Knick SensoGate WA131 User manual

User Manual SensoGate WA131
Retractable Fitting
www.knick.de
Read before installation.
Keep for future use.

SensoGate WA131
2
Supplemental Directives
READ AND SAVE THIS DOCUMENT FOR FUTURE REFERENCE. BEFORE ATTEMPTING TO ASSEMBLE,
INSTALL, OPERATE OR MAINTAIN THE PRODUCT, PLEASE ENSURE A COMPLETE UNDERSTANDING OF
THE INSTRUCTIONS AND RISKS DESCRIBED HEREIN. ALWAYS OBSERVE ALL SAFETY INFORMATION.
FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS DOCUMENT COULD RESULT IN SERIOUS INJURY
AND/OR PROPERTY DAMAGE. THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.
These supplemental directives explain how safety information is laid out in this document and
what content it covers.
Safety Chapter
This document's safety chapter is designed to give the reader a basic understanding of safety. It
illustrates general hazards and gives strategies on how to avoid them.
Warnings
This document uses the following warnings to indicate hazardous situations:
Symbol Category Meaning Remark
WARNING Designates a situation that can lead to death or serious
(irreversible) injury.
The warnings contain
information on how to
avoid the hazard.
CAUTION Designates a situation that can lead to slight or moderate
(reversible) injury.
None NOTICE Designates a situation that can lead to property or
environmental damage.
Symbols Used in this Document
Symbol Meaning
Reference to additional information
Interim or final result in instructions for action
Sequence of figures attached to an instruction for action
Item number in a figure
Item number in text

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Table of Contents
1 Safety............................................................................................................................................. 5
1.1 Intended Use ......................................................................................................................................................... 5
1.2 Personnel Requirements ................................................................................................................................... 5
1.3 Safeguards.............................................................................................................................................................. 6
1.4 Residual Risks ........................................................................................................................................................ 7
1.5 Safety Accessories................................................................................................................................................ 8
1.6 Hazardous Substances ....................................................................................................................................... 9
1.7 Operation in Explosive Atmospheres ........................................................................................................... 9
1.7.1 Possible Ignition Hazards During Installation and Maintenance.......................................... 9
1.7.2 Possible Ignition Hazards During Operation................................................................................ 10
1.8 Safety Training ...................................................................................................................................................... 10
1.9 Maintenance and Spare Parts.......................................................................................................................... 10
2 Product .......................................................................................................................................... 11
2.1 Package Contents ................................................................................................................................................ 11
2.2 Product Identification......................................................................................................................................... 11
2.2.1 Example of a Version ............................................................................................................................. 11
2.2.2 Product Code ........................................................................................................................................... 12
2.3 Nameplates ............................................................................................................................................................ 14
2.4 Symbols and Markings....................................................................................................................................... 16
2.5 Design and Function........................................................................................................................................... 16
2.5.1 Retractable Fitting.................................................................................................................................. 17
2.5.2 Drives and Sensor Holders.................................................................................................................. 18
2.5.3 Process Connections ............................................................................................................................. 18
2.5.4 Immersion Tubes .................................................................................................................................... 19
2.6 Permissible Changes........................................................................................................................................... 19
2.7 SERVICE/PROCESS Limit Positions ................................................................................................................. 20
2.7.1 Service and Process Position.............................................................................................................. 20
2.7.2 Limit Signals ............................................................................................................................................. 21
3 Installation .................................................................................................................................... 22
3.1 Retractable Fitting: Installation....................................................................................................................... 22
3.2 Safety Accessories: Installation ....................................................................................................................... 22
3.3 Outlet Hose: Installation.................................................................................................................................... 23
3.4 Inlet Hose (Option): Installation...................................................................................................................... 23
3.5 Pneumatic Control: Installation ...................................................................................................................... 24
4 Commissioning ............................................................................................................................. 25
5 Operation ...................................................................................................................................... 26
5.1 Moving into the Process Position (PROCESS Limit Position) ................................................................ 26
5.2 Moving into the Service Position (SERVICE Limit Position)................................................................... 26
5.3 Installing and Removing Sensors................................................................................................................... 27
5.3.1 Safety Instructions on Installing and Removing Sensors......................................................... 27
5.3.2 Solid-Electrolyte Sensor, Short Immersion Depth: Installation ............................................. 27

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5.3.3 Solid-Electrolyte Sensor, Short Immersion Depth: Removal .................................................. 28
5.3.4 Solid-Electrolyte Sensor, Long Immersion Depth: Installation .............................................. 29
5.3.5 Solid-Electrolyte Sensor, Long Immersion Depth: Removal ................................................... 30
5.3.6 Liquid-Electrolyte Sensor: Installation ............................................................................................ 31
5.3.7 Liquid-Electrolyte Sensor: Removal................................................................................................. 33
6 Maintenance ................................................................................................................................. 34
6.1 Inspection............................................................................................................................................................... 34
6.1.1 Inspection and Maintenance Intervals........................................................................................... 34
6.1.2 Knick Premium Service......................................................................................................................... 34
6.2 Preventive Maintenance.................................................................................................................................... 35
6.2.1 Approved Lubricants............................................................................................................................. 35
6.2.2 Characteristics of Process-Wetted Materials................................................................................. 35
6.3 Corrective Maintenance .................................................................................................................................... 36
6.3.1 Corrective Maintenance Safety Instructions ................................................................................ 36
6.3.2 Drive Unit: Removal............................................................................................................................... 36
6.3.3 Drive Unit: Assembly............................................................................................................................. 37
6.3.4 Immersion Tube: Removal .................................................................................................................. 38
6.3.5 Immersion Tube: Installation.............................................................................................................. 39
6.3.6 Calibration Chamber: Removal ......................................................................................................... 40
6.3.7 Calibration Chamber: Installation..................................................................................................... 41
6.3.8 Knick Repair Service .............................................................................................................................. 41
7 Troubleshooting ........................................................................................................................... 42
7.1 Malfunction States............................................................................................................................................... 42
8 Removal from Operation ............................................................................................................. 43
8.1 Retractable Fitting: Removal............................................................................................................................ 43
8.2 Returns..................................................................................................................................................................... 43
8.3 Disposal ................................................................................................................................................................... 43
9 Spare Parts, Accessories, and Tools............................................................................................. 44
9.1 Seal Kits.................................................................................................................................................................... 44
9.2 Spare Parts.............................................................................................................................................................. 46
9.3 Accessories ............................................................................................................................................................. 47
9.4 Tools.......................................................................................................................................................................... 51
10 Dimension Drawings .................................................................................................................... 52
11 Specifications................................................................................................................................ 58

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1 Safety
This document contains important instructions for the use of the product. Always follow all
instructions and operate the product with caution. If you have any questions, please contact
Knick Elektronische Messgeräte GmbH & Co. KG (sometimes hereafter referred to as "Knick")
using the information provided on the back page of this document.
1.1 Intended Use
The SensoGate WA131 is a retractable fitting for installation in boilers, tanks, and pipes. The product is
used to mount a sensor for measuring process parameters. The sensor is immersed in the process
medium by the SensoGate WA131. The SensoGate WA131 is pneumatically operated.
Cleaning, calibration, or sensor replacement under process conditions by the customer (hereinafter
sometimes referred to as the "operating company") may be conducted, subject to the requirements
set forth herein, by placing the product into the service position (SERVICE limit position).
If the product is used with any product or part not authorized by Knick, the operating company
assumes all risks and liabilities related thereto.
The SensoGate WA131 can be used with the following sensor types:
Solid-electrolyte sensors Outer diameter 12mm, length225 mm, sensor head thread PG13.5
Liquid-electrolyte sensors Outer diameter 12mm, length 250mm
Optical sensors Outer diameter 12mm
For further information, refer to the applicable documentation of the sensor manufacturer.
The defined operating conditions must be observed when using this product. ➜Specifications, p. 58
Thanks to its modular design, the SensoGate WA131 can be adapted to changed conditions by the
customer.
➜Permissible Changes, p. 19
USE CAUTION AT ALL TIMES WHEN INSTALLING, USING, MAINTAINING OR OTHERWISE INTERACTING WITH
THE PRODUCT. ANY USE OF THE PRODUCT EXCEPT AS SET FORTH HEREIN IS PROHIBITED, AND MAY RESULT
IN SERIOUS INJURY OR DEATH, AS WELL AS DAMAGE TO PROPERTY. THE OPERATING COMPANY SHALL BE
SOLELY RESPONSIBLE FOR ANY DAMAGES RESULTING FROM OR ARISING OUT OF AN UNINTENDED USE OF
THE PRODUCT.
The SensoGate WA131-X version is certified for operation in hazardous locations.
➜Operation in Explosive Atmospheres, p. 9
1.2 Personnel Requirements
The operating company shall ensure that any personnel using or otherwise interacting with the
product is adequately trained and has been properly instructed.
The operating company shall comply and cause its personnel to comply with all applicable laws, regu-
lations, codes, ordinances and relevant industry qualification standards related to product. Failure to
comply with the foregoing shall constitute a violation of operating company’s obligations concerning
the product, including but not limited to an unintended use as described in this document.

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1.3 Safeguards
1
2
Leakage Bores
The calibration chamber (1) is provided with three radial
leakage bores (2).
Process medium escaping from the leakage bores (2) is
indicative of damage to the calibration chamber’s
O‑rings. This damage can be detected and repaired.
SensoLock Immersion Lock
The SensoLock immersion lock prevents the SensoGate
WA131 from accidentally moving into the process posi-
tion (PROCESS limit position) while the sensor is being re-
placed or serviced. Setting the SensoLock ring to “lock”
mechanically locks the SensoGate WA131.
The SensoGate WA131 is in the service position (SERVICE
limit position). The SensoLock ring is set manually to
“lock” and the SensoGate WA131 cannot be moved to the
process position (PROCESS limit position).
After installing the sensor, the SensoLock ring is set to
“unlock”.
Information on SensoLock is provided on a safety label.
The safety label is attached to the fixing bracket of the
SensoGate WA131.
1
2
Immersion lock without a mounted liquid-electrolyte
sensor
The safeguard is only available with special version V.
➜Product Code, p. 12
The immersion lock can be seen at the yellow indicator
ring (2) above the bellows(1). If the yellow indicator ring
(2) is missing, the safeguard function is not available.
A mechanical lock prevents the SensoGate WA131 with-
out a mounted liquid-electrolyte sensor from being
moved into the process position (PROCESS limit position).
1
Immersion lock without a mounted solid-electrolyte
sensor
The safeguard is only available with special version W.
➜Product Code, p. 12
The immersion lock can be seen at the yellow indicator
ring (1) on the drive unit of the SensoGate WA131. If the
yellow indicator ring (1) is missing, the safeguard func-
tion is not available.
A mechanical lock prevents the SensoGate WA131
without a mounted solid-electrolyte sensor from being
moved into the process position (PROCESS limit position).

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1.4 Residual Risks
The product has been developed and manufactured in accordance with generally accepted safety
rules and regulations, as well as an internal risk assessment. Despite the foregoing, the product may
among others bear the following risks:
Environmental Influences
The effects of moisture, ambient temperature, chemicals, and corrosion can negatively impact the safe
operation of the product.
Please observe the following instructions:
• If possible, install the product inside a protected area of the plant. Alternatively, take appropriate
measures to protect the SensoGate WA131 (e.g., install ZU0759protective cap1)).
➜Accessories, p. 47
• If using aggressive chemical process media, adjust the inspection and maintenance intervals
accordingly. ➜Inspection and Maintenance Intervals, p. 34
• Adhering and sticky process media can impact the functionality of SensoGate WA131 (e.g.,by
causing components to stick together). Adjust the inspection and maintenance intervals accord-
ingly. ➜Inspection and Maintenance Intervals, p. 34
1) The ZU0759 protective cap protects against the effects of weather exposure and prevents the ingress of external
liquids or particles into the area of the sensor connections.

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1.5 Safety Accessories
Specially developed accessories are available to increase safety. ➜Accessories, p. 47
ZU0818 Retainer Clamp for Ingold Socket, 25 mm
The retainer clamp prevents the coupling nut of the Ingold socket (25 mm) screw
joint from accidentally loosening.
The wires of the retainer clamp connect SensoGate WA131 to the customer’s
process port. A locking lug on the retainer clamp engages in the groove of the
coupling nut (form-fit).
ZU1055 Retainer Clamp for Process ConnectionK8
The retainer clamp prevents the coupling nut of the screw joint for a K8 process
connection from unintentionally loosening.
The wires of the retainer clamp connect SensoGate WA131 to the customer’s
process port. A locking lug on the retainer clamp engages in the groove of the
coupling nut (form-fit).
ZU0877 Locking Clamp for Process Connection G1″, G1¼″, R1″, R1¼″, 1″NPT
The locking clamp prevents the process screw joint of a SensoGate WA131 with
threaded connection from accidentally coming loose. The locking clamp is avail-
able for process connections with the following threads: G1″, G1¼″, R1″, R1¼″,
1″NPT.
The locking clamp can be used with threaded couplings with a minimum length
of 10mm and an outer diameter of 39mm to 57mm.
ZU1138 Retainer Clamp for SensoGate Retractable Fitting
The accessory prevents the screw joint between the retractable fitting’s drive
unit and the process connection from accidentally coming loose. This serves to
increase safety during operation of the retractable fitting.
The retainer clamp wires connect the drive unit of the SensoGate WA131 to the
coupling nut. The locking lugs on the retainer clamp engage in the grooves of the
coupling nut (form-fit) and secure the screw joint.

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1.6 Hazardous Substances
IN THE EVENT OF ANY CONTACT WITH HAZARDOUS SUBSTANCES OR OTHER INJURY HEREUNDER, SEEK IM-
MEDIATE MEDICAL ATTENTION OR FOLLOW APPLICABLE PROCEDURES TO ADDRESS HEALTH AND SAFETY
OF PERSONNEL. FAILURE TO SEEK IMMEDIATE MEDICAL ATTENTION MAY RESULT IN SERIOUS INJURY OR
DEATH.
In certain situations (e.g., sensor replacement or corrective maintenance), personnel may come into
contact with the following hazardous substances:
• Process medium
• Lubricant
The operating company is responsible for conducting a hazard assessment.
See the relevant manufacturers’ safety data sheets for hazard and safety instructions on handling
hazardous substances.
1.7 Operation in Explosive Atmospheres
The SensoGate WA131-X is certified for operation in explosive atmospheres.
• EU Type Examination Certificate KEMA04ATEX4035X
The conditions for installation and operation in hazardous locations can be found on the correspond-
ing certificates.
Exceeding the standardized atmospheric conditions within the manufacturer’s specifications, e.g., with
regard to the ambient temperature and pressure, does not endanger the retractable fitting’s durability.
➜Specifications, p. 58
Related certificates are included in the product’s scope of delivery and are available at www.knick.de
in the current version.
Observe all applicable local and national codes and standards for the installation of equipment in ex-
plosive atmospheres. For further guidance, consult the following:
• IEC60079-14
• EU directives 2014/34/EU and 1999/92/EC(ATEX)
1.7.1 Possible Ignition Hazards During Installation and Maintenance
To avoid mechanically generated sparks, handle the SensoGate WA131-X with care and apply suitable
measures, e.g., use covers and pads.
The metallic parts of the SensoGate WA131-X must be connected to the plant’s equipotential bonding
using the metallic process connection and 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 information given on the nameplate may deviate from the actual version of the SensoGate
WA131-X. The operating company must assess and document this deviation.
➜Nameplates, p. 14
Electrostatic Charging
The drive unit of specific versions of the SensoGate WA131-X contains housing components made of
non-conductive plastic. Due to their surface, the housing components may build up an electrostatic
charge. To prevent this charge from becoming an effective ignition source in Zone0, ensure that the
following conditions are met:
• There is no risk of highly efficient charge-generating mechanisms.
• Non-metallic components are cleaned with a moist cloth only.

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Mechanically Generated Sparks
Single impacts on metal parts or collisions between metal parts of the SensoGate WA131-X are not a
potential ignition 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.
1.7.2 Possible Ignition Hazards During Operation
When using non-water-based cleaning, rinsing, or calibration media with low conductivities of less
than 1nS/m with a calibration chamber made of polypropylene (PP), electrostatic charging of internal,
conductive components may occur. The operating company must assess the associated risks and im-
plement appropriate measures.
The sensors that are used must be approved for operation in hazardous locations. Further information
can be found in the sensor manufacturer’s documentation.
1.8 Safety Training
Upon request, Knick Elektronische Messgeräte GmbH & Co. KG will provide safety briefings and
product training during initial commissioning of the product. More information is available from the
relevant local contacts.
1.9 Maintenance and Spare Parts
Preventive Maintenance
Preventive maintenance can keep the product in good condition and minimize downtimes. Knick
provides recommended inspection and maintenance intervals. ➜Maintenance, p. 34
Lubricants
Only use lubricants approved by Knick. Special applications or upgrades to special lubricants are avail-
able on request. Usage of any other lubricants shall constitute an unintended use of the product.
➜Maintenance, p. 34
Tools and Mounting Aids
Special and accessory tools help maintenance personnel to replace components and wear parts safely
and professionally. ➜Tools, p. 51
Spare Parts
For professional corrective maintenance of the product, only use Knick genuine spare parts. Usage of
any other spare parts shall constitute an unintended use of the product.
➜Spare Parts, p. 46
Repair Service
The Knick Repair Service offers professional corrective maintenance for the product to the original
quality. Upon request, a replacement unit can be obtained for the period of the repair.
Further information can be found at www.knick.de.