Knick Unical 9000 User manual

Installation Guide Electro-Pneumatic Controller
for Retractable Fittings
for Fully Automated pH Measurement,
Cleaning and Calibration
Unical 9000(X)
Probe Controller
www.knick.de
Read before installation.
Keep for future use.

Trademarks
The following trademarks are used in this manual without further marking:
CalCheck®, Calimatic®, Ceramat®, Protos®, Sensocheck®, Sensoface®, SensoGate®, Unical®, Uniclean®,
VariPower®
are registered trademarks of Knick Elektronische Messgeräte GmbH & Co. KG, Germany
is a registered trademark of Mettler-Toledo AG
Return of Products Under Warranty
Please contact our Service 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/dis-
infected before shipment. In that case, please attach a corresponding certificate, for the health and safety
of our service personnel.
Disposal
Please observe the applicable local or national regulations concerning the disposal of
“waste electrical and electronic equipment”.
NOTICE
These installation instructions do NOT describe
• how to operate the retractable fitting
• how to control the programs via the Protos 3400(X) process analysis system.
The user manuals for retractable fittings and the Protos3400(X) modular process analysis
system are available for free download at www.knick.de.
1 Basics

3
Table of Contents
1 Basics ........................................................................................................ 2
Return of Products Under Warranty.......................................................................... 2
Disposal................................................................................................................................ 2
Trademarks ......................................................................................................................... 2
2 Short Description .................................................................................... 5
3 Intended Use............................................................................................ 8
4 Safety Information ................................................................................ 10
5 Package Contents .................................................................................. 12
6 Product Range ....................................................................................... 13
7 Checklist for Installation....................................................................... 17
8 Assembly ................................................................................................ 18
Wall Mounting.................................................................................................................19
Pipe Mounting.................................................................................................................20
Mounting Dimensions of Service Switch ..............................................................21
Media Adapter with Metering Pumps....................................................................22
Attaching the Media Connection to the Media Adapter ...............................23
8.1 Media Adapter and Metering Pumps................................................... 24
Connections .....................................................................................................................24
Function Description of Metering Pump...............................................................26
Bills of Materials..............................................................................................................27
8.2 Media Connection ................................................................................. 28
Variants, Assembly.........................................................................................................28
Bill of Material..................................................................................................................29
8.3 Media Supply to Unical 9000(X)........................................................... 30
Compressed Air, Water, Purge Air, Auxiliary Media............................................30
Arrangement of Functional Elements ....................................................................31
Pilot Valves, Control Valves .........................................................................................32
Pressure Gauges and Valve Block.............................................................................33
Connecting the Media Tubes (Media Connection)............................................34
Connecting the Tubes ..................................................................................................35

4
Table of Contents
8.4 Connecting the Retractable Fitting ..................................................... 38
Media Connection to Ceramat..................................................................................38
Media Connection to SensoGate WA 130(X)........................................................39
Recommended Connection of Retractable Fittings from Other
Manufacturers e.g.InTrac7xx (Mettler-Toledo)...................................................40
9 Electrical Installation............................................................................. 45
Connecting the Cable to the Service Switch .......................................................45
Connecting the Cables to the Unical 9000(X) .....................................................45
Terminal Assignments of Unical 9000(X)...............................................................48
10 Process Control System......................................................................... 51
11 Control Programs and Measurement Procedures .............................. 53
12 Service and Maintenance...................................................................... 54
Service Switch and “Service“ Position.....................................................................54
Manual Control via Protos 3400(X)..........................................................................56
13 Commissioning ..................................................................................... 58
Start-Up on the Protos: Automatic Hardware Recognition............................59
Unical 9000(X) Parameter Setting on the Protos................................................60
Start-Up Program ...........................................................................................................61
14 Specifications......................................................................................... 62
15 Appendix................................................................................................ 67
Pneumatic Diagram of Unical 9000.........................................................................68
Pneumatic Diagram of Media Connection ...........................................................69
Cleaning Agents for Unical 9000 and their Applications ................................70
16 Index....................................................................................................... 72

5
2 Short Description
The Unical 9000(X) is an electro-pneumatic controller for fully automated
pHmeasurement, cleaning and calibration.
The device is modular and functionally structured. The enclosure contains the
electronic controller, filters, and valves. An external media adapter is provided
for calibration buffers and cleaning solution.
The manufacturer offers the following components which form an optimally
matched, fully automated process analysis system:
• Protos 3400(X) Modular process analysis system
• Unical 9000(X) Controller for retractable fittings (retractable probes)
• Ceramat WA 15 … /16 … Retractable fitting with ceramic sealing to the
process
• SensoGate WA 13… Universal, pneumatically operated retractable fitting
with modular design
max. 10 m
To retractable fitting
(pH/temp)
max. 20 m
Power supply Compressed air Rinse water
Unical 9000(X)
controller for retractable ttings
Protos 3400(X)
process analysis system
Retractable tting
e.g. Ceramat WA 150
Media adapter
with metering
pumps
(calibration buffers,
cleaner)
Media connection
Max. 17 m
(Unical - Ceramat)
pH sensor
max. 10 m
Unical 9000(X)
service switch

6
2 Short Description
Metering Pump with Container for Buffer or Cleaning Solution
The maintenance-free pumps are located in the “head” of a 3.5 liter bottle.
The integrated funnel allows easy refilling of buffer or cleaning solution,
without removing the pump.
Media adapter Container with integrated
metering pump
Media Adapter
The media adapter allows connecting up to 3 metering pumps for calibration
buffers and cleaning agent. The pumps are automatically recognized by the
system.
A cleaner pump can be connected to port III of the media adapter
(e.g. for dilute acids, dilute alkalis, or solvents, see table on page 70).
Media Connection
The media connection (corrugated hose) connects probe controller, media
adapter and retractable fitting (probe). Each fluid is fed to the retractable fitting
through a separate tube of the media connection. A multiplug provided with
check valves is connected at the retractable fitting to prevent contamination or
mixing of the different fluids.
Service Switch
The service switch moves the retractable fitting into a safe position for mainte-
nance operations. It should be installed next to the retractable fitting.

7
2 Short Description
Monitoring Functions
• Leak detection (alerts you to a water leak in the Unical)
• Compressed-air monitoring (with pressure switch)
• Sensor dismount guard (by monitoring the air flow) – with Ceramat only
• Media monitoring
allows monitoring the process value or temperature of each medium in the
calibration chamber of the retractable fitting.
False media or a faulty pumping function are recognized.
• A level monitoring system
generates the NAMUR* messages “maintenance request” and “failure”.
• A “wear counter” monitors the number of probe movements and generates
a message when a critical value is reached.
Measurement Procedures
• Continuous measurement
With continuous measurement the pH sensor is located in the
process medium and is retracted for calibration or cleaning.
• Short-time measurement
(interval measurement, sampling, sample mode ...)
The pH sensor is only momentarily moved into the process medium.
This method is applied when measuring aggressive or thermally demand-
ing process media which require short measurement times with long rest
periods.
Connection to Process Control / Process Evaluation
The Unical 9000(X) probe controller can be connected to a superordinated
control system, a PLC or DCS (Digital Control System).
NOTICE
Be sure to take account of the chemical resistance of the process-wetted
materials of the media adapter, media connection and pump.
When hot vapor or aggressive cleaning agents are to be used, an adapter for
additional media (ZU 0654, ZU 0655) is available for the retractable fittings
of the Ceramat Series. The SensoGate WA130(H) provides a suitable option
(PEEK media connection with integrated connection for additional medium).
* international user association of automation technology in process industries

8
3 Intended Use
The Unical 9000(X) probe controller allows fully automated pH measurement
including rinsing, calibration and cleaning.
The Unical 9000X is approved for operation in hazardous locations.
The sturdy enclosure (IP 65) can be wall or pipe mounted.
The version with hygienic, polished stainless steel enclosure allows applica-
tion in the field of biotechnology, food processing, and in the pharmaceutical
industry.
The version with coated steel enclosure – extremely corrosion resistant – has
been developed for application in the chemical industry, environmental engi-
neering, water and wastewater treatment, and for application in power plants.
The Unical 9000(X) evaluates pneumatic and electric check-back signals from
retractable fittings. Inductive limit position switches are not supported.
Separate wear-resistant and maintenance-free metering pumps with a very
long service life are used for calibration buffers and cleaner.
Each fluid is fed to the retractable fitting through a separate tube.
A multiplug provided with check valves is connected at the retractable fitting
to prevent contamination or mixing of the different fluids.
Buffer consumption is extremely low.
We recommend using the Unical9000(X) in combination with the Protos
3400(X) process analysis system and a Ceramat or SensoGate retractable fitting.
This combination ensures optimal media monitoring (pH value and tempera-
ture) as well as traceability according to FDA 21 CFR Part 11 (AuditTrail).
The Protos 3400(X) process analysis system allows easy adaptation of the
calibration and cleaning programs to the process.
NOTICE
Frost-Free Operation
Unical 9000(X) is designed for operation in frost-free environments.
If required, protective cabinets and heatable media connections are available
as accessory.

9
3 Intended Use
NOTICE
Drinking Water Pipes
Observe the general requirements of protection devices to prevent pollution
of potable water (EN 1717) when drawing water from drinking water pipes.
We recommend installing a suitable check valve on the water supply to the
Unical to protect the drinking water from pollution.

10
4 Safety Information
Application in Hazardous Locations
The Unical 9000X probe controller is intended for operation in ambient
conditions and applications as specified in this manual (see “Intended Use“,
page8 and “Specifications“, page 62).
The Unical 9000X may be opened during operation.
NOTICE
These installation instructions do NOT describe
• how to operate the retractable fitting
• how to control the programs via the Protos 3400(X) process analysis
system.
The user manuals for retractable fittings and the Protos3400(X) modular
process analysis system are available for free download at www.knick.de.
!
CAUTION
Power Supply
The Unical 9000(X) should preferably be supplied through the Protos
3400(X). Be sure to observe the safety information in the user manual for the
Protos 3400(X) basic unit.

11
4 Safety Information
!
WARNING
Application in Hazardous Locations
• Observe all applicable local codes and standards for the installation of
electrical equipment in hazardous locations. For orientation, please refer to
IEC 60079-14, EU directives 2014/34/EU and 1999/92/EC (ATEX), NFPA 70
(NEC), ANSI/ISA-RP12.06.01.
• Take account of the influences of humidity, ambient temperature, chemi-
cals and corrosion. If the specifications in the manual are not sufficient for
assessing the safety of operation, e.g., because your specific applications
are not described, please contact the manufacturer to make sure that the
application is possible and safe. You must observe the specified ambient
conditions and the ranges for temperature and pressure to ensure safe
operation of the device.
• In a dust explosion hazardous area you must install the bottles for buffer
and cleaning liquids in a way that there is no explosion risk due to elec-
trostatic discharge. For example, the bottles must be mounted within a
grounded, electrostatically conductive container / cabinet or be sheathed
with grounded, electrostatically conductive material.
• You must install the media connection in an electrostatically protected area
or sheath it with grounded, electrostatically conductive material.
• Clean the surfaces of media connection and media adapter including the
bottles for buffer and cleaning solutions only with a damp cloth to prevent
electrostatic charging.
For further information, refer to the CENELEC PD CLC/TR 60079-32-1 guidance
for avoiding ignition hazards due to electrostatic charges and EN60079-14,
Explosive Atmospheres - Part 14: “Electrical installations design, selection and
erection“.

12
Unical 9000(X) Basic unit incl. wall mounting brackets (mounted)
Media connection (corrugated hose) incl. slotted securing
nut and suitable hook wrench
Media adapter (for metering pumps)
3 metering pumps
Service switch
Cable set, consisting of:
• 2 identical cables
(for service switch and basic Protos unit)
• 1 connecting cable for basic unit – media adapter
(with plug)
Unical 9000(X) installation guide
Unical 9000X:
EU Declaration of Conformity,
Control Drawings
5 Package Contents
Checking the Package Contents
Use the following table to check the package contents:
(Listed here: maximum configuration)

13
Order No.
Basic unit Unical 9000 /
Explosion protection for hazardous area Zone 1
Without
Housing Steel, coated
Stainless steel, polished
Media connection
(rinse function only)
5 m (gasket material: FKM)
10 m (gasket material: FKM)
15 m (gasket material: FKM)
5 m (gasket material: EPDM)
10 m (gasket material: EPDM)
15 m (gasket material: EPDM)
Media connection
(calibration and
rinse function)
5 m (gasket material: FKM)
10 m (gasket material: FKM)
14 m (gasket material: FKM)
17 m (gasket material: FKM)
5 m (gasket material: EPDM)
10 m (gasket material: EPDM)
14 m (gasket material: EPDM)
17 m (gasket material: EPDM)
Media interface With (for standard probes)
Without (for WA 130, WA 150, WA 154, WA 160)
Media adapter
with port
I–III
With (gasket material: FKM)
With (gasket material: EPDM)
Without
Media
port I
Metering pump with empty 3.5-L bottle (EPDM)
Without
Media
port II
Metering pump with empty 3.5-L bottle (EPDM)
Without
Media
port III
Metering pump with empty 3.5-L bottle (EPDM)
Metering pump with empty 3.5-L bottle (FKM)
Without
Supplementary
air purging kit
With
Without
Supplementary
ext. valve kit
External valve
Without
Special variant Without
Protective cabinet Various models,
heated or unheated, also for application in
hazardous locations.
Please contact us.
6 Product Range

14
6 Product Range
Accessories, Spare Parts
Accessories for Unical 9000(X) Order No.
Pipe-mount kit for Unical 9000(X) ZU 0601
Pipe-mount kit for media adapter ZU 0606
Connection kit for Unical 9000(X) (water and air) ZU 0656
Commissioning Unical 9000(X)
Commissioning comprises the following steps.
– Connection of hoses and cables and commissioning of the Unical 9000(X) system
– Operator training
Prior to arrival of our engineer, the customer must prepare the following:
– Assembling the Protos 3400(X), Unical 9000(X) and retractable fitting.
(Observe maximum length of connecting hose between Unical 9000(X) and retractable fitting.)
– Electric supply: Cable ducts/rails must be present.
Auxiliary power supply for Protos 3400(X) must be pre-installed in 2 x 1.5 mm wires.
– Air supply: Hose with connection nipple for G 1/4" female thread, nominal hose width > d = 6 mm.
Water supply: Hose with connection nipple for G 1/4" female thread or G 3/4" male thread,
nominal hose width > d = 6 mm.
ZU 0649
Chemical pump (supplementary ext. valve kit required) ZU 0741
Check valve RV01
Spare Parts and Retrot Parts for Unical 9000(X) Order No.
Media connection, rinse, 5 m (FKM gaskets)
Media connection, rinse 5 m (EPDM gaskets)
ZU 0572/1
ZU 0572/2
Media connection, rinse, 10 m (FKM gaskets)
Media connection, rinse 10 m (EPDM gaskets)
ZU 0573/1
ZU 0573/2
Media connection, rinse, 15 m (FKM gaskets)
Media connection, rinse 15 m (EPDM gaskets)
ZU 0652/1
ZU 0652/2
Media connection, rinse + cal, 5 m (FKM gaskets)
Media connection, rinse + cal, 5 m (FKM gaskets), steel balls instead of glass balls*
Media connection, rinse + cal, 5 m (EPDM gaskets)
ZU 0574/1
ZU 0574/1S
ZU 0574/2
Media connection, rinse + cal, 10 m (FKM gaskets)
Media connection, rinse + cal, 10 m (EPDM gaskets)
ZU 0575/1
ZU 0575/2
Media connection, rinse + cal, 14 m (FKM gaskets)
Media connection, rinse + cal, 14 m (EPDM gaskets)
ZU 0932/1
ZU 0932/2
Media connection, rinse + cal, 17 m (FKM gaskets)
Media connection, rinse + cal, 17 m (EPDM gaskets)
ZU 0653/1
ZU 0653/2
Media interface for standard probes ZU 0576
Metering pump (PP, FKM) with empty 3.5-L bottle
Metering pump (PP, EPDM) with empty 3.5-L bottle
Metering pump (PP, EPDM) with empty 3.5-L bottle, steel balls instead of glass balls*
ZU 0580/1
ZU 0580/2
ZU 0580/2S
Metering pump (PP, FKM) with empty 3.5-L bottle, Ex
Metering pump (PP, EPDM) with empty 3.5-L bottle, Ex
ZU 0580 X/1
ZU 0580 X/2
*) included with special version -001

15
6 Product Range
Spare Parts, Service Parts
Accessories for Unical 9000(X) Order No.
Pipe-mount kit for Unical 9000(X) ZU 0601
Pipe-mount kit for media adapter ZU 0606
Connection kit for Unical 9000(X) (water and air) ZU 0656
Commissioning Unical 9000(X)
Commissioning comprises the following steps.
– Connection of hoses and cables and commissioning of the Unical 9000(X) system
– Operator training
Prior to arrival of our engineer, the customer must prepare the following:
– Assembling the Protos 3400(X), Unical 9000(X) and retractable fitting.
(Observe maximum length of connecting hose between Unical 9000(X) and retractable fitting.)
– Electric supply: Cable ducts/rails must be present.
Auxiliary power supply for Protos 3400(X) must be pre-installed in 2 x 1.5 mm wires.
– Air supply: Hose with connection nipple for G 1/4" female thread, nominal hose width > d = 6 mm.
Water supply: Hose with connection nipple for G 1/4" female thread or G 3/4" male thread,
nominal hose width > d = 6 mm.
ZU 0649
Chemical pump (supplementary ext. valve kit required) ZU 0741
Check valve RV01
Spare Parts and Retrot Parts for Unical 9000(X) Order No.
Media connection, rinse, 5 m (FKM gaskets)
Media connection, rinse 5 m (EPDM gaskets)
ZU 0572/1
ZU 0572/2
Media connection, rinse, 10 m (FKM gaskets)
Media connection, rinse 10 m (EPDM gaskets)
ZU 0573/1
ZU 0573/2
Media connection, rinse, 15 m (FKM gaskets)
Media connection, rinse 15 m (EPDM gaskets)
ZU 0652/1
ZU 0652/2
Media connection, rinse + cal, 5 m (FKM gaskets)
Media connection, rinse + cal, 5 m (FKM gaskets), steel balls instead of glass balls*
Media connection, rinse + cal, 5 m (EPDM gaskets)
ZU 0574/1
ZU 0574/1S
ZU 0574/2
Media connection, rinse + cal, 10 m (FKM gaskets)
Media connection, rinse + cal, 10 m (EPDM gaskets)
ZU 0575/1
ZU 0575/2
Media connection, rinse + cal, 14 m (FKM gaskets)
Media connection, rinse + cal, 14 m (EPDM gaskets)
ZU 0932/1
ZU 0932/2
Media connection, rinse + cal, 17 m (FKM gaskets)
Media connection, rinse + cal, 17 m (EPDM gaskets)
ZU 0653/1
ZU 0653/2
Media interface for standard probes ZU 0576
Metering pump (PP, FKM) with empty 3.5-L bottle
Metering pump (PP, EPDM) with empty 3.5-L bottle
Metering pump (PP, EPDM) with empty 3.5-L bottle, steel balls instead of glass balls*
ZU 0580/1
ZU 0580/2
ZU 0580/2S
Metering pump (PP, FKM) with empty 3.5-L bottle, Ex
Metering pump (PP, EPDM) with empty 3.5-L bottle, Ex
ZU 0580 X/1
ZU 0580 X/2
*) included with special version -001
Spare Parts and Retrot Parts for Unical 9000(X) (continued) Order No.
Supplementary air purging kit
Supplementary Aux2 kit
ZU 0587
ZU 0588
Media adapter (FKM gaskets)
Media adapter (EPDM gaskets)
ZU 0577/1
ZU 0577/2
Media adapter, Ex (FKM gaskets)
Media adapter, Ex (EPDM gaskets)
ZU 0577 X/1
ZU 0577 X/2
Service switch for Unical 9000/NC
Service switch for Unical 9000/XC
Service switch for Unical 9000/NS
Service switch for Unical 9000/XS
ZU 0729 NC
ZU 0729 XC
ZU 0729 NS
ZU 0729 XS
Service Parts for Unical 9000(X) Order No.
Air pressure switch
Water pressure switch
ZU 0632
ZU 0633
Probe valve, complete
Water valve
ZU 0634
ZU 0714
Sensor dismount guard, complete ZU 0644
Air purge valve, complete
Aux 2 valve, complete
Piezo valve for valve block
ZU 0636
ZU 0637
ZU 0638
Gasket for port at media adapter (EPDM) ZU 0639
Filter insert (5 … 10 µm) ZU 0640
Replacement filter housing ZU 0641
Electronics module, tested, encapsulated
Electronics module, tested, encapsulated, Ex
ZU 0642
ZU 0642 X
Small parts set (various screws, springs etc.) ZU 0643
Multiplug service set, FKM gaskets
Multiplug service set, EPDM gaskets
ZU 0812/1
ZU 0812/2
Reed switch, short (service part for multiplug) ZU 0813/1

16

17
7 Checklist for Installation
Protos 3400(X) • Unical 9000(X) • Retractable Fitting
Protos 3400(X)
Correct power supply?
Protos 3400(X) - Unical 9000(X)
• Mounting surface / pipe (incl. drilling plan) for Protos 3400(X)
(see Protos manual)
• Mounting surface (incl. drilling plan) for Unical 9000(X) (see page 19 and
following)
• Mounting surface (incl. drilling plan) for media adapter (see page22)
• Mounting surface / pipe (incl. drilling plan) for service switch (see page21)
• Permissible mounting clearances corresponding to specifications (see
page18)
Unical 9000(X)
• Flexible compressed air connection for G 1/4” female thread
(e.g. accessory ZU0656)
• Compressed air 0.4 ... 1.0 MPa, oil- and condensate-free
• Flexible rinse water connection G 1/4” female thread or 3/4” coupling
(e.g. accessory ZU0656)
• Rinse water 0.2 … 0.6 MPa, 5 … 65°C, 100 µm filtered
Retractable Fittings
SensoGate or Ceramat
• Check if the process adaptation corresponds to your
order acknowledgement (compare product coding)
• Installation position and clearance above connecting flange
according to documentation for retractable fitting
!
CAUTION
Only operate the retractable fitting when a sensor is installed!
When the sensor has been removed, it must always be replaced by a dummy!
SensoGate WA 130(X)
Turn the SensoLock ring to ” lock ” position to prevent that the retractable
fitting is accidentally moved into the process. This is only possible with the
retractable fitting in “Service“ position (see SensoGate manual).

18
8 Assembly
Arrangement of Components Without Protective Cabinet (Accessory):
Permissible Distances and Lifting Heights
295
200
800700 ± 250 ± 250
90
Max. 300
(left or right)
Unical 9000(X)
Media adapter
4x Ø 6.4
2x Ø 8.5 Cable lengths:
Unical - Protos 3400(X): 10 m
Unical - Service switch: 10 m
Unical - Retractable fitting: 5, 10, 14, 15 or 17 m
Lifting height of pumps: max. 10 m
!
CAUTION
Mounting Site
The mounting site must have sufficient mechanical strength and be free of vibrations.
Ambient Temperature
Be sure to observe the permissible ambient temperature (see Specifications in the
respective user manual). It should never sink below +5 °C.
Direct Sunlight
Special measures must be taken for outdoor installation:
Direct sunlight can cause an impermissible temperature increase.
Mounting Distances
The cables are pre-assembled and cut to length.
Be sure to observe the appropriate mounting distances.
You can use the media adapter (corrugated hose) to check the mounting distances.
Dimensions in mm

19
8 Assembly
Wall Mounting
Media connection
Connection to retractable tting (e.g. Ceramat WA 150)
and to media adapter
295
106
26
6.4
200
Ø 6.5
200
310
310
Cable glands
M20 x 1.5
Equipotential bond-
ing terminal ("PA")
Media
connection
Air connec-
tion G 1/4" Air lter
Water
connection
G 1/4" or
G 3/4"
Water
connection
Air lter
Dimensions in mm

20
8 Assembly
Pipe Mounting
Media connection
Connection to retractable fitting (e.g. Ceramat WA 150) and to media adapter
200
200
310
310
Cable glands
M20 x 1.5
Equipotential bonding
terminal ("PA")
Media
connection
Air connection
G 1/4"
Air lter
Water
connection
G 1/4" or
G 3/4"
Water
connection
Air lter
200
23
72
92
Ø 30 … 65 mm
transverse or longitudinal pipe
Hex bolts
M6 x 10 (4 x)
Washers M6 (4 x)
Cap nuts M6 (4 x)
Threaded rods
M6 x 110 (4 x)
Washers M6 (4 x)
Hex nuts
M6 x 10 (4 x)
Dimensions in mm