Knick Ceramat WA160 User manual

Ceramat® WA160(X)
Ceramic Retractable Fitting
User Manual
www.knick.de
Read before installation.
Keep for future use.

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 43), for the health and safety of our service personnel.

3
Safety Instructions
Ceramat® WA 160(X) Retractable Fitting
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 WA 160(X) retractable fitting.
WARNING
Always make sure that the retractable fitting cannot be activated by other persons
during servicing or installation (e.g., cleaning or replacing the sensor).
During operation the drive unit of the Ceramat® retractable fitting is rotating rather
quickly by 140°. There is a risk of injury!
Be sure to observe:
Work on the retractable fitting shall only be performed by personnel authorized by the
operating company and specially trained for handling and operating the retractable
fitting.
Note:
Supplementary information is provided in the Ceramat WA 160(X) Maintenance
Instructions (Maintenance / Spare Parts / Accessories)

4
Safety Instructions ............................................................................................................ 3
Table of Contents............................................................................................................... 4
Intended Use......................................................................................................................5
Package Contents..............................................................................................................7
Ceramat® WA 160(X) Product Code..................................................................................8
Function Description.......................................................................................................10
Composition of the Retractable Fitting.........................................................................11
Modules Available: Drives, Process Connections ...............................................................................12
Information on Installation ............................................................................................13
Mounting on Holding Bracket, Installing the Outlet Hose.............................................................14
Installing the Multiplug,Installing the Sensor Cable.........................................................................15
Positioning the Sensor Protection ...........................................................................................................16
Connection to Unical® or Uniclean®...............................................................................17
Installing and Removing a Sensor .................................................................................18
Removing the Drive Unit ................................................................................................19
Installing the Drive Unit..................................................................................................21
Installing the Sensor .......................................................................................................22
Removing the Sensor......................................................................................................24
Functioning of the Cavity Rinsing..................................................................................26
Condensate Drain............................................................................................................27
Automatic Condensate Drain .........................................................................................28
Installation Dimensions..................................................................................................30
Permissible Forces and Flow Rates ................................................................................31
Ceramat® WA 160(X), 1.4571 Variant.......................................................................................................31
Specifications...................................................................................................................32
Maintenance Work on the Drive Unit ............................................................................33
Maintenance Intervals ....................................................................................................34
Gasket Sets for Maintenance and Servicing .................................................................35
Material Properties of the Available Probe Housings and Sensor Sockets................36
Lubricants, O-Rings .........................................................................................................37
Accessories / Spare Parts ................................................................................................38
Declaration of Contamination........................................................................................43
Table of Contents
Ceramat® WA 160(X) Retractable Fitting

5
Intended Use
Ceramat® WA 160(X) Retractable Fitting
The Ceramat® WA 160 (X) pneumatic retractable fitting 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 retractable fitting are sepa-
rate modules, the drive unit can be removed and replaced under process conditions.
The retractable fitting is suitable for sensors with an outer diameter of 12 mm,
· Length 225 mm, sensor head with PG 13.5
Sensors with refillable liquid electrolyte are not suitable.
The Ceramat® WA 160(X) retractable fitting allows:
• inserting and retracting the sensor under process pressure (retractable fitting)
• 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)
Take account of the influences of humidity, ambient temperature, chemicals, and corrosion.
Safe Use
If you are not sure whether the retractable fitting can be safely used for your intended
application, please contact the manufacturer.
To ensure safe use of the equipment, you must follow the instructions given in the manual and
observe the specified temperature and pressure ranges.
The SensoGate WA 160(X) retractable fitting has been developed and manufactured in compli-
ance with the applicable European guidelines and standards. Compliance with the European
Harmonized Standards for use in hazardous locations is confirmed by the EC-Type-Examination
Certificate. Compliance with the European directives and standards is confirmed by the EC
Declaration of Conformity.
For hazardous-area applications, the sensors used must ensure proper separation of the ATEX
zones. When the retractable fitting is in SERVICE position, the sensor may be replaced within a
Zone 1 hazardous location.
There is no particular direct hazard caused by the operation of the device in the specified environ-
ment.
To ensure smooth performance of the measuring points with the Ceramat®, a number of impor-
tant operating and maintenance parameters must be complied with (see Ceramat WA160
Maintenance Instructions).

6
Intended Use
Ceramat® WA 160(X) Retractable Fitting
Rating Plates
Ceramat® WA 160(X)- N
Drive unit
Process
Ceramat® WA 160(X)- X
Drive unit
Process
Process, small rating plates
Process, small rating plates

7
Package Contents
Ceramat® WA 160(X) Retractable Fitting
Check the shipment for transport damage and completeness.
The package should contain:
• Retractable fitting
• Documentation
• Test certificates

8
Ceramat WA160- -000
Basic device with pneum. drive, stainless steel version
Explosion protection ATEX Zone 0 X 
Without N 
Sensor connection VP 1
InduCon 2
Memosens 3
Gasket material FKM   A
EPDM   B
FFKM / FKM   C
EPDM - FDA   E
FFKM - FDA   H
FFKM   K
Material of probe housing and
sensor socket
PEEK with integrated sensor protection    A
PVDF with integrated sensor protection    B
PEEK without integrated sensor protection    C
PVDF without integrated sensor protection    D
1.4435 without integrated sensor protection,
sensor socket PEEK   E
PEEK w/o integrated sensor protection,
long sensor socket, 1.4404    H
PEEK w/o integrated sensor protection,
long sensor socket, C22    J
PVDF w/o integrated sensor protection,
long sensor socket, 1.4404    K
PVDF w/o integrated sensor protection,
long sensor socket, C22    L
PEEK, w/o integrated sensor protection,
sensor socket PEEK with PEEK scraper ring    M
PEEK, w/o integrated sensor protection,
sensor socket with full sensor protection, 1.4404   N
PVDF, w/o integrated sensor protection,
sensor socket with full sensor protection, 1.4404   O
PEEK, w/o integrated sensor protection,
sensor socket with full sensor protection, C22   P
PVDF, w/o integrated sensor protection,
sensor socket with full sensor protection, C22   R
Process connections Flange, loose, 1.4571, PN10/16, DN 65 1)    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, PN40, DN 65     E 2    
Flange, loose, 1.4571, PN40, DN 80     E 3    
Flange, loose, 1.4571, PN40, DN 100     E 4    
Flange, loose, 1.4571, PN40, DN 125     E 5    
Flange, loose, 1.4571, PN40, DN 150     E 6    
Flange, loose, 1.4571, PN40, DN 200     E 7    
Ceramat® WA 160(X) Product Code

9
Ceramat WA160- -000
Process connections Dairy pipe DN 80     C 3    
Dairy pipe DN 100     C 4    
Flange, loose, ANSI 316, 150 lbs, 2 1/2“ 1)    D 2    
Flange, loose, ANSI 316, 150 lbs, 3“ 1)    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 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    
Immersion depth 600 A  
1000 B  
1500 C  
2000 D  
Immersion tube material Stainless steel 1.4571 1 
Stainless steel 1.4435, polished 2 
Stainless steel, PP sheathed 3 
Stainless steel, PVDF sheathed 4 
Special variant Without 000
Equipped with special grease
(provided by customer) 1
Fixation ring (process unit) from
Hastelloy C22; driving pin
(rotary drive) from Hastelloy C22

A
Customer-specic special data sheet F
1)Not with immersion tube material 3 or 4
Ceramat® WA 160(X) Product Code

10
Function Description
Ceramat® WA 160(X) Retractable Fitting
The pneumatically operated retractable fitting allows calibrating or adjusting the measuring sys-
tem and cleaning 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 probe 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 retractable fitting into SERVICE position.
With the Unical® 9000 probe controller, all media, control air, and the check-back cable for posi-
tion indication of the probe are connected to the retractable fitting through a compact connector
(multiplug).
Since the pneumatic drive unit and the process unit with the ceramic retractable fitting are sepa-
rate modules, the drive unit can be removed and replaced under process conditions.
Installation
The Ceramat® WA 160(X) retractable fitting is intended for vertical installation in tanks. When mea-
suring in media with high flow rates, the lower end of the fitting should be provided with an addi-
tional support or be inserted in a protection tube installed in the tank.
The load caused by the flowing process medium depends on the flow rate, the viscosity and tem-
perature of the process medium, as well as on pressure variations caused by pumps, for example.
For applications with low-viscosity media without significant pressure variations, the illustration
on page 31 provides an orientation.
When the fitting is provided with an additional support, it might also be installed through the side
wall of the tank.
Please contact our technical service team in this case.