Related Manuals for Knick Ceramat WA154
Summary of Contents for Knick Ceramat WA154
- Page 1 Ceramat WA154 User Manual Retractable Fitting Read before installation. www.knick-international.com Keep for future use.
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Page 2: Supplemental Directives
Ceramat WA154 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 WA154 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 6.1.3 Immersion Lock Without a Mounted Solid-Electrolyte Sensor: Functional Test ..... 34 6.2 Corrective Maintenance ............................ 35 6.2.1 Corrective Maintenance Safety Instructions ................35 6.2.2 Knick Repair Service ..........................35 6.2.3 Drive Unit: Removal..........................36 6.2.4 Drive Unit: Installation .......................... 37 7 Troubleshooting ...........................
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Page 5: Safety
1.1 Intended Use The Ceramat WA154 (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 WA154. -
Page 6: Safeguards
Ceramat WA154 1.3 Safeguards The safety concept of the Ceramat WA154 expands on the interaction within a Knick process analysis system. The safeguards and safety functions of the Ceramat WA154 rely on the functionalities of the electro-pneumatic controller and the industrial transmitter. -
Page 7: Hazardous Substances
When components are replaced with genuine Knick spare parts made of other materials (e.g., O-rings), the information on the nameplate may then deviate from the actual version of the Ceramat WA154-X. The operating company must assess and document the changes. -
Page 8: Possible Ignition Hazards During Operation
Ceramat WA154 Mechanically Generated Sparks Single impacts on metal parts or collisions between metal parts of the Ceramat WA154-X are not a potential ignition source if the following conditions are met: • Possible impact velocity is less than 1 m/s. • Possible impact energy is less than 500 J. -
Page 9: Product
• EU Type Examination Certificate 2.2 Product Identification The various versions of the Ceramat WA154 product are coded in a model designation. The model designation is stated on the nameplate, the delivery note, and the product packaging. 2.2.1 Model Designation Example Basic unit with pneum. -
Page 10: Product Code
Ceramat WA154 2.2.2 Product Code Basic unit with pneum. drive unit, stainless steel design WA154 – _ _ _ _ _ _ _ _ _ _ _ _ _ _ – _ _ _ Explosion protection ATEX Zone 0 –... - Page 11 Ceramat WA154 Basic unit with pneum. drive unit, stainless steel design WA154 – _ _ _ _ _ _ _ _ _ _ _ _ _ _ – _ _ _ Loose flange, PN40, DN 100 – Loose flange, PN40, DN 125 –...
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Page 12: Nameplates
Ceramat WA154 2.3 Nameplates The Ceramat WA154 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 WA154. Nameplate, Version without ATEX Approval Note: The figure shows a nameplate for the Ceramat WA154-N version by way of example. - Page 13 Ceramat WA154 Nameplate, Version with ATEX Approval Note: The figure shows a nameplate for the Ceramat WA154-X version by way of example. WA154-X0HBB31*******-000 2235348 / 2341 WA154-X*H****300BB20-000 2235208 / 2332 1 Drive unit nameplate 10 Model designation 2 Process unit nameplate...
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Page 14: Symbols And Markings
Different versions of the drive unit and the process unit can be combined. Changes for Different Conditions, p. 17 ➜ The process connection is use to fasten the Ceramat WA154 at the process port of the measuring point. The pneumatically operated drive unit moves the Ceramat WA154 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 package contents of the Ceramat WA154. -
Page 16: Drive Units
Ceramat WA154 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
It is recommended that changes to the Ceramat WA154 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 WA154 can assume two limit positions (service or process position). Note: The Ceramat WA154 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 Service switch 6 Media adapter with metering pumps Note: Alternatively, it is possible to operate the Ceramat WA154 without a process analysis system. To do this, accessory ZU0631 “standard media connection” is required. In that case, the Ceramat WA154 is automatically controlled by a process control system (PCS) or manually using accessory ZU0646 “man-... -
Page 20: Retractable Fitting: Installation
Dimension Drawings, p. 48 ➜ Note: The installation angle of the Ceramat WA154 depends on the sensor type. An installation angle from 10° above the horizontal is permitted for all sensor types. An upside down installation angle (see View A) is only permitted when using sensors that are approved for upside down oper- ation Fasten the Ceramat WA154 to the process port with the process connection. -
Page 21: Media Connection: Installation At Strain Relief Bracket
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 WA154. 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 WA154. In the process, correctly position the coding ribs (5) in the coding recesses (3) -
Page 23: Media Connection
When using a process analysis system from Knick, all supply lines and the connecting cable for the limit signal are joined in one hose: the media connection (1). The connection to the Ceramat WA154 is established via a common plug-in connection, the multiplug (2). -
Page 24: Multiplug: Installation
3.5.3 Electro-Pneumatic Controller: Connection The associated documentation contains a description of how to connect the Ceramat WA154 to the electropneumatic controller with the media connection. 1 Electropneumatic controller connection 3 Multiplug for connection of the Ceramat WA154... -
Page 25: Sensor Cable: Installation
Note: Loosely fasten the sensor cable with the clamp, but do not constrict it. If you do, rotary movement of the Ceramat WA154 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 WA154. -
Page 26: Commissioning
Check the Ceramat WA154 for leaks under process conditions. ✓ The Ceramat WA154 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 WA154 while it is moving to the limit positions. Note: Depending on the installation of the Ceramat WA154, moving it into the limit positions is trig- gered differently: industrial transmitters, service switch of the electro-pneumatic controller, process control system (PCS) or ZU0604 “Pneumatic manual control valve". -
Page 28: Installing And Removing A Sensor
Note: The Ceramat WA154 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 WA154 into the service position (SERVICE limit position). Moving into the Service Position (SERVICE Limit Position), p. -
Page 30: Liquid-Electrolyte Sensor: Installation
Note: The electrolyte liquid of the Ceramat WA154 may leak out of the sensor if the installation position is tilted. While moving to the limit position, a rotational movement is performed in addi- tion to a lifting movement. Therefore, rotate the filling hole by approx. 70° from the vertical. -
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 WA154 into the service position (SERVICE limit position). Moving into the Service Position (SERVICE Limit Position), p. -
Page 32: Cavity Rinsing
Ceramat WA154 5.4 Cavity Rinsing In the service position (SERVICE limit position), the inlet and outlet of the Ceramat WA154 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
➜ The intervals listed are approximate recommendations based on the experience of Knick. The actual intervals de- pend on the specific application. Following successful first inspection and confirmation of the suitability of all materials used, the interval may be... -
Page 34: Lubricants Used And Permitted
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 WA154 intended for solid-electrolyte sensors and during operation within a Knick process analysis system. -
Page 35: Corrective Maintenance
WARNING! Process medium, potentially containing hazardous substances, may escape from the Ceramat WA154. Only perform corrective maintenance in the service position (SERVICE limit posi- tion). Disconnect the Ceramat WA154 from all power sources and secure it against accidental recon- nection. Follow the safety instructions. -
Page 36: Drive Unit: Removal
Note: The drive unit needs to be removed for procedures such as maintenance, cleaning, or trouble- shooting. Troubleshooting, p. 38 ➜ Move the Ceramat WA154 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 37: Drive Unit: Installation
Ceramat WA154 6.2.4 Drive Unit: Installation Make sure that the drive unit (1) is located in the service position (SERVICE limit position). Service and Process Position, p. 18 ➜ Note: The coupling nut can only be tightened if the process unit is correctly inserted and pushed in far enough that the coupling nut’s thread can engage. -
Page 38: Troubleshooting
SET FORTH HEREIN MAY RESULT IN SERIOUS INJURY OR DEATH, AS WELL AS DAMAGE TO PROPERTY. Fault status Possible cause Remedy Medium escapes from Ceramic rotary slide defective. Send the Ceramat WA154 to the responsible local repre- the outlet hose. sentative for repair. knick-international.com ➜ Sensor housing defective. - Page 39 ➜ If required, stop the process (depressurize or drain off the process medium if necessary) and remove the Ceramat WA154. Remove glass splinters from the ceramic rotary slides and check the sensor housing gaskets for damage; replace them if necessary.
- Page 40 Perform maintenance on the drive unit or check the functionality of the process unit using a substitute drive. Troubleshooting unsuccessful: Stop process, depressurize or discharge process medium if neces- sary. Remove Ceramat WA154 and send to the local representative responsible for repairs. knick-international.com ➜...
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Page 41: Decommissioning
Remove the multiplug. Remove the outlet hose. Remove the media connection bracket from the strain relief bracket of the Ceramat WA154. Loosen the process connection. Remove the Ceramat WA154 from the customer’s process port. Close off the process port appropriately. -
Page 42: Spare Parts, Accessories, And Tools
Product Identification, p. 9 ➜ The seal kits for the Ceramat WA154 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 WA154. Note: Option 1 (pH sensor 12 mm with pressurization) encoded in the Ceramat WA154 product... - Page 43 ZU0988 seal kit contains all O‑rings for the selected version. The sensor socket is not included. Spare Parts, p. 45 ➜ Note: Option 1 (pH sensor 12 mm with pressurization) encoded in the Ceramat WA154 product ⌀ code is integrated in Option 0 of the seal kit product code. Seal kit without sensor socket ZU0988 –...
- Page 44 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 WA154 product ⌀ code is integrated in Option 0 of the seal kit product code.
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Page 45: Spare Parts
Ceramat WA154 9.2 Spare Parts Sensor sockets The sensor socket is screwed together with the sensor protection tube and seals the sensor for the process while the sensor socket slides into the ceramic lock. The interface between the sensor socket and ceramic is also sealed. -
Page 46: Accessories
ZU0654/ZU0655 Adapter for Additional Media The adapter enables an additional medium, e.g., hot water or steam, to be directly fed into the Ceramat WA154. A check valve is integrated into the media connec- tion of the adapter. The adapter is installed between the Ceramat WA154 and the multiplug of the media connection. -
Page 47: Tools
(e.g., when using an open-end wrench). ZU0999 Spanning Wrench On versions of the Ceramat WA154 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 48: Dimension Drawings
Ceramat WA154 10 Dimension Drawings Retractable Fitting for Solid-Electrolyte Sensor Note: All dimensions are listed in millimeters [inches]. - Page 49 Ceramat WA154 Retractable Fitting for Liquid-Electrolyte Sensor Note: All dimensions are listed in millimeters [inches].
- Page 50 Ceramat WA154 Process Connections (Excerpt From the Product Line) Flange Max. immersion depth (ID = immersion depth) = 300 mm (11.81") min. immersion depth (ID = immersion depth) = 23 mm (0.91") Min. immersion depth 23 mm (0.91”) only for non-standard immersion depths. Min. immersion depth 150 mm (5.91”) for standard versions. Product Code, p. 10...
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Page 51: Specifications
(7.25 … 14.5 psi) above the process pressure of max. 7 bar (101.5 psi) For compressed air, rinsing media, and calibration For Unical multiplug solutions (control air retractable fitting) Weight Depending on material and version. Please contact Knick or your designated sales representative for detailed infor- mation. - Page 52 Ceramat WA154 Abbreviations Width across flats ANSI American National Standards Institute ATEX Atmosphères Explosibles (explosive atmospheres) Conformité Européenne (European conformity) Deutsches Institut für Normung (German Institute for Standardization) Diamètre Nominal (inside diameter) EPDM Ethylene propylene diene monomer rubber European Union U.S.
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Page 53: Glossary
Ceramat WA154 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 54 Knick Elektronische Messgeräte GmbH & Co. KG Beuckestraße 22 14163 Berlin Germany Phone: +49 30 80191-0 Fax: +49 30 80191-200 info@knick.de www.knick-international.com Translation of the original instructions Copyright 2024 • Subject to change Version 3 • This document was published on July 26, 2024.
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