Knick Protos II 4400 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 PID 3400(X)-121 Communication Module
PID Controller Module with 2 Current Outputs and
4 Relay Outputs
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
Returns........................................................................................................................................... 2
Disposal ......................................................................................................................................... 2
Trademarks ................................................................................................................................... 2
Intended Use.................................................................................................... 5
Safety Instructions .......................................................................................... 6
Operation in Explosive Atmospheres: PID 3400X-121 Module................................. 6
Firmware Version ............................................................................................ 7
Terminal Plate.................................................................................................. 9
Installing the Module.................................................................................... 10
Wiring Examples............................................................................................ 11
PID Controller ................................................................................................ 13
Analog Controller IV1/IV2 .....................................................................................................18
PI Controller with Vertices (Analog Controller IV1/IV2)..............................................19
Digital Controller KV1/KV2....................................................................................................22
Pulse Length Controller .........................................................................................................22
Pulse Frequency Controller ..................................................................................................22
PID Controller and Limit Contacts .....................................................................................23
Parameter Setting ......................................................................................... 24
Parameter Setting: Operating Levels ................................................................................25
Administrator level .........................................................................................................25
Operator level ...................................................................................................................25
Viewing level.....................................................................................................................25
Parameter Setting: Locking a Function ...........................................................................26
Configuring the Module ............................................................................... 27
Maintenance .................................................................................................. 30
Diagnostic Functions .................................................................................... 31
Opening the diagnostics menu..........................................................................................32
Message list ...............................................................................................................................32
Specifications................................................................................................. 35
Overview ........................................................................................................ 38
Overview of Parameter Setting...........................................................................................38
Index............................................................................................................... 43
Table of Contents

4
Table of Contents

5
Intended Use
The module is a general-purpose PID controller module. Analog control valves
are actuated via 2 passive current outputs. Digital straightway valves are actu-
ated via 2 relay contacts. In addition, two relay contacts are provided for limit
monitoring or pre-control.
The PID 3400X-121 module is intended for operation in locations subject to
explosion hazards which require equipment of Group II, device category 2(1),
gas/dust.

6
Operation in Explosive Atmospheres: PID 3400X-121 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 draw-
ings.
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! Risk of 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.
Safety Instructions

7
Firmware Version
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
7.00 pH
Operating panel Protos
Module FRONT 3400-011
Hardware: 1.1, Software: A.2
Serial number: 08150815
BASE
Module FRONT
Options
Device description
Return
22.7 °C
7.00 pH
Controller, contacts
Module PID 3400-121
Hardware: 1, Software: 1.1
Serial number: 471101147
BASE
Module FRONT
Options
Query module firmware
Module PID 3400-121,
hardware and firmware version,
serial number –
here installed in slot3.
Note: The display may vary depending on the device version.
Module Compatibility PID 3400-121 PID 3400X-121
Protos 3400 from FRONT firmware version 1.0 x
Protos 3400X from FRONT firmware version 4.01) x
Protos II 4400 from FRONT firmware version 1.0.0 x
Protos II 4400X from FRONT firmware version 1.0.0 x
Module Firmware PID 3400(X)-121: firmware version 1.x
Query actual device/module software
When the analyzer is in measuring mode:
Press menu key, open Diagnostics menu: Device description
1) From FRONT firmware version 8.x an additional PI controller
with vertex points can be configured.

8

9
Terminal Plate
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.
Terminal Plate PID 3400-121 Module

10
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 on the right.
4) Tighten the module’s fastening screws.
5) Connect the signal lines, see “Wiring” on the next page.
6) Check whether all connections are correctly wired.
7) Close the device by tightening the screws on the front.
8) 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.

11
Wiring Examples
Analog and Digital Controller Outputs
Wiring Example 1
Analog controller outputs IV 1, IV 2 (passive, supply unit required)
9
10
7
8
IV 2
IV 1 Supply unit
Module
+
-
0(4) ... 20 mA
Controller output

12
18
19
16
17
K 10K 9
Limit contact
Module
Max. 30 V DC
100 mA
+
+
-
-
Power supply, e.g. 24 V DC
Wiring Example 3
Electronic relay contacts K 9, K 10
Load circuit
14
15
12
13
KV 2KV 1
Relay contact
Module
Max. 30 V DC
100 mA
+
+
-
-
Power supply, e.g. 24 V DC
Wiring Example 2
Digital controller outputs KV 1, KV 2 (electronic relay contacts)
Wiring Examples
Relay Contacts

13
PID Controller
Short Introduction
PID control requires a closed loop. The control loop is made up of individual
components which must be in permanent operation. The process variable to be
controlled (controlled variable) is continuously measured and compared with
the desired value (setpoint). The aim is to keep the controlled variable at the
setpoint.
The controlled variables (e.g. pressure, temperature, pH value, concentration,
...) are measured using suitable sensors which provide the continuously mea-
sured values for comparison with the setpoint. The comparison intervals can
be selected as desired. Deviations trigger a control procedure with the aim to
adjust the controlled variable to the setpoint within a preset time.
This comparison procedure and the calculation of the required change of the
controlled variable is performed by the controller.
Controllers are classified according to their characteristic, dynamic response,
and mode of operation.
• Characteristic
A distinction is made between continuous (linear) and discontinuous
controllers.
• Dynamic response:
A change in the error variable at the controller input influences the
manipulated variable at the controller output.
There is a great variety of classification criteria for linear controllers.
Particular importance must be placed on their dynamic response, however.
The following text describes the components of dynamic action and their
typical combinations.

14
Schematic diagram of P controller
Time response of control as reaction to a disturbance:
After a short settling time a deviation xB remains.
The desired value is not reached.
0 5 10 15 25
Setpoint
0.2
0.5
1.0
xB
P controller
Without controller
P Controller (Parameter: Controller Gain)
The proportional-action component of a P controller transforms the control
deviation (error variable) to a proportional controller output (manipulated
variable). The range of the manipulated variable is limited. Therefore, also the
usable range of the controller input signal (control range) is limited.
t
Controlled variable (e.g. pH)
PID Controller
Short Introduction

15
PID Controller
Short Introduction
I Controller (Parameter: Reset Time)
The integral-action component takes account of the rate of change of the
manipulated variable, i.e. it forms the time integral of the error variable.
Each value of the controlled variable is assigned to a particular rate of change
of the manipulated variable.
PI Controller
These controllers combine proportional and integral action. Compared
to Pcontrollers, which only provide a proportional relationship between
controlled variable and manipulated variable, here an integration over time is
also performed.
First, the value of the manipulated variable is calculated in proportion to the
error variable, and then the integral-action component is added.
Schematic diagram of PI controller
Time response of control as reaction to a disturbance.
The desired value is reached after several oscillations.
0 5 10 15 25
Setpoint
0.2
0.5
1.0
PI controller
Without controller
t
Controlled variable (e.g. pH)

16
PID Controller
Short Introduction
D Control (Parameter: Derivative)
A derivative control alone is completely unsuitable since it only reacts to
changes of the error variable, that is, constant errors remain unnoticed.
PD Controller
This controller adds the proportional change of the input signal and the rate of
change of the controlled variable to the resulting manipulated variable.
PID Controller
This controller comprises the P, I, and D components of linear controllers.
The manipulated variable of a PID control system is the sum of the output
variables of a P, an I, and a D control system.
Schematic diagram of PID controller
Time response of control as reaction to a disturbance.
The desired value is reached after a short overshoot.
0 5 10 15 25
Setpoint
0.2
0.5
1.0
PID Controller
Without controller
t
Controlled variable (e.g. pH)

17
PID Controller
Short Introduction
The maximum overshoot of the PID controller is even smaller than that of
the PD controller. Due to its I-action component there is no remaining offset.
However, the components (P, I, D) of a PID controller implement a universally
applicable, classical controller thanks to the fast reaction of the P component,
the regulating capacity of the I component, and the attenuating effect of the
Dcomponent.
Typical Applications
P Controller
Application for integrating control systems (e.g. closed tank, batch processes).
PI Controller
Application for non-integrating control systems (e.g. drains).
PID Controller
The additional derivative action compensates for measurement peaks.
Setpoint
Controller
output Y
[%]
+100 %
-100 %
e.g. pH
Neutral zone Y=0
Controller characteristic
Gradient KC

18
Linear PID Controller
Analog Controller IV1/IV2
Analog Controller IV1/IV2
The following controller characteristics can be defined:
• Values are adjusted toward the setpoint.
• In the neutral zone (symmetrical to setpoint) no control takes place.
• Controller parameters: Controller gain, reset, and derivative.
• Feed time alarm: determines how long the controller output may be at
maximum until an alarm is released. This allows recognition of a defective
valve or an error in the process.
• Behavior during HOLD:
User-defined Constant controller output (“last usable value”)
Controller output = 0 (controller switched off)
100
50
0
-50
-100
5 6 7 8
Controller output Y [%]
Controlled variable X
[e.g. pH]
Neutral zone
Setpoint
[e.g. pH = 7]
20 20
0 (4)
20 0 (4)
Output IV1
Output IV1Output IV2
3-way mixing valve
2 straightway valves
Characteristic of analog controller
(3-way mixing valve or straightway valves)
Gradient KR
(Proportional action)

19
Nonlinear PI Controller
Analog Controller IV1/IV2
PI Controller with Vertices (Analog Controller IV1/IV2)
For control of pH neutralization processes, a nonlinear controller (controller
with vertices) often provides better results since the control curve can be better
adapted to a titration curve.
The PID 3400(X)-121 controller module provides an additional nonlinear PI con-
troller. Selection is made in the initial menu. With the “PI nonlinear“ controller,
you can specify a vertex for each control section using X/Y coordinates.
Module PID 3400-121 (Administrator)
25.0°C
Return
Digital controller KV1/KV2
Limit contact K9
7.10 pH
Limit contact K10
Block
Analog controller IV1/IV2
Controller
PI nonlinear
PID linear
The nonlinear PI controller with vertices is
selected in the menu
Parameter setting /
Module PID 3400-121
The following parameters can be set:
• Controller type
• Controlled variable
• Setpoint
• Neutral zone
• < Control beginning
• < Vertex X
• < Vertex Y
• > Control end
• > Vertex X
• > Vertex Y
• (I) Reset time
• Feed time alarm after
• Behavior during HOLD
• Output IV1/IV2

20
100
50
0
-50
-100
3 5 7 9
Controller output Y [%]
Controlled variable X
[pH]
Neutral zone
Setpoint XW
[e.g. pH = 7]
Controller characteristic of PI controller with vertices
Characteristic of Nonlinear PI Controller
Analog Controller IV1/IV2
11
Output range
below XW
Output range
above XW
Vertex <
Vertex >
Y
X
Y
X
Control beginning Control end
Limit contact 1
("alkali valve")
Limit contact 2
("acid valve")