PROCESSING GUIDELINE for the manufacture of insulating glass · PDF filePROCESSING GUIDELINE for the manufacture of insulating glass ... preparation of ECONTROL laminated glass 4 2.1

ECONTROL®

PROCESSING GUIDELINE

for the manufacture of

insulating glass

EControl-Glas GmbH & Co. KG

Otto-Erbert-Straße 8

08527 Plauen

Phone: +49 (0) 3741 148 20 – 261 / -100

Fax: +49 (0) 3741 148 20 150

E-mail: [email protected]

www.econtrol-glas.de

Version: 2.3

mailto:[email protected]

Author Date Version Date Released Page Document no.

Dr. Jödicke 03.02.2010 2.3.1 06.02.2017 Dr. Jödicke 2/34 EC_ISG\DOCU02

1 Table of contents

1 Table of contents 2

2 Delivery, storage, preparation of ECONTROL® laminated glass 4

2.1 Terms and definitions 4

2.2 Delivery, storage 5

2.3 Accompanying documents 6

2.4 Test report 7

2.5 Marking the ECONTROL® laminated glass units 8

2.6 Marking the ECONTROL® insulating glass units 8

2.7 Preliminary cleaning of the ECONTROL® laminated glass 8

3 Provision of the counter pane (with low-e coating) 9

3.1 Quality and selection of the counter pane 9

3.2 Edge stripping 10

4 Spacer production 11

4.1 Spacer materials 11

4.2 Positioning the spacer 11

5 Washing the counter pane and the ECONTROL® laminated glass 12

6 Butyling of the spacer 13

7 Fixation of the spacer on the ECONTROL® laminated glass 13

8 Joining and pressing the ECONTROL® laminated pane to the counter pane 15

9 Connection technology (cable harness) 15

9.1 Appearance and shape of the cable harness 15

9.2 Assignment and colour coding 18

9.3 Positioning the temperature sensor 20

10 Connection technology: Attaching the cable harness 22

10.1 Attaching the butyl adhesive strip 22



10.2 Soldering the positive contact 23

10.3 Soldering the negative contact 24

10.4 Fixing the connection cable and the temperature sensor 25

10.5 Test of the temperature sensor and the connections 27

11 Insulating glass adhesive 28

11.1 Material selection regarding the insulating glass adhesive 28

11.2 Performance 28

12 Gas filling 30

13 Packaging, transportation, storage, shipment 31

13.1 In-house transportation 31

13.2 Storage 31

13.3 Packaging and shipment 31

This processing guideline describes the individual steps for the manufacture of ECONTROL® insulating

glass with ECONTROL® laminated glass panes.

This processing guideline is based on the process of a normal insulating glass production for the manu-

facture of solar control insulating glass units and heat protection insulating glass units. It describes, in

particular, the process steps deviating from the standard process, which must be considered for the

manufacture of ECONTROL® insulating glass units.



2 Delivery, storage, preparation of ECONTROL® laminated glass

2.1 Terms and definitions

EControl-Glas provides the insulating glass manufacturer with a laminated glass, which is referred to as

either EC9 or EC11 - depending on the total thickness. Each ECONTROL® laminated glass consists of

2 glass panes, which are interconnected with a conductive film (1 mm thick):

EC9 4 mm glass / 1 mm film / 4 mm glass

EC11 6 mm glass / 1 mm film / 4 mm glass

The ECONTROL® laminated glass has a step of 4 mm at one of the two narrow edges. At this step, the

two contact tabs (so-called Polyflex contacts) protrude.

The positions 1 and 4 are uncoated float glass surfaces.

The ECONTROL®

laminated glass has 2 circumferential

seals. Together, the two seals have a width of 8 mm on

the step edge and a width of 12 mm on the other edges

The external visible seal is a sealant made of Polyisobu-

tylene, PIB, (in the insulating glass industry simply re-

ferred to as “butyl”). The second internal sealing com-

pound is transparent.

As a rule, EControl-Glas delivers the sealed ECON-

TROL®

laminated glass with an edge cover to the insulat-

ing glass manufacturer. This edge cover consists of a

dark green PET adhesive tape. The adhesive tape pre-

vents the carryover of butyl sealing compound to the

machines of the insulating glass manufacturer.

Figure 1: Schematic structure of the ECONTROL®

laminated glass [EC9] with the dimensions of the

step edge (4mm), seals, glass thicknesses (here: 4

mm in each case); Polyflex contacts at the step edge

step edge: 4 mm

4 4

4 mm

4 mm

6 mm

4 mm

8 mm

sealant „butyl“

transparent

sealant

conductive

polymer film

sealant „butyl“

transparent

sealant



Attention!

The ECONTROL®

laminated glass units must always be put down, stored or transported in such a way

that the step edge is never the standing edge. Otherwise, there is the risk of damaging the contact tabs.

Depending on the requirements or preferences of the customer, the ECONTROL® laminated glass can

be refined with another glass pane and PVB film to form an ECONTROL®

laminated safety glass.

2.2 Delivery, storage

ECONTROL®

laminated glass units are delivered to the customer in the following condition: on glass

racks, wrapped in black film1, heat-sealed, packed on wooden frames or crated.

Attention!

ECONTROL®

laminated glass units on glass racks must not be stored outdoors. Direct sunlight to the

ECONTROL®

laminated glass units (with or without partial shading) must be avoided by all means.

Attention!

ECONTROL®

laminated glass units on racks without lightproof film may only be transported in closed

trucks.

Basically, EControl-Glas delivers the ECONTROL®

laminated glass units in bright (decoloured) state to

the insulating glass manufacturer.

In addition, EControl-Glas provides the insulating glass manufacturer with all cable harnesses required

for the manufacture of the ECONTROL® insulating glass units. A testing device for determining the cor-

rect polarity (ISOPOL testing device) and associated insulating glass test reports are also provided by

EControl-Glas.

The scope of supply of EControl-Glas includes:

ECONTROL®

laminated glass (one or more)

Cable harness

Butyl strip (for fixing the cable harness to the spacer)

Heat shrink tube

ISOPOL testing device (item on loan2)

1 EControl-Glas uses the following film type: Stretch film HSC standard, 20µm, black (cast film, adhesion

inside); supplier: Antalis Verpackungen GmbH; http://shop.antalis-verpackungen.de; other suppliers are possible



Insulating glass test reports (as an Excel document by mail)

Model drawings (by mail) with marked cable outlet and the position of the temperature sensor

Shipping documents: Rack accompanying certificate3 and/or delivery note

The insulating glass manufacturer provides the following materials: Counter pane, spacer, noble gases,

primary butyl (polyisobutylene), sealing (polyurethane, polysulphide or silicone adhesive), materials and

equipment for soldering the cable harness.

2.3 Accompanying documents

Each delivery of ECONTROL®

laminated glass units includes the test

report with the written information in the form of the following table.

The table shows the EC pane number, dimensions (width x height in

mm), structure and customer or order. Furthermore, a model sketch is

enclosed in case of deviations from the standard structure (see Sec-

tion 9 - Connection technology (cable harness)). In preparation for the

insulating glass manufacture, such information is sent to the manufac-

turer by mail in advance.

Figure 2: Model sketch with marked step edge (yellow) and

specified position of the temperature sensor “T” (bottom)

2 EControl-Glas asks to return the ISOPOL testing device upon completion of the manufacture of the

insulating glass units. 3 One copy of the rack accompanying certificate is attached to the delivered rack and contains informa-

tion on the delivered ECONTROL® laminated glass panes: Pane numbers, order numbers, name of the

customer or commission, number, dimensions, date etc.



2.4 Test report

EControl-Glas requires the insulating glass manufacturer to test the ECONTROL® insulating glass. The

test must be performed after laying and soldering the cable harness, but before carrying out the sealing

process. For the test, EControl-Glas provides the insulating glass manufacturer with the testing device

ISOPOL on loan.

The testing device ISOPOL answers the following questions:

Is the polarity of the cable harness correct?

Does the temperature sensor provide a plausible value?

Is the total resistance of the ECONTROL®

laminated glass within the plausible range?

If the polarity is correct and the measured values are plausible, a green indicator light is illuminated on

the ISOPOL testing device and a 6-digit checksum is shown on the display. This checksum must be

entered manually in the form Test report.

If the polarity is reversed, or the measured values for the temperature sensor or the measured values of

the total resistance are not within the plausible range, the indicator light on the ISOPOL testing device is

illuminated in red.

Further information are provided by EControl-Glas in the operating manual of the ISOPOL testing device.

Figure 3 shows an example of a test report that contains the following information:

Order number, customer, commission

Item number, dimensions, pane number

Measured values Ip, Im and R (are shown on the display of the ISOPOL testing device)

Checksum (is also shown on the display of the ISOPOL testing device)

Comments, date

Name and signature of the tester

Figure 3: The completed insulating glass test report must be returned to EControl-Glas by fax to:

03741 148 20-150 and/or e-mail to: [email protected]

mailto:[email protected]



2.5 Marking the ECONTROL® laminated glass units

ECONTROL®

laminated glass units are marked with an EC pane label on the side directed towards the

outside in the insulating glass (position 1) between the contact tabs. The EC pane label contains the

information on order number, item number and pane number as well as the dimensions [in mm].

Figure 4: Sample of an EC pane label with company logo, dimensions, customer name (here:

sample), pane number (here 20000_1_1) and Data Matrix Code. The first five digits correspond to

the order number (20000). Then, the item number (_1) and the serial pane number (_1) are shown.

2.6 Marking the ECONTROL® insulating glass units

The insulating glass manufacturer is responsible for the information given on the pane label of the fin-

ished ECONTROL®

insulating glass. The pane label contains: Commission, customer name, order num-

ber, item number, pane number and information on the pane size.

Attention: (see also figures in Section 13.3; Packaging and shipment)

The label and the note “Inside” must be affixed to the inner pane (counter pane) of the insulating glass

in order to avoid shadowing effects on the ECONTROL®

laminated glass.

It is not allowed to affix labels to the outside (position 1) of the ECONTROL®

insulating glass.

2.7 Preliminary cleaning of the ECONTROL® laminated glass

Before starting the production of the ECONTROL®

insulating glass, strongly adhering contaminants (e.g.

edge sealing material) on the ECONTROL®

laminated glass must be removed using suitable aids.

Edge sealing residues on the ECONTROL®

laminated glass and along the edges must be carefully re-

moved using a razor blade (or other suitable aids).

Attention: There is the risk of damaging the glass surfaces by scratching!

During the manufacturing process concerning ECONTROL®

insulating glass, the EC pane label (see

Figure 4) must remain on the ECONTROL®

laminated glass. The EC pane label and its lettering are

waterproof and suitable for standard glass washers.



3 Provision of the counter pane (with low-e coating)

3.1 Quality and selection of the counter pane

Regarding its quality (glass thickness, toughened safety glass, heat-strengthened glass, laminated

safety glass, emissivity), the counter pane can, basically, be freely selected according to the technical

regulations of the insulating glass production. The insulating glass manufacturer is responsible for the

quality of the counter pane. In general, the insulating glass manufacturer can freely select the manufac-

turer of the counter pane (PILKINGTON, GUARDIAN, TRÖSCH, AGC-INTERPANE, SAINT-GOBAIN

and others). However, if the end customer wants a defined counter pane, EControl-Glas passes this

request on to the insulating glass manufacturer (obligatory).

For the selection of the counter pane, the requirements of the customer, the structural engineers and the

relevant building regulations must be observed.

The standard structure of the insulating glass laminate provides for the use of 4 mm float glass with a

low-emission coating (low-e coating) with an emissivity εn ≤ 0.04, a black spacer for a gap between inner

and outer pane of 16 mm and a gas filling with argon.

The insulating glass manufacturer is solely responsible for ensuring the required Ug values pursuant to

DIN EN 673.

If deviating structures are produced (gap between inner and outer pane, gas filling, glass thickness,

glass type, εn), the technical values (Ug values and g values in particular) must be checked according to

the standards DIN EN 673 and EN 410 and corrected, if necessary.

Comment: For the useful operation of an ECONTROL® insulating glass pane, the counter pane must

definitely be provided with a low-e coating. Without this low-e coating, the variation of the g value is low.

As a result, the sun protection function is insufficiently fulfilled in dark state. An ECONTROL® insulating

glass without low-e coating does not meet the specification of EControl-Glas.



3.2 Edge stripping

The insulating glass manufacturer is responsible for performing the edge stripping of the low-e glass

units used. The edge stripping of the low-e coatings is necessary to avoid corrosion of the silver-based

coatings that is caused by air (oxygen and/or moisture). If no edge stripping is performed, the low-e

coating may corrode (starting at the edges). As a result, the adhesion to the insulating glass adhesive

and the butyl seal is reduced. This may lead to the destruction of the insulating glass laminate.

Figure 5: Schematic representation of insulating glass constructions with different depths of the

edge stripping of the low-e counter pane: on the left with 10 mm edge stripping, on the right with

13 mm edge stripping; the edge stripping of a depth of 10 mm corresponds to the minimum re-

quirement by EControl-Glas

The edge stripping of the low-e glass must be at least 10 mm all round. For the production of insulating

glass with EControl laminated glass, EControl-Glas recommends to make an edge stripping at such a

depth that the dividing line between low-e coating and decoated zone is approximately centrally below

the primary seal (butyl, polyisobutylene) - see Figure 5. At a depth of the spacer of 6 mm, an edge

stripping of 13 mm is optimal.

For information on the exact positioning of the spacer, see the following section 4.2

16 mm

16 mm

Arg

on

16 mm

4 4

2 m

m4

mm

co

unte

rp

ane

with

low

-e c

oatin

g

13

mm

13

mm

16 mm

16 mm

Arg

on

16 mm

4 4

2 m

m4

mm

co

unte

rp

ane

with

low

-e c

oatin

g

10

mm

10

mm

primary sealant

Butyl, Polyisobutylen

low-e-

coatingspacer



4 Spacer production

4.1 Spacer materials

Materials made of metal (stainless steel and aluminium), plastic and metal/plastic combinations can be

used as spacers.

The use of thermoplastic spacers (TPS) is forbidden and not approved by EControl-Glas.

The standard structure provides for a spacer made of stainless steel in a width of 16 mm. Deviations

relating to the dimensions of the spacer are possible. However, such deviations have to be checked by

the insulating glass manufacturer regarding the practicability of the connection technology (see Section

9) und the influence on the Ug value. EControl-Glas recommends the use of black spacers.

4.2 Positioning the spacer

The spacer must be positioned in such a way that it overlaps the transparent edge sealing at the step

edge by approx. 2 mm in the edge area of the ECONTROL® laminated glass (see Figure 6: red circles).

For this, the all-round distance from the inner edge

of the spacer to the glass edges must be 16 mm. On

the non-step edges, the overlap of the spacer to the

transparent edge sealing is 4 mm.

Attention:

The insulating glass manufacturer is responsible for

the correct dimensioning of the spacer.

Figure 6: Dimensions of the ECONTROL® lami-

nated glass [EC9] and insulating glass with in-

formation on the step edge [4 mm], width of the

sealing compounds and position of the spacer at

a typical depth of 16 mm; red circles: covering of

the transparent seal of the ECONTROL®

lami-

nated glass with the spacer.

16 mm

16 mm

Arg

on

16 mm

4 4

2 m

m4

mm

co

unte

rp

ane

with

low

-e c

oatin

g

13

mm

13

mm

step edge: 4 mm



5 Washing the counter pane and the ECONTROL® laminated glass

The counter pane is edge-stripped and washed according to the instructions of the manufacturer or the

supplier.

The ECONTROL® laminated glass is placed - with the step edge - in such a way on the inlet section of

the washer that the step of the ECONTROL® laminated glass is directed towards the inside to the gap

between inner and outer pane in the insulating glass, and that the Polyflex connections are arranged

against the running direction of the washer (see Figure 7). Otherwise, there is the risk of damaging the

connections during the washing process.

The ECONTROL® laminated glass can be washed just as ordinary laminated glass.

Figure 7: Direction for the entry of the ECONTROL® laminated glass into the washer.

IMPORTANT:

During the washing process, attention must be paid to the correct position of the step edge and the Poly-

flex connections: see sketch in Figure 8.

The EC pane label with the EC serial number remains on the laminated glass during the washing proc-

ess.

After the ECONTROL® laminated glass has passed through the washer, the ECONTROL

® laminated

glass must be dried. Subsequently, the step edge must be free of water drops. If this is not the case,

adhering drops must be removed manually using an absorbent cloth.

washing

maschine

ECONTROL

laminated pane

attention!

Polyf lex

connections are

arranged against

the running

direction of the

washer



6 Butyling of the spacer

The butyling of the spacer is performed according to the plant configuration and is the responsibility of

the insulating glass manufacturer.

With regard to the ECONTROL® laminated glass, the following particularities must be considered when

butyling the spacer.

The butyling must be applied all round and without interruption(s) to both sides of the spacer. It has

to be complied with the system description of the licensor.

The butyling is performed with the thermoplastic resin polyisobutylene (PIB). In everyday speech, this

plastic is referred to as butyl. EControl-Glas recommends polyisobutylene by FENZI or Kömmerling.

The plastic polyisobutylene (PIB = butyl) is also referred to as insulating glass sealant and fulfils the func-

tion of sealing the gap between inner and outer pane to the environment (if performed correctly) since

the permeability of water vapour, noble gases or air is very low. The terminological counterpart to the

insulating glass sealant is the insulating glass adhesive. The insulating glass adhesive may be made of

polysulphide, polyurethane or polysilicones and has - compared to the insulating glass sealant PIB - a

significantly reduced sealing function, but a significantly increased adhesive function.

When using insulating glass adhesives based on silicones for a UV-resistant edge compound (e.g. Dow

Corning 3362 or Kömmerling GD 920), special attention must be paid to the quality of the spacer butyling

since silicone adhesives have a high gas permeability for noble gases such as argon and krypton.

7 Fixation of the spacer on the ECONTROL® laminated glass

When fixing the spacer, it must be ensured that it is positioned on the smaller pane of the ECON-

TROL® laminated glass in such a way that the transparent sealing tape at the inner edges is completely

covered (see Figure 8, red circles).

For information on the dimensions of the spacer, see chapter 4.

Attention:

After positioning the spacer and pressing it into position, the transparent sealing tape of the ECON-

TROL® laminated glass must no longer be visible. Due to the fact that the area of the transparent seal-

ing tape is not dimmable, a bright streak would otherwise be visible on the finished insulating glass from

the outside when the ECONTROL® insulating glass is coloured.



Attention:

Attention must be paid to an accurately fitting positioning.

Attention:

The spacer must always be positioned on the smaller glass pane of the ECONTROL® laminated glass.

Figure 8: Fixation of the ECONTROL® laminated glass: The

distance from the inner edge of the spacer to the edges of

the larger glass pane is always 16 mm. The overlap of the

spacer to the transparent sealing compound is to be at least 2

mm (red circles) 16 mm

16 mm

Arg

on

16 mm

4 4

2 m

m4

mm



8 Joining and pressing the ECONTROL® laminated pane to the counter pane

The joining and pressing of the ECONTROL® laminated glass and the counter pane is performed ac-

cording to the specification of the insulating glass manufacturer.

Attention:

It must be ensured that the ECONTROL® laminated glass and the counter pane are always placed in

such a way that - after the bonding - the step edge of the ECONTROL® laminated glass is directed to-

wards the gap between inner and outer pane, i.e. towards the inside. The EC pane label (see Figure 4)

with the EC pane number is located on the outside on position 1.

Attention:

Further labels may only be affixed to the inside of the ECONTROL® insulating glass! Labels on the out-

side of the ECONTROL® insulating glass result - when exposed to the sun – can lead to colour differ-

ences in later operation.

9 Connection technology (cable harness)

9.1 Appearance and shape of the cable harness

EControl-Glas uses 2 different types of cable harnesses (see Figure 9):

GV 07 “Small” plug with “thin” cable

SVG 04 “Large” plug with “thick” cable

For each insulating glass to be produced, EControl-Glas defines the type of the cable harness depend-

ing on the glass dimensioning and the length of the pane cable (cable from the insulating glass to the

control unit).

The cable harness with the “small” plug is symmetrical. Thus, there is no reverse polarity protection. In

order to distinguish the front from the back, however, one side is marked with a white dot (see Figure 9

left).

The “thick” plug is not symmetrical. It has 2 different sides. Thus, there is a reverse polarity protection

regarding the “thick” plug.

In general, i.e. for most applications, EControl-Glas uses the cable type SVG 04. However, in some spe-

cific cases, the cable type GV 07 must be used.



Figure 9: Cable (white) with 2 different plugs, front and back in each case; the “small” plug is

symmetrical regarding front and back; one side is marked with a white dot for distinction (left);

the front and back of the “thick” plug are different; thus, there is a reverse polarity protection

regarding the “thick” plug

The cable harnesses of both types consist of a 4-wire cable with white cable sheath and a 4-pin plug

(see Figure 10), which is preassembled by EControl-Glas and delivered to the insulating glass manufac-

turer both suitably for the respective ECONTROL® laminated glass pane and in coiled form.

Figure 10: Coiled cable harness of suitable length with plug and labelling with information (order

number, name of the customer, dimensions of the ECONTROL® laminated pane)

blackplug with yellow

protecting cap

blackplug with yellow

protecting cap and whitepoint

blackplug mit yellow

protecting cap and whitepoint

labeling with data: job account

number, name of customer, sizes/dimensions ofECONTROL®-laminated pane

4-wire cable with white

cable sheath and a 4-pin plug



The cable harness with its 4-wire cable is

partially stripped. The part that is not stripped

has a length of 20 cm. With regard to the

finished insulating glass, 15 cm of the 20 cm

are outside the insulating glass adhesive and

5 cm are inside the insulating glass adhesive.

The border is marked with a black line (see

Figure 11).

Figure 11: Uncoiled cable harness with

“small” plug and the black mark

The temperature sensor is soldered with a grey connection cable to the green and yellow wire and

protected by two heat shrink tubes (see Figure 12). Figure 13 shows the end of the cable harness with

the temperature sensor (red circle).

Figure 12: Middle part of the uncoiled cable harness with the 4 colour-coded wires and the sol-

dered grey connection cable to the temperature sensor

4-wire cable without white

cable sheath

red and black wire for the

power supply ofECONTROL®-laminatedpaneconnection to the temperatur-

sensor (yellow and green wire) with heat shrink tube (black)

cable (grey) for the

temperature sensor

blackplug mit yellow protecting

cap and white point

4-wire cable

with colourcode

black line as a

mark

5 cm of white cable

disappearwithininsulating glass adhesive

15 cm of white cable lie outside

of insulating glass adhesive



Figure 13: Uncoiled cable harness with the temperature sensor (small bulge within the black heat

shrink tube)

9.2 Assignment and colour coding

The colour coding of the 4 individual cable wires is different for both cable harness types:

GV 07

“Small” plug with “thin” cable

SVG 04

“Large” plug with “thick” cable

red Positive contact white Positive contact

black Negative contact brown Negative contact

green Temperature sensor green Temperature sensor

yellow Temperature sensor yellow Temperature sensor

The red and black wire of the “thin” cable harness GV 07 (or the white and brown wire of the “thick” cable

harness SVG 04, respectively) are provided for the power supply of the ECONTROL® laminated glass.

The cross-sections of the individual wires and the total cross-section are different for both cable harness

types:

heat shrink tube

(black)

cable (grey) to the

temperatur-sensor

temperatur-sensor



GV 07

“Small” plug with “thin” cable

SVG 04

“Large” plug with “thick” cable

Cable cross-section

of single wire

0.14 mm² Cable cross-section

of single wire

0.25 mm²

Total cable cross-

section

3.2 mm Total cable cross-

section

4.0 mm

Attention:

When manufacturing the insulating glass, the yellow protective cap must always be in the black plug in

order to avoid contaminating and/or breaking off the contacts.

Figure 14: Assignment of the connection plug, with “white dot” on top; the temperature sensor

has no predefined polarity

blackplug with

yellow protectingcap and whitepoint: closed

blackplug with

yellow protectingcap : opened

blackplug without yellow protecting

cap :• in front: 4 gold-plated contacts• above: white point

left:

PLUS-contact

right:

MINUS-contact

middle:

contacte fortemperatur-sensor



Meaning (when the white spot is on top):

Left: POSITIVE contact with red wire for connection to the positive terminal on the ECON-

TROL® laminated glass

Right: Negative contact with black wire for connection to the negative terminal on the ECON-

TROL® laminated glass

Middle: Connecting contacts for the temperature sensor: Yellow and green wire

9.3 Positioning the temperature sensor

The position of the temperature sensor is fixed and must be strictly observed. In the standard case, the

white pane cable with the cable plug is located centrally at the step edge. The temperature sensor is

positioned centrally with the grey cable at the standing edge (see Figure 16). Here, the temperature sen-

sor is to be positioned in such a way that it has to be in direct contact with the ECONTROL® laminated

pane (for details and sketches, see Section 10.4)

The position, where the temperature sensor is to be positioned, is marked with a sticker on all ECON-

TROL®

laminated panes. This sticker comprises black letters (T-Sensor) on a red background (see Fig-

ure 15). The sticker can be found on position 1 of the ECONTROL® laminated glass.

Figure 15: Labels which defines the position of the temperature

sensor

Figure 16: Position-

ing the temperature

sensor for the verti-

cal installation of a

rectangular ECON-

TROL® insulating

glass. The tempera-

ture sensor is al-

ways located at the

bottom of the stand-

ing edge. The cable

length depends on

the installation

situation.

temperatur-

sensor

interior view

exit of plug and

cable

ECONTROL® „standard“

• cable exit in the middle of theabove edge

• temperatur-sensor in the

middle at the base edge

T-Sensor



With regard to models, EControl-Glas specifies the position of the temperature sensor and informs the

insulating glass manufacturer about this position in the form of a model drawing (see e.g. Figure 17).

Figure 17: ECONTROL® laminated pane shaped as a triangle. At the step edge, the outlet of the

white pane cable with the plug is to be positioned at the finished ECONTROL® insulating glass;

here, the temperature sensor is positioned exemplarily at the lower glass edge.

temperatur-

sensor

exit of cable

and plug

ECONTROL® „irregular shape“

• exit of cable in the middle ofsteppededge „left“

• temperatur-sensor will be

positioned in dependence ofshape, dimensions and position

of installation.interior view



10 Connection technology: Attaching the cable harness

10.1 Attaching the butyl adhesive strip

In order to attach the cable harness, the insulating glass laminate is positioned - with the ECONTROL®

laminated glass facing down - on a level surface (roller table, cutting table or similar), as shown in Fig-

ure 18.

If the step edge is at the front facing the processor, the step edge can be viewed directly. In this case,

the Polyflex contact to the positive terminal (+) is on the left and

the Polyflex contact to the negative terminal (-) is on the right.

Figure 18: Positioning the ECONTROL® laminated pane (bottom) with a look at the step edge and

the contact tabs; the positive terminal is on the left and the negative terminal is on the right. The

shown black strips on the spacer consist of pre-cut butyl strips for fixing the cable harness; the

stickers with the plus and minus are below the contact tabs on the glass pane at the bottom

For easy distinction between positive terminal and negative terminal, stickers are attached to the outlets

of the Polyflex contacts. These stickers are located in the immediate vicinity of the Polyflex contacts on

the surface of the glass pane4 at the bottom (position 1). The stickers with the plus and minus can be

seen easily using a small mirror.

4 The stickers with the plus and minus cannot be fixed to position 4. Otherwise, they would interfere with

the placement of the spacer.



Figure 19: Sticker for the positive contact: Red PLUS with red circle on a white background

Sticker for the negative contact: Black MINUS with black circle on a brown background

In order to fix the cable harness, pre-cut butyl adhesive strips (Gerband 622; length approx. 6 cm; width

8 mm) are applied to the spacer (approximately in the centre) - see Figure 20. In case of “small” pane

dimensions, the distance between the butyl adhesive strips should be about 5 cm. In case of large

panes, the distance between the butyl adhesive strips can be increased to e .g. 10 - 15 cm.

It is necessary to ensure that the left adhesive strip goes 2 cm around the corner. Subsequently, the

white silicon paper can be removed from the butyl adhesive strips using a removing aid (e.g. tweezers).

10.2 Soldering the positive contact

First, one drop of tin solder is applied to the contact point of both Polyflex connections.

Following this, a heat shrink tube is pulled over the red wire (regarding cable type GV 07) or the white

wire (regarding cable type SVG 04) of the cable harness (positive contact). Then, the metal end of the

red or white wire is soldered to the left Pollyflex connection (positive contact). By pulling the cable gently,

the connection of the cable to the Polyflex connection can be checked.

Figure 20: Before soldering the wires to the contacts

heat shrink tube



Subsequently, the heat shrink tube is positioned centrally above the solder joint of the positive contact

and shrunk using a heat gun. Afterwards, the cable of the positive contact is fixed to the left butyl strip,

so that it is parallel to the spacer. Then, the left Polyflex connection is bent by 90° to the right, so that it

can be put in the step edge of the ECONTROL® laminated glass (see Figure 21).

10.3 Soldering the negative contact

Subsequently, the black wire of the connection cable (regarding cable type GV 07) or the brown wire

(regarding cable type SVG 04) is tin-plated. Afterwards, a heat shrink tube is put over the cable and

it is soldered to the right contact.

By pulling the cable gently, the connection of the cable to the Polyflex connection can be checked. The

heat shrink tube is pulled centrally over the solder joint, and shrinking is performed using the heat gun.

Subsequently, the right Polyflex connection is folded by 90°to the left (inverted L) and bent towards the

inside in the direction of the spacer, so that this connection is also positioned in the step edge of the

ECONTROL® laminated glass.

Attention:

Always applicable:

On the left: = Positive terminal = Red or white wire of the cable harness

On the right: = Negative terminal = Black or brown wire of the cable harness

Figure 21: Red and black wires are soldered to the corresponding contact and covered with one

heat shrink tube each and shrunk on. The fixation of the cable harness to the butyl strip is shown

as well

heat shrink tube



A taut cable routing is achieved by slightly pulling apart the two ECONTROL® connecting lines on the

cable. After soldering and shrinking the heat shrink tube, this cable part is fixed to the butyl adhesive strip

as well (see Figure 21).

The 4-wire cable with the connecting plug is fixed - towards the centre - to the butyl strips in such a way

that it protrudes approx. 15 cm from the insulating glass (see Figure 21 and Figure 22). For this purpose,

approx. 5 cm of the cable harness must be fixed to the butyl strips on the spacer. For the strain relief, a

butyl strip should be affixed over the cable.

ATTENTION:

The individual wires must be strung together in parallel and straight.

10.4 Fixing the connection cable and the temperature sensor

In order to fix the connection cable and the temperature sensor, the insulating glass laminate is rotated

counter-clockwise by 90°. Pre-cut butyl adhesive strips (Gerband 622; length approx. 6 cm; width 8 mm)

are applied to the centre of the spacer (see Figure 22). Again, the distance between the butyl adhesive

strips should be about 10 - 15 cm. It is necessary to ensure that some cm (e.g. 3 cm) are always led

around both edges at one corner of the butyl adhesive strips. Now, the white silicon paper can be re-

moved using a removing aid (e.g. tweezers).

Figure 22: Fixing the connection cable and installation of the temperature sensor on the standing

edge (in case of a standard design)

temperatur-sensor



Figure 23: Fixing the temperature sensor to the standing edge

The two cables connected to the temperature sensor are pressed parallel and tightly along the spacer

against the butyl adhesive strips. (ATTENTION: The formation of loops is not allowed).

Subsequently, the insulating glass laminate is rotated once more counter-clockwise by 90°. More butyl

adhesive strips are applied to the spacer at the standing edge (approx. up to the centre of the insulating

glass pane).

As a final step, the temperature sensor is pressed centrally (see Figure 23) into the angle between

spacer and ECONTROL® laminated glass and fixed using a butyl strip. A handling device made of plastic

(Teflon) may be useful for fixing the temperature sensor.

Attention!

In the angle between spacer and ECONTROL® laminated glass, the temperature sensor is to be at-

tached closely and fixed with a piece of butyl strip (see Figure 24).

T



Figure 24 above: The temperature sensor is positioned centrally on the spacer (incorrect posi-

tioning of the sensor); Figure below: The temperature sensor is positioned directly on the

ECONTROL®

laminated pane (correct positioning of the sensor)

10.5 Test of the temperature sensor and the connections

In order to test the ECONTROL® insulating glass, the ECONTROL

® pane testing device (hereinafter

referred to as ISOPOL testing device) is used. This device tests the temperature, the connections and

the polarity of the contacts. See: Operating manual ECONTROL® pane testing device.

Attention

Prior to the final assembly of the cable harness, an intermediate test must be performed using the ISO-

POL testing device.

If the test was successfully completed, the green LED of the testing device is illuminated. In this case,

wiring and sealing can be continued. If the test indicates an error (the red LED is illuminated and an error

is shown in text form on the display of the ISOPOL testing device), this error must be corrected before

continuing with other work steps.

Possible errors: Reverse polarity error, cold solder joint, defective temperature sensor

If the error cannot be corrected by the insulating glass manufacturer on his own, EControl®-

-Glas must

be contacted: Phone: 03741 / 148 20-100

wrong position of temperatur-

sensors, which does not touchthe ECONTROL®-laminatedpane

right position of temperatur-

sensorswhich touches theECONTROL®-laminated pane

ECONTROL®-

laminatedpane

spacer

top pane

ECONTROL®-

laminatedpane

spacer

top pane



11 Insulating glass adhesive

11.1 Material selection regarding the insulating glass adhesive

For reasons of compatibility with the ECONTROL® edge compound, only polysulphide, polyurethane and

silicone adhesives approved by EControl-Glas may be used as insulating glass adhesive (often also

referred to as insulating glass sealing).

In particular, this includes:

Insulating glass adhesives based on polysulphide:

THIOVER F by FENZI

NAFTOTHERM M82 by Kömmerling

GD 116 by Kömmerling

Insulating glass adhesives based on polyurethane:


Insulating glass adhesives based on silicone:

DC 3362 by Dow Corning

DC 993 by Dow Corning


Ködiglaze S by Kömmerling

11.2 Performance

The sealing must be performed in accordance with the plant specifications and the manufacturing speci-

fications of the insulating glass manufacturer.

The insulating glass bonding is to be carried out neatly and tidily according to the recognised rules. Par-

ticular attention must be paid to ensuring that the pane cable lies within the sealing compound and that

no air bubbles become visible (neither in the corners nor elsewhere). A bubble-free integration of the

temperature sensor must be observed in particular.

In order to avoid subsequent cleaning work, prevent insulating glass sealant from reaching the glass

surfaces.

The pane cable (type: AGV by LINK company) is to be lead out of insulating glass sealant centrally (see

Figure 25 and Figure 26) between the contacts.

When using insulating glass adhesives

based on silicones, it is essential to

consider that only the adhesives of

EControl-Glas mentioned on the left are

approved. Other adhesives based on

silicone or materials containing silicone

must not be used.

The processing information or process-

ing regulations of the adhesive manufac-

turers must be considered by all means.

In particular, this applies to the use of

the above-mentioned insulating glass

adhesives based on silicones which

were approved by EControl-Glas.



When carrying out the sealing (usually manually), the pane cable can be fixed to the counter pane (to

the outside surface) using a piece of crepe tape. In doing so, it must be ensured that the pane cable is

not fixed tautly, but slackly (without tension). After the hardening process of the sealant, the pane cable

is to be adhered to the dry sealing compound. This prevents the pane cable from being damaged at a

glass edge during subsequent process steps (e.g. packaging or transportation).

Note!

During the hardening of the sealing compound, the glass units must be stacked on a rack (Pay attention

to sufficient clearance between the glass units). When stacking and storing glass units on a rack, it must

be ensured that the outer and inner panes of the insulating glass does not slip or shift. When using sili-

cone as insulating glass adhesive (e.g. Dow Corning DC 3362 or DC 993), the instructions of the manu-

facturer (Dow Corning) must be followed.

Figure 25: Exit of the white pane cable from the adhesive compound; CORRECT above, INCOR-

RECT below

R I G H Ttop view on the edge with exit of cable

and plug: the cable is positioned in the middle between the two glass panes

W R O N Gtop view on the edge with exit of cable

and plug: the cable is positioned at the edge of one glass pane.



Figure 26: Exit of the white pane cable from the adhesive compound in the side view; CORRECT

above, INCORRECT below

With its thickness of 5.5 mm, the plug of the pane cable is thicker than common cork pads which are

used as spacers by many igu manufacturers. It must be ensured that the plug of the pane cable is not

jammed between two ECONTROL® insulating glass units and thus damaged when stacking the insulat-

ing glass units. This procedure also ensures that the insulating glass units, which are not yet fully cured,

harden in the 90° angle prescribed.

12 Gas filling

The gap between inner and outer pane is filled with a noble gas according to the plant specifications and

the standard operating procedures of the insulating glass manufacturer.

Note!

The standard ECONTROL® double insulating glass structure provides for a filling with argon.

R I G H Tside view on the edge with exit of cable

and plug: the cable is positioned in the middle between of the edge

W R O N Gside view on the edge with exit of cable

and plug: the cable is positioned near the corner of the insulated glass unit

EC-insulated glass unit



13 Packaging, transportation, storage, shipment

13.1 In-house transportation

The in-house transportation and storage can be made on clean and dry usual glass racks (A- or L-

racks).

Attention!

Pay attention to edge damage. Edge cracks and serious conchoidal fractures impair the thermal stabil-

ity of the insulating glass units.

If the edge sealing of the insulating glass unit has not yet completely hardened, the insulating glass

structure must be secured against slipping of the individual panes!

If the ECONTROL® insulating glass pane is provided with a step at the standing edge, the ECONTROL

®

unit must necessarily be protected against shearing forces by means of suitable substructures!

Clean racks that are free from defects must be used.

13.2 Storage

Storing ECONTROL® insulating glass panes on usual glass racks in a hall is also possible, unless there

is the risk of direct sunlight.

Outdoor storage is not permitted!

Comment:

Due to different temperatures or light and shadow effects, direct sunlight may give rise to structures in

the ECONTROL® laminated glass, which may lead to irregular colouring. Such structures have to be

avoided.

13.3 Packaging and shipment

The shipment should preferably be made on standard glass racks (panes protected against falling and

standing on the edge) or in wooden crates.



When transporting and shipping with glass racks, the ECONTROL® insulating glass units must always

be covered or wrapped (with rear ventilation) with non-transparent tarpaulin or film. It must be possible

to remove this film from the glass units again without leaving residues. EControl-Glas recommends

the following film (see Figure 28):

Stretch film HSC standard, 20µm, black

(cast film, adhesion inside);

Supplier: Antalis Verpackungen GmbH;

http://shop.antalis-verpackungen.de

The ECONTROL® insulating glass units must be

transported with a closed truck.

Attention!

Direct sunlight to the insulating glass panes must

be avoided by all means.

Figure 27: ECONTROL® label (written in two

languages: German and English) which must

be filled in by the insulating glass manufacturer

and affixed to the internal glass pane, i.e. to the

inner pane of the insulating glass. The ECON-

TROL® label contains important information for

the subsequent identification and notes on the

installation of the insulating glass unit.

If the finished insulating glass units are delivered to the customer directly after the insulating glass pro-

duction, the ECONTROL® label must be affixed to the inner pane. The pane number and the dimensions

must be entered in the label!

At the building site, the ECONTROL® label serves as a unique identifier for the control of the ECON-

TROL® panes by the electrician.



Figure 28: Finished ECONTROL® insulating glass unit with ECONTROL

® label (top), note “This

side INSIDE” and label of the insulating glass manufacturer (bottom) with CE conformity mark

and other information

When stacking the ECONTROL® insulating glass units, it is particularly important to ensure that the ca-

bles and their plugs are not situated between two ECONTROL® insulating glass units. As shown in Fig-

ure 28, the cables are fixed to the adjacent edge of the insulating glass using a piece of adhesive crepe

tape.

ECONTROL® insulating glass units must NEVER be stacked in such a way that the cable exits at the

standing edge. Otherwise, there is the extreme risk that the weight of the insulating glass unit damages

the cable and thus prevents the ECONTROL® insulating glass unit from functioning properly.

ECONTROL®-label with advices

for installation of insulated glass

units on building site

label with information:

this side: inside

label of igu manufacturer with

CE-conformity sign



Figure 29: Finished ECONTROL® insulating glass units on A-rack (here: with serial number EC

036) and positioning of the cables lead out of the insulating glass adhesive, with plug and yellow

protective cap; the cables are fixed with adhesive creped tape.

Figure 30: Finished ECONTROL® insulating

glass units on A-rack and subsequent wrap-

ping with black film and attached shipping

documents.

End

Documents

PROCESSING GUIDELINE for the manufacture of insulating glass · PDF filePROCESSING GUIDELINE for the manufacture of insulating glass ... preparation of ECONTROL laminated glass 4 2.1