditions processes anchor types locations and quantities should be verified by project professional Page 38 of 38
22. l informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 3 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Glass Care and Maintenance 1 General Overview and Contact Boyd Windows are tested manufactured and supplied in accordance with AAMA standards specifications and requirements however Boyd Aluminum can not protect against adverse environmental conditions extreme or unusual use of the products provided in the field The information contained in this manual has been compiled for general and typical window types Boyd can not warrant or guarantee products that are used in any manner other than normal use and results may differ from those expressed in this manual Due to custom applications design and specifications of this industry some of the information may not apply and should be analyzed and reviewed before action is taken Users of material should conduct their own tests to verify that material is applicable for the field application In the event that a part or piece has broken or become defective please send requests for information or possible replacement to Boyd Replacement Department Boyd Aluminum P O Box 1565 Springfield MO 65801 Or Call P 800 737 2800 F 417 862 1232 Or Visit www boydaluminum com Service Manual Instructions are to be used for general
23. lass stop from its frame Apply pressure on the interior side of the glass stop to disengage out of track Continue this process for the head and jambs while being careful not to damage material You will need this material to complete the glazing process Glazing material is sent loose for Boyd Aluminum 600 amp 300 series windows Step 1 Remove Interior Glass Stop Glass stop is the same on sash and of fixed lites Place your glass stop in a safe place and label by either location or elevation so that you can reuse as shown in Step 6 Upon removing the glass stop wipe down the interior side of the exterior glazing leg as shown in Step 2 Be sure to remove any and all r contaminates or foreign substances to ensure that a P clean surface is ready for glazing i a Pe ME og E Clean Inside portion of Glazing Leg pee eo oo with Alcohol Based Cleanser Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 20 of 38 Boyd Aluminum Mfg Co After cleaning the glazing leg and removing any impurities apply a bead of Dow 995 Silicone or compatible sealant for glazing See Step 3 and Step 3 1 below for clarification Step 3 Run continous bead of Dow 995 Silicone or compatible sealant around comer glazing leg to seal properly ag
24. minum Mfg Co Service Manual 3825 968 Rev 08 08 DO NOT start cleanme without reading the entre GANA bulletin on glass cleaning DO NOT use scrapers of any size or type for cleaning glass DO NOT allow dirt and residue to remain on glass for an extended period of time DO NOT begin cleaning glass without knowing if a coated surface 1s exposed DO NOT clean tinted or coated glass m direct sunlight DO NOT allow water or cleaning residue to remam on the glass or adjacent materials DO NOT begin cleamme without mnsing excessive dirt and debris DO NOT use abrasive cleaning solutions or materials DO NOT allow metal parts of cleanmeg equipment to contact the glass DO NOT trap abrasive particles between the cleammmg materials and the glass surface DO NOT allow other trades to lean tools or materials agamst the glass surface DO NOT allow splashed matenals to dry on the glass surface This buvetin was devefoped by Ihe GANA Tempenng Daision Consiucton Subcommittee and approved by te Tempering Division Standards amp Engineering Commitee and GANA Board of Directors This fs the original version of fhe document as approved and pubiished in March 2000 GANA 01 0300 4 Copynzht GANA 2000 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project profession
25. o proceeding with any glazing applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 28 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Sash Removal and Reinstallation 8 Boyd Side Load Sash Removal and Reinstall This Process is a typical side load sash removal instructions Double Hung windows must remove the lower interior sash first and then the upper outer sash Failure to follow these instructions correctly may lead to injury or damage due to falling sashes Read completely and follow for proper and correct sash removal and installation Once the window system has been properly shimmed anchored plumbed and sealed the next step is to unlock and lift the sash Lift sash to clear top of interior sill by min of 4 See Figure 1 Figure 1 Reach under sash and release balance shoe clip on left and right side Figure 2 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 29 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Balance shoe clip released for hold down Figure 3 Fig
26. offered as a supplement to the Glass Association of North America GANA Glass Informational Bulletin Proper Procedures for Cleaning Architectural Glass Products DO clean glass when dirt and residue appear DO determine if coated glass surfaces are exposed DO exercise special care when cleanme coated glass surfaces DO avoid cleaning tinted and coated glass surfaces m direct sunlight DO start cleanme at the top of the bulding and contmue to lower levels DO soak the glass surface with a clean water and soap solution to loosen dirt and debris DO use a mild non abrasive commercial window cleanme solution DO use a squeegee to remove all of the cleammeg solution DO dry all cleamme solution from window gaskets sealants and frames DO clean one small window and check to see if procedures have caused any damage DO be aware of and follow the glass supplier s specific cleamng recommendations DO caution other trades against allowing other materials to contact the glass DO watch for and prevent conditions that can damage the glass DO read the entire GANA bulletm on glass cleaning before startmeg to clean glass Gis GANA 01 0300 Copyright GANA 2000 i Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 8 of 38 Boyd Alu
27. ommercial office spaces By providing natural dayheht views of the suroundings thermal comfort and design aesthetics glass usage and condition often affect our selection of where we hve work shop play and seek education Architectural glass products must be properly cleaned durme comstruction activites and as a part of routine maintenance m order to mamtam visual and aesthetic clanty Since glass products can be penmanenth damaged if improperly cleaned glass producers and fabricators recommend strict comphance with the following procedures for properly cleanme glass surfaces As dirt and residue appear interior and exterior glass surfaces should be thoroughly cleaned Concrete or mortar shury which mms down or is splashed on glass can be especially damaging and should be washed off as soon as possible Before proceedme with cleammzg determme whether the glass is clear tinted or reflective Surface damage 1s more noticeable on reflective glass as compared with the other glass products If the reflective surface is exposed erther on the exterior or interior special care must be taken when cleamme as scratches to the reflective class surface can result m coating removal and a visible change m light transmittance Cleamng tmted and reflective glass surfaces in direct sunlight should be avoided as the surface temperature may be excessively hot for optimum cleamme Cleanme should beem at the top of the buildme and contmme to the lower levels to re
28. ould be verified by project professional Page 14 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 After Butyl Tape application peel backing off of setting block and attach to sill and jamb Locate setting blocks at industry standard 4 points but verify with glass manufacturer as shown in Step 4 and Figure 4 1 Peel and stick 1 4 x 1 x 3 710 02 04 Setting Blocks 1 4 points Place two at jambs for side blocks for proper spacing ONY RI LR POE AD Xx ISN eee oo aE 4L In swing and out swing casements must be cross blocked to prevent sag and drag of sash See figure 10 1 40 NTS 20 NTS 20 NTS 10 NTS 1 4 point 10 NTS 1 4 point BST IOI E EE IOFOTO EE EE e e a E Peel and stick 1 4 x 1 x 3 710 02 04 Setting Blocks 1 4 points Quarter Points are determined by taking the day light opening and dividing by 4 This dimension is C L for the setting block Figure 4 1 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 15 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 After the setting and side blocks have be installed the framing is ready for glass Locate the correct size color and or configuration of glass for the unit being glazed and lo
29. raming Figure 5 Figure 5 Cut Gasket square and straight Do not cut edge of gasket at comer DO NOT CUT THIS EDGE ee EITHER SIDE Make sure to cut gasket straight at 2 behind the edge of glass Do not cut edge as it is needed to turn corner of assembly Figure 6 Cut Marine Gasket 1 2 back from edge of glass Edge of glass Figure 6 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 27 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Continue with gasket around all four corners of the glass Be sure to run gasket continuously as this is needed for assembly Trim gasket 1 2 long and pull back to butt up tight against the starting edge of the gasket Figure 7 Trim gasket 1 2 long and butt together mportant Orient glass for Low e tints special coatings and glass make up as the project requires Boyd recommends that proper tools for detection of tints coating or laminates be used for field glazing and installation Attach jamb members on glass and center on glass height Place head and sill on glass and reattach assemblies with screws Figure 8 Reinstall sash in correct framing If any questions or items need to be addressed contact your nearest Boyd Representative prior t
30. s secured and controlled as dropping sashes may cause damage or injury Follow these instructions to prevent both from happening If window unit is a double hung repeat process for upper sash To reinstall sash repeat process in reverse order After sash reinstallation double check to make sure that proper adjustment and spacing in sash caps are done for proper operation of sash If you have any questions or items that need to be addressed contact your nearest Boyd Aluminum Representative prior to proceeding with any applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 32 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 9 Boyd Tilt Window Sash Removal and Reinstall This process is a typical tilt in sash removal instructions For Double Hung windows you must remove the lower interior sash first and then the upper outer sash Failure to follow these instructions correctly may lead to injury or damage due to falling sashes Read completely and follow for proper and correct sash removal and installation Once the window system has been properly shimmed anchored plumbed and sealed the next step is to unlock and lift the sash Lift sash to clear top of interior sill by minimum of 1 See Figure 1 Figure
31. ses anchor types locations and quantities should be verified by project professional Page 36 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Slide sash to center location of frame Use a phillips head screwdriver turn roller adjustment screw counter clockwise to lowest setting point to clear frame Figure 3 Figure 3 Lift sash up in head as shown in Figure 3 1 Viewed from Interior Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 37 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Tilt sash bottom to the interior to a full horizontal position Figure 4 Make sure that sash is secured and controlled as dropping sashes may cause damage or injury Follow these instructions to prevent both from happening Figure 4 Viewed from Interior After removing sash repeat these steps for the fixed panel Figure 5 Viewed from Interior Figure 5 To reinstall fixed or sliding sash repeat process in reverse order If you have any questions or items that need to be addressed contact your nearest Boyd Aluminum Representative prior to proceeding with any applications Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and fina
32. to clean masonry and many other materials are very harmful to anodized and painted finishes and should not be allowed to come in contact with the window system In the event that any does come in contact it should be removed immediately with mild soap and water Start at the top of material and soak the entire location with water and mild soap solution to remove soil and large pieces of debris Start by wiping with a non abrasive brush in a horizontal manner and then a vertical top to bottom motion Rinse cleaning materials with clean water and dry with a clean non abrasive cloth 3 2 Removal of debris and oils Cleaning of painted aluminum surfaces should be in accordance with AAMA 609 amp 610 02 Cleaning and Maintenance Guide for Architecturally finished Aluminum Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 11 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 ATTENTION Use of duct tape masking tape and similar products to painted aluminum surfaces will produce permanent adhesion of tape to the finish This adhesion will promote adhesion failure of finish to aluminum surface upon removal of the tape If protective coatings are required these should be tested prior to application and removed prior to using
33. ure 3 Push sash down to within 1 of closing completely This will push sash clips past hold down notches in frame Lift sash until balance shoe catches in frame notch Figure 4 Figure 4 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 30 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Let sash rest on clipped balances Use a phillips head screwdriver to unscrew but do not remove screw on sash cap guide Figure 5 Figure 5 After disengaging tilt sash screw slide caps to center of window This will allow sash to shift to either side for removal Lift sash off of balance shoe clips and move to side Sash can be moved to either side for removal as left side is shown for removal Figure 6 Rotate sash to inside to clear opposite frame rail for removal Figure 6 Service Manual Instructions are to be used for general informational purposes only Actual job conditions may vary and final Installation conditions processes anchor types locations and quantities should be verified by project professional Page 31 of 38 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Remove sash from frame and proceed with proper maintenance cleaning or reglazing as needed Make sure that sash i
34. ya Boyd Service Manual Lets Shine Boyd window systems meet not only our high performance standards but also those of AAMA s Certified Testing Program So whether its a C Rated AW Rated Impact Resistant or Blast and Impact systems rest assured you are receiving a proven system for your project PO Box 1565 Springfield MO 65801 1565 800 737 2800 417 862 5084 Fax 417 862 1232 Email info boydaluminum com Twitter Boyd_LetsShine 2012 Boyd Aluminum Manufacturing Company The Logo including the sunburst is a registered trademark of Boyd Aluminum Manufacturing Company All rights reserved PN 3825 968 Rev 02 2012 Boyd Aluminum Mfg Co Service Manual 3825 968 Rev 08 08 Table of Contents Glass Care and Maintenance 1 General Overview and Contact Page 4 10 1 1 General Cleaning 1 2 Glass Association of North America GANA Proper Procedures for Cleaning Architectural Glass Products Copyright GANA 2000 Document GANAO1 300 1 3 Care During Installation Finish Care and General Maintenance 2 Anodized Aluminum Cleaning and Maintenance Page 11 2 1 General Cleaning 2 2 Removal of debris and oils 3 Painted Aluminum Cleaning and Maintenance Page 11 3 1 General Cleaning 3 2 Removal of debris and oils 4 Maintenance Schedule for Windows and Sliding Doors Page 12 4 1 Quarterly 4 2 Annually 4 3 Frequently Boyd Reglazing Instructions 5 Reglazing Instructions for Butyl
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