Knick Ceramat WA 154 User manual

User Manual
English
Latest Product Information: www.knick.de
Ceramat WA 154
Sensor Lock-Gate

Warranty
Defects occurring within 1 year from delivery date shall be remedied free of charge at our plant
(carriage and insurance paid by sender).
©2020 Subject to change without notice
Exclusions from warranty
Wear parts (gaskets) and damage caused by improper use are excluded from warranty.
Return of products
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/
disinfected before shipment. In that case, please attach a corresponding Declaration of Contamination
(seepage39), for the health and safety of our service personnel.
Trademarks
The following trademarks are used in this manual without further marking:
Ceramat®, Protos®, Unical®, Uniclean®
are registered trademarks of Knick Elektronische Messgeräte GmbH & Co. KG, Germany
2
Safety Information
!
WARNING
Always make sure that the sensor lock-gate cannot be activated by other persons during servicing or
installation (eg, cleaning or replacing the sensor).
During operation the drive unit of the sensor lock-gate is rotating rather quickly by 140°.
There is a risk of injury!
Be sure to observe:
Work on the sensor lock-gate must only be performed by personnel authorized by the operating company
and specially trained for handling and operating the sensor lock-gate.
Please note:
Supplementary information is provided in the Ceramat Maintenance Instructions (Maintenance / Spare Parts /
Accessories)
NOTICE
Process-related risks
Knick Elektronische Messgeräte GmbH & Co. KG assumes no liability for damages caused by process-related
risks known to the operator, which would in fact not permit the use of the sensor lock-gate.

3
Safety Information
Operation in Explosive Atmospheres
The Ceramat WA154-X is certified for operation in explosive atmospheres.
• EU-Type Examination Certificate KEMA04ATEX4035X
Exceeding the standard atmospheric conditions within the manufacturer’s specifications, such as ambient tem-
perature, process pressure and temperature, does not impair the durability of the retractable fittings.
Related certificates are included in the product’s scope of delivery and are available at www.knick.de in the cur-
rent version.
Observe all applicable local and national codes and standards for the installation of equipment in explosive at-
mospheres. For further guidance, consult the following:
•IEC60079-14
• EU directives 2014/34/EU and 1999/92/EC(ATEX)
Possible Ignition Hazards During Installation and Maintenance
To avoid mechanically generated sparks, handle the Ceramat WA154-X with care and apply suitable measures,
e.g., use covers and pads.
The metallic parts of the Ceramat WA154-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 infor-
mation given on the nameplate may deviate from the actual version of the Ceramat WA154-X. The operating
company must assess and document this deviation.
Mechanically generated sparks
Single impacts on metal parts or collisions between metal parts of the Ceramat WA154-X are not a potential igni-
tion 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
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.
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 documentation.

4Table of Contents
Safety Information .........................................................................................................................2
Table of Contents ............................................................................................................................4
Intended Use ...................................................................................................................................5
Rating Plates ................................................................................................................................................................ 6
Package Contents ...........................................................................................................................7
Product Coding ...............................................................................................................................8
Function Description ....................................................................................................................10
Composition of the Sensor Lock-Gate ........................................................................................11
Information on Installation .........................................................................................................13
Connection to Unical or Uniclean ...............................................................................................17
Installing/Removing a Sensor .....................................................................................................18
pH Sensors .................................................................................................................................................................19
Sensor Dismount Guard ........................................................................................................................................19
Installing/Removing a Solid-Electrolyte Sensor ........................................................................20
pH Sensors, Oxygen Sensors, Conductivity Sensors ..................................................................................20
Installing/Removing a Liquid-Electrolyte Sensor ......................................................................21
pH Sensors .................................................................................................................................................................21
Cavity Rinsing Function ...............................................................................................................23
Maintenance Work on the Drive Unit .........................................................................................24
Removing the Drive Unit .............................................................................................................25
Installing the Drive Unit ...............................................................................................................26
Installation Dimensions ...............................................................................................................27
Solid Electrolyte .......................................................................................................................................................27
Liquid Electrolyte .....................................................................................................................................................28
Immersion Depths (Process Adadaption: Flange) ....................................................................................... 29
Specifications ................................................................................................................................30
Maintenance Intervals .................................................................................................................31
Lubricants, O-Rings ......................................................................................................................32
Sealing Kits for Maintenance and Servicing ..............................................................................33
Accessories / Spare Parts .............................................................................................................34
Declaration of Contamination .....................................................................................................39
Index ..............................................................................................................................................40

5
The Ceramat pneumatic sensor lock-gate with ceramic sealing is used for installing a sensor for measuring
process variables in liquid media. The sensor can be cleaned, calibrated, or replaced under process conditions
(pressure and temperature).
Since the pneumatic drive unit and the process unit with the ceramic sensor lock-gate are separate modules,
the drive unit can be removed and replaced under process conditions.
The sensor lock-gate is suitable for sensors with an outer diameter of 12 mm, for sensors:
•with solid electrolyte, length 425 mm, sensor head with PG 13.5
•with liquid electrolyte, length 450 mm
•for optical sensors with a body diameter of 12 mm or 12.7 mm (1/2“)
(For installing an optical sensor, you require a special adapter which is listed in the Product Coding under
“Special version”. Information on design and use of the suitable adapter is provided in a supplementary
datasheet.)
The Ceramat sensor lock-gate allows:
•inserting and retracting the sensor under process pressure (sensor lock-gate)
•calibrating or adjusting the measuring system and cleaning the sensor in the running process (different
options available)
•removing or replacing the sensor after separation from the process (in SERVICE position)
The Ceramat sensor lock-gate has been developed and manufactured in compliance with the applicable
European directives and standards.
Compliance with the European directives and standards is confirmed by the EC Declaration of Conformity.
Compliance with the European Harmonized Standards for use in hazardous locations is confirmed by the
EC-Type-Examination Certificate.
To ensure smooth performance of the measuring points with the Ceramat, a number of important operating
and maintenance parameters must be complied with (see Maintenance Instructions).
There is no particular direct hazard caused by the operation of the device in the specified environment.
Intended Use
!
CAUTION
Safe use
•If you are not sure whether the sensor lock-gate can be safely used for your intended application,
please contact the manufacturer.
•Take account of the influences of humidity, ambient temperature, chemicals, and corrosion.
•To ensure safe use of the equipment, you must follow the instructions given in the manual and observe
the specified temperature and pressure ranges.

6Intended Use
Rating Plates
Ceramat WA 15x-N
Drive
Process
Ceramat WA 15x-X
Drive
Process
66
IP
Max. pressure
Temperature range
14163 Berlin Made in Germany
Ceramat ®
Retractable Fitting / Drive Unit
Type
No.
Type
No.
Ceramat®
Retractable Fitting/Process Unit Max. pressure
Temperature range
14163 Berlin
Made in Germany
KEMA 04 ATEX 4035X
II 1 G Ex h IIC T6 ... T3 Ga
II 1 D Ex h IIIC T80°C ... 140°C Da
No self-heating
Special conditions
Tamb -10 ... 70°C
66
IP
Max. pressure
Temperature range
14163 Berlin Made in Germany
Ceramat ®
Retractable Fitting / Drive Unit
Type
0044
No.
Ceramat®
Retractable Fitting / Process Unit
14163 Berlin Made in Germany
Type
No.
0044
Max. pressure
Temperature range
See Drive Unit
for Ex marking

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

8Product Coding
WA 154 - –
Explosion protection ATEX Zone 0 X
Without N
Sensor Sensor, Ø 12 mm, with PG 13.5 0
pH sensor, Ø 12 mm, pressurized 1
Optical sensor, Ø 1/2” (12.7 mm) 2
Optical sensor, Ø 12 mm 3
Material of gaskets FKM A
EPDM B
EPDM - FDA E
FKM - FDA F
FFKM - FDA H
FFKM K
Material of sensor
protection sleeve
Hastelloy C22 B
1.4404 H
Titanium T
Material of sensor socket Hastelloy C 22, without protection B 0
Hastelloy C 22, 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 Without 0
PEEK, natural 1
Immersion depth Special immersion depth 26 - 299 mm (increase in 1 mm steps) 000
Immersion depth 150 - 300 mm (increase in 10 mm steps) 000
Process-wetted material Hastelloy C22 B
1.4404 H
Titanium T
Process adaptation 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 B 5
Flange, loose, 1.4571, PN10/16, DN 150 B 6
Flange, loose, 1.4571, PN16, DN 200 B 7
Flange, loose, 1.4571, PN 40, DN 50 E 1
Flange, loose, 1.4571, PN 40, DN 65 E 2
Flange, loose, 1.4571, PN 40, DN 80 E 3
Flange, loose, 1.4571, PN 40, DN 100 E 4
Flange, loose, 1.4571, PN 40, DN 125 E 5
Flange, loose, 1.4571, PN 40, DN 150 E 6
Flange, loose, 1.4571, PN 40, DN 200 E 7

9
WA 154 - –
Dairy pipe DN 50 C 1
Dairy pipe DN 65 C 2
Dairy pipe DN 80 C 3
Dairy pipe DN 100 C 4
Flange, loose, ANSI 316,150 lbs, 2” D 1
Flange, loose, ANSI 316, 150 lbs, 2 1/2” D 2
Flange, loose, ANSI 316, 150 lbs, 3” D 3
Flange, loose, ANSI 316, 150 lbs, 3.5” D 4
Flange, loose, ANSI 316, 150 lbs, 4” D 5
Flange, loose, ANSI 316, 150 lbs, 5” D 6
Flange, loose, ANSI 316, 150 lbs, 6” D 7
Flange, loose, ANSI 316, 300 lbs, 2” P 1
Flange, loose, ANSI 316, 300 lbs, 2 1/2” P 2
Flange, loose, ANSI 316, 300 lbs, 3” P 3
Flange, loose, ANSI 316, 300 lbs, 3.5” P 4
Flange, loose, ANSI 316, 300 lbs, 4” P 5
Flange, loose, ANSI 316, 300 lbs, 5” P 6
Flange, loose, ANSI 316, 300 lbs, 6” P 7
Clamp 2" J 2
BioControl, 1.4404, DN 65 L 2
Varivent, 1.4404, ≥ DN 50 V 1
Special flange, to customer requirements SA-Y
Probe guard Without 0
With, version 1 1
Special version Without 000
Equipped with special grease (provided by customer) 1
Sensor protection sleeve for optical sensor with Ø 1/2” (12.7 mm) for RAMAN probe,
with additional anti-twist protection for the sensor cables,
adapter, rotating, 1/2”/PG13.5 (according to drawing) 7
Sensor protection sleeve for optical sensor (Hellma) with Ø 1/2 mm, with additional
anti-twist protection for the sensor cables,
adapter, rotating, 12 mm/PG13.5 (according to drawing) B
Customer-specific special datasheet F
Product Coding
Entries shown in italics are special options, delivery time on request

10 Function Description
Mounting
• Possible mounting angle: 15° above horizontal.
• Mounting angle 360° (i.e. even upside down) for
special sensors only containing thickened electrolytes
which thus cannot flow.
The pneumatically operated sensor lock-gate allows calibrating or adjusting the measuring system and clean-
ing the sensor in the running process. For that purpose, the sensor can be moved between two positions:
PROCESS position: The sensor is located in the process medium.
SERVICE position: The sensor is located in the calibration chamber.
In SERVICE position the measuring system can be calibrated or adjusted or the sensor can be cleaned.
Using compressed air, a control unit such as the Unical 9000 moves the sensor between SERVICE position
and PROCESS position and leads different calibration and/or cleaning liquids to the sensor located in the
calibration chamber.
These liquids leave the calibration chamber through an outlet hose, i.e. they are displaced from the
calibration chamber by following liquids or by compressed air.
To replace the sensor, you must move the sensor lock-gate into SERVICE position.
With the Unical 9000 probe controller, all media, control air, and the check-back cable for position indication
of the probe are connected to the sensor lock-gate through a compact connector (multiplug).
Since the pneumatic drive unit and the process unit with the ceramic sensor lock-gate are separate modules,
the drive unit can be removed and replaced under process conditions.
15°
15°