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1. general information on necessary maintenance intervals is difficult to provide If proven experience has been gained from similar points of measurement with regard to materials used and their resistance unter process conditions the maintenance intervals can be adjusted by the customer If previous experience is positive parts of the first inspection may be omitted The following maintenance intervals are generally recommended Maintenance interval Operations required TO TO First inspection after a few weeks Move the probe to the PROCESS position and observe the outlet If the sensor lock gate is not tight process fluid will leak from the outlet hose Move the probe to the SERVICE position Remove the drive unit no process interruption nec essary To do so see Maintenance Work on the Drive Unit on page 24 Visually inspect the O rings to check the general suit ability of the material used under the present process conditions MM After 1 2 years or 30 000 cycles Check replace the dynamically loaded O ring on the after successful first inspection and sensor socket check the statically loaded O rings suitability of all materials used this time without process interruption period may be extended Where required examine the cavity rinsing If deposits or chemical attacks on the probe hous ing are suspected visible in the probe housing after removing the drive unit check the process unit I ee After 10 years
2. DN 100 loose Flange 1 4571 steel PN10 16 DN 125 loose Flange 1 4571 steel PN10 16 DN 150 loose Flange 1 4571 steel PN10 16 DN 200 loose Flange 1 4571 steel PN40 DN 50 loose Flange 1 4571 steel PN40 DN 65 loose Flange 1 4571 steel PN40 DN 80 loose Flange 1 4571 steel PN40 DN 100 loose Flange 1 4571 steel PN40 DN 125 loose m a eoe s o In RWNANAUAWHD Product Coding WA 153 Flange 1 4571 steel PN40 DN 150 loose Flange 1 4571 steel PN40 DN 200 loose Dairy pipe DN 50 Dairy pipe DN 65 Dairy pipe DN 80 Dairy pipe DN 100 Flange ANSI 316 150 Ibs 2 Flange ANSI 316 150 Ibs 2 1 2 Flange ANSI 316 150 Ibs 3 Flange ANSI 316 150 Ibs 3 5 Flange ANSI 316 150 Ibs 4 Flange ANSI 316 150 Ibs 5 Flange ANSI 316 150 Ibs 6 Flange ANSI 316 300 Ibs 2 Flange ANSI 316 300 Ibs 2 1 2 Flange ANSI 316 300 Ibs 3 Flange ANSI 316 300 Ibs 3 5 Flange ANSI 316 300 Ibs 4 Flange ANSI 316 300 Ibs 5 Flange ANSI 316 300 Ibs 6 Clamp 2 BioControl 1 4404 DN 65 Varivent 1 4404 DN 50 Special flange to customer requirements Probe guard Without 0 vu lt p uUi gU OO ucc qu ee uc Aka C GY m m O N N NN O u UJ N NOA Q N FL Ww N s Oo With version 1 1 Special version Without 000 Equipped w
3. Luftversorgung f r druckbeaufschlagte Sensoren 0 5 4 bar ZU 0670 2 Luftversorgung f r druckbeaufschlagte Sensoren 1 7 bar Diese Baugruppen dienen zum Aufrechterhalten des definierten Uberdrucks in der Druckkammer des Sensors Zubeh r Ersatzteile Adapter f r Zusatzmedium Dieser Adapter erm glicht das Einleiten eines zus tzlichen Sp lmediums au erhalb des vorhandenen Medienanschlusses Medienschlauches Er wird zwischen der Ceramat und dem Multistecker des Medienschlauches montiert Folgende Ausf hrungen sind lieferbar e ZU 0654 1 Adapter aus PEEK O Ringe FKM e ZU 0654 2 Adapter aus PEEK O Ringe EPDM e ZU 0654 3 Adapter aus PEEK O Ringe FFKM e ZU 0655 1 Adapter aus 1 4571 O Ringe FKM e ZU 0655 2 Adapter aus 1 4571 O Ringe EPDM ZU 0655 3 Adapter aus 1 4571 O Ringe FFKM Standard Medieninterface ZU 0631 Anschluss Set f r Sensorschleusen zum manuellen Betrieb vgl ZU 0646 oder zum Betrieb an einer SPS Pneumatisches Handsteuerventil ZU 0646 Schalter zum manuellen Betrieb Kippschalter zum Umsteuern der Druckluft am Standard Medieninterface ZU 0631 Declaration of Contamination Knick gt Return Form Declaration of potential hazards in the enclosed products from exposure to chemicals We can only accept and carry out the service order if this declaration is filled out completely Please include it with the shipping documents If you have any questions please contact our
4. Pr P d AE m m Connection for operation with Connection for operation with Unical Uniclean und Protos ZU 0631 standard media interface Information on Installation Installing the outlet hose Do not install the outlet hose more than 1 meter downwards see figure 2 Doing so raises the danger of air being sucked out of the calibration chamber due to the drop in pressure Leakage of the calibration chamber due to gravity alone is prevented by the loop in the outlet hose when the Ceramat is installed at an angle of up to 15 above the horizontal see figure 1 Fig 1 With horizontal to upside down installations you must install an appropriate hose bend above the level of the calibration chamber to prevent leakage from the calibration chamber see figure 2 Hose bend Above level of calibration chamber Outlet hose f 5 max 1 meter Calibration chamber Fig 2 Information on Installation Connecting the outlet hose Turn the outflow nipple so that the outlet hose points outwards see figure on the left Before tightening the coupling nut correctly align and insert the outflow nipple NOTICE Check positioning of coding recesses and coding bars to lock the connection Outlet hose Coupling nut Coding recesses Outflow nipple Coding bars Installing the sensor cable pH oxygen and conductivity cables Attach th
5. not included with sensor lock gate Sensor connecting cable Drive unit Multiplug Holding bracket Outlet for rinsing calibration media outlet hose not included with sensor lock gate Coupling nut Process adaptation e g flange Probe housing with ceramic rotary slides Process unit Composition of the Sensor Lock Gate Drive units Drive unit for sensors with Drive unit for sensors with solid electrolyte liquid electrolyte Process adaptations examples Dairy pipe screw joint Information on Installation For operation of the Ceramat you must connect control air rinsing or calibration media and the electrical check back signal for indicating the probe position There are two basic options for this When the Ceramat is operated with a Unical or Uniclean electro pneumatic controller and the Protos measur ing system the cables and tubings for air pressure rinsing calibration media and check back are combined in a single hose with just one plug connection multiplug This hose is referred to as media connection This media connection is installed on the Ceramat together with the outlet hose When you do not use a probe controller Unical or Uniclean and Protos measuring system you can connect the supply lines for control air rinsing calibration media and electrical check back to the Ceramat with a free hose connection via the ZU 0631 standard media interface ar PA a ae
6. hose 14 Intended use 5 L Lubricants 32 M Maintenance drive unit 24 Maintenance interval 31 Maintenance lubricants 32 Maintenance operations required 31 Maintenance sealing kits 33 Media adapter connection 17 Media connection description 13 Media connection to Ceramat 16 Media connection to Unical or Uniclean 17 Media connection variants 17 Mounting angle 10 Mounting wrench for Ceramat ZU 0648 35 Multiplug 17 Multiplug connection 16 O Optical sensors 5 O rings material 32 Outlet hose installation 14 15 Overview 11 P Package contents 7 Pneumatic manual control valve ZU 0646 38 Process adaptations 29 Process conditions 31 PROCESS position 10 Process pressure 30 Process unit description 11 Product coding 8 9 R Rating plates 6 Removing a sensor 18 Removing the drive unit 24 Repair sealing kits 33 S Safety information 3 Scraper ring and sensor dismount guard 19 Sealing kits 33 Sealing rings material 32 Sensor cable connection 15 Sensor connection 18 Sensor dismount guard 19 Sensor mounting wrench ZU 0647 35 Sensor preparation 19 Sensor sockets 35 Sensor with liquid electrolyte 21 Sensor with liquid electrolyte dimensions 28 Sensor with solid electrolyte 20 Sensor with solid electrolyte dimensions 27 SERVICE position 10 Servicing sealing kits 33 Spare parts 34 Specifications 30 Standard media interface installation 16 Standard media interface ZU 0631 38 Su
7. or Complete maintenance at the factory with replace 500 000 cycles ment of pneumatic sealings lubricants and check of all functions pressure test leak test These maintenance intervals are rough recommendations The actual intervals depend on the application of the sensor lock gate Lubricants O Rings For fittings used in the chemical industry the lubricant Syntheso Glep1 silicone free is applied For fittings used in the pharmaceutical food industry when FDA conformity is required the lubricant Beruglide L silicone free is applied registered according to NSF H1 On request the lubricant Paraliq GTE 703 can be applied excellent lubricating properties also at increased temperatures and for a large number of stroke movements This lubricant contains silicone and is only used as special application on specific request Application Pharma Food Chemistry Wastewater Lubricant Beruglide L Paraliq GTE 703 Syntheso Glep 1 silicone free containing silicone silicone free FDA conforming FDA conforming NSF H1 registered USDA H1 Materials eather O rings elastomeric eather FM XK FFKM EPDM Sealing Kits for Maintenance and Servicing The sealing kits are available in different materials The new O rings must be lubricated with the included lubricant The following sealing kits are available for repair and servicing Sealing kit Process wetted rinse wetted sealings Order no Suitable l
8. replacing the sensor after separation from the process in SERVICE position The Ceramat sensor lock gate has been developed and manufactured in compliance with the applicable European guidelines and standards Compliance with the European guidelines and standards is confirmed by the EC Declaration of Conformity Compliance with the European Harmonized Standards for use in hazardous locations is confirmed by the EC Type Examination Certificate To ensure smooth performance of the measur ing points with the Ceramat a number of important operating and maintenance parameters must be com plied with see Ceramat Maintenance Instructions There is no particular direct hazard caused by the operation of the device in the specified environment A CAUTION Safe use If you are not sure whether the sensor lock gate can be safely used for your intended application please contact the manufacturer Take account of the influences of humidity ambient temperature chemicals and corrosion To ensure safe use of the equipment you must follow the instructions given in this manual and observe the specified temperature and pressure ranges A WARNING Application in hazardous locations For hazardous area applications the sensors used must ensure proper separation of the ATEX zones When the sensor lock gate is in SERVICE position the sensor may be replaced within a Zone 1 hazardous location Rating Plates Ceramat WA
9. 15x N Drive Knick gt Ceramat Retractable probe Drive unit Type 4 5 7 bar C max 7 bar Compressed air Rinsing water Process Knick gt Ceramat Retractable probe Insertion fitting Type C Made in Germany Ns Process small rating plates Knick gt Ceramat Retractable probe Insertion fitting Type Mye Ceramat WA 15x X Drive Knick gt Ceramat Retractable probe Drive unit Type 4 5 7 bar C max 7 bar Made in Germany EN Compressed air Rinsing water C Tamb 0 to 55 C Process Knick gt Ceramat Retractable probe Insertion fitting ne Ex Made in Germany C No Process small rating plates Knick gt Ceramat Retractable probe Insertion fitting Type Knick gt Ceramat Retractable probe Insertion fitting Made in Germany C A A C 6 KEMA 04 ATEX 4035 Il 1 G D c Il 14163 Berlin No self heating For temp specs see manual A C 6 KEMA 04 ATEX 4035 No self heating For temp specs see manual For Ex specs see drive unit Made in Germany KEMA 04 ATEX 4035 No self heating For temp specs see manual For Ex specs see drive unit Intended Use Knick gt Ceramat Retractable probe Insertion fitting Made in Germany C A Package Contents Check the sh
10. DA Zubeh r Ersatzteile Sensorbuchse lang mit montierten O Ringen Diese Sensorbuchse wird bei spr den Verkrustungen z B Kalk empfohlen Werkstoff Hastelloy C22 erkennbar an einer fehlenden Griffmulde e ZU 0672 A Sensorbuchse 1 4571 O Ringe FKM e ZU 0672 B Sensorbuchse 1 4571 O Ringe EPDM e ZU 0672 C Sensorbuchse 1 4571 O Ringe FFKM e ZU 0673 A Sensorbuchse Hastelloy O Ringe FKM ZU 0673 B Sensorbuchse Hastelloy O Ringe EPDM e ZU 0673 C Sensorbuchse Hastelloy O Ringe FFKM Sensorbuchse Sensorvollschutz mit montierten O Ringen Diese Sensorbuchse wird bei spr den Verkrustungen z B Kalk empfohlen Zus tzlich wird der Sensor mechanisch besser gesch tzt Werkstoff Hastelloy C22 erkennbar an einer fehlenden Griffmulde e ZU 0808 A Sensorbuchse 1 4571 O Ringe FKM e ZU 0808 B Sensorbuchse 1 4571 O Ringe EPDM e ZU 0808 C Sensorbuchse 1 4571 O Ringe FFKM e ZU 0820 A Sensorbuchse Hastelloy O Ringe FKM e ZU 0820 B Sensorbuchse Hastelloy O Ringe EPDM e ZU 0820 C Sensorbuchse Hastelloy O Ringe FFKM Zubeh r Ersatzteile Sensorbuchse mit montierten O Ringen und Abstreifring mit Abstreifkante aus PEEK Diese Sensorbuchse wird bei anhaftenden oder klebrigen Medien sowie bei Partikeln im Prozessmedium empfohlen Bitte Hinweis auf Seite 19 beachten e ZU 0705 Sensorbuchse PEEK O Ringe FKM e ZU 0706 Sensorbuchse PEEK O Ringe EPDM e ZU 0707 Sensorbuchse PEEK O Ringe FFKM ZU 0670 1
11. El The Art of Measuring Knick gt User Manual Ceramat WA 153 English Sensor Lock Gate Latest Product Information www knick de Warranty Defects occurring within 1 year from delivery date shall be remedied free of charge at our plant carriage and insurance paid by sender 2014 Subject to change without notice Exclusions from warranty Wear parts gaskets and damage caused by improper use are excluded from warranty Return of products Please contact our Service Team before returning a defective device Ship the cleaned device to the address you have been given Ifthe device has been in contact with process fluids it must be decontaminated disinfected before shipment In that case please attach a corresponding Declaration of Contamination see page 39 for the health and safety of our service personnel Trademarks The following trademarks are used in this manual without further marking Ceramat Protos Unical Uniclean are registered trademarks of Knick Elektronische Messgerate GmbH amp Co KG Germany Safety Information NOTICE Process related risks Knick Elektronische Messger te GmbH amp Co KG assumes no liability for damages caused by process related risks known to the operator which would in fact not permit the use of the sensor lock gate A WARNING Always make sure that the sensor lock gate cannot be activated by other persons during servicing or installation e g cleaning o
12. Intervals euere 31 Lubricants O Rings neun ernennen anne 32 Sealing Kits for Maintenance and Servicing 33 Accessories 7 Spare PaITYIS9uu u nn Runen 34 Declarat on or ContaminallOD a asian 39 Intended Use The Ceramat pneumatic sensor lock gate with ceramic sealing is used for installing a sensor for measuring process variables in liquid media The sensor can be cleaned calibrated or replaced under process conditions pressure and temperature Since the pneumatic drive unit and the process unit with the ceramic sensor lock gate are separate modules the drive unit can be removed and replaced under process conditions The sensor lock gate is suitable for sensors with an outer diameter of 12 mm for sensors with solid electrolyte length 225 mm sensor head with PG 13 5 with liquid electrolyte length 250 mm for optical sensors with a body diameter of 12 mm or 12 7 mm 1 2 For installing an optical sensor you require a special adapter which is listed in the Product Coding under Special version Information on design and use of the suitable adapter is provided in a supplementary datasheet The Ceramat sensor lock gate allows inserting and retracting the sensor under process pressure sensor lock gate e calibrating or adjusting the measuring system and cleaning the sensor in the running process different options available removing or
13. Unical or Uniclean 17 Instaling Removind a Sensor 18 DHL SGS ONS nee nennen A 19 Sensor Dismount GIU euere nennen ah 19 Installing Removing a Solid Electrolyte Sensor 20 pH Sensors Oxygen Sensors Conductivity Sensors 20 Installing Removing a Liquid Electrolyte Sensor 21 DH SENSOR een N m 21 Cavity Rinsing FUNCTION m 23 Maintenance Work on the Drive Unit 24 Removing the Drive Unit os oic tide eee o IY URN PERIERE NNI VEPEEN REGEL VUA UI VER VR VIS FE SUE VAR ERE Ve NUR EVEN AVR PERSE TUR VET LUI VERE 25 Installing the Drive Unit cases suu es veo eit Vasa o DkE QUE nn 26 Installation Dimensions user 27 SONG Pi IO yl ee ee Renee 27 Liquid FPG UNI CC ne ETT 28 Process Adaptations and Immersion Depths Examples 29 Specirical ONS PE A E E A AI E TA E EE E T E 30 Maintenance
14. anically fixed by screwing Each fluid is fed to the sensor lock gate through a separate tube of the media connection Check valves in the multiplug minimize contamination and prevent mixing of the calibration fluids Connection to media adapter REM _ omitted for rinsing only variant 35 ey Connection to Unical 9000 X Multiplug for connecting the Ceramat or Uniclean 900 X Connection to Unical or Uniclean The corrugated hose is screwed to the joining piece of the Unical or Uniclean 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 color coded See also Unical 9000 X Uniclean 900 X installation manual Connection to media adapter This connection is plugged and screwed to the media adapter It includes the media tubing Electrical connection is made via a plug in connector See also Unical 9000 X Uniclean 900 X installation manual Installing Removing a Sensor NOTICE Sensors must only be installed or removed by trained personnel authorized by the operating company The Ceramat sensor lock gate must be in SERVICE position This position is attained by e the Maintenance menu when controlled by Protos 3400 X see user manual of PHU 3400 X 110 module e the service switch see Unical 9000 X installation manual Installing Removing a Sen
15. ary slides i e even after a breakage in the ceramics or a defect in the probe housing an uncontrolled escaping of process fluid is prevented When removing the drive unit under process condi tions you must check whether the first barrier rotary slides probe housing functions properly Removing the Drive Unit NOTICE Be sure to follow these instructions in the correct sequence Take appropriate safety precautions against escaping process fluids 1 Move probe into SERVICE position Only in this position can the drive unit be removed 2 Switch off compressed air and deaerate device 3 Make sure that no process fluid is leaking from the outlet ZU 0648 4 Turn coupling nut counterclockwise using the ZU 0648 mounting wrench see Accessories page 35 This pulls the drive unit out of the process unit You can slightly lift up the drive unit while turning the nut to support its movement Do not cant the unit and do not exert force Do not loosen the coupling nut completely 5 Make sure that no process fluid is leaking from the outlet 6 Completely loosen the coupling nut and pull off the drive unit upwards Installing the Drive Unit NOTICE Be sure to follow these instructions in the correct sequence 1 Before installing the drive unit in the process unit check whether the drive unit is in SERVICE position Only then can the drive unit be inserted suffici
16. e connecting cable A to the sensor and connect to the fixing bracket B in a loop as shown in the illustration Using clamp C attach the cable lightly so that the cable is secured and not constricted The rotational movement of the Ceramat would otherwise damage the cable NOTICE The cable loop must be long enough so that the cable does not impede the stroke movement of the fitting Connect equipotential bonding cable to terminal F if required Information on Installation The following procedure is recommended for installing the media connection also applies to installation of ZU 0631 standard media interface Attaching the hose to the fixing bracket of the Ceramat Attach the bracket of the media connection to the fixing bracket of the Ceramat with mounting screws Mounting screws Connecting the multiplug Connect multiplug A with 2 screws B as shown Connection to Unical or Uniclean The media connection is available in 5 m 10 m 14 m or 17 m length other lengths on request It consists of a 30 mm corrugated hose with a metal coil You can also order special lengths also heated or with wall ducts 2 variants are available for rinsing only without branch outlet to media adapter for calibration and cleaning function with branch outlet to media adapter Connections The connections for media adapter and sensor lock gate are of a plug in design They are mech
17. ensor check that there is no liquid flowing out of the outlet ceramic slides or probe hous ing might be defective 3 Loosen the sensor plug 4 Loosen the sensor using a Suitable tool and pull it out Be sure not to cant the sensor because it might break recommended tool for removing the sensor 19 mm A F e g Knick ZU 0647 wrench Installing Removing a Liquid Electrolyte Sensor pH Sensors You can use sensors with a length of 250 mm and an electrode diameter of 12 mm e g Knick SE 551 To ensure that the electrolyte flows from the reference electrode to the process medium the air pressure in the sensor pressure chamber must be 0 5 to 1 bar above that of the process medium We recommend the ZU 0670 1 or ZU 0670 2 module see Accessories on page 35 to maintain the defined overpressure in the pressure chamber of the sensor It is connected to the sensor pressure chamber via connection nipple NW 6 mm A Check whether the sensor is damaged glass broken Remove watering cap from the sensor tip and rinse sensor with water NOTICE In the case of inclined installation the sensor must be installed as described below to prevent electrolyte from flowing out during operation of the sensor lock gate First move the sensor lock gate into SERVICE position Within the permitted installation angle the probe can be positioned as desired at least at 15 As the Ceramat performs a rotary movement i
18. ently deep into the process unit so that the groove can engage with the coupling nut 2 When mounting the drive unit to the process unit make sure that the guiding grooves of the drive unit A engage with the guiding bars of the process unit B 3 After successful alignment you can insert the drive unit and screw the coupling nut tight until it noticeably stops Where required continue to press the drive unit in while screwing the coupling nut to make screwing easier Hand tighten the coupling nut using the ZU 0648 Ceramat mounting wrench see Accessories page 35 ZU 0648 N c an c Q e c wn T lies N Solid Electrolyte Wiig BN LU HU uonej e1sul JOSUAS 104 2ue1e 3 WW 009 Xolddy 28 Installation Dimensions Liquid Electrolyte Approx 800 mm clearance for sensor installation Installation Dimensions 29 Process Adaptations and Immersion Depths Examples ID max ID max ID max Process adaptation Max ID in mm ID max Varivent Dairy pipe Min ID inmm Flanges 105 32 Dairy pipe 105 28 Varivent 105 23 Tri Clamp 2 105 23 BioControl DN65 105 40 ID immersion depth Specifications Permissible process pressure and temperature 10 bar up to 140 C during movement Permissible process pressure and temperature statically in SERVICE position 16 ba
19. including scraper ring as accessory ZU 0705 ZU 0706 or ZU 0707 see Accessories page 35 the proper functioning of the sensor dismount guard in combination with the Unical Uniclean cannot be guaranteed Buildup of contaminations can result in high stripping forces which impair the functioning of the sensor dismount guard NOTICE Therefore the operator of the Ceramat must always make sure that a sensor is installed before moving the probe to PROCESS position measuring Installing Removing a Solid Electrolyte Sensor pH Sensors Oxygen Sensors Conductivity Sensors ZU 0647 Installing the sensor Tool for sensor installation 1 Move probe into SERVICE position The sensor must only be installed in SERVICE position 2 Use appropriate sensors C only Diameter 12 0 5 mm Length 225 mm Observe pressure resistance of the sensor 3 Before installing the sensor check that there is no liquid flowing out of the outlet ceramic slides or probe hous ing might be defective 4 Check whether slide ring A or O ring B on the sensor are damaged 5 Screw in the sensor head 19 mm A F PG 13 5 thread with a max torque of 3 Nm recommended tool 19 mm wrench e g Knick ZU 0647 6 Install sensor cable and media connection see Information on Installation on page 13 Removing the sensor 1 Move probe into SERVICE position The sensor must only be removed in SERVICE position 2 Before removing the s
20. ipment for transport damage and completeness The package should contain e Sensor lock gate e Documentation Test certificates Product Coding WA 153 Explosion protection For hazardous area Zone 1 X Without N Sensor Sensor 12 mm with PG 13 5 pH sensor 12 mm pressurized Optical sensor 1 2 12 7 mm w N O Optical sensor 12 mm Material of gaskets FKM Viton EPDM EPDM FDA FKM FDA FFKM FDA FFKM Material of Hastelloy C22 sensor protection sleeve PEEK 1 4404 Titanium Material of sensor socket Hastelloy C 22 without protection Hastelloy C 22 short protection A Immo gt 1 4404 without protection 1 4404 short protection 1 4404 long protection 1 4404 full protection PEEK without protection Titanium without protection I il eels m ma wale es os mes nm g O OWN O O Titanium short protection Scraper for sensor socket Without 0 PEEK natural Immersion depth Special immersion depth 26 104 mm increase in 1 mm steps 0 0 0 Immersion depth 105 mm max EE Process wetted material Hastelloy C22 B 1 4404 Titanium T Process adaptation Flange 1 4571 steel PN10 16 DN 50 loose Flange 1 4571 steel PN10 16 DN 65 loose Flange 1 4571 steel PN10 16 DN 80 loose Flange 1 4571 steel PN10 16
21. ith special grease provided by customer 1 Sensor protection sleeve for optical sensor with 1 2 12 7 mm for RAMAN probe with additional anti twist protection for the sensor cables Z adapter rotating 1 2 PG 13 5 according to drawing Sensor protection sleeve for optical sensor with 1 2 mm with additional anti twist protection for the sensor cables B adapter rotating 12 mm PG 13 5 according to drawing Ceramat inlet and outlet made of PEEK D Additional radial sealing on the front face of the process unit for Q 50 mm bore with O ring material according to sealing kit Customer specific special datasheet F Entries shown in italics are special options delivery time on request Function Description The pneumatically operated sensor lock gate allows calibrating or adjusting the measuring system and clean ing the sensor in the running process For that purpose the sensor can be moved between two positions PROCESS position The sensor is located in the process medium SERVICE position The sensor is located in the calibration chamber In SERVICE position the measuring system can be calibrated or adjusted or the sensor can be cleaned Using compressed air a control unit such as the Unical 9000 moves the sensor between SERVICE position and PROCESS position and leads different calibration and or cleaning liquids to the sensor located in the calibration chamber These liquids leave the calibration chambe
22. n addition to the stroke movement you must position the sensor D in a way that the filling hole B e g Schott or the TOP labeling e g Mettler C of the sensor is turned out of the ver tical by approx 70 when the sensor lock gate is inclined see figure Only this prevents electrolyte leakage during movement of the Ceramat Installing Removing a Liquid Electrolyte Sensor Installing or removing the sensor 1 Only install or remove the sensor when the sensor lock gate is in SERVICE position 2 Loosen small coupling nut A do not remove it 3 Unscrew large coupling nut B completely counterclockwise 4 Pull the detached unit upwards 5 Install or remove sensor C 6 Replace the unit you have detached in step 4 First hand tighten the large coupling nut B and then the small coupling nut A clockwise Cavity Rinsing Function In SERVICE position inlet and outlet are directly connected with the calibration chamber The ceramic slides are mounted in an outer housing which is in contact with the process There is a risk that process fluid penetrates into the cavity between ceramic and outer housing Such fluids can be drained off using the cavity rinsing function For this procedure the inlet is rerouted to the cavities when the sensor lock gate moves to PROCESS position When the rinsing function is activated e g by Unical the cavities are rinsed and the fluids are drained off thr
23. n exposed to infectious substances The product was subjected to suitable cleaning procedures to prevent exposure to hazards prior to return The product was not freed of hazardous substances prior to return have answered the above questions to the best of my knowledge Company Signature Knick Elektronische Messger te GmbH amp Co KG Beuckestr 22 14163 Berlin Germany Il III l II Phone 49 0 30 801 91 0 Fax 49 0 30 801 91 200 TE Kontaminationserklaerung KNX01 E mail knick knick de Internet www knick de 087148 40 A Accessories 34 Adapter for additional medium 38 Adjustment 10 Air supply for pressurized sensors ZU 0670 37 Ambient temperature 30 C Calibration 10 Calibration chamber 23 Calibration media 13 Cavity rinsing 23 Ceramic slides 23 Composition of the sensor lock gate 11 Connecting the multiplug 16 Connecting the outlet hose 15 Connection to Unical or Uniclean 17 Control air 13 Control pressure 30 D Declaration of Contamination 39 Drive unit description 11 Drive unit installation 26 Drive unit removal 24 E Electrical check back 13 Equipotential bonding cable 15 F Function description 10 G Gaskets material 32 Grease 32 H Hazardous area application 5 Hose connection 13 Immersion depths 29 Installation 13 Installation angle 10 Installation dimensions 27 Installing removing a sensor 18 Installing the drive unit 26 Installing the outlet
24. ng Stahl 1 457 1 EPDM ZU 0672 B Sensorbuchse lang Stahl 1 457 1 FFKM ZU 0672 C Sensorbuchse lang Stahl Hastelloy C22 FKM ZU 0673 A Sensorbuchse lang Stahl Hastelloy C22 EPDM ZU 0673 B Sensorbuchse lang Stahl Hastelloy C22 FFKM ZU 0673 C Sensorbuchse Vollschutz Stahl 1 4571 FKM ZU 0808 A Sensorbuchse Vollschutz Stahl 1 4571 EPDM ZU 0808 B Sensorbuchse Vollschutz Stahl 1 4571 FFKM ZU 0808 C Sensorbuchse Vollschutz Hastelloy FKM ZU 0820 A Sensorbuchse Vollschutz Hastelloy EPDM ZU 0820 B Sensorbuchse Vollschutz Hastelloy FFKM ZU 0820 C Sensorbuchse PEEK FKM mit Abstreifring ZU 0705 Sensorbuchse PEEK EPDM mit Abstreifring ZU 0706 Sensorbuchse PEEK FFKM mit Abstreifring ZU 0707 Zubeh r Ersatzteile ZU 0647 Sensor Montageschl ssel SW 19 Dient zum sicheren Einschrauben des Sensors ohne das Kunststoffgewinde des Sensorkopfes PG 13 5 durch zu starkes Anziehmoment z B Maulschl ssel zu berlasten ZU 0648 Montageschl ssel Ceramat Dient zum Trennen und Montieren des Antriebs von der Prozesseinheit ber die berwurfmutter des Antriebs Sensorbuchse mit montierten O Ringen e ZU 0616 Sensorbuchse PEEK O Ringe FKM ZU 0617 Sensorbuchse PEEK O Ringe EPDM ZU 0618 Sensorbuchse PEEK O Ringe FFKM e ZU 0619 Sensorbuchse PEEK O Ringe EPDM FDA e ZU 0620 Sensorbuchse PVDF O Ringe FKM e ZU 0621 Sensorbuchse PVDF O Ringe EPDM ZU 0622 Sensorbuchse PVDF O Ringe FFKM e ZU 0623 Sensorbuchse PVDF O Ringe EPDM F
25. ough the outlet Normally rinsing should be performed every 8 hours for 30 seconds With very frequent probe movements aggressive or sticky process media the rinsing intervals should be accordingly reduced Outer housing _ PVDF PEEK Sensor Cavity Ceramic rotating Cavity Ceramic fixed Ceramic sensor lock gate in PROCESS position Maintenance Work on the Drive Unit The drive unit must be removed for example for general maintenance or inspection e to clean the calibration chamber e g after a sensor has broken to change the sensor calibration chamber gaskets e in the event of a technical fault of the drive unit NOTICE Before working on the drive unit make sure that the sensor lock gate is in SERVICE position This position is attained by the service switch see Unical 9000 X installation manual or the Maintenance menu of the Protos 3400 X see user manual of PHU 3400 X 110 module While working on the sensor lock gate other persons must be prevented from actuating the control unit The position indicator shows whether the sensor lock gate is in SERVICE position Position indicator A WARNING When the drive unit must be removed under process conditions be sure to wear protective clothing gloves and goggles to protect yourself against process fluid that might escape The drive unit serves as second bar rier after the ceramic rot
26. pply lines 13 T Technical data 30 Trademarks 2 Knick Elektronische Messger te GmbH amp Co KG Beuckestra e 22 14163 Berlin Tel 49 0 30 801 91 0 Fax 49 0 30 801 91 200 Internet www knick de Email knick knick de TA 203 100 KNEO1 C 088222 20140606
27. r at O 40 C Ambient temperature 10 70 C Ingress protection IP 66 Permissible pressure for probe control 4 7 bar un Quality of compressed air Standard Quality class Solid contaminants Water content for temperatures gt 15 C Water content for temperatures 5 15 C Oil content LAL acc to ISO 8573 1 2001 3 3 3 or 3 4 3 3 max 5 um max 5 mg m Class 4 pressure dew point 3 C or below Class 3 pressure dew point 20 C or below Class 3 max 1 mg m Sensors with solid electrolyte with liquid electrolyte Optical sensors 012 mm length 225 mm with temp detector PG 13 5 thread 012 mm length 250 mm with temp detector 12 mm 12 7 mm 1 2 Process adaptations See product coding Connections Outlet for pressurized sensors for compressed air rinse and calibration media control air for retractable fitting Socket for Unical media hose Hose connection NW 6 Pressure in sensor chamber 0 5 1 bar above process pressure max 7 bar for Unical multiplug Immersion depths Dimensions See dimension drawings Process wetted materials Control pressure required for process pressure Control pressure bar Process pressure bar See product coding 5 7 6 8 10 Maintenance Intervals Because of the highly variable process conditions pressure temperature chemically aggressive media etc
28. r replacing the sensor During operation the drive unit of the Ceramat sensor lock gate is rotating rather quickly by 140 There is a risk of injury Be sure to observe Work on the sensor lock gate must only be performed by personnel authorized by the operating company and specially trained for handling and operating the sensor lock gate Note Supplementary information is provided in the Ceramat Maintenance Instructions Maintenance Spare Parts Accessories Table of Contents Safety Informatio mer 3 Table or Contents caceccescccceseveccsavsccvsccuccessevancvassssieecouasscossecodevesivencessaveiesscevaudvagevadeuavissnsossunctevspavapeves 4 Duro WIS Cis e P 5 IO INE 6 Package Contents 7 Product CONG ood S UR EIS GR NUEUR UR FUEL NOR FOL SENE ETE ER EISE VELO CY YR NEEE EHE Rn CEP ORE NEUE NES une 8 Function Description 10 Composition of the Sensor Lock Gate 11 Information on Installation sissscvesstacecsccinccecesincoxesivessxcvederavecticscecsisrcecexstacevsseracouucsinevnssiieiexesatenstee 13 Connection to
29. r through an outlet hose i e they are displaced from the calibration chamber by following liquids or by compressed air To replace the sensor you must move the sensor lock gate into SERVICE position With the Unical 9000 probe controller all media control air and the check back cable for position indication of the probe are connected to the sensor lock gate through a compact connector multiplug Since the pneumatic drive unit and the process unit with the ceramic sensor lock gate are separate modules the drive unit can be removed and replaced under process conditions Mounting i Possible mounting angle 15 above horizontal e Mounting angle 360 i e even upside down for special sensors only containing thickened electrolytes which thus cannot flow Composition of the Sensor Lock Gate The Ceramat sensor lock gate consists of 2 main units drive unit and process unit The drive unit performs the movements required to open and close the ceramic rotary slide and to move the sensor into and out of the process The process unit comprises the ceramic sensor lock gate with calibration chamber in the probe housing as well as the process adaptation e g flange or dairy pipe screw joint Drive unit and process unit can be separated by the operator even under process pressure when certain safety precautions are taken see Maintenance Work on the Drive Unit on page 24 Media connection to Unical 9000 X probe controller
30. repairs department in Berlin RMA number can be obtained by calling 49 30 80 191 233 Customer information must be completed if no RMA no available Company Address Contact Tel E mail e e e e e e e o o e o o e o e o o o o o o o o o o o oooooooooo oo o o o o o o o o o o o o o o o o o o o o o oo o o o o o o ooo ooo L O Oe6p oo o eoo oo o o oo o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o oo o Information on the product Product name e e e o e e o e o e o e o o es eo o o o o o o o o o o o o ooo oo o o o o o o o ooo oo o o o o o o ooo ooo o o o o oo ooo o o o o o o o o oo oo o oo o o o o o o o ooo ooo oo o o o o o oooo o o o o o o o eee eee o oo o o o o oo o o o o oo o o ooo o Serial number Included accessories e 2902029292062090292920602920929202092290292240292902922929202929029290292292029290209292902929029029292029992994029292929292920299 920292902929292090920299029294929020990209902922090292992020990292902929029929292922902920299202992909299 92929062922992 0299 92929202929292929299 The product being returned is new unused or has not been exposed to hazardous substances The product has been exposed to hazardous substances Please preferably state the classification of the hazardous substance as applicable together with the H phrases or R phrases or at minimum provide the relevant hazard pictograms L U Lj Od x The product has bee
31. sor pH Sensors Be sure to follow the assembly instructions step by step Preparations e Check whether the sensor is damaged glass broken Never install a damaged sensor e Check whether slide washer or O ring on the sensor are damaged and replace if required e Remove watering cap from the sensor tip and rinse sensor with water Sensor Dismount Guard only for sensors with solid electrolyte In conjunction with the Unical or Uniclean electro pneumatic controllers and the Protos measuring system the Ceramat is fitted with a sensor dismount guard This serves to prevent the immersion of the sensor lock gate without sensor a message is triggered in the Protos If the sensor is absent or incorrectly mounted compressed air noticeably and audibly escapes from below the drive s coupling nut The outflowing compressed air is detected by a flow switch in the Unical and signals the missing or incorrectly mounted sensor to the Protos The sensor dismount guard only works with a correctly installed O ring B and slip ring A on the sensor If these elements are not present the Sensor dismounted message is shown in the Protos display Before installing a new sensor check whether there are any sealing elements at the bottom of the sensor holder from previous installations which have not been removed Note When using a PEEK scraper ring on the sensor socket of the Ceramat or when retrofitting a Ceramat with sensor socket
32. ubricant included Set A FKM FKM On request Syntheso Glep1 Set B EPDM EPDM On request Syntheso Glep1 Set E EPDM FDA EPDM FDA On request Beruglide L Set F FKM FDA FKM FDA On request Beruglide L Set H FFKM FDA FFKM FDA On request Beruglide L Set K FFKM FFKM On request Syntheso Glep1 Zubeh r Ersatzteile Zubeh r Ersatzteile Bestell Nr Sensor Montageschl ssel SW 19 ZU 0647 Luftversorgung f r druckbeaufschlagte Sensoren 0 5 4 bar ZU 0670 1 Luftversorgung f r druckbeaufschlagte Sensoren 1 7 bar ZU 0670 2 Montageschl ssel Ceramat ZU 0648 pneumatisches Handsteuerventil ZU 0646 Standard Medien SM Interface ZU 0631 pneumatisch gesteuertes 3 8 Ventil f r Zusatzmedium ZU 0669 Adapter f r Zusatzmedium PEEK FKM ZU 0654 1 Adapter f r Zusatzmedium PEEK EPDM ZU 0654 2 Adapter f r Zusatzmedium PEEK FFKM ZU 0654 3 Adapter f r Zusatzmedium Stahl FKM ZU 0655 1 Adapter f r Zusatzmedium Stahl EPDM ZU 0655 2 Adapter f r Zusatzmedium Stahl FFKM ZU 0655 3 Sensorbuchse Ceramat PEEK FKM ZU 0616 Sensorbuchse Ceramat PEEK EPDM ZU 0617 Sensorbuchse Ceramat PEEK FFKM ZU 0618 Sensorbuchse Ceramat PEEK EPDM FDA ZU 0619 Sensorbuchse Ceramat PVDF FKM ZU 0620 Sensorbuchse Ceramat PVDF EPDM ZU 0621 Sensorbuchse Ceramat PVDF FFKM ZU 0622 Sensorbuchse Ceramat PVDF EPDM FDA ZU 0623 Sensorbuchse lang Stahl 1 4571 FKM ZU 0672 A Sensorbuchse la

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