Knick Ceramat WA 153 User manual

User Manual Ceramat WA153
Retractable Fitting
www.knick.de
Read before installation.
Keep for future use.

Ceramat WA153
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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 illustrates 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 environ-
mental 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
Supplementary Documents for Special Versions
• Special datasheet for special version B 1)
• Special datasheet for special version J 1)
1) Further information on the special versions is available in the “Product Code” section. ➜Product Code, p. 10

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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
1.6.1 Possible Ignition Hazards During Installation and Maintenance........................................... 7
1.6.2 Possible Ignition Hazards During Operation................................................................................. 8
1.7 Safety Training....................................................................................................................................................... 8
1.8 Maintenance and Spare Parts .......................................................................................................................... 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............................................................................................................................................................. 12
2.4 Symbols and Markings ....................................................................................................................................... 14
2.5 Design and Function........................................................................................................................................... 14
2.5.1 Retractable Fitting .................................................................................................................................. 15
2.5.2 Drive Units ................................................................................................................................................. 16
2.5.3 Process Connections.............................................................................................................................. 16
2.6 Changes for Different Conditions................................................................................................................... 17
2.7 SERVICE/PROCESS Limit Positions ................................................................................................................. 18
3 Installation.................................................................................................................................... 19
3.1 General Installation Instructions..................................................................................................................... 19
3.2 Retractable Fitting: Installation ....................................................................................................................... 20
3.3 Media Connection / ZU0631: Installation on Strain Relief Bracket..................................................... 20
3.4 Outlet........................................................................................................................................................................ 21
3.4.1 Outlet Hose: Installation Instructions .............................................................................................. 21
3.4.2 Outlet Hose: Installation ....................................................................................................................... 22
3.5 Media Connection................................................................................................................................................ 23
3.5.1 Media Connection: Installation Instructions ................................................................................. 23
3.5.2 Multiplug: Installation ........................................................................................................................... 24
3.5.3 Electro-Pneumatic Controller: Connection.................................................................................... 24
3.5.4 ZU0631 Standard Media Connection: Installation...................................................................... 24
3.6 Sensor Cable: Installation .................................................................................................................................. 25
4 Commissioning............................................................................................................................. 26

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5 Operation ...................................................................................................................................... 27
5.1 Moving into the Process Position (PROCESS Limit Position)................................................................. 27
5.2 Moving into the Service Position (SERVICE Limit Position)................................................................... 27
5.3 Installing and Removing a Sensor.................................................................................................................. 28
5.3.1 Safety Instructions when Installing and Removing Sensors ................................................... 28
5.3.2 Solid-Electrolyte Sensor: Installation ............................................................................................... 28
5.3.3 Solid-Electrolyte Sensor: Removal .................................................................................................... 29
5.3.4 Liquid-Electrolyte Sensor: Installation............................................................................................. 30
5.3.5 Liquid-Electrolyte Sensor: Removal.................................................................................................. 31
5.4 Cavity Rinsing ........................................................................................................................................................ 32
6 Maintenance ................................................................................................................................. 33
6.1 Inspection and Maintenance ........................................................................................................................... 33
6.1.1 Inspection and Maintenance Intervals............................................................................................ 33
6.1.2 Used and Approved Lubricants ......................................................................................................... 33
6.1.3 Knick Premium Service.......................................................................................................................... 34
6.1.4 Immersion Lock Without a Mounted Solid-Electrolyte Sensor: Functional Test .............. 34
6.2 Corrective Maintenance..................................................................................................................................... 34
6.2.1 Corrective Maintenance Safety Instructions ................................................................................. 34
6.2.2 Drive Unit: Disassembly ........................................................................................................................ 35
6.2.3 Drive Unit: Assembly.............................................................................................................................. 36
6.2.4 Knick Repair Service ............................................................................................................................... 37
7 Troubleshooting........................................................................................................................... 38
8 Removal from Operation ............................................................................................................. 40
8.1 Retractable Fitting: Removal............................................................................................................................ 40
8.2 Returns ..................................................................................................................................................................... 40
8.3 Disposal.................................................................................................................................................................... 40
9 Spare Parts, Accessories, and Tools............................................................................................. 41
9.1 Seal Kits .................................................................................................................................................................... 41
9.2 Spare Parts .............................................................................................................................................................. 44
9.3 Accessories.............................................................................................................................................................. 45
9.4 Tools .......................................................................................................................................................................... 46
10 Dimension Drawings.................................................................................................................... 47
11 Specifications................................................................................................................................ 51
Appendix....................................................................................................................................... 52
Glossary......................................................................................................................................... 55
Index.............................................................................................................................................. 56

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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 Ceramat WA153 is a retractable fitting for installation in boilers, tanks, and pipes. The product is
used to mount a sensor for measuring process parameters. The sensor is immersed in the process
medium by the Ceramat WA153. The Ceramat WA153 is pneumatically operated.
Cleaning, calibration, or sensor replacement under process conditions by the customer (hereinafter
sometimes referred to as the "operating company") may be conducted, subject to the requirements
set forth herein, by placing the product into the service position (SERVICE limit position).
If the product is used with any product or part not authorized by Knick, the operating company as-
sumes all risks and liabilities related thereto.
The Ceramat WA153 can be used with the following sensor types:
Solid-electrolyte sensors Outer diameter 12mm, length225 mm, sensor head thread PG13.5
Liquid-electrolyte sensors Outer diameter 12mm, length 250mm
Optical sensors1) Body diameter 12mm or 12.7mm (½″)
For further information, refer to the applicable documentation of the sensor manufacturer.
The defined operating conditions must be observed when using this product. ➜Specifications, p. 51
Thanks to its modular design, Ceramat WA153 can be adapted to changed conditions by the customer.
➜Changes for Different Conditions, p. 17
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. CUSTOMER SHALL BE SOLELY RESPON-
SIBLE FOR ANY DAMAGES RESULTING FROM OR ARISING OUT OF AN UNINTENDED USE OF THE PRODUCT.
The Ceramat WA153-X version is certified for operation in explosive atmospheres.
➜Operation in Explosive Atmospheres, p. 7
1.2 Personnel Requirements
Customer 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.
1) Use with optical sensors requires additional adapters. The special datasheets contain information on the design
and use of the adapters. ➜Product Code, p. 10

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1.3 Safeguards
The Ceramat WA153 safety concept is based on the interplay of functions within a Knick process analy-
sis system. The Ceramat WA153 safeguards and safety functions require the functions of the electro-
pneumatic controller and the process analyzer. ➜Process Analysis System: Installation Example, p. 19
Safeguards and safety functions are not available if the Ceramat WA153 is operated without a Knick
process analysis system. The operating company must assess the risks and take appropriate action. It
must be possible to safely isolate media and power connections from the Ceramat WA153 using shut-
off devices.
Use the product as intended only. ➜Intended Use, p. 5
1
2
3
Immersion lock without a mounted solid-electrolyte sensor
The safeguard is only available for versions of the Ceramat
WA153 intended for solid-electrolyte sensors and when using a
Knick process analysis system.
➜Process Analysis System: Installation Example, p. 19
The safeguard is not available in versions of the Ceramat WA153
that have a sensor socket with a PEEK scraper or if a sensor
socket is retrofitted with a PEEK scraper. ➜Spare Parts, p. 44
The safeguard function is only available if the O‑ring and the
compression ring are correctly installed on the solid-electrolyte
sensor(1). ➜Installing and Removing a Sensor, p. 28
Function: Moving into the process position (PROCESS limit posi-
tion) without or with an incorrectly mounted solid-electrolyte
sensor(1) can be detected and prevented.
Compressed air noticeably and audibly escapes through holes un-
derneath the coupling nut(3) of the drive(2). This compressed air
is detected by a flow switch in the electro-pneumatic controller.
The process analyzer displays a Sensor Removed message; the
Ceramat WA153 does not move into the process position
(PROCESS limit position).
Environmental influences may affect the functionality of safeguards (e.g. components stuck together
by process medium). ➜Residual Risks, p. 6
See also
➜Immersion Lock Without a Mounted Solid-Electrolyte Sensor: Functional Test, p. 34
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:
Environmental Influences
The effects of moisture, ambient temperature, chemicals, and corrosion can negatively impact the safe
operation of the product. Please observe the following instructions:
• Only operate Ceramat WA153 in compliance with the stated operating conditions.
➜Specifications, p. 51
• Install the product inside a protected area of the plant. Alternatively, take appropriate action to
protect the Ceramat WA153.
• If using aggressive chemical process media, adjust the inspection and maintenance intervals
accordingly. ➜Inspection and Maintenance, p. 33

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• Adhering and sticky process media can impact the functionality of Ceramat WA153 (e.g.,by caus-
ing components to stick together). Adjust the inspection and maintenance intervals accordingly.
➜Inspection and Maintenance, p. 33
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
• Calibration or cleaning medium
• Lubricant
The operating company is responsible for conducting a hazard assessment.
See the relevant manufacturers’ safety data sheets for hazard and safety instructions on handling haz-
ardous substances.
1.6 Operation in Explosive Atmospheres
The Ceramat WA153-X is certified for operation in explosive atmospheres.
• EU-Type Examination Certificate KEMA04ATEX4035X
Explosion protection is ensured under atmospheric conditions with an absolute pressure of
0.8…
1.1bar and an ambient temperature of -20…60°C. See the manufacturer’s specifications for in-
formation on the durability of the retractable fitting. ➜Specifications, p. 51
Exceeding the standardized atmospheric conditions within the manufacturer’s specifications, e.g., with
regard to the ambient temperature and pressure, does not endanger the retractable fitting’s durability.
Related certificates are included in the product’s scope of delivery and are available at www.knick.de
in the current version.
Observe all applicable local and national codes and standards for the installation of equipment in
explosive atmospheres. For further guidance, consult the following:
• IEC60079-14
• EU directives 2014/34/EU and 1999/92/EC(ATEX)
1.6.1 Possible Ignition Hazards During Installation and Maintenance
To avoid mechanically generated sparks, handle the Ceramat WA153-X with care and apply suitable
measures, e.g., use covers and pads.
The metallic parts of the Ceramat WA153-X must be connected to the plant’s equipotential bonding
using the metallic process connection or the grounding connection provided for that purpose.
When components are replaced with genuine Knick spare parts made of other materials (e.g. O-rings),
the information given on the nameplate may deviate from the actual version of the Ceramat WA153-X.
The operating company must assess and document this deviation.
➜Nameplates, p. 12
Mechanically generated sparks
Single impacts on metal parts or collisions between metal parts of the Ceramat WA153-X are not a
potential ignition source only if the following conditions are met:
• Possible impact velocity is less than 1m/s
• Possible impact energy is less than 500J

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If these conditions cannot be ensured, the operating company must reassess single impacts on metal
parts or collisions between metal parts as potential sources of ignition. The operating company must
implement suitable risk minimization measures, e.g., by ensuring a non-explosive atmosphere.
1.6.2 Possible Ignition Hazards During Operation
When using non-water-based cleaning, rinsing, or calibration media with a low conductivity of less
than 1nS/m, electrostatic charging of internal, conductive components may occur. The operating
company must assess the associated risks and implement appropriate measures.
The sensors that are used must be approved for operation in hazardous locations. Further information
can be found in the sensor manufacturer’s documentation.
1.7 Safety Training
Upon request, Knick Elektronische Messgeräte GmbH & Co. KG will provide safety instruction and
product training during initial commissioning of the product. Further information is available from the
relevant Knick representatives.
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. 33
Lubricants
Only use lubricants approved by Knick. Special applications or upgrades to special lubricants are avail-
able on request. Usage of any other lubricants shall constitute an unintended use of the product.
➜Maintenance, p. 33
Tools and Mounting Aids
Special and accessory tools help maintenance personnel to replace components and wear parts safely
and professionally. ➜Tools, p. 46
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.
➜Spare Parts, p. 44
Repair Service
The Knick Repair Service offers professional corrective maintenance on the Ceramat WA153 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.

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2 Product
2.1 Package Contents
• Ceramat WA153 in the version ordered
• User Manual
• As applicable, supplementary datasheet for special versions 1)
• EU Declaration of Conformity
• EU-Type-Examination Certificate 1)
2.2 Product Identification
The different versions of the Ceramat WA153 are coded in a product code.
The product code is stated on the nameplate, the delivery note, and the product packaging.
➜Nameplates, p. 12
2.2.1 Example of a Version
Basic device with pneum. drive, stainless steel WA153–N0KBB01105BD10–000
Explosion protection None N –
Sensor Sensor ⌀ 12mm with PG 13.5 0 –
Material of seals FFKM K –
Sensor protection tube material Hastelloy C22 B –
Sensor socket material Hastelloy C22, without protection B 0 –
Scraper for sensor socket PEEK, natural 1 –
Immersion depth Immersion depth 105mm (max.) 1 0 5 –
Process-wetted material Hastelloy C22 B –
Process connection Flange, loose, ANSI 316, 150lbs, 2″D 1 –
Probe guard None 0 –
Special version None – 0 0 0
1) Supplied depending on the ordered version of the Ceramat WA153 ➜Product Code, p. 10

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2.2.2 Product Code
Basic device with pneum. drive, stainless steel version WA153 – _ _ _ _ _ _ _ _ _ _ _ _ _ _ – _ _ _
Explosion protection ATEX Zone0 X –
None N –
Sensor Sensor ⌀ 12mm with PG13.5 0 –
pH sensor ⌀ 12mm with pressurization unit,
pressure chamber for compressed air supply 1 –
Optical sensor ⌀½″ (12.7mm) 2 –
Optical sensor ⌀ 12mm 3 –
Gasket material FKM A –
EPDM B –
EPDM – FDA E –
FKM – FDA F –
FFKM – FDA H –
FFKM K –
Sensor protection
tube material
Hastelloy C221) B –
PEEK E –
1.4404 H –
Titanium1) T –
Sensor socket
material
Hastelloy C22, without protection B 0 –
Hastelloy C22, short protection B 1 –
1.4404, without protection H 0 –
1.4404, short protection H 1 –
1.4404, long protection H 2 –
1.4404, full protection H 3 –
PEEK, without protection E 0 –
Titanium, without protection T 0 –
Titanium, short protection T 1 –
Scraper for sensor
socket
None 0 –
PEEK, natural 1 –
Immersion depth Special immersion depth 23 - 104 mm (1mm increments) 0 0 0 –
Immersion depth 105mm (max.) 1 0 5 –
Process-wetted
material
Hastelloy C221) B –
1.4404 H –
Titanium1) T –
Process connection Flange, loose, 1.4571, PN10/16, DN50 B 1 –
Flange, loose, 1.4571, PN10/16, DN65 B 2 –
Flange, loose, 1.4571, PN10/16, DN80 B 3 –
Flange, loose, 1.4571, PN10/16, DN100 B 4 –
Flange, loose, 1.4571, PN10/16, DN1251) B 5 –
Flange, loose, 1.4571, PN10/16, DN1501) B 6 –
Flange, loose, 1.4571, PN10/16, DN2001) B 7 –
Flange, loose, 1.4571, PN40, DN50 E 1 –
Flange, loose, 1.4571, PN40, DN65 E 2 –
Flange, loose, 1.4571, PN40, DN80 E 3 –
1) Special option, lead time on request