TM
Equipment Catalog
Integrated Equipment Solutions™
Vol. 1
TM
Henkel Corporation
Integrated Equipment Solutions™
32100 Stephenson Hwy.
Madison Heights, MI 48071 U.S.A.
800.438.5975
Fax 248.589.4806
www.equipment.henkel.us
Process Control Systems
Pretreatment Support Equipment
Test Equipment &
Henkel Corporation
Henkel Canada Corporation
Industry and Maintenance
1001 Trout Brook Crossing, Rocky Hill, CT 06067 U.S.A.
• 800-562-8483 • www.henkel.us • www.loctite.com
Industry and Maintenance
2225 Meadowpine Blvd., Mississauga, Ontario L5N 7P2
• 905-814-6511 • 800-263-5043 (within Canada)
All trademarks, except where noted, are trademarks of Henkel Corporation, KGaA. ®= reg. US Patent & Trademark Office. Allen-Bradley is
a registered trademark of Allen-Bradley. Windows is a registered trademark of Microsoft Corporation. Iomega and Zip are registered
trademarks of Iomega Corporation. © Copyright 2005. Henkel Corporation. All rights reserved. 2162/LT-4022 (2/05)
Data Management Systems
Integrated Equipment Solutions™
Equipment Catalog – Volume 1
For nearly a century, Henkel has been the global leader in metal pretreatment technologies. Over
the past 30 years, Henkel has designed, built and integrated advanced equipment solutions to
optimize the application of metal pretreatment products, providing trusted, high quality services
to its customers. We offers a complete line of application equipment, process controls, pretreatment
support equipment and other specialty systems which can easily be integrated into existing
manufacturing processes. Backed by this broad product range and technical expertise, Henkel is
the single, comprehensive source for integrated equipment and works together with its customers
to deliver solutions that fit all needs.
Henkel’s Lineguard® product line has been used worldwide to control a range of Henkel pretreatment
chemical processes, and ensure consistent end-product quality. Key Henkel surface technologies
processes include:
Parco® cleaners
Bonderite® treatments
Alodine® treatments
Mobility Enhancers
Ridoline® cleaners
Granodine® treatments
Autophoretic® coatings
DTI® lubes and coolants
Fixodine® conditioners
Prep-N-Cote®
Parcolene® sealing rinses
Bonderloc™ processes
Purchasing Henkel Integrated Equipment Solutions™ equipment provides far more than leading
edge chemical process management: customers receive technical support from the IES™ group to
assist with equipment selection, equipment maintenance, and production staff training. Henkel
products, with IES™ equipment and services, deliver total solutions to help meet the intense quality
and efficiency challenges of today’s competitive manufacturing environment.
These are just a few of Henkel’s proven surface technologies featured in this catalog. The following
content is geared to address specific application, control and process management needs. For a
more complete overview of other Henkel product lines, including our world-renowned Loctite®
adhesives and sealant products, visit our website at www.henkel.us or
www.equipment.henkel.us for more information.
PROCESS CONTROL SYSTEMS
Solid State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lineguard® 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lineguard® 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Solid State Parts & Accessories . . . . . . . . . . . . . . . . . . . . . . . . 5-6
PLC Based. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Lineguard® 760 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lineguard® PC 2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lineguard® PC 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PLC Based Parts & Accessories . . . . . . . . . . . . . . . . . . . . . . 11-12
PC Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19
Lineguard® SC 1000 SmartControl ™ System . . . . . . . . . . . . . . . 14
Lineguard® SC 2000 SmartControl ™ System . . . . . . . . . . . . . . . 15
Typical SmartControl ™ System Layout. . . . . . . . . . . . . . . . . . . . 16
SmartControl ™ Example Control Screens. . . . . . . . . . . . . . . . . . 17
PC Based Parts & Accessories . . . . . . . . . . . . . . . . . . . . . . . 18-19
PRETREATMENT SUPPORT EQUIPMENT
Chemical Metering Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-25
HST 1, 2, 5, 8, 25, 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PA 1-CL Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lineguard® Flow Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chemical Metering Pumps Replacement Parts & Accessories . . 25
Air Diaphragm Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
Air Diaphragm Pumps Replacement Parts & Accessories. . . . . . 27
Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–32
Level Control Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Level Control Assemblies Replacement Parts & Accessories . . . 30
Bulk Level Monitoring System & Accessories. . . . . . . . . . . . . . . 31
Low Drum Alarm & Replacement Parts . . . . . . . . . . . . . . . . . . . 32
Spray Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-44
Spray Nozzle Selection Guides & Accessories . . . . . . . . 34-41, 43
Nozzle Application Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Bonderloc™ Nozzle Application Drawing. . . . . . . . . . . . . . . . . . . 44
Coalescing Oil Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-46
20 & 3 GPM Coalescing Oil Separators . . . . . . . . . . . . . . . . . . . 46
Ion Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-48
Ion Exchange Optional Spare Parts . . . . . . . . . . . . . . . . . . . . . . 47
Lineguard® Ion Exchange 870 System . . . . . . . . . . . . . . . . . . . . 48
TEST EQUIPMENT & DATA MANAGEMENT SYSTEMS
Lineguard® 101D Meter & Options. . . . . . . . . . . . . . . . . . . . . . . 50
Lineguard® Data Monitoring System . . . . . . . . . . . . . . . . . . . . . 51
Lineguard® DocSys™ IV System . . . . . . . . . . . . . . . . . . . . . . . . . 52
Process Control Systems
Henkel has maintained a tradition of supplying
state-of-the-art process control systems to manage
our customer’s pretreatment operations for more
than forty years. In providing these Lineguard®
systems to our customers, Henkel has documented
washer chemical savings of 10-25%, water usage
savings of 5-30%, and quality improvements
(drop in paint line rejections) of 1-10%.
In addition to working with our customers during
the initial design phase, Henkel maintains high
quality standards by involving our customers during
the phases of final design and system build.
All of our customers are offered the opportunity
to have one of our trained equipment specialists
visit their plant prior to the installation of all input/
output devices, and during the commissioning
phase of each system, as well as conducting
Our Lineguard® product line has traditionally in-plant training of all operational shifts in the
been comprised of both solid state and PLC system’s proper use and maintenance.
based systems, each customized for both small
paint lines and larger, more complex pretreatment In a world where quality is of the utmost importance,
configurations. Henkel’s Integrated Equipment both our PLC based Lineguard® and PC based
Solutions™ (IES™) group visits each potential SmartControl ™ systems can document and archive
customer’s plant, discussing with all levels of production data, provide Statistical Process
plant personnel their end-product quality Control (SPC) analysis of any set of data, and
requirements, before proposing a system assist our customers in meeting their ISO/QS
designed to meet both quality and budgetary quality requirements that their customers demand.
requirements and before recommending the The stringent requirements of data and quality
most appropriate system for their plant.
management investigated during external audits
of Henkel customers are often satisfied once it is
Recently, with advances in personal computer discovered that a Henkel process management
(PC) technology and reliability, Henkel was the system is in control of the pretreatment and
first chemical and resin supplier to introduce paint line.
their PC based SmartControl ™ family of products
to the pretreatment and painting industries. Whether your line is small or large, and whether
These SmartControl ™ systems have been found your interest is in our Solid State, PLC or PC based
to be easy to install, maintain and teach to all systems, ask your Henkel sales representative
levels of plant personnel the system features of about an in-plant survey to review your plant’s
process management, while maintaining the same requirements today.
reliability as our Lineguard® PLC based product
line has provided confidently to our customers
for many years.
1
SOLID STATE
Lineguard® 46, Item 60009000
Process Control Systems
Solid State
Henkel has designed these systems to be easily installed, at
most customer plants, and to contain an easy to read operator
interface. Changes in set-points and alarm settings are made
with the touch keypad on the faceplate of both the Lineguard®
46 and Lineguard® 96 units. With the use of our cable extension
kits for conductivity probes, these units can be mounted up to
100' away from the on-line pretreatment tanks.
Both the Lineguard® 46 and Lineguard® 96 systems can be
coupled with our Lineguard® Data Monitoring System for
trending and SPC analysis of all on-line measured variables.
All instructions, manuals, and easy-to-read installation guides
are provided to our customers with each Lineguard® 46
and Lineguard® 96 unit, and can normally be installed and
commissioned without in-plant assistance. Our IES™ Help
Desk is always available to assist our customers with any
questions they may have during installation, and our IES™ field
service team is prepared to provide in-plant training to all
levels of plant personnel.
Lineguard® 46
The Lineguard® 46 system features several types of alarms to
notify plant personnel of changes in operating conditions:
concentration high/low alarm, chemical feed pump over-run
alarm and an alarm for a low chemical drum level. Process
set-points and alarm limits are easily adjusted on the faceplate
of the panel and can be viewed on the LCD display.
While the Lineguard® 46 system can be used as a stand-alone
process controller for smaller lines, it can also be part of a
Henkel distributed process control system, utilizing more than
one unit. Special modules are available for controlling rinse
bath contamination, auto-draining (contamination control) of
alkaline cleaner baths, and dual chemical feed pump control.
The various modules can then be integrated into our
Lineguard® Data Monitoring System for a complete, low cost,
quality management system.
Lineguard® 96
FEATURES AND SPECIFICATIONS
• Enclosure:
2
Item #
60009000
60009100
Typical Control System
Input Devices
Alkaline cleaner bath
or phosphating bath
Electrodeless conductivity only
Probe Cable Length
12'
Both alkaline cleaner bath
and phosphating bath
Electrodeless / contact
conductivity, pH, or ORP
12'
Cable Extension kit
Yes, optional 100'
Yes, optional 100', except pH
Data Acquisition Included
No, optional
No, optional
PROCESS CONTROL SYSTEMS
If it is a simple, inexpensive chemical feed system you need,
Henkel has a complete line of solid state automatic chemical
dosing systems to offer. Both our Lineguard® 46 and
Lineguard® 96 systems can be configured with a variety of
sensing systems to control most cleaning and/or phosphating
chemical replenishment requirements, as well as manage
rinse water quality.
Henkel’s Lineguard® 46 solid state control system is
microprocessor based and designed for the control of cleaner,
rinse and surface treatment processes. Utilizing an electrodeless
conductivity sensor, and with temperature compensation over
a wide range of processing bath temperatures, this unit
provides high quality, cost-effective concentration control for
most pretreatment solutions. The unit is built to endure
rigorous factory conditions, as the chemical resistant plastic
enclosure meets NEMA 12 requirements. Installation is easy,
maintenance requirements are minimal and it is easy to learn
how to make changes to process solution concentrations.
Chemical Resistant plastic
NEMA 12 rated
• Dimensions:
8.8" H x 7.25" W x 3.4" D
• Operating range:
32º to 122ºF (0 to 50ºC)
0 to 90% relative humidity (non-condensing)
• Power requirements:
120 VAC 50/60 Hz
5 amp minimum
• Sensor:
Electrodeless conductivity
Immersion assembly with 12' cable
(Cable extension kits of 100' are available)
• Scaled readouts:
0–19.9 mS/cm
0–199 mS/cm
• Inputs:
One for external “one-shot” chemical charge
One for external mode selection
One for optional low drum alarm (P/N 60009003)
• Outputs:
All 120 VAC 50/60 Hz, 2 amps, non-fused relays
One output for chemical addition off set-point
One output for concentration remote alarm
One output for general system alarm
• Operation:
Manual / off / auto
Bath temperature compensation ambient to 185°F (85°C)
One set-point for chemical concentration control
One set-point for concentration alarm, low, or high
3
SOLID STATE
Parts & Accessories: Solid State
Description
The Henkel Lineguard® 96 solid state control system is a
multi-channel microprocessor based unit, designed for the
control of cleaner, rinse and surface treatment processes. The
system has three individual sensing and control loops which
can be configured for any combination of electrodeless
conductivity, Oxidation/Reduction Potential (ORP), pH or
temperature control. The unit provides high quality, cost-effective
control for most small to mid-size pretreatment lines. It is built
to endure rigorous factory conditions, as the chemical resistant
plastic enclosure meets NEMA 12 requirements. Installation is
easy, maintenance requirements are minimal and it is easy to
learn how to make changes to process solution concentrations.
The Lineguard® 96 system features several types of outputs to
notify plant personnel of changes in operating conditions: each
channel offers a chemical feed output, an alarm output, and a
4-20 ma DC analog output. Process set-points and alarm
limits are easily adjusted on the faceplate of the panel and can
be viewed on the LCD display. Also included are spray pump
interlock relays with each channel (module) to limit chemical
additions to only when the bath’s spray pump is in operation.
While the Lineguard® 96 system can be used as a stand-alone
process controller for smaller lines, it can also be part of a
Henkel distributed process control system, utilizing more than
one unit. Special modules are available for controlling rinse
bath contamination, auto-draining (contamination control) of
alkaline cleaner baths, and dual chemical feed pump control.
The various modules can then be integrated into our
Lineguard® Data Monitoring System for a complete, low cost,
quality management system.
4
FEATURES AND SPECIFICATIONS
• Enclosure:
Chemical Resistant plastic
NEMA 12 rated
• Dimensions:
11.4" H x 8.8" W x 3.8" D
• Operating range:
32º to 113ºF (0 to 45ºC)
0 to 90% relative humidity (non-condensing)
• Power requirements:
120 VAC, 50/60 Hz
5 amp minimum
• Sensors:
Electrodeless conductivity
pH
ORP
Temperature
All immersion assemblies with 12' cable
(Cable extension kits of 100' available for conductivity, ORP)
• Scaled readouts:
Conductivity – 0 to 2, 0 to 20, or 0 to 2,000 mS/cm
pH – 0 to 14
ORP – appropriate millivolts (MV)
• Inputs:
One auxiliary contact per channel (module)
• Outputs, per channel (module):
All 120 VAC 50/60 Hz, 2 amps, non-fused relays
One output for chemical addition off set-point
One 4-20 ma DC signal (for data management)
One unit output for general system alarm
• Operation:
Manual / off / auto
Bath temperature compensation ambient to 185°F (85°C)
One set-point for each chemical concentration control
Set-points for each concentration alarm, low and high
Dead band adjustment on each module, low and high
60003012
Platinum electrode
60004257
Reference electrode
60009001
Lineguard® 46 panel
60009002
Conductivity sensor, immersion
60009003
Chemical drum low level probe (Lineguard® 46 only)
60009004
Starter/control module with manual/on/off switch
60009006
Carrier summer module
60009008
Lineguard® 46/Lineguard® 96 summer module
60009009
Lineguard® counter/feed module
60009101
Electrodeless conductivity chemical control kit (EC control module, EC immersion sensor and sliding disk)
60009102
Electrodeless conductivity rinse control kit (EC control module, EC immersion sensor and sliding disk)
60009104
Temperature control kit (temperature control module, temperature immersion sensor and sliding disk)
60009106
Conductivity sensor, insertion
60009108
pH electrode, old style (for system sold prior to April 2003)
60009110
Temperature probe
60009113
Conductivity input module Lineguard® 96
60009114
pH Input module Lineguard® 96
60009115
Relay output module
60009116
Temperature input module
60009117
Lineguard® 96 conductivity cable extension kit
60009119
Lineguard® 96 ORP module
60009121
ORP control kit (includes ORP module, immersion sensor and sliding disk)
60009122
Lineguard® ORP cable extension kit
60009123
Lineguard® 96 pH insertion sensor
60009124
pH flowcell
60009125
pH control flowcell kit with pH control module, pH sensor and flowcell
60009129
Fuse Lineguard® 96
60009130
pH sensor assembly
60009132
Contact conductivity control kit, with CC control module immersion sensor with sliding disk
PROCESS CONTROL SYSTEMS
PROCESS CONTROL SYSTEMS
Item #
SOLID STATE
Lineguard® 96, Item 60009100
5
SOLID STATE
Parts & Accessories: Solid State (continued)
PROCESS CONTROL SYSTEMS
Item #
Description
60009134
Lineguard® 96 motherboard
60009136
pH control kit (includes module and pH immersion assembly)
60227953
Calibration kit (loop resistors)
60228019
Autodrain module
FOR MORE INFORMATION
Our Solid State Control Systems are easy to design and lay out to meet your process
management needs. For most applications, we can develop a system proposal within 24
hours after discussing your specific requirements. When contacting the IES™ Sales Group,
having the following information available to discuss with your sales representative will
facilitate this process:
Process Control Systems
PLC Based
Henkel has been the leader in providing PLC based process
control systems to the metal finishing industry for more than
20 years with our Lineguard® line of automation products.
Based on the Allen-Bradley® family of PLCs, our Lineguard®
process control systems are available in a wide variety of
sizes and capabilities, from smaller 5- or 6-Stage pretreatment
lines to larger, multiple paint line customer plants. Our
Lineguard® process control systems are each customized to
meet the needs for both pretreatment and finishing needs and
are available in both centralized unit or distributed I/O
(Input/Output) configurations.
When coupled with our Lineguard® DocSys™ statistical quality
control/data acquisition system, our PLC based process
management system offers customers a complete system
Lineguard® 760
1) Pretreatment line layout, stage-by-stage
2) Henkel chemical process name for each stage
3) Operating concentration of each process
4) Operating temperature of each process
5) What needs you have for data management
Call our IES™ group at [800] 438.5975 or 248.589.4647 with your information and have
a system layout and proposal e-mailed or faxed to you in 24 hours. Or visit our website
at www.equipment.henkel.us for more details.
Henkel offers in-plant assistance from our experienced field
service engineering staff during the commissioning phase of
each Lineguard® system, including in-plant training of customer
personnel in the nuances of each customized controller. In
addition, Henkel also offers Service Contracts to our customers
for pro-active in-plant visits to review controller accuracy,
calibrate all devices, examine statistical data collected by the
system, and perform additional training classes for newer
plant personnel.
Ask your Henkel sales representative about which Lineguard®
PLC based process control system can best suit your plant’s
needs and a customized system will be designed for you.
Lineguard® PC 2500
Lineguard® PC 5000
Item #
60257006
60257062
60257071
Typical Control System
6 or 7 stage metal
beverage can lines
No, optional
5, 7, or 8 stage
phosphating lines
No, optional
All pretreatment systems,
E-coat systems
Yes, customized
Expandability
Allen-Bradley®
PLC 5/03
Two-panel, one
input, one output
None
Communications
None
Allen-Bradley®
PLC 5/04 or 5/05
Centralized
control
Minimum 20%
additional I/O
Remote support,
through modem
Allen-Bradley® PLC 5/20,
5/30 or Control Logix 5555
Centralized or
distributed I/O
Remote I/O
panels possible
Remote support,
through modem
Data Acquisition Included
PLC Control
Configuration(s)
6
of maintaining consistent end-product quality, as well as
documentation to meet their ISO conformance needs.
7
PLC BASED
Lineguard® PC 2500, Item 60257062
PROCESS CONTROL SYSTEMS
The Lineguard® 760 is the newest of our series of process
control systems developed specifically for the two-piece
aluminum beverage container industry. This new design is a
highly cost effective, centralized, multi-stage control system
for a single aluminum container washer.
The unique split panel design permits the operator interface
panel to be located in any area convenient to the operator,
while the termination panel may be located in the immediate
vicinity of the washer to minimize the cost of wiring and for
ease of installation. A single communication cable is all that is
required between the two NEMA 12 panels.
The Lineguard® 760 is clearly the easiest to use of any control
system available to the metal finishing industry. All functions
are displayed and adjusted through a single, touch sensitive,
color CRT display. All operational data is displayed on the
same device. In addition to being easy to use, the Lineguard®
760 provides the operator with more information on the status
of the washer than any comparable system. All alarms,
set-points, actual values, and multi-range trend charts may be
viewed and easily adjusted as necessary.
®
The Lineguard 760 provides the capability of up to four
complete sensing and feedback control channels, each with
multi-mode operation, and a fifth channel for can count or
timed based control functions. These control channels may be
used in any combination with available sensing packages to
provide exactly the control required for each specific washer
and process chemistry combination.
8
FEATURES AND SPECIFICATIONS
Processor
• Allen-Bradley® SLC 5/03 (optional SLC 5/04)
• Four(4) analog inputs:
Channel #1 – Conductivity
Channel #2 – Conductivity
Channel #3 – Fluoride (RmV)
Channel #4 – Conductivity or pH
Channel #5 – Can count only
• Outputs:
Outputs are 120 VAC
Four outputs for auto, timed, and count
One for timed and count only
• Alarms:
One 120 VAC output, customer to provide device
• Operator interface:
Alphanumeric display with keypad
• Display:
Dual range trending, short & long term
Engineering units: Relative Fl mV, mL F. A. titration, pH
Operator panel
• Power supply:
Universal, 190, 208, 360, 400, 440, 480 VAC 50/60 Hz
• Power requirement: 3 amps
• Enclosure: NEMA 12 / IP65
• Ambient temperature:
Max. Ambient 90°F without cooling
• Weight: Approx. 100 lbs.
• Dimensions:
24" W x 32" H x 10" D (with top mount transformer)
Termination panel
• Power supply:
Universal, 190, 208, 360, 400, 440, 480 VAC 50/60 Hz
• Power requirement: < 5 amps
• Enclosure: NEMA 12 / IP65
• Ambient temperature:
Max. Ambient 120°F without cooling
• Weight: Approx. 100 lbs.
• Dimensions:
24" W x 32" H x 10" D (with bottom mount transformer)
The Lineguard® PC 2500 Process Control System is an
integrated process controller which will provide closed loop
control for chemical concentrations and rinse contamination
of process stages.
The Process Control Panel provides centralized control functions
in a single panel. The standard Lineguard® PC 2500 Process
Control System may incorporate the following control and/or
monitoring functions:
Control of process concentrations
Control of rinses
Temperature control
Counterflow and water management
Spray/Circulation pump pressure or power monitoring
The monitored variables will be alarmed and displayed on the
operator interface mounted on the face of the control panel. This
operator interface will be a color LCD screen with membrane
keypad unit which will provide the operator with text and
graphic screens to observe changing set-points, alarms, etc.
In addition, the most critical parameters will be trended.
The Lineguard® PC 2500 Process Control System is built
to standard Henkel specifications. The panel is of NEMA
12 construction, neat, serviceable and of the highest
quality workmanship.
FEATURES AND SPECIFICATIONS
Processor
• Allen-Bradley® SLC 5/04 (optional SLC 5/05)
• Operator interface:
Color, panelmate with membrane keypad
Screens to allow viewing of process variable, alarms,
operating modes, and trending
Screens to provide trending of analog process variables
and set-point for chemical stages only
Types of trends: 8 hour and 1 hour. 8 hour to contain
set-point and process variable. 1 hour to contain process
variable only
• Input voltage:
230/460 VAC, 50/60 Hz, three phase, grounded system
Three phase distribution block required, 30 amp service
• Output voltage:
120 VAC
• Operating modes:
Auto/off/timed/count, to be by PLC and operator interface,
manual mode by customer, using external H/O/A switches
and starters
• Measuring devices:
pH, conductivity, ORP, temperature
• 10 discrete outputs 120 VAC:
5 chemical feed pumps
1 alarm beacon/PLC down/extreme high alarms (requires
1discrete output)
4 autodrain per approved AD algorithm (requires 4 discrete
outputs)
• 8 discrete inputs 120 VAC:
Spray pump interlock (requires 5 inputs)
Line run (requires 1 discrete input)
Production count (requires 1 discrete input)
Output power on/off (requires 1 discrete input)
• 13 Analog inputs (2 wire only):
Process variables (trended on Panelmate)
PROCESS CONTROL SYSTEMS
Like all Henkel process control systems, the Lineguard® 760,
is backed by the training, documentation, parts support,
manuals, customer support desk and field technical support
necessary to maintain your system for many years.
PLC BASED
Lineguard® 760, Item 60257006
The system is based on Allen-Bradley® programmable control
components (SLC 5/04) and includes the SLC, rack, modules
and cables that may be required. Henkel will be responsible
for all programming of the Lineguard® System and its related
functions. The SLC will contain communication capability for a
Lineguard® DocSys™ IV or the Lineguard® Data Monitor
System.
9
All chemical concentration, temperature monitors/controls,
and rinse water quality process variables will be monitored,
alarmed and displayed on the panel-mounted operator
interface, which will be an Allen-Bradley® Panelview with a
membrane keypad. This will enable the operator to enter and
adjust set-points, alarm limits, timer settings, and operation
mode selection (i.e. Automatic or Semi-Automatic). The
Panelview will provide color graphic screens which will
provide the current operational status to the operator on each
process stage and all controlled variables.
The central control panel will be of NEMA 12 construction and
of the highest quality workmanship. The Lineguard® PC 5000
panel will contain interior lighting, utility outlet, cooler, constant
voltage transformer, DC voltage supply, terminals, fuses and
push-to-test pilot lights as required.
The standard system will be based on an Allen-Bradley® PLC
5/20 and will include the PLC, racks, modules and cables as
required. Henkel will be responsible for programming the
Lineguard® PC 5000 system and its related functions. The PLC
will have communication capability to a Henkel DocSys™.
The Lineguard® PC 5000 process control system will include the
required sensors and mountings, transmitters and mountings
necessary for complete process control of the line.
FEATURES AND SPECIFICATIONS
Processor
• Allen-Bradley® PLC 5/20 (optional PLC 5/20, PLC 5/30,
PLC 5/40, PLC 5/60)
• Operator interface:
Color, Panelview with membrane keypad
Screens to allow viewing of process variable, alarms, and
operating modes
• Input voltage:
230/460 VAC, 50/60 Hz, three phase, grounded system
Three phase distribution block required, 30 amp service
• Output voltage:
110 VAC
• Operating modes:
Auto/off/timed/count, to be by PLC and operator interface,
manual mode by customer, using external H/O/A switches
and starters
• Measuring devices:
pH, conductivity, ORP, temperature, and other specialty
devices
• 29 discrete outputs 120 VAC:
13 direct PLC fused chemical feed pumps output
1 alarm beacon/PLC down/extreme high alarms (requires 1
discrete output)
Up to 8 autodrain per approved AD algorithm (requires 8
discrete outputs)
• 29 discrete inputs 120 VAC:
Spray pump interlocks, as needed
Line run (requires 1 discrete input)
Production count (requires 1 discrete input)
Output power on/off (requires 1 discreet input)
• 31 Analog inputs (2 wire only):
Process variables (trended on Panelmate)
50001002
Conductivity sensor immersion assembly with SS disk
50001003
pH sensor immersion assembly with SS disk
60003012
Platinum electrode
60003129
SS disk
60004088
pH electrode
60004257
Reference electrode, with 6" lead wire
60004263
pH cable
60004362
Fluoride transmitter, 7-wire
60004379
Grommet
60004380
O-ring
60004404
Transmitter, 7-wire, without meter, complete fluoride immersion assembly with SS disk
60004581
Preamp
60004638
Contact conductivity transmitter, 2-wire, with analog meter
60004642
pH transmitter, 2-wire, with digital meter (millivolts)
60004643
Fluoride transmitter, 2-wire, with digital meter (millivolts)
60004712
Contact conductivity sensor, 2-wire cable
60004994
Electrode dummy ring
60006026
Electrodeless conductivity transmitter, 2-wire, with analog meter
60006044
Proximity sensor, inductive, plastic body, without meter
60006045
Mounting bracket for proximity sensor
60225800
Hex bushing, stainless steel
60225828
Protective sleeve
60225930
pH electrode kit
60225931
pH reference electrode kit
60226007
Flow chamber, stainless steel
60226039
Conductivity sensor, PTFE coated, 7-wire cable
60226043
ORP measure electrode platinum kit
60226082
Contact conductivity sensor, 100 micro-mho
60226084
500 micro-mho contact conductivity sensor
PROCESS CONTROL SYSTEMS
PROCESS CONTROL SYSTEMS
PLC BASED
Description
Item #
The Lineguard® PC 5000 process control systems are unique
in that they have the capability not only to manage the largest
process control requirements, but also to manage the related
machine control functions of the pretreatment system as well. In
addition, the various sensor and computer inputs are integrated
to provide the optimum in process and machine control while
minimizing both initial and long term maintenance costs. The
system can be customized to suit the special requirements of
your metal treatment process and machine operation.
10
Parts & Accessories: PLC Based
PLC BASED
Lineguard® PC 5000, Item 60257071
11
PLC BASED
PROCESS CONTROL SYSTEMS
12
Parts & Accessories: PLC Based (continued)
Description
Item #
60227128
Conductivity sensor (hockey stick style – 2-wire cable)
60227236
Sensor preamp circuit board pH & Fl
60227345
I/P transducer, 2-wire, 4-20 ma output, 3–15 PSI requires TE1H or TE1I for output signal
60227347
Conductivity sensor, peek
60227427
Reference electrode, with 3' lead wire
60227429
Complete fluoride sensor assembly with preamp (2-wire cable) with SS disk
60227505
Complete glass pH sensor assembly with preamp (2-wire cable) with SS disk
60227803
Conductivity sensor, PTFE coated (7-wire cable) modified for immersion
60227886
Lower Fl/pH sensor assembly
60227889
Fluoride electrode
60227948
pH sensor, 2-wire smart
60227950
Electrodeless conductivity transmitter, 2-wire smart, with digital display
60227951
Conductivity sensor, peek modified for immersion
60227952
pH transmitter, 2-wire smart, with digital display
60227960
Fluoride quick disconnect sensor assembly, 2-wire, CPVC
60227961
Fluoride quick disconnect sensor assembly, 7-wire, CPVC, including transmitter
60227962
3 pin sensor cable, Fl/pH, female
60227965
pH sensor, 2-wire flat smart
60227968
ORP transmitter, smart, 2-wire, with analog meter
60227995
3 pin sensor cable, Fl/pH, male
60227999
pH quick disconnect assembly, 7-wire, CPVC
60228044
Power monitor module to be mounted in customer’s motor control center
60228047
Temperature RTD in 4" 316 stainless steel thermal well with integral transmitter
60228048
Temperature RTD in 24" 316 stainless steel thermal well with integral transmitter
60228156
pH sensor, quick disconnect, bottom only, CPVC
60228163
Contact conductivity sensor, modified for immersion
60228174
pH flat sensor (Fl resistant)
Process Control Systems
PC Based
Henkel has recently introduced their most complete automated
process control and data acquisition systems in their
SmartControl ™ family of PC based logic control products.
Whether you have the need to control a basic pretreatment
line operation, a complete electro-coat paint line or a need for
complete process automation utilizing minimal manpower
support, Henkel has the right SmartControl ™ control system
for your plant. Our PC based SmartControl ™ products require
less capital for initial system design, less in-plant installation
wiring, and are more cost-effective for future expansion when
compared to similar PLC based control systems. The operator
training curve to learn how to manage a control system is
significantly reduced with our SmartControl ™ line of PC based
control products, when compared to similar PLC based control
systems. A familiar Windows® environment and “point and
click” mouse functions ease decision making.
the planned need of an engineer to travel to our customer’s plant.
Alarms and other problems can be automatically communicated
to both Henkel and customers at locations outside of the plant
as well.
Ask your Henkel sales representative about your plant’s
eligibility for enrolling in our SmartControl ™ Program for our
chemical and resin customers where you can get all of your
SmartControl ™ hardware and software, in-plant training, spare
parts, and future upgrades, all for a monthly or quarterly fee.
One of the most convenient features of our SmartControl ™
systems is the ability of the systems to communicate outside
of the plant-manufacturing environment. The systems can be
commissioned, troubleshot, and upgraded by Henkel without
Lineguard® SC 1000
SmartControl ™ System
Lineguard® SC 2000
SmartControl ™ System
Item #
60257142
60257255
Typical Control System
Data Acquisition Included
All pretreatment systems,
E-coat systems
Yes, customized
All pretreatment systems,
E-coat systems, motor controls
Yes, customized
PC Control
Desktop or industrial PC
Desktop and industrial PC
Expandability
Second line, additional plant operations
Communications
Remote support, network capable
System Back-Up
Spare hard drive
Second line, additional plant operations,
power management
Remote support, network capable,
E-mail alerts
Spare hard drives, PC redundancy
13
PC BASED
PROCESS CONTROL SYSTEMS
SmartControl ™ systems will provide the operator with a visual
display of all process variables, trends, and control events
such as alarms, set-point changes, and current operating
modes. In addition, the system will provide SPC charts for any
monitored variables with automatically calculated upper and
lower control limits, Cp and Cpk values.
The Lineguard® SC 1000 process management system is
comprised of a series of small Remote Process I/O Panels,
located throughout the production line. All input devices, such
as conductivity, temperature, pH, level, etc. for the process
tanks are connected to their respective Remote Process I/O
Panel, as well as any local output requirements (solenoid
valves, heating systems, etc.). Each chemical feed pump is
connected to the Central Chemical Feed Panel. All of these
panels are connected via ethernet cable to the main PC located
in the lab or office. The SC 1000 system comes standard with
a desktop PC, and can be ordered with an optional backup
PC mini-tower. Our SC 1000 systems are accessible by
Henkel through remote communication for upgrading and
trouble-shooting needs.
The Lineguard® SC 1000 SmartControl ™ line of process
controllers have proven to be reliable in many customer facilities
across the globe, continuing a long line of innovations in over
40 years of Henkel Process Control Systems development.
14
Remote process I/O panel
• Dimensions:
16" H x 16" or 20" W x 10" D
• Enclosures:
NEMA 12
• Inputs:
Up to 8, 12, or 16 analog inputs (depending on panel size)
Analog Inputs Devices available are: conductivity, pH,
temperature, ORP, pressure, line speed, horsepower, level,
production count, amperage and other specialty input devices
Up to 8 discrete inputs
• Outputs:
Up to 8 discrete outputs
Controlled output panel
• Dimensions:
16" H x 16" W x 10" D
• Outputs:
110/220 VAC
Up to 11 outputs: 4 outputs are relayed, 5 amps each;
7 outputs are not relayed, up to 3 amps each
• Miscellaneous:
Industrial grade, shielded ethernet cable included
All of the above panels will contain an ethernet switch or hub
Henkel’s Lineguard® SC 2000 SmartControl ™ control systems
are our most powerful PC based products for complete
process management and data acquisition utilizing a personal
computer based system. Our SmartControl ™ SC 2000
controllers communicate using ethernet protocol and are
highly customizable to fully automate paint lines and other
manufacturing operations. Advanced features include:
auto-start up sequencing of the production line, conveyor
speed control, oven controls (temperature and air movement),
all motor control functions, electro-coat paint controls (feed,
contamination, filtration, water quality, rectifier settings, and
usage), bulk inventory management, waste treatment control,
production count and many other functions to complete each
unique full automation process.
The SmartControl ™ system will provide the operator with a
visual display of all process variables, trend charts, and control
events such as alarms, set-point changes, and current operating
modes. In addition, the system will provide SPC charts for any
monitored variables, with automatically calculated Upper and
Lower Control Limits and Cp and Cpk values.
The Lineguard® SC 2000 process management system is
comprised of a series of small Remote Process I/O Panels,
located throughout the production line. The SC 2000 system
comes standard with two PCs working in a redundant ethernet
control network, and is available in any combination of standard
desktop PCs and/or industrial PCs. Our SC 2000 systems are
accessible by Henkel through remote communication for
upgrading and troubleshooting needs, and can communicate
alarms externally via email communications.
FEATURES AND SPECIFICATIONS
Personal computer
• Dell, mini-tower, 1.7 GHz or higher
• Minimum specs:
512 MB SDRAM
Dell Enhanced Quiet Key PS/2 keyboard
17.0" flat panel color monitor
Integrated video; Intel DVMT No 4 MB AGP
20GB, EIDE, 7200 RPM, ATA100 hard drive
Microsoft PS/2 IntelliMouse
CD-ROM, EIDE, 48X, OptiPlex
Integral Iomega® Zip® 250
HP 800 Series color inkjet printer
Various industrial computers available with each system
Spare back-up hard drives supplied with each system
• Software:
Microsoft Windows® NT or XP
Wonderware version 7.1 or higher
Northwest Analytical Quality Analyst
PROCESS CONTROL SYSTEMS
Henkel’s Lineguard® SC 1000 SmartControl™ systems are our
most popular PC based products for complete pretreatment
and paint system management, incorporating both control and
data acquisition capabilities into a personal computer. Our
SmartControl™ SC 1000 systems communicate using ethernet
protocol and are highly customizable to each customer’s pretreatment and paint line operations. Each SC 1000 system has
the capability of controlling multiple lines within a single facility,
and can be networked for centralized information gathering.
FEATURES AND SPECIFICATIONS
Personal computer
• Dell, Mini-tower, 1.7 GHz or higher
• Minimum specs:
512 MB SDRAM
Dell enhanced Quiet Key PS/2 keyboard
17" flat panel color monitor
Integrated video; Intel DVMT No 4 MB AGP
20 GB, EIDE, 7200 RPM, ATA100 hard drive
Microsoft PS/2 IntelliMouse
CD-ROM, EIDE, 48X, OptiPlex
Integral Iomega® Zip® 250
HP 800 Series color inkjet printer
Various industrial computers available as an option with
each system
Back-up hard drives supplied w/each system
• Software:
Microsoft Windows® NT or XP
Wonderware version 7.1 or higher
Northwest Analytical Quality Analyst
Lineguard® SC 2000 SmartControl ™ System, Item 60257255
PC BASED
Lineguard® SC 1000 SmartControl ™ System, Item 60257142
Remote Process I/O Panel
• Dimensions:
16" H x 16" or 20" W x 10" D
• Enclosures
NEMA 12
• Inputs:
Up to 8, 12, or 16 analog inputs (depending on panel size)
Analog inputs devices available are: conductivity, pH,
temperature, ORP, pressure, line speed, horsepower, level,
production count, amperage and other specialty input devices
Up to 8 discrete inputs
• Outputs:
Up to 8 discrete outputs
Controlled Output Panel
• Dimensions:
16" H x 16" W x 10" D
• Outputs:
110/220 VAC
Up to 11 outputs: 4 outputs are relayed, 5 amps each;
7 outputs are not relayed, up to 3 amps each
• Miscellaneous:
Industrial grade, shielded ethernet cable included
All of the above panels will contain an ethernet switch or hub
The Lineguard® SC 2000 SmartControl ™ is most suited for new
line projects, and can save significant capital when integrated
and installed during the construction phase of your project. For
more information on the SmartControl ™ 2000 Systems, please
contact our IES™ group for your individual application needs.
15
CHEMICAL FEED PUMPS
CENTRAL CHEMICAL FEED PANEL
LOCAL CONTROLLED
OUTPUTS
ETHERNET CABLE
REMOTE PROCESS I/O PANEL
STAGES 3 & 4
REMOTE PROCESS I/O PANEL
STAGES 1 & 2
ETHERNET
CABLE
ETHERNET CABLE
ETHERNET CABLE
LINEGUARD® SMARTCONTROL™ SYSTEMS
PC BASED
CORPORATE COMMUNICATIONS
OTHER PLANT OPERATIONS
PAINT AND OVEN SYSTEMS
BULK STORAGE
WASTE TREATMENT
ETHERNET CABLE TO:
LOCAL CONTROLLED
OUTPUTS
REMOTE PROCESS I/O PANEL
STAGES 7 & 8
REMOTE PROCESS I/O PANEL
STAGES 5 & 6
ETHERNET
CABLE
PROCESS VARIABLES
Easy –
Point-and-Click changes to set-points
PROCESS CONTROL SYSTEMS
PROCESS VARIABLES
PROCESS CONTROL SYSTEMS
SmartControl ™ Example Control Screens
PC BASED
16
Typical SmartControl ™ System Layout
Visual display of all tank conditions
17
PC BASED
Description
Item #
50001002
Conductivity sensor immersion assembly with SS disk
60227128
Conductivity sensor (hockey stick style – 2-wire cable)
50001003
pH Sensor immersion assembly with SS disk
60227236
Sensor preamp circuit board pH & Fl
60003012
Platinum electrode
60227345
I/P transducer, 2-wire, 4-20 ma output, 3-15 PSI requires TE1H or TE1I for output signal
60003129
SS disk
60227347
Conductivity sensor, peek
60004088
pH electrode
60227427
Reference electrode, with 3' lead wire
60004257
Reference electrode, with 6" lead wire
60227429
Complete fluoride sensor assembly with preamp (2-wire cable) with SS disk
60004263
pH cable
60227505
Complete glass pH sensor assembly with preamp (2-wire cable) with SS disk
60004362
Fluoride transmitter, 7-wire
60227803
Conductivity sensor, PTFE coated (7-wire cable) modified for immersion
60004379
Grommet
60227886
Lower Fl/pH sensor assembly
60004380
O-ring
60227889
Fluoride electrode
60004404
Transmitter, 7-wire, without meter, complete fluoride immersion assembly with SS disk
60227948
pH sensor, 2-wire Smart
60004581
Preamp
60227950
Electrodeless conductivity transmitter, 2-wire smart, with digital display
60004638
Contact conductivity transmitter, 2-wire, with analog meter
60227951
Conductivity sensor, peek modified for immersion
60004642
pH transmitter, 2-wire, with digital meter (millivolts)
60227952
pH transmitter, 2-wire smart, with digital display
60004643
Fluoride transmitter, 2-wire, with digital meter (millivolts)
60227960
Fluoride quick disconnect sensor assembly, 2-wire, CPVC
60004712
Contact conductivity sensor (2-wire cable)
60227961
Fluoride quick disconnect sensor assembly, 7-wire, CPVC, including transmitter
60004994
Electrode dummy ring
60227962
3 pin sensor cable, Fl/pH, female
60006026
Electrodeless conductivity transmitter, 2-wire, with analog meter
60227965
pH sensor, 2-wire flat smart
60006044
Proximity sensor, inductive, plastic body, without meter
60227968
ORP transmitter, smart, 2-wire, with analog meter
60006045
Mounting bracket for proximity sensor
60227995
3 pin sensor cable, Fl/pH, male
60225800
Hex bushing, stainless steel
60227999
pH quick disconnect assembly, 7-wire, CPVC
60225828
Protective sleeve
60228044
Power monitor module to be mounted in customer’s motor control center
60225930
pH electrode kit
60228047
Temperature RTD in 4" 316 stainless steel thermal well with integral transmitter
60225931
pH reference electrode kit
60228048
Temperature RTD in 24" 316 stainless steel thermal well with integral transmitter
60226007
Flow chamber, stainless steel
60228156
pH sensor, quick disconnect, bottom only, CPVC
60226039
Conductivity sensor, PTFE coated (7-wire cable)
60228163
Contact conductivity sensor modified for immersion
60226043
ORP measure electrode platinum kit
60228174
pH flat sensor (Fl resistant)
60226082
Contact conductivity sensor (4-wire cable), 100 micro-mho
60226084
500 micro-mho contact conductivity sensor
PROCESS CONTROL SYSTEMS
PROCESS CONTROL SYSTEMS
Description
Item #
PC BASED
18
Parts & Accessories: PC Based (continued)
Parts & Accessories: PC Based
19
Pretreatment Support Equipment
Pretreatment Support Equipment
Chemical Metering Pumps
Henkel’s HST pumps are versatile, high quality, chemical
metering pumps. Designed and manufactured by Henkel
specifically for our chemical processes, the HST pumps deliver
accurate feed rates from less than 1 GPH up to 60 GPH. Henkel
offers six models: HST 1, HST 2, HST 5 , HST 8, HST 25 and
HST 60. All pumps are compatible with most Henkel chemicals
and are built to the high quality and reliability standards that
are a trademark of Henkel.
A major part of any effective process control
system is the ancillary or “Support Equipment”
chosen to maximize process efficiencies. Support
Equipment can be used to maintain tighter
control limits to the process, recycle processing
solutions for longer bath life, reduce fresh water
requirements, or to minimize waste loading to a
general waste collection system. Henkel offers a
wide range of both standard and custom
Pretreatment Support Equipment, all designed
around Henkel pretreatment processes and
proven to ensure those processes run optimally.
The overall effectiveness of any pretreatment
operation lies in the Spray Nozzles chosen
appropriately for each different chemical and
rinse process. Typically, cleaners need to be
applied with as much impingement on the work
piece as necessary to remove all soil contaminants.
Water rinses require high volume flooding over
parts, in as short as time as possible. Reactive
treatments require the proper balance of
application and allowance of reaction time
before additional solution is introduced. Henkel
Spray Nozzles are designed to address each
specific process need, while being easy to
A key component to any pretreatment system is maintain. Henkel’s IES™ group is expert in matching
the Chemical Feed Pumps used for the dosing of our Spray Nozzles to each customer’s needs.
Henkel products to the working baths. Chemical
Feed Pumps must be durable, resistant to the These are just some of the more standard
various concentrated products, and reliable in Pretreatment Support Equipment items Henkel
maintaining flow to the processing baths. Our offers. Many special applications require unique
HST series of chemical feed pumps have provided Support Equipment to ensure usage is optimized,
our customers with dependability in maintaining and waste is minimized. For your Pretreatment
continuous operation of their manufacturing Support Equipment needs, look to Henkel’s IES™
processes, whether used as stand-alone feed group for your unique solution.
systems, or integrated into a Henkel process
management system.
Our Level Control products have set the industry
standard for both accuracy and longevity in
maintaining process solution levels in working
tanks. Henkel’s Level Controls design overcomes
many problems associated with other level
controls, where foam present in these tanks
often distorts the ability to accurately maintain
a consistent level.
20
When used in combination with our Chemical Metering
Pumps, Henkel’s Flow Totalizer system provides an accurate
means of measuring chemical usage over any period of time.
Our Flow Totalizer system can act as either a stand-alone
system, or they can be integrated in our Process Control
Systems for either fixed dosing of product over a period of
time, fixed chemical dosing per measured production unit(s),
or as a means of trending chemical usage from day-to-day.
HST 1
HST 2
HST 5
HST 8
HST 25
HST 60
N/A
Item #
60009140
60009141
60009142
60009143
60009145
60009160
Voltage
120 VAC/
60 Hz
0 – 1 GPH
120 VAC/
60 Hz
0 – 2 GPH
120 VAC/
60 Hz
1 – 5 GPH
120 VAC/
60 Hz
1 – 8 GPH
120 VAC/
60 Hz
3 – 25 GPH
120 VAC/
60 Hz
3 – 60 GPH
Delivery Rate
21
CHEMICAL METERING PUMPS
PA 1-CL Pump, Item 60241044
The HST 1 and HST 2 pumps provide the high accuracy and
repeatability required for lower volume applications.
The PA 1-CL pump is a versatile, low cost, high quality,
degassing metering pump which delivers accurate feed rates
from 0.10 GPH up to 1.0 GPH. The unique degassing valve
system makes this pump a perfect choice for metering
chemical products with high vapor pressures, such as chlorine
and hydrogen peroxide-containing materials. The PA 1-CL is
designed to allow gas bubbles to be vented from the pump
head while minimizing the return fluid volume. This also
prevents the pump from losing its prime due to gas build-up,
especially when the pump is running intermittently.
FEATURES AND SPECIFICATIONS
• Both stroke and pulse (frequency) adjustment for fine
control of delivery rate (HST 1 and HST 2)
• On/off switch
• Dual check valve assemblies to ensure better self-priming
and consistent delivery rates
• Indicator lights, power on, stroke indicator, and fault
• High reliability
• Voltage is 120 VAC, 60 Hz
• Materials compatible with most of Henkel’s liquid products
The HST 5, HST 8, HST 25 and HST 60 pumps provide the
superior operation and longer life for the higher demand of a
larger pump.
FEATURES AND SPECIFICATIONS
• Manual stroke adjustment for control of delivery rate
• On/off switch
• Dual check valve assemblies to ensure better self-priming
and consistent delivery rates
• Power on indicator light
• High reliability
• Voltage is 120 VAC, 60 Hz (220 VAC available upon request)
22
FEATURES AND SPECIFICATIONS
• Both stroke and pulse (frequency) adjustment for fine control
of delivery rate
• Auto/off (manual switch)
• Panel mounted circuit breaker
• Power on indicator light
• High reliability
• Available voltages are 110-120 or 230 VAC, 50/60 Hz
PRETREATMENT SUPPORT EQUIPMENT
HST 5/HST 8/HST 25/HST 60,
Items 60009142, 60009143, 60009145, 60009160
The materials of construction for the degassing head and
fittings are PVC. The valve seats and O-rings are made of Viton
and the check balls are ceramic.
CHEMICAL METERING PUMPS
PRETREATMENT SUPPORT EQUIPMENT
HST 1/HST 2, Items 60009140, 60009141
FOR MORE INFORMATION
Not only is it important to choose the proper pump delivery rate for each
chemical feed application, but the choice of materials of construction for all
pump parts coming in contact with the chemical is equally as important.
Our IES™ Sales group are expert in matching the proper chemical feed pump
size and material compatibility for all pretreatment, waste treatment, and
other chemicals requirements. Please contact the IES™ Sales department at
248.589.4647, or the Order Desk at 800.438.5975 and they will assist you
with your needs.
23
Lineguard® Flow Totalizer, Items 60228106, 60228022
Replacement Parts & Accessories: Chemical Metering Pumps
Item #
PRETREATMENT SUPPORT EQUIPMENT
Enclosed in a NEMA 4X panel, the Flow Totalizer display is
easy to read and easy to install. Just mount the display panel
near the pump, install the flow sensor on the input of the
pump, and plug the unit into a 110 VAC outlet. The unit is
prewired with easy, plug-in cables. Perform a simple calibration
procedure and the Lineguard® Flow Totalizer system is ready
for operation.
FEATURES AND SPECIFICATIONS
• Input Power:
110 VAC, 50/60 Hz
• Flow Rates:
0.07 to 5 GPM
• Maximum Ambient Temperature:
60ºF
• Display:
8-digit LCD
• Maximum Feed Pump Pressure:
150 PSI
• Tubing Connections:
3
⁄8" ID x 1⁄2" OD
HST pump kit: consisting of extended foot valve assembly & 50' tubing (for acids)
50001305
HST pump kit: consisting of extended foot valve assembly & 50' tubing (for alkalis)
50001315
Lineguard® flow totalizer for HST & PA series pumps
50001316
Polypro foot valve assembly (no tubing)
50001321
Lineguard® flow totalizer, 2"
60009146
HST 1 & 2 suction valve
60009147
HST 1 & 2 discharge valve
60009148
HST 1 diaphragm
60009149
HST 2 diaphragm
60009150
HST 5 & 8 suction valve
60009151
HST 5 & 8 discharge valve
60009152
HST 5 diaphragm
60009153
HST 8 diaphragm
60009154
HST 25 & 60 suction/discharge valve
60009155
HST 25 diaphragm
60009163
HST 1 & 2 coupling nut with SS ferrule
60009164
HST 5 & 8 coupling nut with SS ferrule
60009165
HST 25 coupling with SS ferrule
60225389
Injection check valve assembly, 1⁄2" NPT, for conditioner injection
60225395
Tubing connector
60225491
Foot valve, only (for acids)
60225512
Extended foot valve assembly, all pumps
60225513
Tubing 1⁄2" (for acids), all pumps, use this part number for lengths greater than 50'
60227902
Foot valve, only (for alkalis)
60227926
Tubing 1⁄2" (for alkalis), all pumps, use this part number for lengths greater than 50'
60228152
Tubing 1⁄2" (for alkalis), 50'
60228165
HST 1 & 2 pump multi-purpose valve
60228166
HST 5 & 8 pump multi-purpose valve
60228167
HST 25 pump multi-purpose valve
60228330
Tubing 1⁄2" (for acids), 50'
60241045
PA 1-CL degassing re-build kit, complete
PRETREATMENT SUPPORT EQUIPMENT
24
The Lineguard® Flow Totalizer system is very accurate, easy
to install and compatible with most of Henkel’s surface
technologies products. It is an effective tool for customers who
need to track their chemical costs or usage rates to the
various stages of their washers. The Lineguard® Flow Totalizer
system can either act as “stand-alone” devices on a processing
line, or can be integrated into most of our Lineguard® Process
Control Systems as part of a complete process management
program. A DC pulse output is available on the flow display
unit for this purpose.
50001300
CHEMICAL METERING PUMPS
CHEMICAL METERING PUMPS
Henkel’s Lineguard® Flow Totalizer system is the combination
of a digital flow monitor (Item 60228106) with our proven
“paddle-wheel” design flow sensor (Item 60228022) to
measure the amount of chemical dosages to various processes.
Our Lineguard® Flow Totalizer system has been developed to
fit the entire line of Henkel Chemical Metering Pumps. The
flow monitor will display the total gallons of chemical used
and, if desired, may be switched to display the current flow
rate in GPH (average rate only). The reading may be re-set by
the operator.
Description
25
Air Diaphragm Pumps, Items 60225559, 60225884, 60225978, 60227993
Pretreatment Support Equipment
Air Diaphragm Pumps
Our Air Diaphragm Pumps are actuated by plant air which has
been regulated by filter-regulator assemblies, available from
Henkel, to provide the desired delivery rate. When used in
conjunction with an air solenoid valve, also available from
Henkel, our Air Diaphragm Pumps can be used with our
Lineguard® Process Control Systems to manage appropriate
feed of the chemical slurry or high viscosity product to the
desired processing tank.
COMMON USES
Feeding chemical slurries to a process tank
Transferring products from a bulk tank to a day tank
Moving process solutions to and/or from a coalescing
oil separator
Metering chemical slurries or high viscosity products
with a Lineguard® Process Control system
Transferring waste streams from waste collection sumps
60225559
11⁄2" NPT
Pump
60225884
1" NPT
⁄2" NPT
1
The air operated 11⁄2" NPT pump has a cast iron head
with Buna-N diaphragm and Buna-N elastomers.
Capacity is 55 gal/min at 40 PSI.
The air operated 1" NPT pump has a 316 stainless
steel head with PTFE diaphragm and Viton elastomers.
Capacity is 20 gal/min at 40 PSI.
Item 60225978
Item 60227993
The air operated 1⁄2" NPT pump has a polypropylene
head with PTFE diaphragm and elastomers. Capacity
is 6 gal/min at 40 PSI.
The air operated 1" NPT pump has a polypropylene
head with PFTE diaphragm and Viton elastomers.
Capacity is 20 gal/min at 40 PSI.
1" NPT
Cast iron
Stainless steel
Polypropylene
Polypropylene
Diaphragms &
Elastomers
Operation
Buna-N
PTFE
PTFE
PTFE
Air operated
Air operated
Air operated
Air operated
Capacity
55 gal/min @ 40 PSI
20 gal/min @ 40 PSI
6 gal/min @ 40 PSI
20 gal/min @ 40 PSI
Please contact your local Henkel
chemical sales rep, or contact the
IES™ Sales group at (248) 589-4647,
or FAX at (248) 589-4806.
Item 60225884
60227993
Head
FOR MORE
INFORMATION
26
60225978
Item 60225559
PRETREATMENT SUPPORT EQUIPMENT
The pumps are constructed of materials ranging from cast
iron, polypropylene, and stainless steel. All pumps have PTFE
diaphragms and seals with the exception of the cast iron
pump, which has Buna-N diaphragm and seals. Pump sizes
range from 1⁄2" NPT to 11⁄2" NPT.
AIR DIAPHRAGM PUMPS
The Air Diaphragm Pumps offered by Henkel are manufactured
for general and special applications found in the chemical
industry. All of Henkel’s air operated pumps are capable of
pumping a wide variety of materials from chemical slurries to
high viscosity materials.
Replacement Parts & Accessories: Air Diaphragm Pumps
Item #
Description
60003061
Needle valve, 1⁄4" IPS (for air diaphragm pump)
60225554
Filter-regulator assembly with needle valve (for use with P/N 225884, 225559 & 227993)
60225560
Air solenoid valve, 1⁄2" NPT, 110 volt, 50/60 Hz VAC
60225979
Filter-regulator assembly with needle valve (for use with P/N 225978)
27
Pretreatment Support Equipment
Level Controls
The first variation is a Master Assembly, which takes in
raw plant air and regulates the pressure to operate the
units. Regulated air from the Master Assembly is then
“daisy-chained” in series with the second variation of units,
the Standard Assemblies. While most lines require only one
Master Assembly, larger pretreatment lines or lines on more
than one level may need more than one Master Assembly unit.
Henkel’s Level Control Assemblies have been used for a wide
range of applications, and have proven to be extremely
durable with systems over 20 years old still in use today.
These Level Control Assemblies are of Henkel design and not
available anywhere else. These units can stand-alone to
regulate all solution levels, or can be integrated into our
Lineguard® process control systems as a key component of
process management. For details on what configuration of
Henkel Level Controls is best for your application, please
contact our Integrated Equipment Solutions™ group for details.
A typical Henkel Level Control System would consist of a
Master Level Control on the first tank to be equipped and a
Standard Level Control on each subsequent tank. All tanks will
require a solenoid valve assembly. The level is maintained by
detecting slight variations in air pressure due to changes in
the liquid level surrounding an immersed air probe. Clean
plant air must be supplied to the master pressure regulator of
the system. A shutdown or loss of sufficient plant air will cause
an automatic shutdown of the Henkel Level Control System
electrical circuit. The electrical and pneumatic components
are housed in a NEMA 12 enclosure. Each level control
includes at least one air purge control to limit the air volume
used and a micro-switch to sense the set-point and operate
the solenoid valve circuit.
BENEFITS
Provides foolproof, corrosion-proof and safe liquid level control.
Eliminates operator errors that result in dangerous and costly
low levels or overflow that often result in lost production time
as well as chemical losses.
Item #
FOR MORE
INFORMATION
All of Henkel’s Pretreatment Support Equipment
include standard installation drawings which are
available even prior to your ordering equipment –
simply by contacting our IES™ Sales group at
248-589-4647, or by fax at 248-589-4806.
28
Description
Assures an adequate and consistent concentration of operating
chemicals when used as part of an Henkel automatic process
control system, aiding in uniform quality of coating and treatment.
The system is not affected by agitation in the tanks or by the
corrosive action of the contents. Only the chemically resistant
air probe is in direct contact with the process solution.
Saves in unnecessary use of water and direct labor expense to
perform the constant checking and adjusting of solution levels.
COMMON USES
Water Tank Level
Sump Pump Operation
Liquid Process Tank Level
Emergency Low Level Alarm
E-Coat Paint Tank Level
Chemical Bulk Tank and Day Tanks
Dilution of Liquids by Volume
Dirty Screen Alarm
Discrete Points
Power
Enclosure
PRETREATMENT SUPPORT EQUIPMENT
Each chemical processing tank, water rinse, electrocoat paint
or other solution has one Level Control Assembly unit assigned
to fully maintain tank operating levels. Our Level Control
Assemblies are offered in two variations with three different
level point capabilities.
Choosing how many point capabilities are required depends
on which process solution or rinse tank is being considered.
Typically, the first point of a Level Control Assembly is used as
the main level control, and could either add fresh water or
open a solenoid valve to allow another line tank to add liquid.
The second point acts as a back-up to the first point, normally
adding fresh water, and the third point as an extreme alarm, to
possibly send a signal to the spray pump controller to shut off
the pump.
Henkel Level Control Assemblies are used to maintain liquid
levels in chemical process operating tanks. Working on factory
air supply, they offer a fail-safe method of solution level control
within 1⁄4". No ball floats, needle valves or hazardous
electrodes are involved. The system is not affected by agitation
in the tanks or by the corrosive action of the contents. Only the
chemically resistant air probe is in direct contact with the
process solution. Each level controller can be supplied in
multi-point configurations for customized applications.
LEVEL CONTROLS
One of Henkel’s most established pretreatment support
equipment product lines is our Level Control systems. These
units have been designed to operate under the principle of
“bubbling” regulated air pressure into the tank solution and
measuring the changes in the back pressure across a
diaphragm located inside the Level Control enclosure. Henkel
has found that this method of level control is best suited for
our surface technologies product line as factors such as slight
to moderate foam levels in the processing solution do not
affect the system accuracy (+⁄- 1⁄4").
Level Control Assemblies,
Items 60225691, 60225692, 60225693, 60225694, 60225526, 60225527
Liquid Level Range
60225691
Standard One Point
Level Control Assembly
1
110 VAC 1 amp
NEMA 4
1 ⁄2" min, 5" max
60225692
Master One Point
Level Control Assembly
1
110 VAC 1 amp
NEMA 4
11⁄2" min, 5" max
60225693
Master Two Point
Level Control Assembly
2
110 VAC 1 amp
NEMA 4
Point 1, 11⁄2" min, 5" max
Point 2, 11⁄2" min, 5" max
60225694
Standard Two Point
Level Control Assembly
2
110 VAC 1 amp
NEMA 4
Point 1, 11⁄2" min, 5" max
Point 2, 11⁄2" min, 5" max
60225526
Master Three Point
Level Control Assembly
3
110 VAC 1 amp
NEMA 4
Point 1, 11⁄2" min, 5" max
Point 2, 11⁄2" min, 5" max
Point 3, 5" min, 44" max
60225527
Standard Three Point
Level Control Assembly
3
110 VAC 1 amp
NEMA 4
Point 1, 11⁄2" min, 5" max
Point 2, 11⁄2" min, 5" max
Point 3, 5" min, 44" max
1
29
Bulk Level Monitoring System, Item 60227931
Accessories: Level Control Assemblies
Description
Item #
60225078
Rotating beacon light (blue)
60227693
Solenoid valve assembly – 11⁄2" brass with Y-Strainer and manual shutoff, 1⁄2" only
60227694
Solenoid valve assembly – 11⁄2" stainless steel with Y-Strainer and manual shutoff, 1⁄2" only
60227695
Solenoid valve assembly – 13⁄4" brass with Y-Strainer and manual shutoff, 3⁄4" only
60227696
Solenoid valve assembly – 13⁄4" stainless steel with Y-Strainer and manual shutoff, 3⁄4" only
60227697
Solenoid valve assembly – 1" brass with Y-Strainer and manual shutoff
60227698
Solenoid valve assembly – 1" stainless steel with Y-Strainer and manual shutoff
PRETREATMENT SUPPORT EQUIPMENT
Outputs:
60225066
Air flow pressure switch with yellow spring
60225284
Air flow regulator for air probe pipe
60225723
Air regulator for plant air reduction (master only)
60225724
Line pressure shut-off switch (master only)
3 wire, 4 to 20 mA, non-isolated
amp SPDT Relay may be configured
for alarming
Measurement Range: 6" to 23' (ultrasonic sensor)
6" to 66' (radar sensor)
Supply Voltage:
120 VAC, 50/60 Hz
Pictured above: Ultrasonic bulk level sensor (item #60228040) and self-aligning
bulk head fitting (item #60228043). Not pictured: Bulk Level Monitoring
stand-alone local display (item #60228164).
* This display is part of the sensor, will be located on top of the tank, and is used
for calibration only.
DID YOU KNOW
FOR MORE INFORMATION
Henkel has a wide variety of standard CAD drawings illustrating typical
configurations for our Air Diaphragm Pumps which can be used to
assist our customer in understanding what components are necessary
for installation of these pumping systems. The IES™ group is happy
to provide these drawings to you upon request, which can either be
ground mailed or e-mailed to you, in a format you can use. For more
information, please contact the IES™ Sales group at 248.589.4647 or
800.438.5975, or FAX us at 248.589.4806.
In addition to offering our Bulk Level Monitoring System,
Henkel’s IES™ group also offers bulk tanks for all chemical
product storage needs. For more information in what size,
material and accessories are best for your bulk storage
needs, contact the IES™ Sales group at 248.589.4647 or
800.438.5975, or FAX us at 248.589.4806.
PRETREATMENT SUPPORT EQUIPMENT
30
Description
Item #
FEATURES AND SPECIFICATIONS
• All plastic with PVDF transducer and 2" mounting threads
• Simple push button calibration using the integral digital
display indicating level in inches or centimeters*
• Built-in logic to profile bulk tank to disregard false echoes
LEVEL CONTROLS
LEVEL CONTROLS
Replacement Parts: Level Control Assemblies
The Henkel Bulk Level Monitor is a unique system for
accurately measuring and monitoring the level of a chemical
product in bulk storage tanks. The system comes with one of
two styles of “non-contact” measurement systems: ultrasonic
or radar sensors (for bulk tanks greater than 23 feet high).
The system also has a scaled 4 to 20 mA DC output, for use in
either our Lineguard® Data Monitoring System, our Lineguard®
DocSys™ IV data management system, or in our Lineguard®
Process Control Systems.
Accessories: Bulk Level Monitoring System
Description
Item #
60228040
Ultrasonic bulk level sensor, with mini-display, 23' maximum
60228041
Radar bulk level sensor, with mini-display, 66' maximum
60228043
Self-aligning bulk head fitting
60228164
Bulk Level Monitoring stand-alone local display, 110 VAC, 50/60 Hz
60228183
Bulk Level Monitoring remote display, 110 VAC, 50/60 Hz
31
Low Drum Alarm, Item 60227860
Pretreatment Support Equipment
Spray Nozzles
The Henkel Low Drum Alarm is a single point, self-contained,
low cost liquid level sensor. It is self-contained due to the fact
that it has its own air compressor which eliminates the need
for plant air and allows for easy installation and maintenance.
PRETREATMENT SUPPORT EQUIPMENT
LEVEL CONTROLS
The alarm operates by sensing the increase or decrease (rising
or falling of liquid level) of back pressure in the sensor and
when a preset limit is reached, a micro-switch is tripped
which then activates a relay to trigger the alarm. Constant air
pressure is supplied by the control module, thus maintaining
uniformity of performance.
BENEFITS
• Higher quality
• Lower scrap/rework costs
• Operator awareness
• Lower operating/repair costs for pumps
• Better manpower utilization and time savings
FEATURES AND SPECIFICATIONS
• Visual alarm
• Audible alarm
• Compressor
• Non-conductive sensor
• 120 VAC, 50/60 Hz input power
Replacement Parts: Low Drum Alarm
Item #
Description
60227861
Pneumatic repair kit (for 227860 low drum alarm)
60227862
Electrical repair kit (for 227860 low drum alarm)
FOR MORE INFORMATION
Henkel has applied our extensive experience to develop a
spray nozzle which we believe is ideal for our customer’s
applications in the metal treatment industry. These nozzles are
easily adapted to most installations and are easy to install.
Constructed from glass reinforced polypropylene, they have an
integral stainless steel spring clamp to fit 1", 11⁄4", 11⁄2" and 2"
metal or plastic pipe and mount to a 21⁄32" drilled hole. Henkel
stocks the 21⁄32" and 9⁄16" sizes in packages of 25. Other sizes may
be ordered on request with a one to two week lead time.
The nozzle bodies and tips are color coded for easy identification
by size and type. Henkel spray nozzles are available in standard
V-jet, flat jet, hollow cone, flood jet, etc. They are designed to
work at pressures up to 60 PSI and temperatures up to 180°F.
(up to 125 PSI is available with a modified spring clamp.) The
nozzle tip can be adjusted within the body to easily optimize
spray patterns.
FEATURES AND SPECIFICATIONS
The Henkel nozzle assemblies contain the optimum combination
of glass and polypropylene to suit your chemistry and operating
temperatures without deforming. The Henkel nozzle has
significantly higher glass content than any competitive nozzle
– thus the Henkel nozzle will perform better and provide the
longest service life.
The “Spring Clamp” is specially tempered stainless steel and
wraps further around the riser than competitive designs. This
provides the most secure mounting available.
The tip is specially machined internally, to resist clogging and
build-up. This gives the nozzle extended life over other brands
of plastic nozzles.
Henkel nozzles are fitted with oversized o-rings to provide
better sealing and service life.
The clamping ring of the Henkel nozzle is larger in diameter
than competitive designs. This provides a more secure locking
of the tip in the socket to ensure that the spray pattern does
not change accidentally.
The orifice from the riser through the nozzle body is the largest
of any nozzle available. This significantly extends the time
between clean-out or replacement.
Tips are available and can be exchanged without replacing the
entire nozzle body providing significant cost savings.
The Henkel nozzles are very competitively priced and in most
cases are available from stock. Larger orders, if quantities are
not in stock, can be shipped in one to two weeks of receipt
of purchase order.
For more information and pricing, please contact our Sales
Desk at (248) 589-4647 or fax (248) 589-4806.
The “Pop-In” design will allow the nozzle tip to stay in place
when the retainer cap is removed. This feature will be
appreciated by anyone who has ever changed a nozzle and
had the tip fall into the process bath.
Contact your local Henkel rep, or contact the
Integrated Equipment Solutions™ Sales at
(248) 589.4647 or FAX at (248) 589.4806
or visit out website at
www.equipment.henkel.us
32
33
Selection Guides: Spray Nozzles
Flat Spray Assemblies: Spray Nozzles
Item #
Spigot Hole Size
Pipe Size
Nozzle Assembly
⁄32"
1"
HST 4050 Assembly
⁄32"
11⁄4"
HST 4050 Assembly
⁄32"
11⁄2"
HST 4050 Assembly
⁄32"
2"
HST 4050 Assembly
⁄32"
1"
HST 5070 Assembly
⁄32"
11⁄4"
HST 5070 Assembly
⁄32"
11⁄2"
HST 5070 Assembly
⁄32"
2"
HST 5070 Assembly
⁄32"
1"
HST 5060 Assembly
⁄32"
11⁄4"
HST 5060 Assembly
⁄32"
11⁄2"
HST 5060 Assembly
⁄32"
2"
HST 5060 Assembly
⁄32"
1"
HST 5050 Assembly
⁄32"
11⁄4"
HST 5050 Assembly
⁄32"
11⁄2"
HST 5050 Assembly
⁄32"
2"
HST 5050 Assembly
⁄32"
1"
HST 50100 Assembly.
⁄32"
11⁄4"
HST 50100 Assembly
⁄32"
11⁄2"
HST 50100 Assembly
⁄32"
2"
HST 50100 Assembly
⁄16"
11⁄4"
HST 5070 Assembly
⁄16"
11⁄4"
HST 4050 Assembly
⁄16"
11⁄4"
HST 5070 Assembly
⁄16"
11⁄2"
HST 4050 Assembly
⁄16"
2"
HST 5070 Assembly
⁄16"
11⁄2"
HST 50100 Assembly
⁄16"
2"
HST 50100 Assembly
⁄16"
11⁄2"
HST 5060 Assembly
⁄16"
11⁄4"
HST 5060 Assembly
⁄16"
11⁄4"
HST 5050 Assembly
Nozzle Performance: Spray Nozzles
4050
5070
5060
50° FLAT
10
15
20
25
30
40
10 PSI
20 PSI
30 PSI
2.5
3.1
3.5
4.0
4.3
5.0
34°
36°
41°
3.5
50° FLAT
3.0
4.3
4.9
3.7
5.5
4.2
6.1
4.7
5.2
7.0
44°
6.0
43°
49°
48°
3.5
4.0
4.3
5.0
44°
48°
51°
6520
65° FLAT
1.0
1.2
1.4
1.6
1.7
2.0
57°
62°
67°
80° FLAT
3.5
2.4
2.8
4.3
3.2
5.0
3.5
5.5
6.1
4.0
54°
7.0
72°
61°
78°
0.6
0.7
0.8
0.9
1.0
52°
70°
82°
9560
95° FLAT
3.0
3.7
4.2
4.7
5.2
6.0
86°
96°
99°
29
2.9
HOLLOW CONE
5.0
7.1
3.5
7.9
4.1
6.1
8.6
4.6
7.1
5.0
7.9
8.7
10.0
45°
6.1
50°
10.4
65°
49°
50°
50002105
21
50002106
21
50002107
21
50002108
21
50002109
21
50002110
21
50002111
21
50002112
21
50002113
21
65°
50002114
21
50002115
21
50002157
21
50°
65°
Distance from Nozzle Orifice (in inches)
8°
10°
12°
15°
18°
24°
30°
36°
42°
48°
50002158
21
40°
5.8
7.3
8.7
10.9
13.1
17.5
21.8
26.2
30.6
34.9
50002159
21
50°
7.5
9.3
11.2
14.0
16.8
22.4
28.0
33.6
39.2
44.8
50002160
21
65°
10.2
12.7
15.3
19.2
22.9
30.5
38.2
45.8
53.5
61.2
50002200
9
80°
13.4
16.8
20.2
25.2
30.3
40.3
50.4
60.4
70.5
80.6
50002205
9
95°
17.5
21.8
26.2
32.8
39.3
52.4
65.5
78.6
91.7
105
50002220
9
50002225
9
50002227
9
50002228
9
50002229
9
50002230
9
50002235
9
50002242
9
FOR MORE
INFORMATION
Please contact your local Henkel rep,
or contact the Integrated Equipment
Solutions™ Sales at (248) 589-4647,
or FAX at (248) 589-4806.
34
21
50°
Spray Coverage Information: Spray Nozzles
Spray Angle
50002104
PRETREATMENT SUPPORT EQUIPMENT
50
HOLLOW CONE
6.1
21
SPRAY NOZZLES
0.5
5.0
50002103
82°
80° FLAT
50° FLAT
21
65°
8010
50100
50002102
50°
3.1
2.0
21
50°
2.5
65° FLAT
50002101
Spray Angle
50° FLAT
8070
SPRAY NOZZLES
40° FLAT
GPM at PSI
5050
6540
PRETREATMENT SUPPORT EQUIPMENT
Type of Spray Pattern
21
NOTE: 1. All items listed are available only in lots of 25.
2. Nozzle Body with 21⁄32" Spigot Hole is the size recommended by Henkel surface technologies.
3. Call for pricing on quantities of 250 or more.
4. Call for pricing on nozzle assembly combinations not shown.
Nozzle Tip
50002100
35
Nozzle Assembly
Item #
⁄32"
1"
HST 6560 Assembly
50002145
21
⁄32"
11⁄4"
HST 6560 Assembly
50002146
21
⁄32"
11⁄2"
HST 6560 Assembly
50002147
21
⁄32"
2"
HST 6560 Assembly
50002148
21
⁄32"
1"
HST 6550 Assembly
50002149
21
⁄32"
11⁄4"
HST 6550 Assembly
50002150
21
⁄32"
11⁄2"
HST 6550 Assembly
50002151
21
⁄32"
2"
HST 6550 Assembly
50002152
21
⁄32"
1"
HST 6540 Assembly
50002153
21
⁄32"
11⁄4"
HST 6540 Assembly
50002154
21
⁄32"
11⁄2"
HST 6540 Assembly
50002155
21
⁄32"
2"
HST 6540 Assembly
50002156
21
⁄32"
1"
HST 6530 Assembly
50002189
21
⁄32"
11⁄4"
HST 6530 Assembly
50002190
21
⁄32"
11⁄2"
HST 6530 Assembly
50002191
21
⁄32"
2"
HST 6530 Assembly
50002192
21
⁄32"
1"
HST 6520 Assembly
50002193
21
⁄32"
11⁄4"
HST 6520 Assembly
50002197
21
⁄32"
11⁄2"
HST 6520 Assembly
50002198
21
⁄32"
2"
HST 6520 Assembly
50002204
9
⁄16"
11⁄4"
HST 6550 Assembly
50002206
9
⁄16"
11⁄2"
HST 6550 Assembly
50002207
9
⁄16"
2"
HST 6560 Assembly
50002224
9
⁄16"
2"
HST 6540 Assembly
50002226
9
⁄16"
11⁄4"
HST 6520 Assembly
50002231
9
⁄16"
11⁄2"
HST 6560 Assembly
50002233
9
⁄16"
11⁄2"
HST 6540 Assembly
50002234
9
⁄16"
2"
HST 6520 Assembly
50002238
9
⁄16"
11⁄4"
HST 6540 Assembly
50002244
9
⁄16"
11⁄2"
HST 6520 Assembly
50002255
21
50002116
21
50002117
21
50002118
21
50002119
21
50002120
21
50002121
21
50002122
21
50002123
21
50002124
21
50002125
21
50002126
21
50002127
21
50002128
21
50002129
21
50002130
21
50002131
21
50002141
21
50002142
21
50002143
21
50002144
21
50002201
9
50002221
9
50002232
9
50002241
9
50002243
9
50002245
9
50002248
9
50002249
9
50002252
9
50002254
9
NOTE: Call for pricing on nozzle assembly combinations not shown.
PRETREATMENT SUPPORT EQUIPMENT
Pipe Size
Spigot Hole Size
Pipe Size
Nozzle Assembly
⁄32"
1"
HST 8070 Assembly
⁄32”
11⁄4"
HST 8070 Assembly
⁄32"
11⁄2"
HST 8070 Assembly
⁄32"
2"
HST 8070 Assembly
⁄32"
1"
HST 8010 Assembly
⁄32"
11⁄4"
HST 8010 Assembly
⁄32"
11⁄2"
HST 8010 Assembly
⁄32"
2"
HST 8010 Assembly
⁄32"
1"
HST 9560 Assembly
⁄32"
11⁄4"
HST 9560 Assembly
⁄32"
11⁄2"
HST 9560 Assembly
⁄32"
2"
HST 9560 Assembly
⁄32"
1"
HST 8060 Assembly
⁄32"
11⁄4"
HST 8060 Assembly
⁄32"
2"
HST 8060 Assembly
⁄32"
11⁄2"
HST 8060 Assembly
⁄32"
11⁄4"
HST 8040 Assembly
⁄32"
11⁄2"
HST 8050 Assembly
⁄32"
11⁄2"
HST 8040 Assembly
⁄16"
11⁄4"
HST 8010 Assembly
⁄16"
11⁄4"
HST 9560 Assembly
⁄16"
11⁄4"
HST 8040 Assembly
⁄16"
11⁄2"
HST 8010 Assembly
⁄16"
11⁄2"
HST 9560 Assembly
⁄16"
2"
HST 8010 Assembly
⁄16"
2"
HST 8040 Assembly
⁄16"
2"
HST 8070 Assembly
⁄16"
2"
HST 9560 Assembly
⁄16"
11⁄4"
HST 8060 Assembly
⁄32"
11⁄4"
HST 12010 Assembly
PRETREATMENT SUPPORT EQUIPMENT
36
Spigot Hole Size
SPRAY NOZZLES
SPRAY NOZZLES
Item #
Flat Spray Assemblies (continued)
NOTE: Call for pricing on nozzle assembly combinations not shown.
Flat Spray Assemblies (continued)
37
Plug Assemblies: Spray Nozzles
Item #
Flat Spray Nozzle Tips: Spray Nozzles
Spigot Hole Size
Pipe Size
Nozzle Assembly
Item #
⁄32"
11⁄4"
HST Plug Assembly
⁄16"
2"
HST Plug Assembly
50002194
21
50002237
9
Hollow Cone Assemblies: Spray Nozzles
Nozzle Assembly
⁄32"
1"
HST 29 Assembly
⁄32"
1 ⁄4"
HST 29 Assembly
⁄32"
1 ⁄2"
HST 29 Assembly
⁄32"
2"
HST 29 Assembly
⁄32"
1"
HST 50 Assembly
⁄32"
1 ⁄4"
HST 50 Assembly
⁄32"
1 ⁄2"
HST 50 Assembly
⁄32"
2"
HST 50 Assembly
⁄16"
1 ⁄4"
HST 50 Assembly
⁄16"
1 ⁄4"
HST 29 Assembly
⁄16"
1 ⁄2"
HST 50 Assembly
⁄16"
11⁄2"
HST 29 Assembly
⁄16"
2"
HST 29 Assembly
⁄16"
2"
HST 50 Assembly
50002161
21
50002162
21
50002163
21
50002164
21
50002165
21
50002166
21
50002167
21
50002168
21
50002202
9
50002203
9
50002222
9
50002223
9
50002239
9
50002246
9
1
1
1
1
1
1
1
Threaded Ball Assemblies: Spray Nozzles
Item #
Spigot Hole Size
Pipe Size
⁄32"
11⁄4"
HST 1/4 NPT
⁄32"
1
1 ⁄2"
HST 1/4 NPT
⁄32"
11⁄4"
HST 3/8 NPT
⁄32"
11⁄2"
HST 3/8 NPT
⁄16"
2"
HST 3/8 NPT
⁄16"
11⁄4"
HST 3/8 NPT
50002170
21
50002171
21
50002174
21
50002175
21
50002250
9
50002253
9
Nozzle Assembly
NOZZLE
HST 4050 Tip
60226105
NOZZLE
HST 5070 Tip
60226108
NOZZLE
HST 5060 Tip
60226111
NOZZLE
HST 5050 Tip
60226114
NOZZLE
HST 6560 Tip
60226117
NOZZLE
HST 6550 Tip
60226120
NOZZLE
HST 6540 Tip
60226123
NOZZLE
HST 6530 Tip
60226126
NOZZLE
HST 6520 Tip
60226127
NOZZLE
HST 8006 Tip
60226128
NOZZLE
HST 8010 Tip
60226129
NOZZLE
HST 8040 Tip
60226131
NOZZLE
HST 9560 Tip
60226145
NOZZLE
HST 50100 Tip
60226218
NOZZLE
HST 8070 Tip
60227844
NOZZLE
HST 8060 Tip
Hollow Cone Nozzle Tips: Spray Nozzles
Item #
NOTE: Call for pricing on nozzle assembly combinations not shown.
PRETREATMENT SUPPORT EQUIPMENT
Pipe Size
60226102
Type
Nozzle Assembly
60226134
NOZZLE
HST 29 Tip
60226136
NOZZLE
HST 50 Tip
Threaded Ball Tips: Spray Nozzles
Item #
Type
Nozzle Assembly
60226140
BALL
HST 1/4 NPT
60226143
BALL
HST 3/8 NPT
Type
Nozzle Assembly
NOZZLE
HST Plug Tip
Plug Tips: Spray Nozzles
Item #
60226154
38
PRETREATMENT SUPPORT EQUIPMENT
Spigot Hole Size
Nozzle Assembly
SPRAY NOZZLES
SPRAY NOZZLES
Item #
Type
39
Nozzle Bodies: Spray Nozzles
Item #
Tank Mixing Eductors: Spray Nozzles
Spigot Hole Size
Pipe Size
Nozzle Assembly
Item #
⁄32"
11⁄2"
Body Assembly
60226174
3
⁄32"
1"
Body Assembly
60226175
3
⁄32"
11⁄4"
Body Assembly
60226176
⁄32"
2"
Body Assembly
⁄16"
1"
Body Assembly
⁄16"
11⁄4"
Body Assembly
⁄16"
11⁄2"
Body Assembly
⁄16"
2"
Body Assembly
60226152
21
60226215
21
60226216
21
60226217
21
60226220
9
60226221
9
60226222
9
60226223
9
Description
⁄8" tank mixing eductor
⁄4" tank mixing eductor
11⁄2" tank mixing eductor
Tank Mixing Eductor
DIP 7100 Assemblies: Spray Nozzles
Item #
60228225
Item #
Description
50002000
EPDM O-ring
50002010
Viton O-ring
60226137
Retainer cap
60228240
Description
⁄2"
DIP 7100 Assembly
11⁄2"
DIP 7100 Assembly
1
SPRAY NOZZLES
SPRAY NOZZLES
Miscellaneous Parts: Spray Nozzles
Pipe Size
DIP Assembly Spare Parts: Spray Nozzles
Item #
Nozzle Assembly
Quick Disconnect Parts: Spray Nozzles
Item #
Pipe Size
Description
Part D:
Coupler x FT
Twinjet nozzle tip
60228242
Nozzle tip cap
60228243
⁄2" split eyelets – Quickjet
1
50002003
11⁄4"
Part D
50002011
11⁄2"
Part D
For Part #60228240 – DIP 7100 assembly, 11⁄2" pipe
50002012
11⁄2"
Part DP
60226137
Retainer cap
50002014
11⁄2"
Part F
60226140
Threaded ball 1⁄4" NPT
50002015
11⁄4"
Part F
60226152
11⁄2" nozzle body assembly, 21⁄32" spigot
50002017
11⁄4"
Part DP
60228238
Twinjet nozzle tip with retainer
50002018
1"
Part F
50002019
1"
Part D
Part DP:
Plug
Part F:
Adapter x MT
TO ORDER:
Quick Disconnect Parts: Spray Nozzles
Item #
40
60228241
PRETREATMENT SUPPORT EQUIPMENT
PRETREATMENT SUPPORT EQUIPMENT
For Part #60228225 – DIP 7100 assembly, 1⁄2" pipe
Pipe Size
Description
50002004
11⁄4"
Riser support
50002013
11⁄2"
Riser support
50002251
2"
Riser support
Riser Support
CALL: 800.438.5975
or FAX: 248.589.4806
Visa, Mastercard & American Express accepted
41
Bonderloc™ Nozzle Assemblies: Spray Nozzles
Nozzle Application Drawing
Item #
™
60228245
Description
11⁄2"
Bonderloc™ Assembly
⁄2"
Bonderloc™ Assembly
1
"
60228248
Pipe Size
'
Bonderloc™ Assembly Spare Parts: Spray Nozzles
Item #
Nozzle Assembly
Retainer cap
60226140
Threaded ball 1⁄4" NPT
60226152
11⁄2" Nozzle body assembly, 21⁄32" spigot
60228244
Atomizing nozzle tip
For Part #60228248 – Bonderloc™ nozzle assembly, 1⁄2" pipe
60228243
"
"
'
60228246
Atomizing nozzle tip
60228247
Nozzle tip cap
"
"
'
'
⁄2" split eyelets – Quickjet
1
PRETREATMENT SUPPORT EQUIPMENT
PRETREATMENT SUPPORT EQUIPMENT
60226137
SPRAY NOZZLES
SPRAY NOZZLES
For Part #60228245 – Bonderloc™ nozzle assembly, 11⁄2" pipe
"
FOR MORE INFORMATION
"
Contact your local Henkel rep, or contact the
Integrated Equipment Solutions™ Sales at
(248) 589.4647 or FAX at (248) 589.4806
or visit out website at
"
www.equipment.henkel.us
42
43
Bonderloc™ Nozzle Application Drawing
'
"
™
Pretreatment Support Equipment
Coalescing Oil Separators
The process cleaner is fed to the system via an air operated
pump. As it passes through the unit, oil accumulates on the
media to a point where it breaks loose and floats to the surface
and is skimmed off to a waste container (provided by others).
The process cleaner is returned to the main tank via gravity or
another air operated pump. The only operating adjustments
required are the initial adjustment of the skim level and pump
rate for flow adjustment. Aside from the pump(s), there are no
moving parts in the Coalescing Oil Separator. The maintenance
requirement is limited to the removal and cleaning of the
coalescing media* and removal of accumulated sediment
from the settling area. The frequency required is dependent on
the amount of product and type of oil being processed.
The size varies depending on the amount and nature of the oil
being removed, as well as the process cleaner being used. The
Coalescing Oil Separators are easy and inexpensive to install,
requiring a supply line, a return line to the process cleaner
stage, and plant air supply. The units may be mounted on a
stand or located on any flat surface.
Note: These units are intended as a means to improve the
operating efficiency of process cleaner baths and not as a
waste treatment device.
*The effectiveness of the coalescing media may diminish after a period of time due to
buildup of contaminants on the media surfaces.
'
'
"
PRETREATMENT SUPPORT EQUIPMENT
SPRAY NOZZLES
The Henkel Coalescing Oil Separators provide an effective
means of reducing the oil content in process cleaners. The
design, coupled with the oleophillic coalescing media, provides
for the settling of suspended particles as well as separation
and removal of a high percentage of dispersed oil contained in
typical process cleaners.
"
3 GPM
Coalescing Oil Separator
Item #
60227584
60227836
Max
Throughput Rate
Plant Air
Needed
20 Gallons Per Minute
3 Gallons Per Minute
30 PSI min, 100 PSI max,
30 SCFM max
30 PSI min, 100 PSI max
"
"
20 GPM
Coalescing Oil Separator
44
45
20 GPM Coalescing Oil Separator, Item 60227584
Pretreatment Support Equipment
Ion Exchange
PRETREATMENT SUPPORT EQUIPMENT COALESCING OIL SEPARATORS
The 20 GPM Coalescing Oil Separator has a maximum
throughput rate of 20 gallons per minute which is normally
sufficient for process tanks up to 5,000 gallons. A floating weir
and 20' of tubing is optional.
SPECIFICATIONS
Dimensions:
Plant Air needed:
8' 5" L x 3' W x 4' H
30 PSI min, 100 PSI max,
30 SCFM max
The Henkel Lineguard® Ion Exchange 870 system is our latest
development in technology to provide an effective means to
reduce the need for bath stabilization as a method of controlling
iron contaminant levels in an Autophoretic® coating bath. In
addition, the Lineguard® Ion Exchange 870 system is effective
in controlling sodium levels in the Autophoretic® coating bath
which can be detrimental to the long-term performance of the
coating system.
3 GPM Coalescing Oil Separator, Item 60227836
The 3 GPM Coalescing Oil Separator has a maximum
throughput rate of 3 gallons per minute. A floating weir and
20' of tubing is provided.
SPECIFICATIONS
Dimensions:
Plant Air needed:
4' 2" L x 5' 8" W x 3' 5" H
30 PSI min, 100 PSI max
Optional Spare Parts: Lineguard® Ion Exchange 870 System
Description
Item #
Recommended Quantity
60008006
Solenoid valve, 3-way
1
60008025
O-rings, Viton
2
60008026
PP weaver for distributor
1
60008060
O-rings for in/out adapter
1
60008078
IEX replacement column w/ Resin*
2
60008079
Air ball valve, 3-way, 2"
1
60008080
Air ball valve, 3-way, 11⁄2", normally closed
1
60008081
Level switch
1
60008082
O-rings, Viton, 1⁄2" valve
2
60008083
O-rings, Viton, 1" valve
2
60008084
O-rings, Viton, 11⁄2" valve
2
60008085
O-rings, Viton, 2" valve
2
60008086
Air ball valve, 3-way, 11⁄2", normally open
1
* Note: It is not recommended that you order longer-term spare replacement columns due to dry shelf-life considerations. Instead, you should order these columns two months
maximum prior to planned installation.
46
47
Lineguard® Ion Exchange 870 System, Item 60257210
Test Equipment & Data Management Systems
BENEFITS
The Lineguard® IEX 870 System will significantly reduce
specific solid and liquid waste treatment concerns.
The system provides variable load capacity and incorporates a
means for operator adjustment of regeneration, due to
changes in the effectiveness of resin capacity and production
loading of the Autophoretic® autodeposition process, via the
number of ion exchange process cycles run per day.
PRETREATMENT SUPPORT EQUIPMENT
ION EXCHANGE
The system provides high reliability. It also includes the latest
in our control equipment technology, to control pump and
valve sequencing during regeneration, and alarm features in
the event of system malfunction.
The control system included with the Lineguard® IEX 870
System is fully expandable to our SmartControl ™ system, with
capabilities of controlling all chemical, heating, and motor
control functions of the entire ACC® production line.
The system is built with industrial rated components to provide
low maintenance and ease of serviceability. The Lineguard® IEX
870 system is comprised of PC based programmable control
components and includes all necessary racks, modules,
cables, power supplies, and utility outlet with ground fault
interrupt. Also included is our data acquisition and SPC analysis
software (DocSys™ IV), providing a complete system capable
of meeting your ISO and QS requirements.
The system is built to the highest standards of workmanship.
The unit is on a compact, skid-mounted, transportable frame
for ease of installation. The unit is enclosed on three sides to
minimize safety hazards, with all utilities and field connections
readily accessible. The frame is acid and corrosion resistant.
FEATURES AND SPECIFICATIONS
Dimensions:
7' 3" H X 3' 4" D X 5' 5" W
Electrical Specs:
120 VAC, 60 Hz, 15 amps
FOR MORE
INFORMATION
While Henkel Process Control Systems will manage bath
concentrations and rinse contaminations, and our
Pretreatment Support Equipment will ensure your
processes run optimally, a good manufacturing quality
control program is not complete without the proper Test
Equipment and Data Management System.
Our Data Management Systems not only allow for
communication of data from all analog devices on the
pretreatment/paint/process line, but also provide a routine
for the manual entry of all end-product test results
performed in the quality control laboratory. Being
capable of analyzing any data sets over any time
period is not only a valuable tool for greater process
Henkel offers several types of Test Equipment which understanding and control, but also serves as a means of
have been specially designed to manage the wide variety making continual improvement a reality.
of surface technologies product applications. Most of this
equipment has been designed while working with our Henkel has always maintained an active new product
customers to evaluate specific testing criteria that may development program. We continue to introduce new
be unique to their way of measuring end-product quality. Test Equipment and have added features to our Data
Management Systems, to even further enhance the
All of our Test Equipment is supported by the Integrated performance of Henkel’s surface technologies product
Equipment Solutions™ group, including exchange programs lines. If you have the need for any special Test
of the equipment during scheduled calibration activities. Equipment, or are looking to boost your ability to manage
These calibration activities are performed by the IES™ end-product quality with a Data Management System,
group, back in our laboratories, with quality certificates please contact the Integrated Equipment Solutions™
group and discuss your needs with our control specialists.
provided for quality record-keeping.
Every good quality programs needs to have a dependable
and user-friendly Data Management System for not only
online measurement of quality for their production, but a
system which presents data in a meaningful manner for
analysis, and stores that information for any future
needs. Our Lineguard® Data Monitoring System and our
Lineguard® DocSys™ IV Process Interface System are
perfectly designed for companies looking to either establish
or maintain quality certifications, with such programs as
ISO 9000/9001 or QS 9000.
To learn whether or not your Autophoretic®
process is suited for use with our Lineguard®
Ion Exchange 870 System, please contact your
local Henkel chemical sales representative and
they can assist you in your evaluation process.
48
49
Lineguard® 101D Meter, Item 60007255
Lineguard® Data Monitoring System, Item 60228171
The Lineguard® Data Monitoring System, Henkel’s automatic
process data acquisition and analysis system, is the result
of our years of experience with process control, customer
feedback, and an extensive development program.
The Lineguard® 101D Meter is a digital meter which measures
the active fluoride ion concentration in certain acidic solutions
used in the treatment of aluminum, carbon steel, and stainless
steel. The instrument measures the magnitude (micro amperes,
DC) of the electrical current through a fluoride sensitive
electrode system. This current is proportional to the concentration
of active fluoride ions present in the sample. The instrument
is capable of the direct measurement of solution samples
containing a maximum equivalent fluoride ion content of
4 grams per liter.
50
®
Options: Lineguard 101D Meter
Item #
Description
60003652
101D meter cable assembly
60228336
101D meter sample cup
Our Lineguard® Data Monitoring System has been designed
to complement our Lineguard® 46 and 96 solid state control
systems, as well as our Lineguard® PC 760 and PC 2500 PLC
based controllers. For our solid state systems, there are two
models available: 16 analog signals input (Item 60228171)
and 32 analog signals input (Item 60228250). The PLC based
controller Data Monitoring System (Item 60228061) can be
used with either the Lineguard® PC 760 or PC 2500 units.
You can connect any number and combination of our
Lineguard® 46 and 96 units to the Lineguard® Data Monitoring
System, as long as the maximum number of analog signals is
not exceeded. A Signal Collection Panel is provided with the
system, and will serve as the interface between the control
unit(s), and the system’s provided personal computer (PC).
Typically, this PC system is located in a lab or office area.
The Lineguard® Data Monitoring System will be set up and
programmed by Henkel’s IES™ group. Henkel has designed
this system to be easy to use and operate, incorporating Help
screens for every operation. Provided with each system is
complete documentation, including all installation prints and a
detailed operation manual. As an option, Henkel’s IES™ group
can provide in-plant installation guidance, as well as formal
training programs for you and your staff.
DID YOU KNOW?
Henkel’s IES™ group offers both unit rentals
and calibrations for all their Lineguard®
101 Meters. Contact the IES™ Sales group
at (248) 589-4647 for more details.
FEATURES AND SPECIFICATIONS
System Management: The color graphic display will provide
a clear understanding of the current status of all the monitored
variables of the wet-section. All alarms and warnings will be
clearly indicated. The operator will be able to adjust any of the
monitored variable alarm limits available (Note: this will not
affect the alarms at the individual controllers).
SPC Report Generation: The system will provide the capability
to produce an SPC analysis of any monitored variable over a
time period selected by the operator. The report may be
viewed on the monitor or printed if an optional printer is used.
Trending: The operator will be able to observe graphs showing
the trend value of any of the monitored variables. These trend
charts will be automatically updated by the system.
Archive Data: The operating data can be archived on a
removable media storage device, such as Iomega® Zip® Disks,
or CD-RW discs, providing convenient and cost effective long
term data storage. The system will provide a warning when
data downloading is recommended.
Lineguard® Quality Analyst: This data entry module enables
the operator to input the data that is collected manually such
as temperature readings, titrations, pressures, pH, etc. This
information is then available to the system to automatically
calculate and produce SPC and trending reports. The information
entered will be archived and available for printing in the same
manner as with the automatically collected data.
Personal computer minimum specifications:
• Dell, Mini-tower, 1.7 GHz or higher
• 512 MB SDRAM
• Dell Enhanced Quiet Key PS/2 keyboard
• 17.0" flat panel color monitor
• 20GB, EIDE, 7200 RPM, ATA100 hard drive
• Microsoft PS/2 IntelliMouse
• CD-ROM, EIDE, 48X, OptiPlex
• Removable media storage device
• HP 800 Series color inkjet printer (optional)
TEST EQUIPMENT & DATA MANAGEMENT SYSTEMS
TEST EQUIPMENT & DATA MANAGEMENT SYSTEMS
FEATURES AND BENEFITS
• Digital display for easy reading and accuracy
• Automatic measurement cycle so that the operator does not
have to remain with the meter to complete an accurate
reading. The operator puts the sample in the sample cup
and simply presses the start button. When the six-minute
measurement time cycle is completed, the reading will
lock-on and the indicator light will illuminate
• All plastic, chemical resistant enclosure
• 110 VAC for bench-top use
• One meter for all required ranges
The Lineguard® Data Monitoring System provides the operator
a clear overview of the process dynamics, providing a valuable
tool for the fine tuning of pretreatment washer variables,
to deliver optimum quality and minimum cost of operation.
The system offers continually updated SPC analysis of all
monitored variables at the operator’s request.
51
Lineguard® DocSys™ IV System, Item 60257038
The Henkel Lineguard® DocSys™ IV washer management system is our most advanced automatic process data acquisition
and analysis system, and is the result of many years working
with our customers in developing the best tools for their quality management programs.
The Lineguard® DocSys™ IV has the advantage of being able to
be used as either the primary or secondary interface for entering
and adjusting all system settings. As a remote human/
machine interface (HMI), this washer management system
can be located near quality control stations where manual
measurements are being made and changes to control
set-points require a quick response.
The Lineguard® DocSys™ IV system also provides the operator
a clear overview of the process dynamics, providing a valuable
tool for the fine tuning of pretreatment washer variables, and
to deliver optimum quality and minimum cost of operation.
The system offers continually updated SPC analysis of all
monitored variables at the operator’s request.
TEST EQUIPMENT & DATA MANAGEMENT SYSTEMS
Our Lineguard® DocSys™ IV system has been designed to
function with and complement our customized Lineguard® PC
5000 PLC based controller systems, and their Allen-Bradley®
(A-B) Series 5 programmable logic controllers. A communication
module is provided, to allow data exchange across the A-B
Data Highway between the Lineguard® PC 5000 PLC and the
washer management system’s personal computer (PC).
52
The Lineguard® DocSys™ IV system will be set up and custom
programmed by Henkel’s IES™ group. Henkel has designed
this system to be easy to use and operate, incorporating help
screens for every operation. Provided with each system is
complete documentation, including all installation prints and a
detailed operation manual. As a recommendation, Henkel’s
IES™ group can provide in-plant installation guidance, as well
as formal training programs for you and your staff.
FEATURES AND SPECIFICATIONS
System Management: The color graphic display will provide
a clear understanding of the current status of all monitored
variables of the wet-section. All alarms and warnings will be
clearly indicated. The operator will be able to adjust any of the
monitored variable alarm limits available (Note: this will not
affect the alarms at the individual controllers). The operator
will be able to adjust any of the system set-points and/
or alarm limits for this system. Changes made through the
computer will show the corresponding change on the main
control panel operator display.
SPC Report Generation: The system will provide the capability
to produce an SPC analysis of any monitored variable over a
time period selected by the operator. The report may be
viewed on the monitor or printed if an optional printer is used.
Alarm/Event Log: The system will maintain a log of all
alarms, listing type, time and date on, time and date off, and
maximum or minimum value. The log will also track “events”
such as set-point changes.
Trending: The operator will be able to observe graphs showing
the trend value of any of the monitored variables. These trend
charts will be automatically updated by the system.
Archive Data: The operating data can be archived on a
removable media storage device, such as Iomega® Zip® Disks,
or CD-RW discs, providing convenient and cost effective long
term data storage. The system will provide a warning when
data downloading is recommended.
Lineguard Quality Analyst: This data entry module enables
the operator to input the data that is collected manually such
as temperature readings, titrations, pressures, pH, etc. This
information is then available to the system to automatically
calculate and produce SPC and trending reports. The
information entered will be archived and available for printing
in the same manner as with the automatically collected data.
Personal computer minimum specifications:
• (Same minimum specifications as the Data Monitoring
System, see page 51)
• HP 800 Series color inkjet printer (optional)
• Allen-Bradley® Data Highway communications module