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Knick Ceramat WA153 User Manual

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Summary of Contents for Knick Ceramat WA153

  • Page 1 Ceramat WA153 User Manual Retractable Fitting Read before installation. www.knick.de Keep for future use.
  • Page 2 Ceramat WA153 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 INSTRUC- TIONS 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.

  • Page 3: Table Of Contents

    Ceramat WA153 Table of Contents 1 Safety............................. 1.1 Intended Use................................1.2 Personnel Requirements............................ 1.3 Safeguards ................................1.4 Residual Risks................................. 1.5 Hazardous Substances............................1.6 Operation in Explosive Atmospheres......................1.6.1 Possible Ignition Hazards During Installation and Maintenance........... 1.6.2 Possible Ignition Hazards During Operation.................
  • Page 4 6.2.1 Corrective Maintenance Safety Instructions ................. 34 6.2.2 Drive Unit: Disassembly ........................35 6.2.3 Drive Unit: Assembly..........................36 6.2.4 Knick Repair Service ..........................37 7 Troubleshooting ........................... 38 8 Removal from Operation ......................40 8.1 Retractable Fitting: Removal ..........................40 8.2 Returns ..................................

  • Page 5: Safety

    1.1 Intended Use The Ceramat WA153 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 Ceramat WA153.

  • Page 6: Safeguards

    Ceramat WA153 1.3 Safeguards The Ceramat WA153 safety concept is based on the interplay of functions within a Knick process analy- sis system. The Ceramat WA153 safeguards and safety functions require the functions of the electro- pneumatic controller and the process analyzer.

  • Page 7: Hazardous Substances

    Nameplates, p. 12 ➜ Mechanically generated sparks Single impacts on metal parts or collisions between metal parts of the Ceramat WA153-X are not a potential ignition source only if the following conditions are met: • Possible impact velocity is less than 1 m/s...

  • Page 8: Possible Ignition Hazards During Operation

    Maintenance, p. 33 ➜ 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. 33 ➜...

  • Page 9: Product

    • EU Declaration of Conformity • EU-Type-Examination Certificate 2.2 Product Identification The different versions of the Ceramat WA153 are coded in a product code. The product code is stated on the nameplate, the delivery note, and the product packaging. Nameplates, p. 12 ➜...

  • Page 10: Product Code

    Ceramat WA153 2.2.2 Product Code Basic device with pneum. drive, stainless steel version WA153 – _ _ _ _ _ _ _ _ _ _ _ _ _ _ – _ _ _ Explosion protection ATEX Zone 0 – None –...
  • Page 11 Ceramat WA153 Basic device with pneum. drive, stainless steel version WA153 – _ _ _ _ _ _ _ _ _ _ _ _ _ _ – _ _ _ Flange, loose, 1.4571, PN40, DN 100 – Flange, loose, 1.4571, PN40, DN 125 ...

  • Page 12: Nameplates

    Ceramat WA153 2.3 Nameplates The Ceramat WA153 is identified by nameplates on the drive unit and the process unit. The informa- tion provided on the nameplates varies according to the version of the Ceramat WA153. Nameplate, Version Without ATEX Approval Note: The figure shows a nameplate for the Ceramat WA153-N version by way of example.
  • Page 13 Ceramat WA153 Nameplate, Version With ATEX Approval Note: The figure shows a nameplate for the Ceramat WA153-X version by way of example. WA153-X0KHH00*******-000 2235209 / 1941 WA153-X*K****035HB10-000 2235211 / 1932 1 Drive unit nameplate 9 Serial number/year and week of production...

  • Page 14: Symbols And Markings

    Different versions of drive and process unit can be combined. Changes for Different Conditions, p. 17 ➜ The process connection is used to fasten the Ceramat WA153 to the process port on the measuring point. The pneumatically operated drive unit moves the Ceramat WA153 into the service position (SERVICE limit position) or the process position (PROCESS limit position).

  • Page 15: Retractable Fitting

    3 Sensor housing with ceramic rotary slides 10 Media connection 4 Process connection (e.g., flange) 11 Sensor cable 5 Coupling nut 12 Strain relief bracket 6 Drive unit 13 Sensor holder 7 Media outlet Not included in the Ceramat WA153 package contents...

  • Page 16: Drive Units

    Ceramat WA153 2.5.2 Drive Units Note: The figure shows a selection from the product line. Product Code, p. 10 ➜ 1 Drive unit, solid-electrolyte sensor 2 Drive unit, liquid-electrolyte sensor 2.5.3 Process Connections Note: The figure shows a selection from the product line.

  • Page 17: Changes For Different Conditions

    In the event of a change to the version, the product must be identified accordingly. It is recommended that changes to the Ceramat WA153 are carried out by the Knick Repair Service. After making the necessary changes, a functional and pressure test is carried out and, if necessary, a modified nameplate is attached.

  • Page 18: Service/Process Limit Positions

    Ceramat WA153 can assume two limit positions (service or process position). Note: The Ceramat WA153 is only disconnected from the process in the service position (position indi- cator points to SERVICE). This is not the case in any other position, i.e., there remains contact with the process.

  • Page 19: Installation

    3 Ceramat WA153 retractable fitting 6 Protos 3400(X) process analyzer Note: The Ceramat WA153 may also be operated without a process analysis system. In this case, acces- sory ZU0631, “Standard media connection”, is required. The Ceramat WA153 is then controlled via the process control system (PCS) or manually with accessory ZU0646, “Pneumatically operated manual...

  • Page 20: Retractable Fitting: Installation

    Dimension Drawings, p. 47 ➜ Note: The installation angle of the Ceramat WA153 depends on the sensor type. An installation angle of up to 10° above the horizontal plane is permissible for all sensor types. An installation angle of 360°...

  • Page 21: Outlet

    Installation angle up to 10° above the horizontal plane Install the outlet hose in an arc and fasten it to the strain relief bracket on the Ceramat WA153. With an installation angle of up to 10° above the horizontal plane, this prevents the calibration chamber from leaking due to gravity.

  • Page 22: Outlet Hose: Installation

    This process medium may splash out during sensor replacement. Push the outflow nozzle (4) into the mount on the Ceramat WA153. In the process, correctly position the coding ribs in the coding recesses (3) (locking device).

  • Page 23: Media Connection

    “Media connection” for operation with process analysis system When using a Knick process analysis system, all media cables and the connecting cable for limit signals are combined in one hose, the media connection (1). It is connected to the Ceramat WA153 using a shared connector, the multiplug (2).

  • Page 24: Multiplug: Installation

    Fasten the multiplug (1) with two screws (2). 3.5.3 Electro-Pneumatic Controller: Connection The method of connecting the Ceramat WA153 to the electro-pneumatic controller with media connection is set out in the relevant documentation. 1 Media connection 3 Electro-pneumatic controller connection 2 Multiplug for connecting the Ceramat WA153 4 Media adapter connection 3.5.4 ZU0631 Standard Media Connection: Installation...

  • Page 25: Sensor Cable: Installation

    Note: Loosely fasten the sensor cable with the clamp, but do not constrict it. If you do, rotary move- ment of the Ceramat WA153 may damage the sensor cable. The sensor cable arc must be long enough so that the sensor cable does not impede the stroke movement of the Ceramat WA153.

  • Page 26: Commissioning

    Check the Ceramat WA153 for leaks under process conditions. The Ceramat WA153 and connections have no leaks. ✓ If using a fully automatic Knick process analysis system, a range of functions can be tested via the process analyzer. Process Analysis System: Installation Example, p. 19 ➜...

  • Page 27: Operation

    (approx. 43 mm). Do not touch the Ceramat WA153 while it is moving to the limit positions. Note: The Ceramat WA153 is only disconnected from the process in the service position (position indi- cator points to SERVICE). This is not the case in any other position, i.e., there remains contact with the process.

  • Page 28: Installing And Removing A Sensor

    Note: The Ceramat WA153 is only disconnected from the process in the service position (position indi- cator points to SERVICE). This is not the case in any other position, i.e., there remains contact with the process.

  • Page 29: Solid-Electrolyte Sensor: Removal

    Note: Rinse the sensor prior to removal in order to prevent entrainment of chemically aggressive process medium in the area of the sensor holders. Move the Ceramat WA153 into the service position (SERVICE limit position) Moving into the Service Position (SERVICE Limit Position), p.

  • Page 30: Liquid-Electrolyte Sensor: Installation

    Note: Electrolyte may escape from the sensor if the Ceramat WA153 is installed at an incline. While moving to the limit positions, both a stroke movement and a rotary movement are performed. It is therefore important to turn the filling hole (e.g., Schott sensors) or the Top marking (e.g., Mettler sensors) approximately 70°...

  • Page 31: Liquid-Electrolyte Sensor: Removal

    Note: Rinse the sensor prior to removal in order to prevent entrainment of chemically aggressive process medium in the area of the sensor holders. Move the Ceramat WA153 into the service position (SERVICE limit position) Moving into the Service Position (SERVICE Limit Position), p.

  • Page 32: Cavity Rinsing

    Ceramat WA153 5.4 Cavity Rinsing In the service position (SERVICE limit position), the inlet and outlet of the Ceramat WA153 are directly connected to the calibration chamber. The ceramic rotary slides are installed in the sensor housing and have contact with the process medium.

  • Page 33: Maintenance

    (visible after removing the drive unit). As required, send the process unit to your local contact for repair. knick.de ➜ After 10 years or Send the Ceramat WA153 to your local contact for full maintenance (replacement of the 500,000 strokes pneumatic gaskets and lubricants, check of all functions, pressure test, leak test). knick.de ➜...

  • Page 34: Knick Premium Service

    Further information can be found at www.knick.de. 6.1.4 Immersion Lock Without a Mounted Solid-Electrolyte Sensor: Functional Test Note: The functional test can only be performed with versions of the Ceramat WA153 intended for solid-electrolyte sensors and during operation within a Knick process analysis system.

  • Page 35: Drive Unit: Disassembly

    Note: The drive unit needs to be removed for procedures such as maintenance, cleaning, or trouble- shooting. Troubleshooting, p. 38 ➜ Move the Ceramat WA153 into the service position (SERVICE limit position) Moving into the Service Position (SERVICE Limit Position), p. ➜ Switch off the compressed air supply and vent the compressed air system.

  • Page 36: Drive Unit: Assembly

    Ceramat WA153 Check the outlet for escaping process medium. If process medium escapes: Stop the process (depressurize or drain off the process medium if necessary) and perform troubleshooting. Troubleshooting, p. 38 ➜ Fully loosen the coupling nut (2). In the process, the drive unit (1)

  • Page 37: Knick Repair Service

    Ceramat WA153 6.2.4 Knick Repair Service The Knick Repair Service offers professional corrective maintenance on the Ceramat WA153 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.

  • Page 38: Troubleshooting

    Malfunction state Possible causes Remedy Medium escapes from Faulty ceramic rotary slide. Send the Ceramat WA153 to your local contact for repair. the outlet hose. knick.de ➜ Faulty sensor housing. Send the Ceramat WA153 to your local contact for repair.
  • Page 39 Perform maintenance on the drive unit or check the functionality of the process unit using a replacement drive. Troubleshooting unsuccessful: Stop the process; depressurize or drain off the process medium if necessary. Remove the Ceramat WA153 and send it to your local contact for repair. knick.de ➜...

  • Page 40: Removal From Operation

    If required, loosen and remove the equipotential bonding line from the media connection bracket. Remove the multiplug. Remove the outlet hose. Remove the media connection bracket from the strain relief bracket of the Ceramat WA153. Loosen the process connection. Remove the Ceramat WA153 from the customer’s process port.

  • Page 41: Spare Parts, Accessories, And Tools

    Product Identification, p. 9 ➜ The seal kits for the Ceramat WA153 are also encoded in a product code. The options in the seal kit product code correspond to the options in the product code for the Ceramat WA153. Example: Seal Kit Product Code, p. 41 ➜...
  • Page 42 ZU0988 seal kit contains all O‑rings for the selected version. The sensor socket is not included. Spare Parts, p. 44 ➜ Note: Option 1 (pH sensor  12 mm with pressurization) encoded in the Ceramat WA153 product ⌀ code is integrated in Option 0 of the seal kit product code. Seal kit without sensor socket ZU0988 –...
  • Page 43 ZU0990 seal kit contains only the sensor socket and all seals and slide rings installed on it. Note: Option 1 (pH sensor  12 mm with pressurization) encoded in the Ceramat WA153 product ⌀ code is integrated in Option 0 of the seal kit product code.

  • Page 44: Spare Parts

    Ceramat WA153 9.2 Spare Parts Sensor Sockets The sensor socket is screwed to the sensor protection tube and seals the sensor from the process. It glides in the ceramic gate. The interface between the sensor socket and the ceramics is also sealed.

  • Page 45: Accessories

    ZU0654 / ZU0655 Adapter for Additional Media The adapter enables use of an additional medium, e.g., hot water or steam, directly on the Ceramat WA153. A check valve is integrated in the adapter’s media connec- tion. The adapter is installed between the Ceramat WA153 and the media connection’s multiplug.

  • Page 46: Tools

    (e.g., when using an open-end wrench). ZU0999 Spanning Wrench On versions of the Ceramat WA153 without sensor protection, the spanning wrench is used to install and remove the sealing ring (e.g., to check the O‑rings of the sealing ring and replace them if necessary).

  • Page 47: Dimension Drawings

    Ceramat WA153 10 Dimension Drawings Retractable fitting for solid-electrolyte sensor Note: All dimensions are given in millimeters [inches].
  • Page 48 Ceramat WA153 Retractable fitting for liquid-electrolyte sensor Note: All dimensions are given in millimeters [inches].
  • Page 49 Ceramat WA153 Process connections (extract from product line) BioControl DN65 Max. immersion depth (ID) = 105 mm (4.14″) Min. immersion depth (ID) = 40 mm (1.57″) Tri-Clamp 2.5″ Max. immersion depth (ID) =105 mm (4.14″) Min. immersion depth (ID) = 23 mm (0.91″) Varivent Max. immersion depth (ID) =105 mm (4.14″) Min. immersion depth (ID) = 23 mm (0.91″)
  • Page 50 Ceramat WA153 Flange Max. immersion depth (ID) =105 mm (4.14″) Min. immersion depth (ID) = 32 mm (1.26″) Dairy pipe Max. immersion depth (ID) =105 mm (4.14″) Min. immersion depth (ID) = 28 mm (1.10″)

  • Page 51: Specifications

    Pressure in sensor chamber 0.5  …  1  bar (7.25  …  1 4.5 psi) above process pressure of max. 7 bar (101.5 psi) For compressed air, rinse and calibration media For Unical multiplug (retractable fitting control air) Weight Depending on material and version. Please contact Knick or your designated sales representative for detailed information.

  • Page 52: Appendix

    Ceramat WA153 Appendix Return Form, p. 53 ➜...
  • Page 53 I have answered the above questions to the best of my knowledge. Name: Company: Date: Signature: Knick Elektronische Messgeräte GmbH & Co. KG Beuckestraße 22, 14163 Berlin, Germany Phone: +49 30 80191-0 Declaration of Contamination Fax: +49 30 80191-200 087148 info@knick.de • www.knick.de...
  • Page 54 Ceramat WA153 Abbreviations ATEX Atmosphères Explosibles (explosive atmospheres) Conformité Européenne (European conformity) Classification, labeling, and packaging Deutsches Institut für Normung (German Institute for Standardization) Diamètre nominal (nominal size) European Union International Electrotechnical Commission International Protection / Ingress Protection International Organization for Standardization...

  • Page 55: Glossary

    Ceramat WA153 Glossary CE Marking Manufacturer's declaration, in accordance with EU Regulation 765/2008, that the product is in conformity with the applicable requirements set out in the European Union harmonization legislation providing for its affixing. Corrective Maintenance Measures taken to return an item under review to an operational condition, with the exception of improvements.

  • Page 56: Index

    Ceramat WA153 Index Accessories Hazard assessment Accompanying slip, seal kit Hazardous substances Ambient temperature Assembly ATEX certificate Immersion lock without a mounted solid-electrolyte sensor Function  6 Functional test  34 Causes, malfunctions Inspection Cavity rinsing Functional tests  33 Certificates Inspection intervals  33...
  • Page 57 Ceramat WA153 Operation with process analysis system Safeguards, overview Operation without process analysis system Safety chapter Order code Safety concept Retractable fitting  11 Safety data sheets Seal kit  41 Safety Instructions Outlet Seal kit Outlet hose Order code  41 Installation  22...
  • Page 58 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 Translation of the original instructions Copyright 2021 • Subject to change Version 5 • This document was published on March 16, 2021.

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