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The Ceramat pneumatic sensor lock-gate with ceramic sealing is used for installing a sensor for measuring

process variables in liquid media. The sensor can be cleaned, calibrated, or replaced under process conditions

(pressure and temperature).

Since the pneumatic drive unit and the process unit with the ceramic sensor lock-gate are separate modules,

the drive unit can be removed and replaced under process conditions.

The sensor lock-gate is suitable for sensors with an outer diameter of 12 mm, for sensors:

• with solid electrolyte, length 225 mm, sensor head with PG 13.5

• with liquid electrolyte, length 250 mm

• for optical sensors with a body diameter of 12 mm or 12.7 mm (1/2“)

(For installing an optical sensor, you require a special adapter which is listed in the Product Coding under

“Special version”. Information on design and use of the suitable adapter is provided in a supplementary

datasheet.)

The Ceramat sensor lock-gate allows:

• inserting and retracting the sensor under process pressure (sensor lock-gate)

• calibrating or adjusting the measuring system and cleaning the sensor in the running process

(different options available)

• removing or replacing the sensor after separation from the process (in SERVICE position)

The Ceramat sensor lock-gate has been developed and manufactured in compliance with the applicable

European directives and standards.

Compliance with the European directives and standards is confirmed by the EC Declaration of Conformity.

Compliance with the European Harmonized Standards for use in hazardous locations is confirmed by the

EC-Type-Examination Certificate.

To ensure smooth performance of the measuring points with the Ceramat, a number of important operating

and maintenance parameters must be complied with (see Ceramat Maintenance Instructions).

There is no particular direct hazard caused by the operation of the device in the specified environment.

Intended Use

CAUTION

Safe use

• If you are not sure whether the sensor lock-gate can be safely used for your intended application, please

contact the manufacturer.

• Take account of the influences of humidity, ambient temperature, chemicals and corrosion.

• To ensure safe use of the equipment, you must follow the instructions given in this manual and observe

the specified temperature and pressure ranges.

WARNING

Application in hazardous locations

For hazardous-area applications, the sensors used must ensure proper separation of the ATEX zones. When

the sensor lock-gate is in SERVICE position, the sensor may be replaced within a Zone 1 hazardous location.

Содержание Ceramat WA 153

Страница 1: ...User Manual English Latest Product Information www knick de Ceramat WA 153 Sensor Lock Gate ...

Страница 2: ...eam 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 39 for the health and safety of our service personnel Trademarks The following trademarks are used in this manua...

Страница 3: ...with the marking II 1 GD c II is a Category 1 device intended for use in Zone 0 or Zone 20 The following shall be observed in accordance with EN 13463 1 The Ceramat WA 1 X sensor lock gate shall not be used as Category 1 equipment if process wetted parts of the process adaptation contain by mass more than 10 in total of aluminum magnesium titanium and zirconium or more than 7 5 in total of magnesi...

Страница 4: ...Electrolyte Sensor 20 pH Sensors Oxygen Sensors Conductivity Sensors 20 Installing Removing a Liquid Electrolyte Sensor 21 pH Sensors 21 Cavity Rinsing Function 23 Maintenance Work on the Drive Unit 24 Removing the Drive Unit 25 Installing the Drive Unit 26 Installation Dimensions 27 Solid Electrolyte 27 Liquid Electrolyte 28 Process Adaptations and Immersion Depths Examples 29 Specifications 30 M...

Страница 5: ...ter separation from the process in SERVICE position The Ceramat sensor lock gate has been developed and manufactured in compliance with the applicable European directives and standards Compliance with the European directives and standards is confirmed by the EC Declaration of Conformity Compliance with the European Harmonized Standards for use in hazardous locations is confirmed by the EC Type Exa...

Страница 6: ...6 Intended Use Rating Plates Ceramat WA 15x N Drive Process Ceramat WA 15x X Drive Process Process small rating plates Process small rating plates ...

Страница 7: ...7 Package Contents Check the shipment for transport damage and completeness The package should contain Sensor lock gate Documentation Test certificates ...

Страница 8: ... long protection 1 4404 full protection PEEK without protection Titanium without protection Titanium short protection Scraper for sensor socket Without PEEK natural Immersion depth Special immersion depth 23 104 mm 1 mm increments Immersion depth 105 mm max Process wetted material Hastelloy C22 1 4404 Titanium Process adaptation Flange loose 1 4571 PN10 16 DN 50 Flange loose 1 4571 PN10 16 DN 65 F...

Страница 9: ...ge loose ANSI 316 300 lbs 6 G2 1 4 for ARF210 215 K 8 Clamp 2 5 J 3 Clamp DN 50 DIN 32676 J H BioControl 1 4404 DN 65 L 2 Varivent 1 4404 from DN 50 V 1 Probe guard Without With version 1 Special version Without Equipped with special grease provided by customer Sensor protection tube for optical sensor Hellma with Ø12 mm and additional anti twist protection for the sensor cables rotating adapter 1...

Страница 10: ... compressed air a control unit such as the Unical 9000 moves the sensor between SERVICE position and PROCESS position and leads different calibration and or cleaning liquids to the sensor located in the calibration chamber These liquids leave the calibration chamber through an outlet hose i e they are displaced from the calibration chamber by following liquids or by compressed air To replace the s...

Страница 11: ...nge or dairy pipe screw joint 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 24 Composition of the Sensor Lock Gate Process adaptation eg flange Drive unit Process unit Fixing bracket Probe housing with ceramic rotary slides Media connection to Unical 9000 X probe cont...

Страница 12: ...mposition of the Sensor Lock Gate Drive units Process adaptations examples Flange Dairy pipe screw joint Varivent Drive unit for sensors with solid electrolyte Drive unit for sensors with liquid electrolyte ...

Страница 13: ...edia 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 electrical check bac...

Страница 14: ... chamber due to gravity alone is prevented by the loop in the outlet hose when the Ceramat is installed at an angle of up to 15 above the horizontal see figure 1 With horizontal to upside down installations you must install an appropriate hose bend above the level of the calibration chamber to prevent leakage from the calibration chamber see figure 2 max 1 meter Calibration chamber level Above lev...

Страница 15: ... cables Attach the connecting cable A to the sensor 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 constricted The rotational movement of the Ceramat would otherwise damage the cable A B C F NOTICE Check positioning of coding recesses and coding bars to lock the connection NOTICE The cable loop ...

Страница 16: ...so applies to installation of ZU 0631 standard media interface Attaching the hose to the fixing bracket of the Ceramat Attach the bracket of the media connection to the fixing bracket of the Ceramat with mounting screws Mounting screws Connecting the multiplug Connect multiplug A with 2 screws B as shown A B ...

Страница 17: ...valves in the multiplug minimize contamination and prevent mixing of the calibration fluids Connection to Unical or Uniclean The corrugated hose is screwed to the joining piece of the Unical or Uniclean You can easily feed the different media tubes through the slit in the securing nut The different tube lengths and diameters provide for a clear assignment to the different connection points color c...

Страница 18: ...ined personnel authorized by the operating company The Ceramat sensor lock gate must be in SERVICE position This position is attained by the Maintenance menu when controlled by Protos 3400 X see user manual of PHU 3400 X 110 module the service switch see Unical 9000 X installation manual ...

Страница 19: ...are any sealing elements at the bottom of the sensor holder from previous installations which have not been removed A B Installing Removing a Sensor Note When using a PEEK scraper ring on the sensor socket of the Ceramat or when retrofitting a Ceramat with sensor socket including scraper ring as accessory ZU 0705 ZU 0706 or ZU 0707 see Accessories page 35 the proper functioning of the sensor dismo...

Страница 20: ...13 5 thread with a max torque of 3 Nm recommended tool 19 mm wrench eg Knick ZU 0647 6 Install sensor cable and media connection see Information on Installation on page 13 ZU 0647 A B C Removing the sensor 1 Move probe into SERVICE position The sensor must only be removed in SERVICE position 2 Before removing the sensor check that there is no liquid flowing out of the outlet ceramic slides or prob...

Страница 21: ...s damaged glass broken Remove watering cap from the sensor tip and rinse sensor with water SERVICE P R O C E S S ca 7 0 As the Ceramat performs a rotary movement in addition to the stroke movement you must posi tion the sensor D in a way that the filling hole B eg Schott or the TOP labeling eg Mettler C of the sensor is turned out of the vertical by approx 70 when the sensor lock gate is inclined ...

Страница 22: ...k gate is in SERVICE position 2 Loosen small coupling nut A do not remove it 3 Unscrew large coupling nut B completely counterclockwise 4 Pull the detached unit upwards 5 Install or remove sensor C 6 Replace the unit you have detached in step 4 First hand tighten the large coupling nut B and then the small coupling nut A clockwise A B C B A ...

Страница 23: ...tion For this procedure the inlet is rerouted to the cavities when the sensor lock gate moves to PROCESS position When the rinsing function is activated eg 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 media the rinsing intervals sh...

Страница 24: ...manual of PHU 3400 X 110 module While working on the sensor lock gate other persons must be prevented from actuating the control unit The position indicator shows whether the sensor lock gate is in SERVICE position WARNING When the drive unit must be removed under process conditions be sure to wear protective clothing gloves and goggles to protect yourself against process fluid that might escape T...

Страница 25: ...s page 35 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 sure that no process fluid is leaking from the outlet 6 Completely loosen the coupling nut and pull off the drive unit upwards ZU 0648 NOTICE Be sure to follow t...

Страница 26: ...ss unit make sure that the guiding grooves of the drive unit A engage with the guiding bars of the process unit B 3 After successful alignment you can insert the drive unit and screw the coupling nut tight until it noticeably stops Where required continue to press the drive unit in while screwing the coupling nut to make screwing easier Hand tighten the coupling nut using the ZU 0648 Ceramat mount...

Страница 27: ...27 Installation Dimensions Approx 600 mm clearance for sensor installation Solid Electrolyte ...

Страница 28: ...28 Installation Dimensions Approx 800 mm clearance for sensor installation Liquid Electrolyte ...

Страница 29: ...es BioControl Tri Clamp Varivent Flange Dairy pipe Process adaptation Max ID in mm Min ID in mm Flanges 105 32 Dairy pipe 105 28 Varivent 105 23 Tri Clamp 2 105 23 BioControl DN65 105 40 ID immersion depth ID max ID min ID max ID min ID max ID min ID max ID min ID max ID min ...

Страница 30: ...re dew point 20 C or below Oil content Class 3 max 1 mg m3 Sensors with solid electrolyte Ø12 mm length 225 mm with temp detector PG 13 5 thread with liquid electrolyte Ø12 mm length 250 mm with temp detector Optical sensors Ø 12 mm Ø 12 7 mm 1 2 Process adaptations See product coding Connections Outlet Socket for Unical media hose for pressurized sensors Hose connection NW 6 Pressure in sensor ch...

Страница 31: ...ally loaded O rings without process interruption Where required examine the cavity rinsing If deposits or chemical attacks on the probe hous ing are suspected 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 tes...

Страница 32: ... can be applied excellent lubricating properties also at increased temperatures and for a large number of stroke movements This lubricant contains silicone and is only used as special application on specific request Application Pharma Food Chemistry Wastewater Lubricant Beruglide L silicone free FDA conforming NSF H1 registered Paraliq GTE 703 containing silicone FDA conforming USDA H1 Syntheso Gl...

Страница 33: ...s are available for repair and servicing Sealing kit Process wetted rinse wetted sealings Order no Suitable lubricant included Set A FKM FKM On request Syntheso Glep1 Set B EPDM EPDM On request Syntheso Glep1 Set E EPDM FDA EPDM FDA On request Beruglide L Set F FKM FDA FKM FDA On request Beruglide L Set H FFKM FDA FFKM FDA On request Beruglide L Set K FFKM FFKM On request Syntheso Glep1 ...

Страница 34: ...KM ZU 0618 Ceramat sensor socket PEEK EPDM FDA ZU 0619 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...

Страница 35: ...erves 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 Sensor so...

Страница 36: ...loy 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 incrustations eg 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 socket 1 4571 ...

Страница 37: ...cles in the process medium Please observe the notice on page 19 ZU 0705 Sensor socket PEEK O rings FKM ZU 0706 Sensor socket PEEK O rings EPDM ZU 0707 Sensor socket PEEK O rings FFKM ZU 0670 1 Air supply for pressurized sensors 0 5 4 bar ZU 0670 2 Air supply for pressurized sensors 1 7 bar These modules maintain the defined overpressure in the pressure chamber of the sensor ...

Страница 38: ... 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 ZU 0655 3 Adapter 1 4571 O rings FFKM ZU 0631 standard media interface Sensor lock gate connection kit for manual operation see ZU 0646 or for operation with a PLC ZU 0646 pneumatic manual control valve Switch for manual oper...

Страница 39: ...er 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 was subj...

Страница 40: ...unit 26 Installing the outlet hose 14 Intended use 5 L Lubricants 32 M Maintenance drive unit 24 Maintenance interval 31 Maintenance lubricants 32 Maintenance operations required 31 Maintenance sealing kits 33 Media adapter connection 17 Media connection description 13 Media connection to Ceramat 16 Media connection to Unical or Uniclean 17 Media connection variants 17 Mounting angle 10 Mounting w...

Страница 41: ...h liquid electrolyte dimensions 28 Sensor with solid electrolyte 20 Sensor with solid electrolyte dimensions 27 SERVICE position 10 Servicing sealing kits 33 Spare parts 34 Specifications 30 Standard media interface installation 16 Standard media interface ZU 0631 38 Supply lines 13 T Technical data 30 Trademarks 2 Index ...

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Страница 44: ...Knick Elektronische Messgeräte GmbH Co KG Beuckestraße 22 14163 Berlin Phone 49 30 80191 0 Fax 49 30 80191 200 Internet www knick de Email info knick de TA 203 100 KNE02 20190403 095802 ...

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