Knick Unical 9000 User manual

Protos II
Service Switch
Unical9000
Error
Meas
Service
User Manual Unical 9000/Protos II 4400
Process Analysis System
www.knick.de
Read before installation.
Keep for future use.

Unical 9000/Protos II 4400
2
Supplemental Directives
READ AND SAVE THIS DOCUMENT FOR FUTURE REFERENCE. BEFORE ATTEMPTING TO ASSEMBLE, INSTALL,
OPERATE OR MAINTAIN THE PRODUCT, PLEASE ENSURE A COMPLETE UNDERSTANDING OF THE INSTRUC-
TIONS AND RISKS DESCRIBED HEREIN. ALWAYS OBSERVE ALL SAFETY INFORMATION. FAILURE TO COMPLY
WITH INSTRUCTIONS IN THIS DOCUMENT COULD RESULT IN SERIOUS INJURY AND/OR PROPERTY DAMAGE.
THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.
These supplemental directives explain how safety information is laid out in this document and what
content it covers.
Safety Chapter
This document's safety chapter is designed to give the reader a basic understanding of safety. It illus-
trates general hazards and gives strategies on how to avoid them.
Warnings
This document uses the following warnings to indicate hazardous situations:
Symbol Category Meaning Remark
WARNING Designates a situation that can lead to death or serious
(irreversible) injury.
The warnings contain
information on how to
avoid the hazard.
CAUTION Designates a situation that can lead to slight or moderate
(reversible) injury.
None NOTICE Designates a situation that can lead to property or
environmental damage.
Symbols Used in this Document
Symbol Meaning
Reference to additional information
Interim or final result in instructions for action
Sequence of figures attached to an instruction for action
Item number in a figure
Item number in text
Related Documents
• Retractable fitting User Manual. ➜www.knick.de
• Protos II 4400 industrial transmitter User Manual. ➜www.knick.de
• Protos modules User Manuals. ➜www.knick.de
• Sensor User Manual. ➜www.knick.de

Unical 9000/Protos II 4400
3
Table of Contents
1 Safety............................................................................................................................................. 5
1.1 Intended Use ......................................................................................................................................................... 5
1.2 Personnel Requirements ................................................................................................................................... 5
1.3 Safeguards.............................................................................................................................................................. 6
1.4 Residual Risks ........................................................................................................................................................ 6
1.5 Hazardous Substances....................................................................................................................................... 7
1.6 Operation in Explosive Atmospheres ........................................................................................................... 7
1.7 Operation and Installation................................................................................................................................ 7
1.8 Maintenance and Spare Parts.......................................................................................................................... 8
1.9 Safety Training ...................................................................................................................................................... 8
2 Product.......................................................................................................................................... 9
2.1 Package Contents ................................................................................................................................................ 9
2.2 Product Identification......................................................................................................................................... 9
2.2.1 Example of a Version............................................................................................................................. 9
2.2.2 Product Code ........................................................................................................................................... 10
2.3 Nameplates ............................................................................................................................................................ 11
2.4 Symbols and Markings on the Product........................................................................................................ 12
2.5 Process Analysis System Design ..................................................................................................................... 13
2.5.1 Electro-Pneumatic Controller Design and Function.................................................................. 14
2.5.2 Media Adapter with Metering Pumps and Containers Design and Function .................. 17
2.5.3 Service Switch Design and Function............................................................................................... 18
2.5.4 Process Connection Design and Function .................................................................................... 19
2.5.5 Changes for Different Conditions..................................................................................................... 19
3 Installation .................................................................................................................................... 20
3.1 General Installation Instructions .................................................................................................................... 20
3.2 Mechanical Installation...................................................................................................................................... 21
3.2.1 Wall Installation....................................................................................................................................... 21
3.2.2 Pipe Installation ...................................................................................................................................... 23
3.2.3 Process Connection Installation........................................................................................................ 25
3.2.4 Installing the Retractable Fitting and Media Adapter Supply................................................ 26
3.2.5 Water Supply Installation .................................................................................................................... 30
3.2.6 Compressed Air Supply Installation ................................................................................................ 31
3.2.7 Installing the Media Adapter with Metering Pumps and Containers.................................. 32
3.2.8 Industrial Transmitter Installation .................................................................................................... 32
3.2.9 Retractable Fitting Installation.......................................................................................................... 32
3.3 Electrical Installation........................................................................................................................................... 33
3.3.1 Service Switch Electrical Installation............................................................................................... 37
3.3.2 Media Adapter Electrical Installation .............................................................................................. 37
3.4 Process Control System Installation .............................................................................................................. 38
4 Commissioning ............................................................................................................................. 40

Unical 9000/Protos II 4400
4
5 Parameter Setting ........................................................................................................................ 41
5.1 Protos Parameter Setting .................................................................................................................................. 41
5.1.1 Calibration Timer .................................................................................................................................... 43
5.1.2 Time Control............................................................................................................................................. 44
5.1.3 Control and Service Programs ........................................................................................................... 47
5.1.4 Configuring the Program Flow.......................................................................................................... 59
5.1.5 Calibration................................................................................................................................................. 60
5.1.6 Installation ................................................................................................................................................ 61
6 Operation ...................................................................................................................................... 66
6.1 Metering Pump: Filling the Containers ........................................................................................................ 66
6.2 Progress Display ................................................................................................................................................... 68
7 Diagnostics.................................................................................................................................... 70
7.1 Protos Diagnostic Functions ............................................................................................................................ 70
7.2 Relay Contacts....................................................................................................................................................... 74
8 Maintenance ................................................................................................................................. 76
8.1 Inspection and Maintenance........................................................................................................................... 76
8.1.1 Protos Maintenance Functions.......................................................................................................... 76
8.1.2 Pilot Valve Functional Test................................................................................................................... 80
8.2 Corrective Maintenance .................................................................................................................................... 81
8.2.1 Corrective Maintenance on the Metering Pumps ...................................................................... 81
8.2.2 Replacing the Air Pressure Switch.................................................................................................... 83
8.2.3 Replacing the Water Pressure Switch.............................................................................................. 84
8.2.4 Knick Repair Service .............................................................................................................................. 84
9 Troubleshooting ........................................................................................................................... 85
9.1 Protos Malfunction Message ........................................................................................................................... 90
10 Decommissioning......................................................................................................................... 91
10.1 Unical: Removal .................................................................................................................................................... 91
10.2 Return....................................................................................................................................................................... 91
10.3 Disposal ................................................................................................................................................................... 91
11 Spare Parts, Accessories, and Tools............................................................................................. 92
11.1 Spare Parts.............................................................................................................................................................. 92
11.2 Accessories ............................................................................................................................................................. 96
12 Dimension Drawings.................................................................................................................... 98
13 Specifications................................................................................................................................102
14 Annex.............................................................................................................................................105
Symbols and Markings on the Display .......................................................................................107
Abbreviations ...............................................................................................................................109
Index..............................................................................................................................................110

Unical 9000/Protos II 4400
5
1 Safety
This document contains important instructions for the use of the product. Always follow all
instructions and operate the product with caution. If you have any questions, please contact Knick
Elektronische Messgeräte GmbH & Co. KG (sometimes hereafter referred to as “Knick”) using the
information provided on the back page of this document.
1.1 Intended Use
The Unical 9000 is an electro-pneumatic controller for fully automatic process control of pH
measurements.
The sensor is immersed in the process medium (PROCESS limit position) by the retractable fitting’s
probe (sensor housing or immersion tube). In the service position (SERVICE limit position), the sensor
can be cleaned, calibrated, or replaced. The cleaning or calibration media are automatically supplied
via the process connection and media adapter.
Unical 9000 can be used in combination with the following products:
Retractable fittings SensoGate
Ceramat
Industrial transmitter Protos II 4400
Further information can be found in the relevant product documentation.
The defined operating conditions must be observed when using this product. ➜Specifications, p. 102
USE CAUTION AT ALL TIMES WHEN INSTALLING, USING, MAINTAINING OR OTHERWISE INTERACTING WITH
THE PRODUCT. ANY USE OF THE PRODUCT EXCEPT AS SET FORTH HEREIN IS PROHIBITED, AND MAY RESULT
IN SERIOUS INJURY OR DEATH, AS WELL AS DAMAGE TO PROPERTY. THE OPERATING COMPANY SHALL BE
SOLELY RESPONSIBLE FOR ANY DAMAGES RESULTING FROM OR ARISING OUT OF AN UNINTENDED USE OF
THE PRODUCT.
All references to “device,” “product,” “Unical9000,” “ProtosII4400,” “MSU4400‑180,” “COMPA3400‑081”
refer to the various versions, both non-Ex and Ex, of the relevant device.
The Unical 9000X version is certified for operation in hazardous locations.
➜Operation in Explosive Atmospheres, p. 7
1.2 Personnel Requirements
The operating company shall ensure that any personnel using or otherwise interacting with the
product is adequately trained and has been properly instructed.
The operating company shall comply and cause its personnel to comply with all applicable laws, regu-
lations, codes, ordinances and relevant industry qualification standards related to product. Failure to
comply with the foregoing shall constitute a violation of operating company’s obligations concerning
the product, including but not limited to an unintended use as described in this document.

Unical 9000/Protos II 4400
6
1.3 Safeguards
1
Water Leakage Detection
There is a circuit board (1) on the base of the controller’s
housing. Its contact surfaces detect the presence of elec-
trically conductive liquids on them. If, for example, water
leaks out, a current flow generates the following error
message in the industrial transmitter: Leakage Sensor
(U224)
1
Sensor Dismount Guard1)
The sensor dismount guard (1) measures the pressure
drop or variations that can occur during operation of the
retractable fitting. A pressure drop is a sign that there is
no sensor in the retractable fitting. Movement of the re-
tractable fitting to the process position (PROCESS limit
position) is stopped. Message in the industrial transmit-
ter: Immersion Lock (U221)
1
Safety Valve
The safety valve (1) is connected upstream of all pilot
valves. When you press the service switch, all pilot valves
are depressurized by the safety valve.
1.4 Residual Risks
The product has been developed and manufactured in accordance with generally accepted safety
rules and regulations, as well as an internal risk assessment. Despite the foregoing, the product may
among others bear the following risks:
The effects of moisture, ambient temperature, chemicals, and corrosion can negatively impact the safe
operation of the product. Observe the following instructions:
• Observe the permissible ambient temperature. Alternatively, use protective cabinets and heatable
process connections. ➜Specifications, p. 102
• Protect the controller from direct sunlight.
• If using aggressive chemical process media, adhere to and adjust the inspection and maintenance
intervals accordingly.
Drinking Water Connection
If the Unical 9000 is connected to the drinking water supply, impurities caused by the rinse and
process media may occur. Note the information in EN1717. Install a suitable check valve at the water
or rinse connection. ➜Accessories, p. 96
1) Applies only when using a Ceramat retractable fitting.

Unical 9000/Protos II 4400
7
1.5 Hazardous Substances
IN THE EVENT OF ANY CONTACT WITH HAZARDOUS SUBSTANCES OR OTHER INJURY HEREUNDER, SEEK IM-
MEDIATE MEDICAL ATTENTION OR FOLLOW APPLICABLE PROCEDURES TO ADDRESS HEALTH AND SAFETY
OF PERSONNEL. FAILURE TO SEEK IMMEDIATE MEDICAL ATTENTION MAY RESULT IN SERIOUS INJURY OR
DEATH.
In certain situations (e.g., sensor replacement or corrective maintenance), personnel may come into
contact with the following hazardous substances:
• Process medium
• Cleaning medium
• Buffer and calibration solutions
The operating company is responsible for conducting a risk assessment.
See the relevant manufacturers’ safety data sheets for hazard and safety instructions on handling
hazardous substances.
1.6 Operation in Explosive Atmospheres
The Unical 9000X is certified for operation in explosive atmospheres.
• EU-Type Examination Certificate KEMA04ATEX1036
• IECEx Certificate of Conformity IECExDEK22.0022
The conditions for installation and operation in explosive atmospheres can be found on the corre-
sponding certificates.
Observe all applicable local and national codes and standards for the installation of electrical equip-
ment in explosive atmospheres. For further guidance, consult the following:
• IEC60079-14
• EU directives 2014/34/EU and 1999/92/EC(ATEX)
Modules which have already been used shall be subjected to a professional routine test before they
may be operated in another type of protection.
• Before the product is commissioned, the operator must provide proof that the product is ap-
proved for connection to other equipment (including cables and wires). Connecting components
designed for explosive atmospheres and those not designed for explosive atmospheres (mixed
equipping) is not permitted.
Unical 9000X Markings
Information on the Unical 9000X markings is available in the enclosed certificates.
Electrostatic Discharge
Some materials used in the product are electrostatic insulators and may be electrostatically charged.
To prevent electrostatic discharge, please observe the following instructions:
• Clean non-metallic components with a damp cloth only, and allow them to dry.
Certificates
The current versions of the applicable certificates are available at www.knick.de.
1.7 Operation and Installation
All national and local regulations relating to the installation and operation of the product in force at
the destination must be followed.

Unical 9000/Protos II 4400
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1.8 Maintenance and Spare Parts
Preventive Maintenance
Preventive maintenance can keep the product in good condition and minimize downtimes. Knick
provides recommended inspection and maintenance intervals. ➜Maintenance, p. 76
Spare Parts
For professional corrective maintenance of the product, only use Knick genuine spare parts. Usage of
any other spare parts shall constitute an unintended use of the product.
Repair Service
The Knick Repair Service offers professional corrective maintenance for the product to the original
quality. Upon request, a replacement unit can be obtained for the period of the repair.
Further information can be found at www.knick.de.
1.9 Safety Training
Upon request, Knick Elektronische Messgeräte GmbH & Co. KG will provide safety briefings and
product training during initial commissioning of the product. More information is available from the
relevant local contacts.

Unical 9000/Protos II 4400
9
2 Product
2.1 Package Contents
• Unical 9000 in the version ordered
• Service switch
• 2 identical cables (to connect Unical 9000 to the service switch and Unical 9000 to the Protos in-
dustrial transmitter)
• Cable with plug (to connect Unical 9000 to the media adapter)
• Hook wrench
• User Manual
• EU Declaration of Conformity1)
• Control Drawing1)
• Test Report 2.2 according to EN 10204
2.2 Product Identification
The different versions of the Unical 9000 are encoded in a product code.
The product code is stated on the nameplate, the delivery note, and the product packaging.
➜Nameplates, p. 11
2.2.1 Example of a Version
Unical 9000 –XSG1A222CE–400
Explosion protection For hazardous area Zone1 X –
Housing Stainless steel, polished S –
Media connection (calibration
and rinse function)
14 m (seal: EPDM) G –
Media interface Without 0 –
Media adapter with port I-III With (seal: EPDM) A –
Port I Metering pump with 3-liter container (EPDM) 2 –
Port II Metering pump with 3-liter container (EPDM) 2 –
Port III Metering pump with 3-liter container (EPDM) 2 –
Supplementary air purging
Aux1
With C –
Supplementary external valve
Aux2
With E –
Special version With protective cabinet and heater, Ex –400
1) Part of package contents only for Ex-approved products.

Unical 9000/Protos II 4400
10
2.2.2 Product Code
Unical 9000 –__________–___
Explosion protection For hazardous area Zone 1 X –
Without N –
Housing Steel, coated C –
Stainless steel, polished S –
Media connection (rinse
function only)
5 m (seal: FKM) 1 0 –
10 m (seal: FKM) 2 0 –
15 m (seal: FKM) 5 0 –
5 m (seal: EPDM) A 0 –
10 m (seal: EPDM) B 0 –
15 m (seal: EPDM) E 0 –
Media connection (calibration
and rinse function)
5 m (seal: FKM) 3 –
10 m (seal: FKM) 4 –
14 m (seal: FKM) 7 –
17 m (seal: FKM) 6 –
5 m (seal: EPDM) C –
10 m (seal: EPDM) D –
14 m (seal: EPDM) G –
17 m (seal: EPDM) F –
Media interface With1) 1 –
Without2) 0 –
Media adapter with port I-III With (seal: FKM) 1 –
With (seal: EPDM) A –
Without 0 –
Port I Metering pump with 3-liter container (EPDM) 2 –
Without 0 –
Port II Metering pump with 3-liter container (EPDM) 2 –
Without 0 –
Port III Metering pump with 3-liter container (EPDM) 2 –
Metering pump with 3-liter container (FKM) B –
Without 0 –
Supplementary air purging
Aux1
With C –
Without N –
Supplementary external valve
Aux2
With E –
Without N –
Special version Without –000
With protective cabinet, non-Ex –100
With protective cabinet and heater, non‑Ex –200
With protective cabinet, Ex –300
With protective cabinet and heater, Ex –400
1) Interface for connecting retractable fittings from other manufacturers.
2) For retractable fittings WA130, WA150, WA153, WA154, or WA160.