Related Manuals for Knick Ceramat WA150
Summary of Contents for Knick Ceramat WA150
- Page 1 Ceramat WA150 User Manual Retractable Fitting Read before installation. www.knick.de Keep for future use.
- Page 2 Item number in text Related Documents • Special datasheet for special version B • Special datasheet for special version J • Maintenance Instructions Ceramat WA150 Further information on the special versions is available in the “Product Code” section. Product Code, p. 10 ➜...
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Page 3: Table Of Contents
Ceramat WA150 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 ................37 6.2.2 Drive Unit: Disassembly ........................37 6.2.3 Drive Unit: Assembly ..........................39 6.2.4 Knick Repair Service ..........................39 7 Troubleshooting ........................... 40 8 Removal from Operation ......................43 8.1 Retractable Fitting: Removal..........................43 8.2 Returns..................................
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Page 5: Safety
1.1 Intended Use The Ceramat WA150 (the “product”) 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 WA150. -
Page 6: Safeguards
Ceramat WA150 1.3 Safeguards The Ceramat WA150 safety concept is based on the interplay of functions within a Knick process analy- sis system. The Ceramat WA150 safeguards and safety functions require the functions of the electro- pneumatic controller and the process analyzer. -
Page 7: Hazardous Substances
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 Ceramat WA150-X. The operating company must assess and document this deviation. -
Page 8: Possible Ignition Hazards During Operation
Ceramat WA150 Mechanically Generated Sparks Single impacts on metal parts or collisions between metal parts of the Ceramat WA150-X are not a potential ignition source only if the following conditions are met: • Possible impact velocity is less than 1 m/s. -
Page 9: Product
• EU Declaration of Conformity • EU Type Examination Certificate 2.2 Product Identification The different versions of the Ceramat WA150 are encoded 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 WA150 2.2.2 Product Code Basic Device with Pneumatic Drive, Stainless Steel WA150 – _ _ _ _ _ _ – _ _ _ Explosion protection ATEX Zone 0 – None – Sensor – Sensor 12 mm with PG 13.5 ⌀ pH sensor 12 mm with pressurization unit,... - Page 11 Ceramat WA150 Basic Device with Pneumatic Drive, Stainless Steel WA150 – _ _ _ _ _ _ – _ _ _ Flange, loose, 1.4571, PN40, DN 100 E 4 – Dairy pipe DN 50 C 1 – Dairy pipe DN 65 C 2 –...
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Page 12: Nameplates
Ceramat WA150 2.3 Nameplates The Ceramat WA150 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 WA150. Nameplate, Version Without ATEX Approval Note: The figure shows a nameplate for the Ceramat WA150-N version by way of example. - Page 13 Ceramat WA150 Nameplate, Version With ATEX Approval Note: The figure shows a nameplate for the Ceramat WA150-X version by way of example. WA150-X******-*** xxxxxxx / xxxx WA150-X******-*** xxxxxxx / xxxx Drive unit nameplate Serial number / year and week of production...
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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 WA150 to the process port on the measuring point. The pneumatically operated drive unit moves the Ceramat WA150 into the service position (SERVICE limit position) or the process position (PROCESS limit position). -
Page 15: Retractable Fitting
10 Media connection 4 Sensor housing with ceramic rotary slides 11 Sensor cable 5 Process connection (e.g., flange) 12 Outlet hose 6 Coupling nut 13 Strain relief bracket 7 Drive unit 14 Sensor holder Not included in the Ceramat WA150 package contents... -
Page 16: Drive Units
Ceramat WA150 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: Option: Deposit Remover
It is recommended that changes to the Ceramat WA150 be 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 And Process Position
The Ceramat WA150 can assume two limit positions (service or process position). Note: The Ceramat WA150 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 Unical 9000 electro-pneumatic controller 6 Media connection with multiplug Note: The Ceramat WA150 may also be operated without a process analysis system. In this case, acces- sory ZU0631, “Standard media connection, ” is required. The Ceramat WA150 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. 50 ➜ Note: The installation angle of the Ceramat WA150 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 WA150. 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 WA150. In the process, correctly posi- tion the coding ribs (5) in the coding recesses (3) -
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 WA150 using a shared connector, the multiplug (2). -
Page 24: Multiplug: Installation
3.5.3 Electro-Pneumatic Controller: Connection The method of connecting the Ceramat WA150 to the electro-pneumatic controller with media connection is set out in the relevant documentation. 1 Electro-pneumatic controller connection 3 Multiplug for connecting the Ceramat WA150... -
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 WA150 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 WA150. -
Page 26: Protective Pane Option: Installation
Note: Accessories ZU0595 protective pane DN80, PEEK; ZU0596 protective pane DN80, PVDF; ZU0597 protective pane DN100, PEEK, and ZU0598 protective pane DN100, PVDF are required to protect the flange of the Ceramat WA150 from aggressive media. Push the protective pane over the sensor housing (3). -
Page 27: Dn50, Ansi 2" Flange Process Connection
Check to ensure the centering ring is present. Fit the elastomeric flange gasket (3), optional thickness 1.5 … 3 mm. Insert the Ceramat WA150 (4), position the screws. Tighten the screws evenly crosswise, without tilting the Ceramat WA150 (4). -
Page 28: Commissioning
Check the Ceramat WA150 for leaks under process conditions. ✓ The Ceramat WA150 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 29: Operation
(approx. 43 mm). Do not touch the Ceramat WA150 while it is moving to the limit positions. Note: The Ceramat WA150 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 30: Installing And Removing A Sensor
Note: The Ceramat WA150 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 31: 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 WA150 into the service position (SERVICE limit position). Moving into the Service Position (SERVICE Limit Position), p. -
Page 32: Liquid-Electrolyte Sensor: Installation
Note: Electrolyte may escape from the sensor if the Ceramat WA150 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 33: 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 WA150 into the service position (SERVICE limit position). Moving into the Service Position (SERVICE Limit Position), p. -
Page 34: Cavity Rinsing
Ceramat WA150 5.4 Cavity Rinsing In the service position (SERVICE limit position), the inlet and outlet of the Ceramat WA150 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 35: Maintenance
➜ The stated intervals are general recommendations based on Knick’s experience. The actual intervals are dependent on the specific application for which the Ceramat WA150 is used. Following successful first inspection and confirmation of the suitability of all materials used, the interval may be... -
Page 36: Used And Approved Lubricants
6.1.3 Immersion Lock Without a Mounted Solid-Electrolyte Sensor: Functional Test Note: The functional test can only be performed with versions of the Ceramat WA150 intended for solid-electrolyte sensors and during operation within a Knick process analysis system. -
Page 37: Cavity Rinsing: Functional Test
WARNING! Process medium, potentially containing hazardous substances, may escape from the Ceramat WA150. Only perform corrective maintenance in the service position (SERVICE limit posi- tion). Disconnect the Ceramat WA150 from all power sources and secure it against accidental recon- nection. Follow the safety instructions. - Page 38 Ceramat WA150 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. 40 ➜ As required, disconnect the multiplug from the drive unit (1).
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Page 39: Drive Unit: Assembly
➜ 6.2.4 Knick 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. -
Page 40: Troubleshooting
SET FORTH HEREIN MAY RESULT IN SERIOUS INJURY OR DEATH, AS WELL AS DAMAGE TO PROPERTY. Malfunction State Possible Causes Remedy Medium escapes from the outlet Faulty ceramic rotary slide. Send the Ceramat WA150 to your local hose. contact for repair. knick.de ➜ Faulty sensor housing. - Page 41 Ceramat WA150 Malfunction State Possible Causes Remedy Ceramat WA150 does not fully Faulty drive unit. Follow the instructions for help. move to the SERVICE or PROCESS Malfunction: Retractable Fitting Does ➜ limit position. Not Fully Move to the Service or Process Position, p.
- Page 42 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 WA150 and send it to your local contact for repair. knick.de ➜...
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Page 43: 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 WA150. Loosen the process connection. Remove the Ceramat WA150 from the customer’s process port. -
Page 44: Spare Parts, Accessories, And Tools
9 Spare Parts, Accessories, and Tools 9.1 Seal Kits The Ceramat WA150 is a modular system. The correct seal kits required for corrective maintenance depend on the version ordered. The ordered version of the Ceramat WA150 is encoded in a product code. -
Page 45: Spare Parts
Ceramat WA150 9.2 Spare Parts ZU0595 Protective Pane DN80, PEEK ZU0596 Protective Pane DN80, PVDF ZU0597 Protective Pane DN100, PEEK ZU0598 Protective Pane DN100, PVDF Protection of the stainless steel flange (material 1.4571) from aggressive media from nominal size DN80, O-ring material FFKM... - Page 46 Ceramat WA150 ZU 0673/A Hastelloy Sensor Socket, O-Rings FKM ZU 0673/B Hastelloy Sensor Socket, O-Rings EPDM ZU 0673/C Hastelloy Sensor Socket, O-Rings FFKM Sensor Socket, Full Sensor Protection with Mounted O-Rings This sensor socket is recommended for brittle scaling (e.g., lime). The sensor is also provided with better mechanical protection.
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Page 47: Accessories
G⅛" ZU0631 Standard Media Connection Connection kit for manual operation of the Ceramat WA150 in conjunction with accessory ZU0646, “Pneumatically operated manual control valve, ” or for opera- tion with the process control system (PCS). ZU0646 Pneumatically Operated Manual Control Valve Switch (rocker switch from reversing compressed air) for manual operation of the Ceramat WA150 in conjunction with accessory ZU0631 “Standard media connec-... - Page 48 ZU0654 / ZU0655 Adapter for Additional Media The adapter enables use of an additional medium, e.g., hot water or steam, directly on the Ceramat WA150. A check valve is integrated in the adapter’s media connection. The adapter is installed between the Ceramat WA150 and the media connection’s multiplug.
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Page 49: Tools
Ceramat WA150 9.4 Tools ZU0648 Spanning Wrench ZU0648 “Spanning wrench” is used to loosen and fasten the drive unit coupling nut (removal or installation of the drive unit). ZU0647 Sensor Spanning Wrench The sensor spanning wrench is used to properly tighten sensors. It prevents damage to the plastic thread of the sensor head PG 13.5 caused by applying an... -
Page 50: Dimension Drawings
Ceramat WA150 10 Dimension Drawings Retractable Fitting for Solid-Electrolyte Sensor Note: All dimensions are given in millimeters [inches]. Ø 50 [1.97] min. Ø 52 [2.05]... - Page 51 Ceramat WA150 Retractable Fitting for Liquid-Electrolyte Sensor Note: All dimensions are given in millimeters [inches]. Ø 50 [1.97] min. Ø 52 [2.05]...
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Page 52: Specifications
Ceramat WA150 11 Specifications Permissible process pressure and temperature during movement PEEK HD process connection 6 bar (87 psi) 0 … 120 °C (32 … 248 °F) 6 bar (87 psi) short-time 30 min 120 … 140 °C (248 … 284 °F) PVDF HD process connection 6 bar (87 psi) 0 … 120 °C (32 … 248 °F) 6 bar (87 psi) short-time 30 min 120 … 140 °C (248 … 284 °F) Permissible process pressure and temperature when static in service position 16 bar (232 psi) - Page 53 Ceramat WA150 Abbreviations Width across flats ANSI American National Standards Institute 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) EPDM Ethylene propylene diene monomer rubber...
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Page 54: Index
Ceramat WA150 Index Accessories Immersion lock without a mounted solid-electrolyte Accompanying slip, seal kit sensor Ambient temperature Function 6 Assembly Functional test 36 ATEX certificate Inspection Functional tests 35 Inspection intervals 35 Installation Causes, malfunctions General Installation Instructions 19 Cavity rinsing Media connection on strain relief bracket 20... - Page 55 Ceramat WA150 Package contents Safeguards, overview Permissible modifications Safety chapter Personnel requirements Safety concept Preventive maintenance Safety data sheets Probe guard Safety instructions Probe housing Seal kit Process analysis system Order code 44 installation example 19 Product code 44 Safety concept 6...
- Page 56 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 2022 • Subject to change Version 7 • This document was published on December 12, 2022.
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