Knick Protos OXY 3400-067 User manual

The Art of Measuring.
Aktuelle Produktinformation: www.knick.de
Analysenmesssystem
Protos 3400(X)
Betriebsanleitung Messmodul Protos CONDI 3400 (X)-051
zur Leitfähigkeitsmessung mit induktiven Sensoren
Deutsch
Protos OXY 3400(X)-067 Measuring Module
For (Trace) Oxygen Measurement in Liquids and Gases
User Manual
Protos II 4400(X) / Protos 3400(X)
Process Analysis System
Latest Product Information: www.knick.de

Trademarks
The following trademarks are used in this document without further marking:
Calimatic®, Protos®, Sensocheck®, Sensoface®, Unical®, VariPower®, Ceramat®, SensoGate®
are registered trademarks of Knick Elektronische Messgeräte GmbH & Co. KG, Germany
Memosens®
is a registered trademark of
Endress+Hauser Conducta GmbH & Co. KG, Germany
Knick Elektronische Messgeräte GmbH & Co. KG, Germany
Returns
Please contact our Service Team before returning a defective device. Ship the cleaned device to the
address you have been given.
If the device has been in contact with process medium, it must be decontaminated/disinfected before
shipment. In this case, place a Declaration of Contamination in the consignment to prevent any risk to the
health and safety of our service personnel. The declaration is available at:
https://www.knick-international.com/en/service/repairs/
Disposal
Please observe the applicable local or national regulations concerning the disposal of “waste electrical and
electronic equipment”.

3
Table of Contents
Protos OXY 3400(X)-067 Module
Returns........................................................................................................................................... 2
Disposal ......................................................................................................................................... 2
Trademarks ................................................................................................................................... 2
Intended Use.................................................................................................... 5
Safety Instructions .......................................................................................... 6
Operation in Explosive Atmospheres: COND 3400X-067 Module ........................... 6
Firmware Version ............................................................................................ 7
ISM - Intelligent Sensor Management........................................................... 8
Plug and Measure ...................................................................................................................... 9
First Calibration.........................................................................................................................10
Parameter Setting ....................................................................................................................11
Predictive Maintenance .........................................................................................................12
Diagnostics .................................................................................................................................13
CIP (Cleaning in Place) / SIP (Sterilization in Place) .....................................................14
Terminal Plate OXY 3400-067 Module......................................................... 15
Installing the Module.................................................................................... 16
Wiring ............................................................................................................. 17
Calibration / Adjustment .............................................................................. 19
Recommendations for Calibration.....................................................................................21
HOLD Function During Calibration ...................................................................................22
Automatic Calibration in Water...........................................................................................24
Automatic Calibration in Air.................................................................................................26
Product Calibration (Calibration with Sampling) ........................................................28
Data Entry of Premeasured Sensors .................................................................................30
Zero Correction.........................................................................................................................31
Temp Probe Adjustment........................................................................................................32
Parameter Setting ......................................................................................... 33
Parameter Setting: Operating Levels ................................................................................34
Parameter Setting: Locking a Function ...........................................................................35
Activating Parameter Setting ..............................................................................................36
Sensoface ....................................................................................................................................42
Calculation Blocks....................................................................................................................43

4
Table of Contents
Protos OXY 3400(X)-067 Module
Logbook.......................................................................................................................................45
Restore Factory Settings........................................................................................................45
Messages: Default settings and selection range..........................................................46
Device limits...............................................................................................................................46
Configuring a Current Output.............................................................................................48
Current Outputs: Characteristics ........................................................................................49
Current Outputs: Output Filter............................................................................................51
Maintenance .................................................................................................. 53
Temp probe adjustment........................................................................................................53
Diagnostic Functions .................................................................................... 54
Point of meas description .....................................................................................................54
Logbook.......................................................................................................................................54
Device description...................................................................................................................55
FRONT module..........................................................................................................................55
BASE module .............................................................................................................................55
Module diagnostics.................................................................................................................56
Sensor monitor .........................................................................................................................56
Cal record ....................................................................................................................................57
Sensor diagram.........................................................................................................................57
Statistics.......................................................................................................................................57
Setting Diagnostic Messages as Favorite ........................................................................58
Message list ...............................................................................................................................60
Specifications................................................................................................. 69
Appendix:....................................................................................................... 72
Minimum Spans for Current Outputs...............................................................................72
Dissolved Oxygen Measurement in Carbonated Beverages
(Only with Protos 3400(X): SW3400-011) ........................................................................73
Overview ........................................................................................................ 74
Overview of Parameter Setting...........................................................................................74
Index............................................................................................................... 78

5
Intended Use
The module is an input module for measuring oxygen in liquids and gases. It
measures the partial pressure of oxygen, air pressure, and temperature simul-
taneously with analog amperometric oxygen sensors or ISM sensors. It is also
able to calculate and display the oxygen saturation index and concentration as
well as volume concentration in gases.
The OXY 3400X-067 module is intended for operation in locations subject to
explosion hazards which require equipment of Group II, device category 2(1),
gas/dust.

6
Safety Instructions
Operation in Explosive Atmospheres: COND 3400X-067 Module
The module is approved for operation in explosive atmospheres.
When installing the product in a hazardous location, observe the information
in the supplements to the certificates and, if applicable, the relevant control
drawings.
Observe all applicable local and national codes and standards for the instal-
lation of electrical equipment in explosive atmospheres. For orientation,
please refer to IEC 60079-14, EU directives 2014/34/EU and 1999/92/EC (ATEX),
NFPA70 (NEC), ANSI/ISA-RP12.06.01.
WARNING! Possible impairment of explosion protection.
• Modules which have already been used shall be subjected to a professional
routine test before they may be operated in another type of protection.
• Prior to commissioning, the operating company must verify the intrinsic
safety in accordance with the installation regulations of IEC60079-14 for
the complete interconnection of all equipment involved, including the
connecting cables.
• The interconnection of Ex and non-Ex modules (mixed assembly) is not
permitted.
• In hazardous locations the device shall only be cleaned with a damp cloth to
prevent electrostatic charging.
Maintenance
The Protos modules cannot be repaired by the user. For inquiries regarding
module repair, please contact Knick Elektronische Messgeräte GmbH & Co. KG
at www.knick.de.

7
Menu Display Device description
Device hardware and firmware
version
Provides information on all modules
installed: Module type and function,
serial number, hardware and firmware
version and device options.
Select the different modules (FRONT,
BASE, slots 1 - 3) using the arrow keys.
Device description
Return
22.7 °C
83.3 %Air
Operating panel Protos
Module FRONT 3400-011
Hardware: 2, Software: A.2
Serial number: 08150815
BASE
Module FRONT
Query actual device/module firmware
When the analyzer is in measuring mode:
Press menu key, open Diagnostics menu: Device description
Options
Device description
Return
22.7 °C
83.3 %Air
Input for O2 and °C
Module OXY 3400-067
Hardware: 1, Software: 3.1
Serial number: 471101147
BASE
Module FRONT
Options
Query module software
Module OXY 3400-067,
hardware and firmware version,
serial number –
here installed in slot3.
Note: The display may vary depending on the device version.
Firmware Version
Module Firmware OXY 3400(X)-067: firmware version 3.x
Module Compatibility OXY 3400-067 OXY 3400X-067
Protos 3400 from FRONT firmware version 7.0 x
Protos 3400X from FRONT firmware version 7.0 x
Protos II 4400 from FRONT firmware version 1.0.01) x
Protos II 4400X from FRONT firmware version 1.0.01) x
1) ISM from FRONT firmware version 02.xx.xx

8
ISM - Intelligent Sensor Management
The module allows the connection of ISM sensors 1).
ISM is an open system that is compatible to existing connection systems (VP 8)
and permits the use of conventional sensors.
An ISM sensor is immediately identified due to the “Plug & Measure” concept.
This ensures the clear assignment of a sensor to a measuring point. The risk of
confusing the sensors is eliminated. The sensors can be precalibrated in the lab.
On-site calibration/adjustment is no more required.
Information Available in the ISM Sensor
The sensor provides information concerning manufacturer, production date,
sensor description, application data, and original calibration data, as well as
information on predictive maintenance, such as the maximum load index and
maximally permitted number of CIP/SIP cycles.
Statistical data inform on the product life cycle of the sensor: data of the last
3 calibrations, adjustment record, media values, partial pressure, temperature,
response time, impedance, barometric pressure.
This allows the following diagnostics to be performed:
- Calculation of the individual load index
- Wear indication
- Membrane changes
- Inner body changes
Taking Over the Minimum/Maximum Temperature
The maximum temperature range is stored in the ISM sensor.
When "Sensor monitoring Auto" has been selected, the value pair for the
maximum + minimum temperature is automatically taken over from the sensor.
1) With Protos II 4400(X) from FRONT firmware version 02.xx.xx

9
ISM
Plug and Measure
An ISM sensor is immediately identified after being connected:
ISM sensor identified
25.6 °C
Proceed
Manufacturer:
Article No.:
99.2 % Air
Adjustment:
Serial number:
Sensor:
Mettler Toledo
52002559
09/06/10 08:15
0000313
InPro 6900
Date 09/06/10 Parameter set
Message list 1 messg.
Return
Warn New sensor, adjustment required
25.6 °C
99.2 % Air
Date 09/06/10 Parameter set
Failure Message
(Incorrect Measured Values)
Measured value, alarm icon, and module slot
identifier are flashing.
The flashing means:
NOTICE!
The displayed value is no “valid” measured value!
All sensor-typical parameters are automatically
sent to the analyzer.
These are, for example, the measuring range,
zero and slope of the sensor, but also the type
of temperature probe. Without any further
parameter setting, measurement starts at once,
the measuring temperature is simultaneously
detected.
Premeasured ISM sensors can be used for mea-
surement without previous calibration.
The ISM logo is displayed as long as an ISM
sensor is connected.
When the ISM sensor has not been adjusted, the
“maintenance request” icon is displayed.
A new entry is added to the message list of the
Diagnostics menu:
Warn New sensor, adjustment required
Note: The display may vary depending on the device version.

10
ISM
First Calibration
Prior to first use, an ISM sensor must be calibrated:
To open calibration
Press menu key to select menu.
The measured values (upper right corner) and
the “alarm” and “calibration” icons are flashing.
(The analyzer classifies the values as “invalid”
because of the missing calibration).
Menu selection
Return to meas
99.2 % Air
25.6 °C
Select: [enter]
Lingua
Select calibration using arrow keys,
confirm with enter. Passcode: 1147.
(To change passcode, select:
Parameter setting/System control/Passcode
entry)
After passcode entry, the system is in function
check mode: Current outputs and relay contacts
behave as configured* and supply either the
last measured value or a fixed value until the
Calibration menu is exited.
* The current outputs / relay contacts are configured
in the BASE module or the communication modules
(OUT).
Calibration
Return Info
Module OXY 3400-067
99.2 % Air
25.6 °C
The function check (HOLD) mode is indicated by
the “Hold” icon (upper left of display).
Select module using arrow keys,
confirm by pressing enter.
Note: The display may vary depending on the device version.

11
ISM
Parameter Setting
Menu selection
Return to meas
20.1 °C
Select: [enter]
Lingua
99.2 % Air
Parameter setting (Administrator)
20.1 °C
Return
Module CONDI 3400-051
Module FRONT 3400-011
Module BASE 3400-029
99.2 % Air
System control
Module PID 3400-121
Module OXY 3400-067
Module OXY 3400-067 (Administrator)
20.1 °C
Return
Pressure correction
Sensor data
Cal preset values
99.2 % Air
Salinity correction
Messages
Input filter
Block
Since ISM sensors have an “electronic datasheet”,
many parameters are already provided by the
sensor and automatically taken over by the
analyzer.
To enter the process-related parameters, select:
• Parameter setting
• Module selection
• Sensor data
Sensor Monitoring Details
The values for slope, zero, response time, and
temperature range are automatically read by the
module*. Additional specifications are required
for sensor wear, CIP/SIP counter, autoclaving
counter, and sensor operating time.
The tolerance limits are displayed in gray.
* Individual specifications are not overwritten
by ISM sensor data.
Sensor monitoring details (Administrator)
20.1 °C
Response time
Zero
Sensocheck
99.2 % Air
Sensor wear
CIP counter
Slope
Return
(Auto)
(Auto)
(Auto)
()
(Auto)
(Auto)
Note: The display may vary depending on the device version.

12
ISM
Predictive Maintenance
Module OXY 3400-067
Return
205 mbar
Adjust temp probe
Membrane body changes
Inner body changes
Autoclaving counter
80.7%Air
Sensor monitor
The settings for predictive maintenance are
made in the
• Maintenance menu /
Module selection
Autoclaving counter
Max. cycles
Count cycles
205 mbar
80.7%Air
Return Cycles+1
050
007
Membrane body changes
Max. changes
Count changes
205 mbar
80.7%Air
Return Take over
004
000
Update sensor data after change:
Serial number
09/06/10
Date
0000772
Inner body changes
Max. changes
Count changes
205 mbar
80.7%Air
Return Take over
004
000
Update sensor data after change:
Serial number
09/06/10
Date
0000772
Autoclaving Counter
When setting the sensor data, the maximum
number of autoclaving procedures permit-
ted must be specified. Then, each cycle can be
recorded in the Maintenance menu. This shows
how many autoclaving cycles are still permitted.
Membrane Body Changes
During parameter setting, the maximum num-
ber of membrane body changes permitted must
be specified. Then, each cycle can be recorded
in the Maintenance menu (date, serial number).
This shows how many changes are still permit-
ted.
Inner Body Changes
During parameter setting, the maximum num-
ber of membrane body changes permitted must
be specified.
Then, each change of an inner body can be
recorded in the Maintenance menu (date, serial
number). This shows how many changes are still
permitted.
Note: The display may vary depending on the device version.

13
ISM
Diagnostics
Sensor wear monitor
23.0 °C
Return
Sensor operating time
Autoclaving cycles
98%Air
SIP cycles
CIP cycles
Membrane wear
312 d
1 of 2
0 of 3
1 of 5
Inner body wear
Sensor Wear Monitor
The Diagnostics menu provides information on
the current wear of inner body and membrane
body.
Generally, the membrane body must be
replaced more often than the inner body:
The “Membrane wear” bargraph shows how
much the membrane is worn out.
The inner body wear is not reset when a mem-
brane body has been replaced - here, the load
on the inner body is added up and represented
as total load on the inner body.
Sensor network diagram OXY
Return
23.0 °C
98%Air
2 - Zero point
1 - Slope
4 - Not in use
3 - Sensocheck
5 - Response time
7 - Sensor wear
6 - Cal timer
Sensor Diagram
• Slope
• Zero
• Sensocheck
• (Not in use)
• Response time
• Cal timer
• Sensor wear
The measured values are continuously moni-
tored during the measurement process. The
sensor network diagram provides at-a-glance
information about critical parameters. If a toler-
ance limit has been exceeded, the respective
parameter is flashing.
Values in gray: Monitoring switched off.
Critical range –
“inner circle”
Value out of tolerance
The tolerance can be
modified as required!
“Outer circle”
Value within tolerance
Note: The display may vary depending on the device version.

14
CIP/SIP Cycles
CIP (Cleaning in Place) / SIP (Sterilization in Place)
CIP/SIP cycles are used for cleaning or sterilizing the process-wetted parts
in the process. They are performed for biotech applications, for example.
Depending on the application, one (alkaline solution, water) or more chemicals
(alkaline solution, water, acidic solution, water) are used.
The temperatures for CIP are around 80 °C/176 °F, for SIP around 110°C/230°F.
These procedures extremely stress the sensors.
ISM sensors can release a message when a preset number of CIP/SIP cycles is
exceeded. This allows replacing the sensor in time.
Default Values for the Counters
(for Evaluating the Sensor Wear):
CIP = 80
SIP = 700
Autoclaving counter = 750 hours for one cycle
Sensor wear monitor
24.1°C
Return
Sensor operating time
Autoclaving cycles
98%Air
SIP cycles
CIP cycles
Sensor wear
316 d
1 of 2
0 of 3
1 of 5
Example of CIP Cycle:
The device automatically recognizes the CIP and SIP cycles and corresponding-
ly increments the counter. The user can specify the max. number of cycles and
decide whether a message is to be generated when this number is exceeded.
These data are not overwritten even after sensor replacement.
The number of CIP cycles is shown in the sensor wear monitor of the
Diagnostics menu when an individual max value has been specified.
Note:
The counters are incremented no earlier than
2hours after start of the cycle, even if the cycle
itself has already been terminated.

15
Terminal Plate OXY 3400-067 Module
Attaching the terminal plates
The terminal plates of the lower modules can
be sticked to the inner side of the door.
This facilitates maintenance and service.

16
Installing the Module
CAUTION! Electrostatic discharge (ESD).
The modules' signal inputs are sensitive to electrostatic discharge.
Take measures to protect against ESD before inserting the module and wiring
the inputs.
Note: Strip the insulation from the wires using a suitable tool to prevent dam-
age.
1) Switch off the power supply to the device.
2) Open the device (loosen the 4 screws on the front).
3) Plug the module into the slot (D-SUB connector),
see figure.
4) Tighten the module's fastening screws.
5) Open the ESD shield (covering terminals 2 and 8).
6) Connect the sensor and separate temperature probe if necessary, see
"Wiring Examples".
Note: To avoid interferences, the cable shielding must be completely
covered by the ESD shield.
7) Fit the ESD shield back into place (covering terminals 2 and 8).
8) Check whether all connections are correctly wired.
9) Close the device by tightening the screws on the front.
10) Switch on the power supply.
CAUTION! Incorrect measurement results.
Incorrect parameter setting, calibration or adjustment may result in incorrect
measurements being recorded. Protos must therefore be commissioned by a
system specialist, all its parameters must be set, and it must be fully adjusted.
ESD shield

17
Wiring
OXY 3400(X)-067
The signal from an external pressure transmitter can be fed in through the
external current input (18, 19). This enables automatic pressure correction for
oxygen measurement.
Sensor type Standard
SE 7*6 ...
VP6-ST cable
Traces 01
SE 7*7 ...
VP6-ST cable
Traces 0011) ISM2)
2 cathode Coax core
transparent
Coax core
transparent
Coax core
transparent
8 anode Coax shield
Red
Coax shield
Red
Coax shield
Red
12 reference n.c. Blue
13 guard/RTD Gray + Green Gray + Green Gray + Green
14 RTD White White White
15 shield Cable shield
Yellow/green
Cable shield
Yellow/green
Cable shield
Yellow/green
16 ISM data K8S connection:
Coax core
(transparent)
17 ISM DGND K8S connection:
Coax shield
(black)
18 - I-Input
19 + I-Input
1) With Protos 3400(X) only
2) With Protos II 4400(X) from FRONT firmware version 02.xx.xx

18

19
• Calibration: Detecting deviations without readjustment
• Adjustment: Detecting deviations with readjustment
Calibration / Adjustment
Note: Function check (HOLD) active for the currently calibrated module
Current outputs and relay contacts behave as configured
NOTICE!
Without adjustment every dissolved oxygen meter delivers an imprecise or
wrong output value! After replacing the sensor, the electrolyte, or the sensor
membrane, you must perform a calibration.
The resulting values must be taken over by an adjustment for calculating the
measured variables (measured value display, output signals)!
Procedure
Every dissolved oxygen sensor has its individual slope and zero point.
Both values are altered, for example, by aging. For sufficiently high accuracy of
oxygen measurement, the meter must be regularly adjusted for the sensor data
(adjustment).
Sensor Replacement (First Calibration)
After replacement of the sensor, electrolyte or sensor membrane, a "First
Calibration" should be performed. During First Calibration, the sensor data are
stored as reference values for the statistics.
The ”Statistics” menu of Diagnostics shows the deviations of zero, slope, cali-
bration temperature, calibration pressure, and response time of the last three
calibrations with respect to the reference values of the First Calibration.
This allows evaluation of the drift behavior and aging of the sensor.
Calibration/Adjustment Methods
• Automatic calibration in water/air
• Product calibration (saturation/concentration/partial pressure)
• Data entry
• Zero correction

20
Adjustment
Adjustment means that the values determined by a calibration are taken over.
The values determined for zero and slope are entered in the calibration record.
(Cal record can be opened in the Diagnostics menu for the module). These
values are only effective for calculating the measured variables when the cali-
bration has been terminated with an adjustment. A passcode ensures that an
adjustment can only be performed by an authorized person (Administrator).
The Operator can check the current sensor data by a calibration and inform
the Administrator when there are deviations. You can use the add-on func-
tion SW3400-107 / FW4400-1071) for granting access rights (passcodes) and
for AuditTrail (continuous data recording and backup according to FDA 21 CFR
Part11).
Calibration / Adjustment
Operator (without administrator
rights)
After calibration, change to measur-
ing mode. Inform Administrator.
When opening the menu (Calibration,
respective module), the Administrator
sees all data of the last calibration and
can take over the values or perform a
new calibration.
Calibration data record
Cal mode
25.6°C
16.8%Air
Slope
Automatic - Air
–067.9 nA
End Adjust
Calibration
Zero
03/29/10 12:26
+0.000 nA
Menu Display Adjustment after calibration
Administrator
With the corresponding access rights,
the device can immediately be adjust-
ed after calibration. The calibration
values are taken over for calculating
the measured variables.
Module OXY 3400-067
Return
25.6°C
View/adjust calibration data record
16.8%Air
Start new calibration
Stored calibration data record
Calibration 03/29/10 12:46
Response time 0042 s
Note: The display may vary depending on the device version.
1) Protos II 4400(X): FW4400-107 only available from
FRONT firmware version 02.xx.xx