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.