Knick Ceramat WA160 User Manual Download Page 1

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Ceramat® WA160(X)

Ceramic Retractable Fitting

User Manual

www.knick.de

Read before installation.

Keep for future use.

Summary of Contents for Ceramat WA160

Page 1: ...Ceramat WA160 X Ceramic Retractable Fitting User Manual www knick de Read before installation Keep for future use ...

Page 2: ...vice Team before returning a defective device Ship the cleaned device to the address you have been given If the device has been in contact with process fluids it must be decontaminated disinfected before shipment In that case please attach a corresponding Declaration of Contamination see page 43 for the health and safety of our service personnel ...

Page 3: ... activated by other persons during servicing or installation e g cleaning or replacing the sensor During operation the drive unit of the Ceramat retractable fitting is rotating rather quickly by 140 There is a risk of injury Be sure to observe Work on the retractable fitting shall only be performed by personnel authorized by the operating company and specially trained for handling and operating th...

Page 4: ...g and Removing a Sensor 18 Removing the Drive Unit 19 Installing the Drive Unit 21 Installing the Sensor 22 Removing the Sensor 24 Functioning of the Cavity Rinsing 26 Condensate Drain 27 Automatic Condensate Drain 28 Installation Dimensions 30 Permissible Forces and Flow Rates 31 Ceramat WA 160 X 1 4571 Variant 31 Specifications 32 Maintenance Work on the Drive Unit 33 Maintenance Intervals 34 Ga...

Page 5: ...midity ambient temperature chemicals and corrosion Safe Use If you are not sure whether the retractable fitting can be safely used for your intended application please contact the manufacturer To ensure safe use of the equipment you must follow the instructions given in the manual and observe the specified temperature and pressure ranges The SensoGate WA 160 X retractable fitting has been develope...

Page 6: ...6 Intended Use Ceramat WA 160 X Retractable Fitting Rating Plates Ceramat WA 160 X N Drive unit Process Ceramat WA 160 X X Drive unit Process Process small rating plates Process small rating plates ...

Page 7: ...7 Package Contents Ceramat WA 160 X Retractable Fitting Check the shipment for transport damage and completeness The package should contain Retractable fitting Documentation Test certificates ...

Page 8: ...g sensor socket C22 L PEEK w o integrated sensor protection sensor socket PEEK with PEEK scraper ring M PEEK w o integrated sensor protection sensor socket with full sensor protection 1 4404 N PVDF w o integrated sensor protection sensor socket with full sensor protection 1 4404 O PEEK w o integrated sensor protection sensor socket with full sensor protection C22 P PVDF w o integrated sensor prote...

Page 9: ...SI 316 300 lbs 3 5 P 4 Flange loose ANSI 316 300 lbs 4 P 5 Flange loose ANSI 316 300 lbs 5 P 6 Flange loose ANSI 316 300 lbs 6 P 7 Immersion depth 600 A 1000 B 1500 C 2000 D Immersion tube material Stainless steel 1 4571 1 Stainless steel 1 4435 polished 2 Stainless steel PP sheathed 3 Stainless steel PVDF sheathed 4 Special variant Without 000 Equipped with special grease provided by customer 1 F...

Page 10: ...position With the Unical 9000 probe controller all media control air and the check back cable for posi tion indication of the probe are connected to the retractable fitting through a compact connector multiplug Since the pneumatic drive unit and the process unit with the ceramic retractable fitting are sepa rate modules the drive unit can be removed and replaced under process conditions Installati...

Page 11: ...s unit comprises the immersion tube the process wetted probe housing with the ceramic rotary slides and an integrated calibration chamber as well as the process connection e g flange Drive unit and process unit can be separated by the operator even under process pressure when certain safety precautions are taken see Maintenance Work on the Drive Unit on page 33 Drive unit Process unit Bail handle ...

Page 12: ...ns for immersion depths 600 1000 1500 2000 mm others on request Versions with flange dairy pipe DN80 pipe clamp Immersion tube made of stainless steel 1 4571 Immersion tube made of PP Immersion tube made of PVDF Composition of the Retractable Fitting Modules Available Drives Process Connections ...

Page 13: ...sing calibration media and check back are combined in a single hose with just one plug connection multiplug This hose is referred to as media connection This media connection is installed on the Ceramat together with the outlet hose When you do not use a probe controller Unical or Uniclean and Protos measuring system you can connect the supply lines for control air rinsing calibration media and el...

Page 14: ... of the Ceramat Screw the bracket of the media connection to the holding bracket of the Ceramat Mounting screws Installing the outlet hose Turn the outflow nipple so that the outlet hose points outwards see figure on the left Before tightening the coupling nut correctly align and insert the outflow nipple NOTICE Check positioning of coding recess es and coding bars to lock the connection Outlet ho...

Page 15: ...r and connect to the fixing bracket B in a loop as shown in the illustration Using clamp C attach the cable lightly so that the cable is secured and not con stricted The rotational movement of the Ceramat would otherwise damage the cable NOTICE The cable loop must be long enough so that the cable does not impede the stroke movement of the fitting Connect the equipotential bonding cable to terminal...

Page 16: ...the position of the sensor protector for example in flowing media With corresponding installation in the flange bores the retractable fitting can be aligned for the process Probe housing Probe guard Free direction of flow Against direction of flow Information on Installation Positioning the Sensor Protection ...

Page 17: ...the fluids Connection to Unical or Uniclean The corrugated hose is screwed to the joining piece of the Unical or Uniclean Thanks to a slitted coupling nut the different media tubes can easily be fed through The tubes are designed and color coded for clear assignment See also Unical 9000 X Uniclean 900 X Installation Guide Connection to media adapter This connection is plugged and screwed to the me...

Page 18: ... install a damaged sensor Check whether slide washer or O ring on the sensor are damaged and replace if required Remove the watering cap from the sensor tip and rinse sensor with water Internally pressurized sensors might have a silicone seal on the diaphragm as transport protection Remove this seal using the knife shipped with the sensor For installing or removing a sensor you must separate the d...

Page 19: ...erate device 3 Make sure that no process fluid is leaking from the outlet 4 Turn coupling nut counterclockwise using the ZU 0648 mounting wrench see Accessories page 39 This pulls the drive unit out of the process unit You can slightly lift up the drive unit while turning the nut to support its movement Do not cant the unit and do not exert force Do not loosen the coupling nut completely 5 Make su...

Page 20: ...20 Removing the Drive Unit Ceramat WA 160 X Retractable Fitting NOTICE Be sure not to damage the glass body of the sensor at the lower end of the drive unit ...

Page 21: ...pling nut 2 When inserting the drive unit in the immer sion tube make sure that the guiding pin A engages with the groove B of the drive unit Only then can the drive unit be moved to its mounting position and the coupling nut be screwed tight 3 After successful alignment you can insert the drive unit and screw the coupling nut tight until it noticeably stops Where required con tinue to press the d...

Page 22: ...ge 19 1 Use appropriate sensors C only Diameter 12 0 5 mm Length 225 mm Observe the pressure resistance of the sensor 2 Check whether slide ring A or O ring B on the sensor are damaged A B C D 3 Bend the sensor end D in direction of the arrow until it noticeably snaps in This gives access to the sensor coupling ...

Page 23: ...ng the Sensor Ceramat WA 160 X Retractable Fitting E F 4 Screw in the sensor head E 19 mm A F PG 13 5 with a max torque of 3 Nm recommended tool 19 mm wrench e g Knick ZU 0647 5 Attach the cable connector F Push the sensor end back direction of arrow ...

Page 24: ...A 160 X Retractable Fitting Removing the Sensor First remove drive unit page 19 1 Bend the sensor end A in direction of the arrow until it noticeably snaps in This gives access to the sensor coupling B A 2 Loosen the cable connector B ...

Page 25: ...25 Removing the Sensor Ceramat WA 160 X Retractable Fitting 3 Remove the sensor ...

Page 26: ...rained off using the cavity rinsing function For this procedure the inlet is rerouted to the cavities when the WA160 moves to PROCESS position When the rinsing func tion is activated e g by Unical the cavities are rinsed and the fluids are drained off through the outlet Normally rinsing should be performed every 8 hours for 30 seconds With very frequent probe movements aggressive or sticky process...

Page 27: ...ng is in PROCESS position these channels are always connected to the outlet D If now in PROCESS position pressure is applied to the pneumatic connection E above the flange the condensate will be drained out of the fitting through the check valve and the outlet The Ceramat WA 160 X retractable fitting is equipped with a condensate drain Specifications Barometric pressure 4 bar recommended max 5 bar...

Page 28: ...ss menu key to select menu Select parameter setting using arrow keys confirm by pressing enter Passcode 1989 default Parameter setting Select Probe control Icons to assign the measured values displayed specifies module slot I specifies module slot II Probe controller Select Fixed interval from the Time control pull down menu Then open the Fixed interval menu Fixed interval Select a new user progra...

Page 29: ...e Drain Ceramat WA 160 X Retractable Fitting Fixed interval Administrator Interval OK 25 6 C Program 7 05 pH Interval Program Interval Program 024 0 h Off 024 0 h Off User 2 024 0 h Back Probe control Administrator Controller Back Fixed interval 7 05 pH Program flow Time control Cal preset values Fixed interval Installation Unical 9000 Block Service Back 25 6 C Parking 7 05 pH User 2 Cal 2point Ca...

Page 30: ...on tube Stainless steel Immersion tube PP or PVDF Drive 190 7 480 178 7 000 DN80 31 2 from DN100 4 115 4 528 A B 600 23 622 1200 47 244 1000 39 370 1600 62 992 1500 59 055 2100 82 677 2000 78 740 2600 102 362 Clearance for disassembly Immersion depth Installation Dimensions Ceramat WA 160 X ...

Page 31: ...31 Permissible Forces and Flow Rates Ceramat WA 160 X 1 4571 Variant Immersion depth Immersion depth 1500 mm 2000 mm Fmax 400 N 300 N Vmax 4 m s 3 m s Vmax Fmax 1 4571 Variant ...

Page 32: ...on IP 66 Permissible control pressure to move the retractable fitting 4 7 bar Quality of compressed air Standard According to ISO 8573 1 2001 Quality class 3 3 3 or 3 4 3 Solid contaminants 3 max 5 μm max 5 mg m3 Water content for temperatures 15 C Class 4 pressure dew point 3 C or below Water content for temperatures 5 15 C Class 3 pressure dew point 20 C or below Oil content Class 3 max 1 mg m3 ...

Page 33: ... rotary slides i e even after a breakage in the ceramics or a defect in the probe housing an uncontrolled escaping of process fluid is prevented When removing the drive unit under process conditions you must check whether the first barrier rotary slides probe housing functions properly NOTICE Before working on the drive unit make sure that the retractable fitting is in SERVICE position This positi...

Page 34: ...ocess interruption Where required examine the cavity rinsing If deposits or chemical attacks on the probe housing are sus pected visible in the probe housing after removing the drive unit check the process unit After 10 years or 500 000 cycles Complete maintenance at the factory with replace ment of pneumatic sealings lubricants and check of all functions pressure test leak test These maintenance ...

Page 35: ...eso Glep1 B EPDM ZU 0663 Syntheso Glep1 C FFKM ZU 0664 Syntheso Glep1 E EPDM FDA ZU 0665 Beruglide L H FFKM FDA On request Beruglide L K FFKM On request Syntheso Glep1 PP or PVDF A FKM ZU 0681 Syntheso Glep1 B EPDM ZU 0682 Syntheso Glep1 C FFKM ZU 0683 Syntheso Glep1 E EPDM FDA ZU 0684 Beruglide L H FFKM FDA On request Beruglide L K FFKM On request Syntheso Glep1 Stainless steel 1 4435 A FKM ZU 06...

Page 36: ... good 5 unsuitable 1 not resistant to hydrochloric or sulfuric acid 2 not resistant to strongly oxidizing media conc sulfuric acid nitric acid or hydrofluoric acid 3 not resistant to ketones amines fuming sulfuric and nitric acid The stated values are reference values and provide general information Concentrations temperatures mechanical influ ences and load duration influence the material resista...

Page 37: ...can be applied excellent lubricating properties also at increased temperatures and for a large number of stroke movements This lubricant contains sili cone and is only used as special application on specific request Application Pharma Food Chemistry Wastewater Lubricant Beruglide L silicone free FDA compliant NSF H1 registered Paraliq GTE 703 silicone containing FDA compliant USDA H1 Syntheso Glep...

Page 38: ...619 Ceramat sensor socket PVDF FKM ZU 0620 Ceramat sensor socket PVDF EPDM ZU 0621 Ceramat sensor socket PVDF FFKM ZU 0622 Ceramat sensor socket PVDF EPDM FDA ZU 0623 Sensor socket long steel 1 4571 FKM ZU 0672 A Sensor socket long steel 1 4571 EPDM ZU 0672 B Sensor socket long steel 1 4571 FFKM ZU 0672 C Sensor socket long steel Hastelloy C22 FKM ZU 0673 A Sensor socket long steel Hastelloy C22 E...

Page 39: ...ch Serves to disconnect the drive unit or mount it to the process unit via the coupling nut of the drive unit Sensor socket with mounted O rings ZU 0616 Sensor socket PEEK O rings FKM ZU 0617 Sensor socket PEEK O rings EPDM ZU 0618 Sensor socket PEEK O rings FFKM ZU 0619 Sensor socket PEEK O rings EPDM FDA ZU 0620 Sensor socket PVDF O rings FKM ZU 0621 Sensor socket PVDF O rings EPDM ZU 0622 Senso...

Page 40: ...t Hastelloy O rings EPDM ZU 0673 C Sensor socket Hastelloy O rings FFKM Grip recesses Sensor socket full sensor protection with mounted O rings This sensor socket is recommended for brittle incrus tations e g lime In addition the sensor is better mechanically protected Hastelloy C22 material can be identified by a missing grip recess ZU 0808 A Sensor socket 1 4571 O rings FKM ZU 0808 B Sensor sock...

Page 41: ... This adapter allows the introduction of an additional rinse medium beyond the available media connec tion media hose It is mounted between the Ceramat and the media hose multiplug The following variants are available ZU 0654 1 Adapter PEEK O rings FKM ZU 0654 2 Adapter PEEK O rings EPDM ZU 0654 3 Adapter PEEK O rings FFKM ZU 0655 1 Adapter 1 4571 O rings FKM ZU 0655 2 Adapter 1 4571 O rings EPDM ...

Page 42: ... mm you should use the ZU 0651 bail handle for maintenance Check valve RV01 RV 01 check valve is suitable for preventing back flow of process medium or rinse calibration solution into the inlet of retractable fittings controllers or fit tings made by Knick Connections G1 8 or G1 4 female or male thread Housing material valve body stainless steel 1 4404 or PEEK Gasket material FKM EPDM FFKM FKM FDA...

Page 43: ...ial number Included accessories The product has not been exposed to hazardous substances or mixtures The product has been exposed to hazardous substances or mixtures State the classification of the hazardous substance as applicable together with the hazard statements or R phrases or at minimum provide the relevant hazard pictograms The product has been exposed to infectious substances The product ...

Page 44: ... Fax 49 30 80191 200 info knick de www knick de Local Contacts www knick international com 096329 TA 203 081 KNE05 Copyright 2019 Subject to change Version 5 This document was last updated on August 2 2019 The latest documents are available for download on our website under the corresponding product description ...

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