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.

11
Composition of the Retractable Fitting
Ceramat® WA 160(X) Retractable Fitting
The Ceramat® retractable fitting consists of 2 main units: drive unit and process unit.
The drive unit performs the movements required to open and close the ceramic rotary slide and
to move the sensor into and out of the process.
The process unit comprises the immersion tube, the process-wetted probe housing with the
ceramic rotary slides, and an integrated calibration chamber as well as the process connection (e.g.
flange).
Drive unit and process unit can be separated by the operator even under process pressure when
certain safety precautions are taken.
(see “Maintenance Work on the Drive Unit” on page 33).
Drive unit
Process unit
Bail handle
Accessory ZU 0651
Process connection
(e.g. flange)
Immersion tube
Probe housing with
ceramic rotary slides
Coupling nut

12
Drive Units
(for immersion depths 600, 1000, 1500, 2000 mm, others on request)
Process Connections
(for immersion depths 600, 1000, 1500, 2000 mm, others on request)
Versions with flange, dairy pipe, DN80, pipe clamp
Immersion tube,
made of stainless steel 1.4571 Immersion tube made of PP Immersion tube made of PVDF
Composition of the Retractable Fitting
Modules Available: Drives, Process Connections

13
Information on Installation
Ceramat® WA 160(X) Retractable Fitting
For operation of the Ceramat®, you must connect control air, rinsing or calibration media, and the
electrical check-back signal for indicating the probe position.
There are two possible ways to do so.
When the Ceramat is operated with a Unical® or Uniclean® electro-pneumatic controller and the
Protos® measuring system, the cables and tubings for air pressure, rinsing/calibration media and
check-back are combined in a single hose with just one plug connection (multiplug). This hose is
referred to as media connection.
This media connection is installed on the Ceramat® together with the outlet hose.
When you do not use a probe controller (Unical® or Uniclean® and Protos® measuring system), you
can connect the supply lines for control air, rinsing/calibration media and electrical check-back to
the Ceramat® with a free hose connection via the ZU 0631 standard-media interface.
Connection for operation with
Unical®/Uniclean® and Protos®
Connection for operation with
ZU 0631 standard media interface

14
Information on Installation
Mounting on Holding Bracket, Installing the Outlet Hose
The following procedure is recommended
for installing the media connection (also
applies to installation of ZU 0631 standard
media interface):
Mounting on the holding bracket of the
Ceramat®
Screw the bracket of the media connection
to the holding bracket of the Ceramat.
Mounting screws
Installing the outlet hose
Turn the outflow nipple so that the outlet
hose points outwards (see figure on the left).
Before tightening the coupling nut, correctly
align and insert the outflow nipple!
NOTICE! Check positioning of coding recess-
es and coding bars to lock the connection.
Outlet hose
Coupling nut
Coding recesses
Coding bars
Outflow nipple

15
Information on Installation
Installing the Multiplug,Installing the Sensor Cable
Installing the multiplug
Install multiplug (A)
with 2 screws (B) as shown.
Installing the sensor cable
Attach the connecting cable (A) to the
sensor and connect to the fixing bracket
(B) in a loop as shown in the illustration.
Using clamp (C), attach the cable lightly
so that the cable is secured and not con-
stricted. The rotational movement of the
Ceramat® would otherwise damage the
cable.
NOTICE! The cable loop must be long
enough so that the cable does not impede
the stroke movement of the fitting.
Connect the equipotential bonding cable
to terminal (F) (if required).
A
B
A
B
C
F

16
Positioning the sensor protection
For the probe housing with sensor protec-
tion option, pay attention to the position of
the sensor protector, for example in flowing
media. With corresponding installation in the
flange bores, the retractable fitting can be
aligned for the process.
Probe housing
Probe guard
Free direction of flow
Against
direction of
flow
Information on Installation
Positioning the Sensor Protection

17
Connection to Unical® or Uniclean®
Ceramat® WA 160(X) Retractable Fitting
The media connection is available in 5 m or 10 m length (other lengths on request).
It consists of a Ø 30 mm corrugated hose with a metal coil.
2 variants are available:
for rinsing only (without branch outlet to media adapter)
for calibration and cleaning function (with branch outlet to media adapter)
Connections
The connections for media adapter and fitting are of a plug-in design. They are mechanically fixed
by screwing. All media are guided separately through the corrugated hose, secured by check
valves. This prevents contamination or mixing of the fluids.
Connection to Unical® or Uniclean®
The corrugated hose is screwed to the joining piece of the Unical® or Uniclean®.
Thanks to a slitted coupling nut the different media tubes can easily be fed through.
The tubes are designed and color-coded for clear assignment.
See also Unical® 9000(X) / Uniclean® 900(X) Installation Guide.
Connection to media adapter
This connection is plugged and screwed to the media adapter. It includes the media tubing.
Electrical connection is made via a plug-in connector.
See also user manuals of Unical® 9000(X) / Uniclean® 900(X) probe controllers and other accom-
panying documents for connecting the Ceramat® to Unical® 9000(X) / Uniclean® 900(X) and the
Protos® measuring system.
Connection to Unical® 9000(X)
Connection to media adapter
(omitted for“rinsing only” variant)
Multiplug for connecting the Ceramat

18
Installing and Removing a Sensor
Ceramat® WA 160(X) Retractable Fitting
NOTICE!
Sensors must only be installed or removed by trained personnel authorized by the
operating company. The Ceramat WA 160(X) retractable fitting must be in SERVICE
position.
This position is attained by:
• the service switch (see Unical® 9000(X) Installation Guide)
• the “Maintenance” menu when controlled by Protos® 3400(X)
- see user manuals of PHU 3400(X)-110, FIU 3400X-140 or
FIU 3400-141 modules
Be sure to follow the assembly instructions step by step.
Preparatory steps:
• Check whether the sensor is damaged (glass broken?). Never install a damaged sensor!
• Check whether slide washer or O-ring on the sensor are damaged and replace if required.
• Remove the watering cap from the sensor tip and rinse sensor with water.
• Internally pressurized sensors might have a silicone seal on the diaphragm (as transport
protection). Remove this seal using the knife shipped with the sensor.
For installing or removing a sensor, you must separate the drive unit from the immersion tube.
To do so, move the drive unit to SERVICE position.
NOTICE!
The drive can only be separated when the SERVICE position has been fully reached.
Any attempt to forcibly detach the drive in any other position will damage the fitting.
Before removing the drive, check that there is no liquid flowing out of the outlet
(ceramic slides or probe housing might be defective).

19
Removing the Drive Unit
Ceramat® WA 160(X) Retractable Fitting
NOTICE:
Be sure to follow these instructions in the correct
sequence.
Take appropriate safety precautions against escaping
process fluids.
1) Move probe into SERVICE position.
Only in this position can the drive unit be removed.
2) Switch off compressed air and deaerate device!
3) Make sure that no process fluid is leaking from the
outlet.
4) Turn coupling nut counterclockwise using the ZU 0648
mounting wrench (see "Accessories", page39).
This pulls the drive unit out of the process unit.
You can slightly lift up the drive unit while turning the
nut to support its movement.
Do not cant the unit and do not exert force.
Do not loosen the coupling nut completely.
5) Make sure that no process fluid is leaking from the
outlet.
6) Completely loosen the coupling nut and pull off the
drive unit upwards.

20
Removing the Drive Unit
Ceramat® WA 160(X) Retractable Fitting
NOTICE:
Be sure not to damage the glass body of the sensor at
the lower end of the drive unit!