GAS FILLING MACHINES
PROCESS MONITORINGPRESSURE BALANCE

www.helantec.deGas filling - visibly better !

2Managing partners Jochen Weiß and Gregor Witrofsky

Advantage for you
Worldwide, HELANTEC is the first address in the insulating glass industry for
manual gas filling technology and the determination of the gas concentration.

For more than 25 years, HELANTEC is well known in the insulation glassindustry. Starting from gas analysis, the company has developed numerous
products and innovative solutions for the insulation glass production. The
high availability and a long service life characterise our devices and provide
you with a sustainable competitive advantage.
Thanks to active communication with our customers and favoured by leanhierarchies and short cut decisions, we can promptly implement the requirements of the markets in our products. The in-house production also allows theimplementation of individual adjustments within a short lead-time.
Since many years, we have been working with the main testing institutes andall leading IG manufactures.

3

Gas filling - visibly better!

Most of our developments
are unique.
Virtually all products and systems are in-house developments that
we produce by ourselves – Made in Germany.

Electronic boards

Specifically designed andengineered components forcertain application

This premium and robust quality ensures and enables a worldwide
distribution of our products and services. Carefully selected trading
partners support our marketing activities.

Sensors

Accurate and reliable
operating sensors
Maintenance-free andlong lasting

Pump unit

Precision pressure sensors

ProbesElectronic board with gas sensor

Suction probes

Well prepared for
new challenges+- Individual software solutions- Custom modifications- Data access via mobile devices- Smart factory / Industry 4.0

The special design of ourprobes allows optimal gas
concentrations

Pumps
and valves
Robust anddurable pumps

High-quality valves
Tested and certified

4ISO-Altimeter PROFESSIONAL

Pressure
is a questionof adjustment
You think, gas-filled IG units,
which are also flat at the installation (without deflection), arenot easy to produce?
You are totally wrong. The ISOAltimeter Professional pressurebalance system now handles thetask of pressure balancing in notime at all.
Each and every IG unit is prepared in the production in such amanner that it is flat at the higher altitude or lower altitude of
the installation site. Additional
after-treatment is not required!
This proven system has alreadybecome standard in the insulating glass industry. Worldwide,
more than 1.5 million IG units
have been pressure balancedwith this system (up to August2016).

5Gas filling - visibly better!

Highest precision

Largest process reliability

Network connectivity

 Pressure balance based on climate annual average at installation altitude

 Input pressure Data transfer directly from orderprocessing Flow Consideration of current production conditions

 Pressure inside IG unit Tightness

 Integrated FTP-server
 Remote access Flow measurement with highresolution

Complete documentation

Safe operation

 Processing of barcodes Short processing time Label printing per IG unit Intuitive operation

IG unitat 1,500m a.s.l.
1500

 Documentation and tracking

1000

500

IG unitat 100m a.s.l.

The HELANTEC-valve
The HELANTEC-valve is a small but important detail. Only with this valve
can it be ensured that the executed pressure balance remains intact andthat your assured characteristic of the IG unit does not change. Tested
and certified by MPA Darmstadt.
Available in diameters of 3, 4 and 5 mm.

06Unique acceleration
A precise control of the filling process is particularly important for large IG units.
Consequently, we have developed the universal “RAPIDE” fast gas filling series.
Physically and aerodynamically, we reach with thesemachines the maximum capacity.
The gas concentration is measured and displayed
continuously during the entire filling process. The filling process is finished automatically as soon as thedesired gas concentration is reached.
Our TURBOFILL model is an optimised solution for
turbulent 1-hole filling technology.

The emphasis is not only on
filling speed, but additionally,achieving the highest possible
efficiency!“7Gas filling - visibly better!

Relax –
all runs smoothly!
Have you had enough of stress and the unforeseeable?
In terms of quality assurance and quality verification,with the HELANTEC IPC you can sit back and relax.

Functional overview

With IPC you can set the desired gas concentration individually. Alabel that lists the most important characteristics can be printed foreach IG unit – as a quality mark. The visualisation of the filling process
informs the user about the current progress during each gas filling
process.
In the option HIGH LINE, automatically and without any additional
effort, all fillings or any IG unit are recorded. The barcode of eachindividual IG unit can be read for identification and tracking. Alldata can be retrieved directly from network. The integration into inhouse quality management systems is possible in a breath.

Automated data record

Analyser for quality control

Efficient and economic

TURBOFILL

Efficient IG unit filling with low gas
consumption, economic gas filling of
extremely large formats

Intelligent and accurate

Filling lines / capacity 1)
Filling line can be retrofitted

RAPIDE L200 RAPIDE L500 RAPIDE L900

High capacity
for small budgets

The entry-level modelof the RAPIDE L series

The best-selling
gas filling system

The highest-capacity
gas filling system

2 / 600
4 / 1200

1 / 400
2 / 800

1 / 600
2 / 1200

1 / 800
2 / 1600

8844

Gas inputs

112

4Intelligent detection of IG unit size,

Gas analyser per line

4444

integrated and precise gas analyser,IPCECO LINE

ECO LINE

HIGH LINEHIGH LINE- Documentation

8844- Network connection

8844- Barcode

8844- Label printing

4444gas savings program for krypton, input
pressure check

Simple andintuitive operation
Now also with 1-hole technology

1)

At 8 hours / day and for IG units with 0.8 m² / 14 mm spacers / 11.2 litre volume / argon / 90% gas concentration.

8SEALANTINSPECTOR
Process monitoring for sealing systems
with 2-component sealants
The processing of 2-component sealants requires a certain
quality inspection of the mixing ratio. Instead of complex
and time-consuming procedures, the SEALANT INSPECTOR monitors continuously the mixing ratio. Moreover, it
informs immediately about any deviation.
This ensures that the requirements of the sealant manufacturer are reached. Therefore, the IG manufacturer
knows that the mixed sealant fulfils the specified guaranteed properties (e.g. tensile strength, adhesion etc.). Variations in the mixture would have both short- and long-term
consequences (for example, a non-hardening edge seal,
missing tightness, or reduced adhesion properties).

IGM/IPA
Process monitoring for gas filling presses
For the first time, the system IGM / IPA offers 100%
process monitoring for gas filling presses. The integrated warning system informs about quality deviations and the efficiency of the gas filling press.
Every filling or each IG unit is recorded – in an automated procedure, without additional effort. Thanks
to network connectivity, all data can be transferred
into the existing quality management system.
Using the gas analyser GAS INSPECTOR, the result of
the random quality test (measuring the gas concentration) can be assigned to the relevant filling opera-tion. Thus, the IG manufacturer has the process “gasfilling” completely and safely under control.

9Gas filling - visibly better!

Complete documentation

Individual configuration

Network connectivity

 Mixing ratio All paste-like sealants

 Integrated FTP server

 Batch number of sealants

 All common barrel pumps

 Permissible limits Manual and automated sealingmachines

 Integration in quality
management systems
 Remote accessSpecial features of this technology

Your benefits with this system

 Sensors are not in direct contact with sealant Increase your quality standard No calibration required Prevent defective products Low wear and virtually maintenance-free No expenditure on personnel for inspection

There are no comparable systems on the market!
Only HELANTEC makes gas visible”
Process monitoring for gas filling presses
Gas filling press

Signalling

Centraldatabase

Visualization +evaluation

Documentation

Process monitoring
IGM / IPA

PC detail evaluation

Randomsampling after
approx. 6-8hours

Quality assurance
GAS INSPECTOR

10

Qualitycontrol
Easyand reliable
The origin of HELANTEC is gas analysis. For morethan 25 years, we supply analysers that were especially developed for the quality control of gas filled
IG units. We deliver the best-suitable device for eachapplication.
The founding of the long endurance of our analysers
are the measuring cells, that work virtually maintenance-free. Thus, there are very little upkeep costs.
All analysers are calibrated with our own test equipment; each analyser is delivered with test certificate.
Of course, we also check and certificate your analysers regularly, if this is required. The inspection including long-term test and the certification is done in ourfactory.

GAS TESTEROur analysers are used worldwide, among othersby accredited auditing companies, in laboratories
and in the production of well-known IG manufactures around the world. The worldwide use of theseanalysers proofs us and our technology.

HELOX 4

Fast quality inspectionin the production

Highest precision forlaboratory and production

GAS INSPECTOR
All-rounder including
documentation

11

Gas filling - visibly better!

HELANTECanalysis technologymeans Precise determinationof the gas concentration
 Usable for all
standard gases / gas mixtures Suitable for multi-coated IG units Suitable for triple-glazed units and all
spacer materials
 Easy calibration and plausibility check Long service life measuring cells(usually more than 10 years)

GAS TESTERHELOX 4

ISO GAS CONTROLGAS INSPECTOR

Oxygen measurement

8

4

8

optional

Gas type measurement (argon)

48

4

4

Other gas types (krypton, etc.)

444

4Sampling via syringe

844

4

Sampling via pump488

optional

Triple-glazed units

444

4

4/8

4/8

4/8

8/4

Battery operation

4

optional

optional

optional

Data storage

4884

Network connection8884Barcode

888

optional

LCD displays / touch screen

Test equipment for quality control must be easy in
use and reliable in operation.
According to these criteria, we have developed ouranalysers.”

12Standard at the highest levelGas filling machines for every budget – filling with timer or integrated gas analyser,
but always with high-quality and innovative components.
This is our standard!
During the entire filling process, the integrated analyser continuously measures and displays the gas concentration. The filling process is ended automaticallyas soon as the desired gas concentration is reached.

Highlights
 Efficient gas filling withlow gas need Special filling probes

Thus, also standard can shine with high capacity.

 Input pressure control
 Simple, intuitive operation

Even the standard gas fillingmachines from HELANTEC are
equipped with intelligence!“

13

Gas filling - visibly better!

EASY.FILL

Simple, inexpensive, reliable.
Terminates the filling process after the set filling time, which is
specified in the corresponding
table.

STANDARD

High capacity for small IG units.
Synchronous filling of 4 IG units,with integrated analyser and automatic re-filling.

SMART 150

Precise, maintenance-free and durable.
The entry-model with integrated gasanalyser. The desired gas concentration can be adjusted individually

Filling lines / capacity

EASY.FILL

SMART 150

STANDARD

2 / 200

1 / 150

4 / 400

Filling line can be retrofitted

888

Gas inputs

1

1 / optional 2

1Gas analyser

81

1Dyn. concentration display

84

4

Number of pumps

81

1

Automatic top-up

88

4

Cylinder pressure monitoring

444All gases / gas mixtures

44

4

Foot switch

48optional1)

1)

At 8 hours / day and for IG units with 0.8 m² / 14 mm spacers / 11.2 litre volume / argon / 90% gas concentration.

14Leakfinder
The Leakfinder 2.0 detects leaks in theinsulated glass production.
With the Leakfinder 2.0 you find theanswers to the questions: “Why do I fail toachieve good and stable gas concentration?” or “Why do I consume so much gas?”
It is easy to handle and easy to operate.

Gas mixing device
Stay self-sufficient and flexible in terms ofgas mixtures.
With our gas mixer, you produce any argon-krypton-mixture by yourself.
The desired gas concentration is set directly at the mixer.

Grinding wheels
 Universally applicable on automatedand manual grinding machines
 Cost-efficient Made in Germany

15

Gas filling - visibly better!

Accessories for gas filling
The special design of our probes allows
optimal gas concentrations
 Robust and durable
 Sophisticated design
Hoses, filters, distribution arms for hoses

Accessories for analysers
 Low-wear Reliable sampling Various needle lengths

Consumables
 Highest fitting accuracy
 Tight tolerances Reliable quality

Gas filling - visibly better !

Innovative thinking and action for more than 25 years!

GERMAN QUALITYHELANTEC GmbH
Werner-von-Siemens-Str. 47A
D 76646 Bruchsal (Germany)
Fon +49 (0)7251 85731
Fax +49 (0)7251 85739
info@helantec.de · www.helantec.de