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Knick Unical 9000 Installation Manual

Electro-pneumatic controller for retractable fittings for fully automated ph measurement, cleaning and calibration
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Installation Guide
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Unical 9000(X)
Probe Controller
Electro-Pneumatic Controller
for Retractable Fittings
for Fully Automated pH Measurement,
Cleaning and Calibration
www.knick.de

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  • Page 1 Unical 9000(X) Probe Controller Installation Guide Electro-Pneumatic Controller for Retractable Fittings for Fully Automated pH Measurement, Cleaning and Calibration Read before installation. Keep for future use. www.knick.de...

  • Page 2: Basics

    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 NOTICE These installation instructions do NOT describe •...

  • Page 3: Table Of Contents

    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...
  • Page 4 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...

  • Page 5: Short Description

    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.
  • Page 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. Container with integrated Media adapter metering pump...
  • Page 7 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). * international user association of automation technology in process industries...

  • Page 8: Intended Use

    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.
  • Page 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.

  • Page 10: Safety Information

    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.
  • Page 11 4 Safety Information WARNING Application in Hazardous Locations • Observe all applicable local codes and standards for the installation of electrical equipment in hazardous locations. For orientation, please refer to IEC 60079-14, EU directives 2014/34/EU and 1999/92/EC (ATEX), NFPA 70 (NEC), ANSI/ISA-RP12.06.01.

  • Page 12: Package Contents

    Service switch Cable set, consisting of: • 2 identical cables (for service switch and basic Protos unit) • 1 connecting cable for basic unit – media adapter (with plug) Unical 9000(X) installation guide Unical 9000X: EU Declaration of Conformity, Control Drawings...

  • Page 13: Product Range

    6 Product Range Order No. Basic unit Unical 9000 / Explosion protection for hazardous area Zone 1 Without Housing Steel, coated Stainless steel, polished Media connection 5 m (gasket material: FKM) (rinse function only) 10 m (gasket material: FKM) 15 m (gasket material: FKM)
  • Page 14 ZU 0649 Commissioning Unical 9000(X) Commissioning comprises the following steps. – Connection of hoses and cables and commissioning of the Unical 9000(X) system – Operator training Prior to arrival of our engineer, the customer must prepare the following: – Assembling the Protos 3400(X), Unical 9000(X) and retractable fitting.
  • Page 15 6 Product Range Spare Parts, Service Parts Spare Parts and Retrofit Parts for Unical 9000(X) (continued) Order No. Supplementary air purging kit ZU 0587 Supplementary Aux2 kit ZU 0588 ZU 0577/1 Media adapter (FKM gaskets) ZU 0577/2 Media adapter (EPDM gaskets)

  • Page 17: Checklist For Installation

    Protos 3400(X) - Unical 9000(X) • Mounting surface / pipe (incl. drilling plan) for Protos 3400(X) (see Protos manual) • Mounting surface (incl. drilling plan) for Unical 9000(X) (see page 19 and following) • Mounting surface (incl. drilling plan) for media adapter (see page 22) •...

  • Page 18: Assembly

    The cables are pre-assembled and cut to length. Be sure to observe the appropriate mounting distances. You can use the media adapter (corrugated hose) to check the mounting distances. 4x Ø 6.4 Unical 9000(X) Media adapter Cable lengths: 2x Ø 8.5...

  • Page 19: Wall Mounting

    8 Assembly Wall Mounting Media Air connec- Air filter connection tion G 1/4" Cable glands M20 x 1.5 Water connection Equipotential bond- G 1/4" or ing terminal ("PA") G 3/4" Ø 6.5 Water connection Air filter Media connection Connection to retractable fitting (e.g. Ceramat WA 150) and to media adapter Dimensions in mm...

  • Page 20: Pipe Mounting

    8 Assembly Pipe Mounting Media Air filter connection Water Cable glands connection M20 x 1.5 G 1/4" or Equipotential bonding G 3/4" terminal ("PA") Air connection Ø 30 … 65 mm G 1/4" transverse or longitudinal pipe Water connection Air filter Media connection Connection to retractable fitting (e.g.

  • Page 21: Mounting Dimensions Of Service Switch

    8 Assembly Pipe Mounting Pipe diameter: 30 … 65 mm Mounting Dimensions of Service Switch dia. 30 … 65 mm Vertical or horizontal pipe mounting Vertical or horizontal wall mounting Dimensions in mm...

  • Page 22: Media Adapter With Metering Pumps

    8 Assembly Media Adapter with Metering Pumps Ø 16 (screw head) Dimensions in mm...

  • Page 23: Attaching The Media Connection To The Media Adapter

    Media adapter The media connection is plugged and screwed on from below. Unical 9000 NOTICE • If the media connection hose is strongly twisted, you must loosen the connection at the basic unit and refasten it with proper orientation using the included special wrench.

  • Page 24: Media Adapter And Metering Pumps

    (see bills of materials for media adapter and media connection, pages 27 and 29). The software for Unical 9000(X) supports one- and two-point calibrations. As default, port I is assigned to buffer I (pH 7.00) and port II to buffer II (pH 4.01).
  • Page 25 8.1 Media Adapter and Metering Pumps Connections Attaching the Media Connection to the Media Adapter 1. Carefully plug the connector of the media connection into the media adapter with the flat side facing the wall (or pipe). 2. Then tighten the 2 fixing screws (PZ-3). Fixing points for metering pump Media adapter Fixing points for storage...

  • Page 26: Function Description Of Metering Pump

    8.1 Media Adapter and Metering Pumps Function Description of Metering Pump The metering pump is a wear-resistant and maintenance-free bellows-type pump without dynamic seals. It provides an integrated pneumatic valve and a level monitoring device. If required, the bottle can be screwed off the pump head for cleaning. Also the check valves can be easily removed and cleaned.

  • Page 27: Bills Of Materials

    8.1 Media Adapter and Metering Pumps Bills of Materials Bill of Material for Media Adapter Component Material Blind plate PP-GF (not wetted) Molded seal EPDM (FKM gasket supplied with FKM pump) Housing PP-H Gasket for media connection FKM / EPDM * Bill of Material for Metering Pump Component Material...

  • Page 28: Media Connection

    Connection to Unical 9000(X) Screw the corrugated hose to the joining piece of the Unical 9000(X). You can easily feed the different media tubes through the slit in the securing nut. The different tube lengths and diameters provide for a clear assignment to the different connection points.

  • Page 29: Bill Of Material

    8.2 Media Connection Bill of Material Bill of Material for Media Connection, Calibration and Rinse Function (gray: omitted for media connection with “rinse function”) Media connection Tubes Outer Material Color dia. Probe compressed-air 6.8 mm PA Green Rinse water, Purge air 6 mm Transparent (with rinse function)

  • Page 30: Media Supply To Unical 9000(X)

    Compressed Air, Water, Purge Air, Auxiliary Media Connecting the Compressed-Air Supply The Unical 9000(X) is operated with an external air pressure of (4)* … 10 bar. Adjust the pressure regulator so that the operating pressure for the retractable fitting is kept within 4 and 7 bar. The air must be condensate- and oil-free.

  • Page 31: Arrangement Of Functional Elements

    8.3 Media Supply to Unical 9000(X) Arrangement of Functional Elements Pilot pressure gauge Sensor dismount guard Air pressure Air pressure regulator gauge (4 bar, indication depending on status (4 … 7 bar) Retractable fitting (probe motion control) Flex. tube, Ø 6 mm, green Flex.

  • Page 32: Pilot Valves, Control Valves

    8.3 Media Supply to Unical 9000(X) Pilot Valves, Control Valves Connections Between Pilot Valves at the Valve Block (H) and Control Valves To ensure low power consumption, the control valves are operated via pilot valves. As delivered, the tubes between the pilot valves at the valve block and the control valves are already connected.

  • Page 33: Pressure Gauges And Valve Block

    8.3 Media Supply to Unical 9000(X) Pressure Gauges and Valve Block Pilot Valves and Pressure Gauges at the Valve Block (H) Pressure indicators: The red pins stick out of Safety valve the valve block when the pilot valve is active.

  • Page 34: Connecting The Media Tubes (Media Connection)

    8.3 Media Supply to Unical 9000(X) Connecting the Media Tubes (Media Connection) Overview Retractable fitting Flex. tube, Ø 6 mm, green Flex. tube, Ø 8 mm, green Compressed-air sup- Water ply to media adapter Flex. tube, Ø 6 mm, Flex. tube, Ø 6 mm, transparent transp.

  • Page 35: Connecting The Tubes

    8.3 Media Supply to Unical 9000(X) Connecting the Tubes Compressed-Air Supply to Media Adapter 1. Connect the tube with the red marking to the compressed-air supply to media adapter (E) (located to the right of the control valves). This tube has a reduced con- nection diameter of 4 mm.
  • Page 36 8.3 Media Supply to Unical 9000(X) Connecting the Tubes Aux 1 Purge Air (Option) 3. When the Aux 1 purge air control valve (C) is connected, unscrew the sealing cap and connect the second transparent tube here. Tighten the coupling nut hand tight.
  • Page 37 8.3 Media Supply to Unical 9000(X) Connecting the Tubes Aux 2 (Option) The tube for the optional Aux 2 control valve is not included in the media connection. The valve has a push-in connector for 6 mm tube. 5. Insert the tube through a...

  • Page 38: Connecting The Retractable Fitting

    8.4 Connecting the Retractable Fitting Media Connection to Ceramat Attaching the Hose to the Fixing Bracket of the Ceramat 1. Attach the hose clamp of the media connection to the fixing bracket of the Ceramat with mounting screws (L) (PZ-2). Connecting the Multiplug 2.

  • Page 39: Media Connection To Sensogate Wa 130(X)

    8.4 Connecting the Retractable Fitting Media Connection to SensoGate WA 130(X) 1. Attach the hose clamp (O) of the media connection to the fixing bracket (P) of the retractable fitting with screws. One possible arrangement is shown here. (3 x 2 threaded holes on the fixing bracket (P) allow 3 dif- ferent arrangements of the hose.)

  • Page 40: Recommended Connection Of Retractable Fittings From Other

    8.4 Connecting the Retractable Fitting Recommended Connection of Retractable Fittings from Other Manufacturers e.g. InTrac 7xx (Mettler-Toledo) Explanation The compressed air used for the probe motion (e.g. Process) is also used to provide the air pressure for the next expected feedback valve (i.e., Feedback Process) to generate the feedback signal for the Unical 9000(X).
  • Page 41 – as required. Use the included connection kit for connecting the tubes and hoses to the InTrac 7xx retractable fitting. All connections to the Unical 9000 are made by screwing on the multiplug. To finish the installation, hang the media connec-...
  • Page 42 8.4 Connecting the Retractable Fitting Recommended Connection of an InTrac 7xx Retractable Fitting 1 Media supply to rinsing chamber 2 Rinsing chamber outlet 3 Feedback of “Service” position 4 Feedback of “Process” position 5 Control air for “Service” position and supply for “Service” feedback unit 6 Control air for “Process”...
  • Page 43 8.4 Connecting the Retractable Fitting Connecting an InTrac 7xx Retractable Fitting 1. Connect the media supply (A) to the rinsing chamber. 2. Connect the outlet hose (B) to the outlet port of the rinsing chamber. 3. Feedback of “Service” position: Connect the “Service”...
  • Page 44 8.4 Connecting the Retractable Fitting Connecting an InTrac 7xx Retractable Fitting 5. Control air for “Service” position and supply for “Service” feed- back unit: Connect a flexible tube from “Service” adapter (F) (control air), to “Service” position feedback sup- ply (G) – connecting port labeled “p / 1”...

  • Page 45: Electrical Installation

    Components”). Connecting the Cables to the Unical 9000(X) 1. Screw off the cover of the Unical 9000(X), pull off ground connection. 2. Connect preassembled cables (see pages 46 and 47): • Cable no. 1: Unical 9000(X) to media adapter (with plug) Tighten the coupling nut to secure the electrical connection at the bottom side of the media adapter.
  • Page 46 • Cable no. 2: Unical 9000(X) – Retractable fitting (probe) (in media connection) • Cable no. 3: Unical 9000(X) – Protos module (PHU or FIU) • Cable no. 4: Unical 9000(X) – Service switch (Cables no. 3 and no. 4 are identical.)
  • Page 47 9 Electrical Installation Brown Media adapter (plug-in connec- Blue tion) White Pink Gray Yellow Green Service switch Brown Green Yellow White Cable in media Brown connection Green (corrugated hose): check-back of White probe position Protos module PHU 3400(X)-110 Green Yellow Brown White Wiring of emergency stop...

  • Page 48: Terminal Assignments Of Unical 9000(X)

    9 Electrical Installation Terminal Assignments of Unical 9000(X) Wire color Terminal Function Manual start of program 2 (default: Cal2point) via external pushbutton Do not connect! Special function Special function Brown Service switch GND Green Service switch LED 1 Yellow Service switch LED 2...
  • Page 49 9 Electrical Installation Terminal Assignments of Unical 9000(X) Wire color Terminal Function DCS message GND Unical program running Probe in “Service“ position Probe in “Process“ position (or alarm output) Do not connect! DCS program GND Start programs 1 ... 6...
  • Page 50 9 Electrical Installation Terminal Assignments of Unical 9000(X) - Beneath Terminal Cover - These contacts are factory prewired. Wire color Terminal Function Do not connect! Do not connect! Pilot valve Aux 2 GND Pilot valve Aux 2 Pilot valve Aux 1 GND...

  • Page 51: Process Control System

    10 Process Control System Inputs/Outputs of Unical 9000(X) Designation I / O Level Function Probe moves to "Process" position * Probe moves to "Service" position Automatic interval control from Protos * Automatic intervals locked Program selection and start, manual/DCS * ** (Program 1 …...
  • Page 52 10 Process Control System WARNING – Observe the safety information given on page 11! Ex Connection to DCS (Digital Control System) With the valve control modules / switch amplifiers listed below, a process control system installed in the safe area can be used for communication with a Unical 9000X installed in the hazardous area.

  • Page 53: Control Programs And Measurement Procedures

    When you control the Unical via Protos 3400(X), you can block the Bin 1, Bin 2, Bin 3 signal lines as well as M/S and A/M to prevent conflicts (Parameter setting / Unical 9000 / Installation / Ext. control (DCS): Off ). Measurement Procedures •...

  • Page 54: Service And Maintenance

    CAUTION You must actuate the service switch before starting maintenance work on the Unical 9000(X), the retractable fitting or the sensor. We recommend installing the switch next to the retractable fitting. The service switch moves the retractable fitting into “Service“ position and actuates an additional safety valve.
  • Page 55 12 Service and Maintenance Service Program: Request and End After a service request the retractable fitting executes the service program steps. The retractable fitting moves into “Service“ position. A currently running program (e.g. calibration) is immediately stopped. All other accesses are blocked. The service program defines steps for moving the retractable fitting as well as rinsing and cleaning procedures (see user manual of Protos module PHU 3400(X)-110 or FIU 3400(X)-14x).

  • Page 56: Manual Control Via Protos 3400(X)

    12 Service and Maintenance Manual Control via Protos 3400(X) “Maintenance / Unical 9000” Menu Manual control via Protos 3400(X) allows actuating the Unical 9000(X) probe controller for servicing. Rinse water, media supply and valve functions can be tested individually. Menu Display...
  • Page 57 12 Service and Maintenance WARNING Potential Electrostatic Charging Hazard! To prevent electrostatic charging in a hazardous location, clean the surfaces of the media connection and the media adapter including the bottles for buffer and cleaning solutions only with a damp cloth.

  • Page 58: Commissioning

    13 Commissioning CAUTION Only operate the retractable fitting when a sensor is installed! When the sensor has been removed, it must always be replaced by a dummy! SensoGate WA 130(X) Turn the SensoLock ring to “lock“ position to prevent that the retractable fitting is accidentally moved into the process.

  • Page 59: Start-Up On The Protos: Automatic Hardware Recognition

    Start-Up on the Protos: Automatic Hardware Recognition (Parameter setting/System control/Factory setting/Probe control... First select “Plug and Play” in the Parameter Setting menu of the Protos: The Unical 9000(X) probe controller automatically recognizes the hardware installed and sets the corresponding installation parameters. Menu Display Plug and Play 7.05 pH...

  • Page 60: Unical 9000(X) Parameter Setting On The Protos

    13 Commissioning Unical 9000(X) Parameter Setting on the Protos Parameter setting Adjustable parameters Controller* Unical 9000 / Uniclean 900 / Off Cal mode Check / Adjustment Time control Fixed interval / Week program Program flow Clean 2-point calibration 1-point calibration...

  • Page 61: Start-Up Program

    13 Commissioning Start-Up Program Parameter Setting: The Start-Up Program At the end of the parameter-setting procedure, a ”Start-up” line appears in the ”Installation” menu. When you are sure to have set all parameters, select ”Yes” to confirm. Now the pumps perform the number of stroke movements required for filling the media tubes completely.

  • Page 62: Specifications

    14 Specifications Compressed air Compressed air quality to ISO 8573-1:2001 Quality class 5.3.3 Solid contaminants Class 5 (max. 40 µm, max. 10 mg/m Water content ... for temperatures ≥ 15 °C: Class 4 With operating temperatures > 15 °C a pressure dew point of max 3 °C is permitted ...
  • Page 63 14 Specifications Metering pump For buffer solution or cleaner Bottle 3.5 L Max. lifting height 10 m Displaced volume Approx. 25 cm /stroke Level monitoring Unical network diagram as well as NAMUR messages: Maintenance request and failure Material See bill of material Ingress protection IP 65 Dimensions...
  • Page 64 14 Specifications Power Supplied via Protos module or external power supply source (Ex ia IIC) 15 … 30 V / 20 mA (see EU-Type-Examination Certificate for hazardous-area application!) PHU 3400(X)-110 6.8 V (± 10 %) / 15 mA Connection Terminals, conductor cross section max 2.5 mm (preassembled connecting cable to Protos, length 10 m) RS 485 Communication with Protos module...
  • Page 65 Connection Terminals, conductor cross section max. 2.5 mm Explosion protection See EU Type Examination Certificate and EU Declaration of Unical 9000X Conformity or www.knick.de EN 61326 Lightning protection EN 61000-4-5, Installation Class 2 Protection against electric shock according to EN 61010...
  • Page 66 14 Specifications Ambient conditions Ambient temperature +2 ... +55 °C (Ex: +2 … +50 °C) (different temperature range on request) Transport/Storage temperature -20 … +70 °C Relative humidity 10 ... 95 %, not condensing Housing Enclosure surface S Stainless steel A2, polished Enclosure surface C Stainless steel A2, coated, Color: pigeon blue...

  • Page 67: Appendix

    < < Tamb + 55 °C D-14163 Berlin Nameplates Typschild Medienadapter Detail drawings • Pneumatic diagram of Unical 9000(X) Typschild Unica • Pneumatic diagram of media connection Media Adapter Table for selecting a cleaning agent Type ZU 0577 0000000 ®...

  • Page 68: Pneumatic Diagram Of Unical 9000

    Pneumatic Diagram of Unical 9000...

  • Page 69: Pneumatic Diagram Of Media Connection

    Pneumatic Diagram of Media Connection...

  • Page 72: Index

    16 Index Accessories 14 Air connection 19 Air consumption during probe activation 30 Air filter 20 Air purge valve, complete, ZU 0636 15 Air purge valve, connecting the tube 36 Ambient conditions 66 Appendix 67 Arrangement of components 18 Arrangement of functional elements 31 Assembling the media adapter 22 Attaching the media connection 34 Aux 1, connecting the tube 36...
  • Page 73 Compressed air supply, pressure gauge 33 Compressed air supply to media adapter 34, 35 Connecting the cables 45 Connection kit, ZU 0656 14 Control programs of Unical 9000(X) 53 Control via process control system 51 Disposal 2 Drinking water pipes 30...
  • Page 74 16 Index Maintenance 54 Manometers 33 Manual control 56 Materials, media adapter and metering pumps 27 Materials, media connection 29 Measurement procedures 7 Media adapter, connecting the media connection hose 25 Media adapter, connecting the metering pumps 24 Media adapter, mounting 22 Media adapter;...
  • Page 75 Pilot pressure 33 Pilot valves 32, 33 Pipe mounting 20, 21 Pipe-mount kit for media adapter; ZU 0606 14 Pipe-mount kit for Unical 9000(X), ZU 0601 14 Pneumatic connection, plugging/detaching 34 Pneumatic diagram of media connection 69 Pneumatic diagram of Unical 68...
  • Page 76 Service switch, mounting dimensions 21 Service switch, order numbers 15 Short description 5 Small parts kit, ZU 0643 15 Spare parts 14 Specifications, Unical 9000(X) 62 Standard media interface, ZU 0576 41 “Start program 2” pushbutton 47 Start-up, checklist 58 Start-up program 61...
  • Page 77 16 Index Table of contents 3 Terminal assignments of Unical 9000(X) 48 Trademarks 2 Tube connections 35 Tube, green 36 Tube, red 35 Tube, transparent 35 Wall mounting 19 Water connection, internal 34, 35 Water pressure 30 Water supply, connection 30...
  • Page 78 ZU 0653/2 media connection, rinse + cal, 17 m (EPDM gaskets) 14 ZU 0656 connection kit 14 ZU 0714 water valve 15 ZU 0729 NC service switch for Unical 9000/NC 15 ZU 0729 NS service switch for Unical 9000/NS 15 ZU 0729 XC service switch for Unical 9000/XC 15...
  • Page 80 Knick Elektronische Messgeräte GmbH & Co. KG Headquarters Beuckestraße 22 • 14163 Berlin Germany Phone: +49 30 80191-0 Fax: +49 30 80191-200 info@knick.de www.knick.de Local Contacts www.knick-international.com Copyright 2019 • Subject to change Version: 12 This document was published on September 18, 2019 The latest documents are available for download on our website below the corresponding product description.

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