Duralite and Duraseal Gas Filling Manual

Transcription

1 Insulating Glass Systems Duralite and Duraseal Gas Filling Manual

2 Disclaimer: Quanex provides this Gas Filling Manual as a service to customers in order to assist customers in the proper use of Quanex Dura Platform Flexible Spacers. The Gas Filling Manual is designed to give basic information on argon gas filling procedures but should not be relied upon as a manufacturing procedure. By providing this manual, Quanex does not endorse, approve, sanction, and undertake to monitor, or take responsibility for its customer s use of Quanex Dura Flexible Spacers, manufacturing processes, gas filling procedures, window design, or the products that customers manufacture. The Customer shall be solely responsible for its manufacturing processes, window design, and products, and Quanex shall have no liability or obligation therefore or arising there from. Customer shall not rely in any manner on Quanex to monitor its manufacturing processes. Quanex's recommendations, approvals, or other involvement will not alter the terms, conditions, or limitations of any agreement between Quanex and Customer.

3 Scope of this Manual This manual is designed to give customers simple, efficient and detailed recommendations on how to gas fill insulating glass units using Quanex Dura Spacer systems. To assist customers in using this manual the information will be presented in detailed sections by topic. The following sections can be found in this manual. Page 1. Introduction to gas filling. 1 a. Purpose of gas filling 1 b. Minimum hardware requirements for gas filling. 1 c. Suggested gas filling setup. 1 d. Safety warning and Disclaimer Preparation of Quanex Dura Spacer IG for gas filling Final Corner sealing (applicable to all methods) Time based gas filling. 7 a. Quanex I.G. Systems Gas Fill Wand Procedure. 7 b. Time based procedure using the FDR Oval Lance. 7 c. Parts List and Photos to Construct Sensor based argon gas filling. a. Follow the instructions of the device or equipment used. 11 b. Procedure Gas filling triple pane IG. a. Stack up methods. 12 b. Instructions specific to triples if applicable Argon gas filling units with grids Quik-Dose Gas Filling Technical Reference and Addendum a. Typical components and hardware used in gas filling 15 b. FDR oval lance 16 c. Technical Data and Conversion Factors 17 d. How do I know there is gas in my units? 17 e. Reference IG test labs 18 f. Krypton Gas Filling 19 g. Gas Filling Non-rectangular IG units 23 h. Argon gas filling charts 24-32

4 1. Introduction to gas filling. a. Purpose of Gas Filling 1. Introducing heavy gases such as argon or krypton into the air space of an insulating glass unit with low-e glass is a cost effective way of further reducing thermal transmission through the IG/Window assembly. As a result windows using gas filled IG show improved U-values over similar windows made with non gas filled IG. b. Minimum hardware requirements for gas filling. 1. In order to successfully gas fill IG units, you need an argon gas tank, a two stage pressure regulator, a flow meter capable of producing 30SCFH (14L/min), a stop watch or timer and proper hoses connectors etc. Proper IG storage racks are a must. See the Technical Reference at the end of this manual for details. 2. Gas filling machines that replace all the above except for the gas tank and regulator are sold by several vendors in this market. Please refer to the Technical Reference at the end of this manual for descriptions and sources for these items. 3. It is each customer s responsibility to make sure that gas filling equipment is used properly and calibrated to the manufacturer specifications. All connections hoses and gas filling wands or lances should be checked for leaks and/or kinks. c. Suggested Gas Filling setup. 1. The photo below gives a general idea of how to set up a gas filling system. The actual set up will vary depending on what equipment is used

5 d. Safety warning. Argon tanks contain compressed gas. All compressed gas tanks should be secured to prevent a possible fall of a tank which could result in an explosive tank rupture. Contact your argon gas supplier for specific recommendations for securing the compressed gas tanks and working with compressed gas. Follow OSHA and local requirements

6 2. Preparation of Quanex Dura Spacer IG for argon gas filling. After washing and staging the raw glass for production, the first step is to apply the spacer to the glass lite as described in the Duraseal and Duralite Application Manual. Before starting the application, ensure that the spacer has a squarely cut end. This will facilitate the final corner sealing operation and thus promote good IG unit seal quality. It is recommended that the application for gas filled units be started on the narrow side of rectangular units. Starting on the narrow side facilitates vertical racking and staging of the IG for argon gas filling and will provide a marginally higher fill %. See figure 1 Application Start Point Figure 1 For PRO tool application, start the spacer application approximately 3/8 (9.5mm) to 7/16 (11.1mm) from the glass edge for gas-filled units.use the application start guide pin (see figure 2) to obtain the correct start point location. This will ensure that a full extrusion-width final corner seal can be produced with a straight sight line. This will also enable a square final corner configuration. See figure 3. Figure 2 Figure 3 When application is finished the opening or gap between the start point and finish point should be (Filling wand thickness ) ± 0.030, or in metric (Filling wand thickness+ 0.8mm) ± 0.8mm. Acceptable gaps Figure 4 Figure 5 Figure 6-3 -

7 For units filled via Quik-Dose, follow the instructions in Section 8 for Quik-Dose & In-Line Argon gas filling, found later in this document. After application, install grids if required. Top with the second piece of glass and process through the heated roller press to the specified overall thickness. As the unit exits the press gently peel back the tail of the flexible spacer to enlarge the opening as shown in figure 7, 8, 9. This will facilitate the insertion of argon gas filling lances. Start Point Figure 7 Figure 8 Figure 9 Place the IG vertically in a rack as indicated in figure 10 or 11 for argon gas filling. Figure 10 Figure

8 3. Final corner (4 th corner) sealing (applicable to all gas fill methods). After gas filling is complete and the filling wand is removed, manually reposition the flared out tail to reduce the remaining gap. Reheat only the 4 th corner area, that is, both glass surfaces and the back of the spacer with a quartz heat lamp or hot air spot heater as shown in figures 12, 13 and 14. Keep the heat source moving around the 4 th corner area in order to prevent overheating of glass to avoid possible breakage, smoking or overheating of the adhesive sealant at the corner. The recommended temperature of the sealant/glass interface after heating should be 115 o F ± 10 o F (46 o C ± 6 o C ) in order to ensure a good butt joint seal. Do not exceed 140 o F (60 o C) as this will introduce voids that may reduce the quality of the corner seal. Do not let the temperature fall below 105 o F (40 o C) as this will not allow the adhesive sealant to self-bond. Heating of the corner area should take 7 to 15 seconds depending on ambient conditions in the factory. Periodic quality control checks of the temperature using an IR thermometer at the 4 th corner area should occur throughout the production day. See figure 15. Figure 12 Figure 13 Figure 14 Figure

9 Final corner sealing (continued) Position the Teflon sealing block in line with the starting leg of the applied flexible spacer and in the same plane as the glass surfaces. The Teflon block must be positioned so that it overlaps the line of the top layer of the starting applied length of flexible spacer by approximately 1/8 or 3mm (see Figure 16). The Teflon block should make contact with the back surface of Duraseal over the full width of the airspace (see Figure 17). If this is not possible, then, use a smaller block placed firmly to the inside of each glass surface and push twice as indicated below Apply sufficient force to flatten the corrugated shim material and fully wet the topcoats; approximately 3/16 to ¼ (5-6 mm) deformation is usually sufficient (see Figures 18 and 19). For detailed corner sealing instructions please refer to Technical Bulletin IG028. Start Point Figure 16 Figure 17 Figure 18 Figure

10 4. Time-based argon gas filling a. Quanex I.G. Systems Gas Fill Wand Procedure. 1. Ensure that the flow meters or the argon gas filling machine are set to deliver 25.4 SCFH or 12L/min of argon; a conversion factor from air is usually needed. Since there are many different types of flow meters in use, please refer to the documentation that comes with your argon gas filling set up. See figure 21 for a typical flow meter setting. The gas filling equipment supplier or the flow meter supplier should provide a calibration chart or settings that correspond to the flow rates suggested above. 2. Argon gas fill wands are available from Quanex I.G. Systems. See the order form in Section 9. Check all gas filling lances for kinks or argon leaks that may reduce argon flow. 3. Take the gas fill wand and place it into the IG unit as shown in figure 22. The wand should be inserted into the IG unit. For units with muntin bars, insert the gas fill wand as far as possible or until the first horizontal bar is reached. 4. Fill the unit for the length of time indicated on the chart in figure 20a or 20b, based on the airspace and the area (ft 2 or m 2 ) of the IG unit. For example to fill a 3ft X 2ft IG unit using ½ spacer, you calculate the area, i.e. 3ft X 2ft = 6ft 2. Then multiply 6ft 2 X 20 sec/ft 2. = 120 seconds to fill. For example to fill a 914mm X 610mm IG unit using 12.7mm spacer, you calculate the area i.e m X 0.610m = 0.56m 2. Then multiply 0.56m 2 X 22 sec/m 2 = 123 seconds to fill. 5. Once argon gas filling is complete, carefully remove the gas fill wand and set up to seal the 4 th corner. See the final corner sealing procedure in Section 3 6. Detailed gas filling time charts are available in the Technical Reference at the end of this manual. Time to Fill 1ft SCFH Air Space Time S 3/16 8 ¼ 10 5/ /8 15 7/16 17 ½ 20 9/ / /16 28 ¾ 30 13/16 33 Figure 20a Figure 21 Figure Time to Fill 0.1m 2 12L/min Air Space Time S Figure 20b

11 b. Time based procedure using the FDR Oval Lance. 1. Ensure that the flow meters or the argon gas filling machine are set to deliver 25.4 SCFH or 12L/min. Since there are many different types of flow meters in use, please refer to the documentation that comes with your argon gas filling set up. See figure 24 below for a typical flow meter setting. 2. The FDR oval lance is available from FDR Design phone (763) Part # is for mm (1/4 3/8 ) air space IG units. Part # is for 9.5 mm and up (3/8 and up) air space IG units. See the picture in the Technical Reference in Section Place the FDR oval lance as shown in figure 25 and place it into the IG unit. Ensure that the oval lance does not mark the topcoat area of any Dura product. 4. Fill the unit for the length of time indicated on the chart in figure 23a or 23b, based on the airspace and the area (ft 2 or m 2 ) of the IG unit. For example to fill a 3ft X 2ft IG unit using ½ spacer, you calculate the area, i.e. 3ft X 2ft = 6ft 2. Then multiply 6ft 2 X 20 sec/ft 2. = 120 seconds to fill. For example to fill a 914mm X 610mm IG unit using 12.7mm spacer, you calculate the area i.e m X 0.610m = 0.56m 2. Then multiply 0.56m 2 X 22 sec/m 2 = 123 seconds to fill. 5. Once argon gas filling is complete, carefully remove the gas fill wand and set up to seal the 4 th corner. See the final corner sealing procedure in Section 3 6. Detailed gas filing time charts are available in the Technical Reference at the end of this manual. Time to Fill 1ft 2 Time to Fill 0.1m SCFH Air Space Time S 3/16 8 ¼ 10 5/ /8 15 7/16 17 ½ 20 9/ / /16 28 ¾ 30 13/16 33 Figure 24 Figure 25 12L/min Air Space Time S Figure 23a Figure 23b

12 c. Construction of typical time based filling station. i. Parts list QNTY 1 (4) FLOW METERS COLE-PARMER # (2-25 l/min.) 2 (4) 1/8 NIPPLES PARKER #216P-2 3 (3) 1/8 BRASS TEES PARKER #2203P (4) 1/8 X 2 NIPPLES PARKER #215PNL (1) 1/8 FEMALE ELBOW PARKER #2200P (5) MINI SHUT OFF VALVE PARKER #PV (4) 1/4 H X 1/8 NPT PARKER #68PL (4) 1/8 STR. ELBOWS PARKER #2202P (4) ADAPTERS 5/32 X1/8 MCMASTER #5117K56, #5116K22 OR #5117K58 10 (6) ¼ HOSE x 6 PARKER #AP (4) 5/32 X 1/8 NPT ADAPT. PARKER #28-4-5/32-2 OR PARKER #28-5/32-2 ii. Illustrated assembly #9 #6 #4 #10 #7 #1 Flow Meters - 9 -

13 --Reverse-- #8 #2 #5 #3-10 -

14 5. Sensor based argon gas filling. a. Follow the instructions of the device or equipment used. 1. Sensor based argon gas filling machines need to be set up and calibrated as per the manufacturer s instructions. There are several types of sensor based argon gas filling machines that are designed for different argon gas filling techniques. Ensure that the argon gas filling machine used is designed for one-hole argon gas filling. If in any doubt please contact the manufacturer. See figure 26 for a typical sensor based machine. 2. These devices need to be calibrated and pressure balanced before argon gas filling. Ensure that a calibration procedure is performed on a schedule that meets the manufacturer s recommendations. 3. The FDR oval lance is available from FDR Design phone (763) Part # is for mm (1/4 3/8 ) air space IG units. Part # is for 9.5 mm and up (3/8 and up) air space IG units. See the picture in the Technical Reference in Section 9. b. Procedure 1. Connect the FDR oval lance to the argon gas filling machine. Make sure the gas flow line and the vacuum sampling line are correctly attached. 2. Insert the FDR oval lance into the IG as shown in figure 27. Start the gas flow. 3. When the sensor alarm sounds, wait until the alarm has stopped before removing the lance. 4. Once argon gas filling is complete, carefully remove the lance and set up to seal the 4 th corner. See the instructions for corner sealing on page 6. Figure 26 Figure 27 c. Non-conforming fill tips and lances: Truseal recommends the flat silicone or FDR fill lances detailed above to avoid damage of the topcoat. If these are not used, Quanex offers duckbill inserts for the 4 th corner to protect the topcoat from damage. Contact your Quanex Representative for more information

15 6. Gas filling triple pane IG: There are many ways to construct a triple-glazed IG, and the main requirement is to plan where you want the 4 th corner to be when filling. Note the chart describing various assembly methods below to provide that location. Method Method A (using two strips of spacer) Description of Method "Two RH tools, but one at second application height" View of bottom lite #1 Std RH trace for lite #1 View of center lite prior to assembly to first lite Top w/clear as middle, then trace on stack w/taller tool View of Step Three Top lite #3 View of Final IG and tail Negatives of Method -Second trace requires a second, special taller Pro Tool -Accuracy of topping clear lite dictates appearance of second trace -Dissimilar airspaces requires two active spools Positives of Method -Tails and corners align -Applied center lite can be flipped, pre-wiped & topped -Ease of gas filling -Easiest access to seal 4 th corner -Aesthetics are best Method B (using two strips of spacer) One standard RH tool for both traces, then "flip and top with crossed tails in single corner" Std RH trace for lite #1 Top w/clear 90º start, then std. RH trace -Corners together, but crossed -Aesthetics not as clean as A, D, E & TL, and not recommended with gray spacer -One tool -Clear center lite can be flipped, pre-wiped & topped -Easy access to seal 4 th corners -No new casters needed over typical duals installation Method C (using two strips of spacer) One standard tool for both traces, then "flip & top Lite #3 with tails in two corners" Std RH trace for lite #1 Top w/clear Std RH trace, then flip & top -More difficult access to seal one 4 th Corner -Aesthetics not as clean as A, D, E & TL, and not recommended with gray spacer -One tool -Clear center lite can be flipped, pre-wiped & topped -No new casters needed over typical duals installation Method D (using two strips of spacer) Method E (using two strips of spacer) "Use both RH & LH tools, then flip & top to match tails" One standard RH tool for both traces, but then stack and top for matching tails" Std RH trace for lite #1 Std RH trace for lite #1 Top w/clear Std RH trace LH trace, then flip & top Top w/clear -Second trace requires a second, special left hand or counter-clockwise Pro Tool -Second trace requires space for a second active spool of spacer to the right of second application operator -Cleaning bottom of second traced lite needs process -Clear center lite can be flipped, pre-wiped & topped -Tails and corners align -Ease of gas filling -Easiest access to seal 4 th corners -Aesthetics are best -Tails and corners align -Ease of gas filling -Easiest access to seal 4 th corners -Aesthetics are best Decosea l & Decosea l TL Undercut second lite is rolled into Decoseal groove -Requires stepped setting blocks -Not easily adaptable to glass over 48 square -Offset airspaces not available -Easy access to seal single 4 th corner -Aesthetics are best -One (versus two) corners to seal

16 7. Argon gas filling IG units with Grids a. All time-based gas fill procedures in this manual are suitable for gas filling IG with grids. However very small units 15 and under using grids with depth near the airspace may benefit from doubled gas fill times in the timer fill methods. i. The volume of the grid hollow will not initially be filled, and will reduce the final fill percentage via diffusion. ii. It is recommended that customers who gas fill IG unit with grids employ the services of a testing lab that can test and report the %gas fill in their units. A list of such labs can be found in the Technical Reference. iii. For sensor based gas filling, please contact the supplier of the gas filling equipment for recommendation on gas filling units with grids. 8. Quik-Dose In-Line Argon gas filling. a. For units filled via Quik-Dose the start point should be (10.7mm) to (12.2mm). The opening after application is complete should be (3.0mm 4.5mm). b. Quik-Dose operators should refer to the equipment documentation in the Quik-Dose user s manual for operating maintenance and calibration procedures. c. This document details the correct procedures for IGUs made with Quanex Dura Spacers when argon filled in-line, using the Besten Quik-Dose equipment. Figure 28 Figure 29 Figure 30 In General, the Process Steps for a steady production cadence are: Heat Press, Argon Dose, Flash Liquid Argon, Corner Seal Bond Heated Press Exit: Units are to exit the heat and compression equipment with the spacer s bond line sealant temperature at 110 F-120 F (43 o C- 49 o C). The open corner is to have a gap of ±.031, or 4.8mm ±0.8mm

17 Argon Dose: Properly pressed units upon press exit, are to immediately be placed onto the Quick Dose equipment and the machine cycle started. Liquid argon must enter the cavity of the unit in an uninterrupted stream. Note: If liquid argon comes in contact with the glass or flexible spacer at the corner opening and produces visible condensation, this area will need to be re-warmed with a heat lamp until all condensation has dissipated. Then proceed with sealing. Additionally, the machine should be adjusted to place the spacer gap in the desired position relative to the stream or the dosing head. Proper and consistent corner details are critical. Flash Liquid Argon: After the argon has been completely dosed and then flashed or vaporized (no venting of gas is noted at the open corner), the unit is nearly ready to be sealed. It is recommended to wait about 2 seconds after flashing ends in order to ensure that the cavity volume of the IGU has normalized with the plant atmospheric conditions. This assumes that steady state IG production is being run and that the bond line sealants in the corner area are still within an acceptable range of 40ºC to 49ºC ( F) for sealing; this will typically take about 3 times the unit s net dosing time, a subset of the full dosing cycle. The goal is to close the final corner at the correct temperature as soon as you can, with sealing done as soon as possible after the flashing step is completed. Seal: To seal the corner the Dura Spacer s bond line sealant temperature must be a minimum of 104 F/40ºC. Seal the IGU while it is vertical and on the machine. If the butyl mastic of the flexible spacer is below the recommended temperature of 104 F/40ºC for any reason (delays, messy dosing, etc.), the corner area will need to be reheated using an IR lamp heater to between 115ºF to 140 F (46ºC to 60ºC ) as noted on page 6 of this manual. Complete the sealing process by following the procedure found on page 6 of this manual. For detailed corner sealing instructions please refer to Technical Bulletin IG028. In no case should a unit be left open for more than 30 seconds after the flash is complete. If that occurs the operator should; Have a heat lamp ready to reheat the corner if the bond line cools below 105ºF/40ºC or 30 seconds has elapsed. If the corner is left open too long and a concern develops about the gas fill %, the unit can be reworked by staging for 5 minutes and recycling through the four major process steps listed above

18 9. Technical Reference and Addendum a. Typical components and hardware used in gas filling. Sources are given where known. Flow Meters Cole Parmer, Inc PART N (Brass) N (Aluminum) DESCRIPTION: 65 MM FLOW METER Argon Supply King Instrument Company (714) Porter Instrument Co. (215) Specify flow meters for use with Argon Gas. Argon can be purchased through a local welding supply company or gas supplier. Most of these companies will also be able to supply an argon gas regulator as well as flow meters. A two gauge regulator is required for use with argon gas filling set ups. On off valves and solenoids A manually operated petcock can be used between the second gauge and the meter manifold. A stopwatch should then be used to time the gas flow. Timer Supplier Automatic Timing & Control Electrosonic, Inc or (215) US Canada Control Valve Suppliers Parker Hannifin: Contact Local dealer Clippard Fluid Power (513) When ordering the Timers and Valves, specify your use and power supply available. The Timer signals the valve to open (a normally closed valve is required). When the timer has completed its cycle, it then signals the valve to close

19 b. FDR oval lance The FDR oval lance is available from FDR Design phone (763) Part # is for mm (1/4 3/8 ) air space IG units. Part # is for 9.5 mm and up (3/8 and up) air space IG units. See the picture in the Technical Reference in Section

20 c. Technical Data and Conversion factors Gas filling requires familiarity with units of length area and volume and volume flow rate. Some conversion factors are provided below. Volume Flow Rate 1 SCFH = L/min 1 L/min = SCFH Area 1 ft 2 = m 2 1 m 2 = ft 2 Length 1 in = 25.4 mm 1 mm = in 1 ft = m 1 m = ft Volume 1 ft 3 = m 3 1 m 3 = ft 3 1 ft 3 = L 1 L = ft 3 d. How do I know there is gas in my units? i. Argon gas can be detected and quantitatively analyzed by several methods. 1. Quanex recommends that producers filling with argon source and maintain a calibrated SES device (Spark Emission Spectrograph) such as Gasglass from Sparklike

21 e. Laboratories The list below is taken from the NFRC web site. However it is by no means an exhaustive list of all available test labs. Please contact the labs listed below to discuss your argon gas program. Air-Ins, Inc Boul. Lionel-Boulet Varennes, Quebec J3X 1P7 Telephone: 450/ Facsimile: 450/ Contact: Gilbert Riopel Architectural Testing, Inc. 130 Derry Court York, Pennsylvania Telephone: 717/ Facsimile: 717/ Contact: Michael Thoman Architectural Testing, Inc East Jensen Avenue Fresno, California Telephone: 559/ Facsimile: 559/ Contact: Leaton Kirk ETC Laboratories, Inc. 297 Buell Road Rochester, New York Telephone: 585/ Facsimile: 585/ Contact: Gurjinder Dhami National Certified Testing Laboratories, Inc. 5 Leigh Drive York, Pennsylvania Telephone: 717/ Facsimile: 717/ Contact: Robert Zeiders Quality Testing, Inc Hill Avenue Everett, Washington Telephone: 425/ Facsimile: 425/ Contact: Randy Van Voorst, Marles McDonald Architectural Testing, Inc. 849 Western Avenue North St. Paul, Minnesota Telephone: 651/ Facsimile: 651/ Contact: Daniel Johnson, Michael Research

22 f. Krypton gas filling: Time filling w/krypton: The following are general guidelines that we can offer on krypton time-filling, including some comments as to how it relates to argon-filling: i. First, the Quanex time-fill methods and the supporting fill times that are in this manual in Section 4 are based on a fill-factor of 350% for argon, to give a good initial fill. This fill factor yields fill levels above 90%, but typically in the 93-95%. This means that 250% more argon is used than the IG s internal airspace volume, to be sure that we have floated most of the air out, and left only 5-to-7% of air mixed with the argon fill gas. ii. Given krypton s greater expense, fill methods must be done at lower flow rates to mix less, and settle better to the bottom of the IG. It is wasteful of the krypton to use it excessively to get the last of the initial volume purged completely. The rationale is to get a lower fill factor than the 350% used with the inexpensive argon elsewhere in this manual. Analysis of sensor-filling has shown that fill-factors can be dropped to about 140% at one-quarter the flow rate. We recommend that the krypton flow rate be at or near 3 lpm when filling into the initially air-filled voids, rather than the flow rates of 12 lpm. iii. It is important that krypton fill lances are recommended to be full-length and get to the bottom of the IG, to also avoid the unnecessary risk of mixing krypton with air too much. Top-filling with short lances kept right at the 4 th corner is a practice that works well with inexpensive argon at higher flow rates, but will be cost prohibitive with krypton. Time to Fill 1ft 2 6.4SCFH Air Space Time S 3/16 13 ¼ 17 5/ /8 25 7/16 28 ½ 33 9/ / /16 46 ¾ 50 13/16 55 Time to Fill 0.1m 2 3L/min Air Space Time S

23 iv. Filling directly with krypton into an air-filled cavity will result in a krypton/air mix, likely at 90%/10% as a rough initial estimate. The customer should model this ratio, as well as the ratio with 80%/20% in a krypton/argon blend to note the relative relationships of these to values. The two may be very close in a finished product. Some users have considered first time-filling with argon from the recommended rates and times, and then topping off as a second step with the krypton. This trade-off of added labor could justify the 25% savings in krypton. These initial argon fills again are based on 350% of volume at 12 L/min. Then, as the next step, time fill with only a 1X volume of krypton, considered strictly by flow. This adjustment to our fill times would be as follows: 1. First-fill with argon at the posted times and 12 lpm, then 2. Top with krypton at 3 lpm and a fill-factor of 1.0 Fill times for topping with krypton and a 100% fill-factor over argon pre-filled units: Time to Fill 1ft 2 6.4SCFH Air Space Time S 3/16 9 ¼ 12 5/ /8 18 7/16 21 ½ 24 9/ / /16 32 ¾ 35 13/16 38 Time to Fill 0.1m 2 3L/min Air Space Time S

24 Two-hole FDR sensor filling w/krypton: This technique should only be used where the access for the long silicone wand cannot be fed past the grids in a very narrow airspace, typically triple-glazed IGU. It is preferred that offset triple-glazed design be used to facilitate easy, single hole access of the krypton fill wand or lance with grids in the larger cavity, but if this cannot be done, a solution is as follows: i. Apply Duralite spacer to generate a nominal fill gap of 1/8 gap ± (for later access of the flattened oval sniffler lance (.200 w x.125 high), which is the tip from FDR part #11697). ii. Assemble and press the triple-glazed IG in the normal fashion, then rack for krypton filling, 4 th corner-up. iii. Prep Kr fill-lance hole in the valley of a Duralite corrugation ~2 from the bottom of the IGU: a. Drill a 5/64 hole using a tapered bit of the same size and with a centering guide or bushing in each of the two cavities (assuring centered holes at a valley of the corrugated PC shim) iv. Fill each of two cavities with two-lance FDR gas-fill technology: a. Insert.073 (1.8mm) Kr fill lance at the lower hole b. Insert the flattened oval sniffler lance (.200 w x.125 high) with vertical positioning clamp in the open 4 th corner c. Initiate the fill cycle v. Sealing the lower, drilled krypton fill hole a. Remove fill lance b. Apply a small volume of the black Tremco polybutene sealant to fill the shim valley with the hole, and use caution not to apply too much sealant pressure to drive sealant inward into the vision area. c. Position a #2-32 x 3/16 type AB screw onto a magnetic Phillips #0 bit, and insert screw into the sealant, centered in the valley d. Seat the screw with hand pressure and use the protrusion of the screw (>0.040 ) and visibility of the sealant on the screw as visual cues of the seal. e. Cover the installed screw with another dab of the same polybutene sealant over the screw head. vi. Repeat steps #4 & #5 for the second cavity in whatever order proves most beneficial for cycle time balancing This completes the special process vii. Remove sniffler and close the top openings of both cavities sequentially, only after both cavities have been filled and sealed as above. a. Use the standard closure detailing from the Dura Spacer manual, Section 3, pages 7 & 8 (heat lamps and Teflon sticks)

25 g. Gas filling non-rectangular units Gas filling of non-rectangular IG units follows the same guidelines as for rectangular units set out in Sections 4 and 5. Some formulas that calculate the area of various shapes are found below. Use the charts labeled Figure 20 a or b and Figure 23 a or b to determine the gas filling time based on the area of the IG The position of the final corner seal on rectangular round top and on half round units will be on the bottom. Make sure that the wand or probe can be used properly with these units. Full circle and ellipses require a different corner sealing procedure that can be found in Duraseal/Duralite manual. Dura Products not recommended for gas-filling Dura Products not recommended for gas-filling Area calculations Area of a Circle = πr 2 for a half round πr 2 /2 Area of an ellipse (simplified) = (π*long axis*short axis)/4 Area of a triangle = (L X W)/2-23 -

26 h. Argon Gas Filling Time Filling Charts Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 6.4 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

27 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 8.0 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

28 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 9.5 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

29 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 11.1 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

30 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 12.7 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

31 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 14.3 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

32 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 15.9 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

33 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 17.5 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

34 Chart for in Pane Spacing Seconds to fill at 12 L/min 25.4 SCFH 19.1 mm Fill factor 3.5 Inches Inches mm mm TIME CHART FOR ARGON GAS FILLING

35 For additional product information, visit Quanex IG Systems 800 Cochran Avenue Cambridge, OH T F Quanex Building Products REV 01/2014