CGS Instruments SAM-1950 User manual

Tel.: +49 8466 / 94 15 - 0
Fax: +49 8466 / 94 15 - 49
[e-mail]
www.cgs-company.de
CGS ANALYSENTECHNIK
CGS PROZESSANALYTIK
Keltenstraße 3
D-85095 Denkendorf
SAM-3000 / SAM 1950
Operating instructions
Language: English
Revision: Version 1.0
Issue: September 2015
NOTE
Read these operating instructions carefully before assembly,
installation and implementation.
These operating instructions are also available as a digital document on:
www.cgs-company.de/downloads/MDZ_M_B_SAM-3000.pdf
MDZ_M_B_SAM-3000_1.0

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Table of contents
Table of contents ....................................................................33
1 General information ................................................................35
1.1 Device version and validity .....................................................35
1.2 Information for our customers ..................................................35
1.3 General ....................................................................35
1.4 Warnings and explanatory texts.................................................35
1.5 Intended use ................................................................36
1.6 Qualified personnel...........................................................36
1.7 Warranty information .........................................................36
1.8 Delivery information ..........................................................37
1.9 Norms and regulations ........................................................37
1.10 Disclaimer .................................................................38
2 Warnings and safety instructions......................................................39
3 Packaging and transport ............................................................40
3.1 Packaging material ...........................................................40
3.2 Shipping labels ..............................................................40
3.3 Transport inspection ..........................................................41
3.4 Storage ....................................................................41
4 Installation, assembly information ....................................................42
5 Setup and function.................................................................43
5.1 Functional description .........................................................43
5.2 Design and operating mode ....................................................44
5.3 Dimensional drawing .........................................................45
5.4 Gas flow schematic ...........................................................46
5.5 Control PCB .................................................................47
5.5.1 Design and operating mode of the control PCB ...............................47
5.5.2 PROFIBUS DPV2 (Optional)................................................51
5.6. Design and functions of solenoid valve manifold ...................................51
6 Technical data.....................................................................53
7 Maintenance & repair...............................................................54
7.1 Replacing the solenoid valves / replacing the filter ..................................54
8 Device configuration (order code) .....................................................55
9 Spare parts .......................................................................56
10 Declaration of conformity...........................................................57
11 Labelling-CD .....................................................................58
12 Cleaning ........................................................................59
12.1 Cleaning the surface .........................................................59
12.2 Cleaning the interior .........................................................59
12.3 Cleaning the control panel ....................................................59

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1 General information
1.1 Device version and validity
This documentation is restricted to the specified product and is only valid for this respective product. The
documentation describes the installation, implementation and maintenance of the device and provides
information about its function.
1.2 Information for our customers
Read this manual before commencing work on this device! It contains important information and data
that, when observed, will ensure the device functions properly and save service costs. Implementation
of this device is thereby considerably facilitated, leads to reliable measurement results and prevents
damage caused by improper use of the product.
1.3 General
This device has left the factory in a technically and operationally safe condition. To maintain this condition
and to ensure safe operation of this product, it must be implemented only in the manner specified by
the manufacturer. In addition, correct and safe operation of this product depends upon proper transport,
proper storage and installation as well as careful operation and maintenance.
This manual contains the information necessary for the proper use of the product described herein.
It is written for technically qualified personnel who are specially trained or have relevant knowledge in
the field of automation technology (measurement, control and feedback control systems).
Knowledge and technically correct implementation of the safety instructions and warnings contained in
this manual are required for the safe installation and implementation of the product described and for
its safety during operation and maintenance. Only qualified personnel have the necessary expertise to
interpret the generally applicable safety instructions and warnings in specific cases and to apply them in
practice.
This manual is an integral part of the scope of delivery even if a separate order is possible due to
logistical reasons.
Because of the large number of technical details, it is not possible to consider all the details for all
versions of the described product and for every conceivable installation, operation, maintenance and
implementation in systems.
If you need additional information, or should particular problems arise which are not sufficiently
covered in this document, please request the necessary information from your local or responsible CGS
representative.
1.4 Warnings and explanatory texts
This manual describes how you can properly run, commission, operate and maintain this device.
You must pay particular attention to all warning and explanatory texts. These are separated from the
text and specifically identified by the relevant icons. They provide you with valuable tips for avoiding
operating errors and accidents.

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1.5 Intended use
The intended use for the purposes of this manual means that this product must only be used for the
applications described in the catalogue and in the technical description and only in conjunction with
external devices and components approved or recommended by CGS.
The product described in this manual has been developed, manufactured, tested and documented in
compliance with the applicable safety standards. No danger to personal health or property damage
therefore normally ensues from compliance with the handling guidelines and safety instructions
described for its project planning, assembly, intended use and maintenance.
1.6 Qualified personnel
Only those persons who are familiar with the installation, assembly, implementation and operation of
the product are qualified.
These persons have the following qualifications:
•They are authorised, trained or instructed to operate and maintain equipment and systems in accordance
with established safety procedures for electrical circuits, high pressures and aggressive and hazardous media.
•For devices with explosion protection: They are authorised, trained or instructed in carrying out work on
electrical circuits for hazardous systems.
•They are trained or instructed in the maintenance and use of protective equipment in accordance with
established safety procedures.
1.7 Warranty information
The contents of this manual is neither part of any previous or existing agreement, commitment or a
previous or existing legal relationship, nor should anyone modify these. All obligations by CGS arise from
the respective sales contract, which also contains the complete and solely applicable warranty terms and
conditions.
These contractual warranty regulations are neither extended nor limited by the contents of the manual.
The manufacturer accepts no liability for damage or malfunctions resulting from failure to observe the
operating instructions.
Apart from the operating instructions and regulations regarding accident prevention applicable in the
country and place of use, you must also observe the recognised technical regulations for safe and proper
work.
The warranty claim expires if the device is not installed, implemented, operated and maintained in
accordance with regulations.

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Proper maintenance means:
•Adherence to the maintenance plan (see Chapter: Maintenance)
•Maintenance by trained maintenance personnel
•Use of original CGS spare parts
Maintenance should be performed by the CGS service technician or, on the operator side, by CGS-trained
service technicians.
The warranty is void in case of:
•improper use
•use of unauthorised equipment
•faulty connection and existing components that are not part of the scope of delivery and service
•failure to use original spare parts and accessories
•retrofitting that was not performed by CGS itself
•non-compliance of prescribed maintenance work
The contents reflect the state of the art at the time of publication.
We reserve the right to make any technical changes due to further development.
1.8 Delivery information
The respective scope of delivery is listed in the shipping documents accompanying the delivery based
on the valid contract.
Please observe the corresponding information on the packaging material when opening the packaging.
Check the delivery for completeness and intactness. In particular, you should, where applicable, compare
the order number on the nameplates with the ordering data.
If possible, please keep the packaging materials so that you can use it for future return deliveries
(see Chapter: Packaging and transport).
1.9 Norms and regulations
The specification and production of this device were based on the harmonised European Norms whenever
possible. If no harmonized European Norms have been applied, then the norms and regulations of the
Federal Republic of Germany shall apply.
When using this product outside the scope of these norms and regulations, you must comply with the
norms and regulations valid in the operator's country.

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1.10 Disclaimer
All technical information, data and operating instructions contained in this manual correspond to the
latest state of development at the creation of this manual and are based on our previous experience and
knowledge to the best of our knowledge.
We reserve the right to make any technical changes in the course of further development of the device
described in these operating instructions. No claims can be derived from the data, illustrations and
descriptions in this manual.
We assume no liability for any damage and interruptions caused by operator error, non-observance of
these operating instructions or improper repairs.
We expressly state that only original spare parts and accessories approved by us must be used. This also
applies to the subassemblies of other manufacturers.
The installation or use of non-approved replacement parts and accessories and any unauthorised
modifications and changes are not permitted for safety reasons and exclude liability by CGS for any resulting
damages.
Claims for damages are excluded regardless of the legal grounds of such claims.
Translations are made in good faith. We cannot accept any liability for any translation errors not even
when the translation was made by us or on our behalf. Only the original text is binding.
The text and illustrations do not necessarily reflect the scope of delivery or a possible spare parts order.
The drawings and diagrams are not to scale.

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2 Warnings and safety instructions
This manual contains important Warnings and safety instructions which you must observe to ensure
your own personal safety and to avoid property damage. The instructions referring to your personal safe-
ty are indicated by a warning symbol. Instructions referring only to property damage have no warning
symbol. Depending on the hazard level, warnings are displayed in descending order as follows.
If more than one hazard level occurs then the warning representing the highest degree of danger will be
used. If a warning triangle is used to warn against personal injury then the same warning can be added
to warn against property damage.
DANGER
indicates that death or severe personal injury will result if no appropriate precautions are taken.
WARNING
indicates that death or severe personal injury can result if no appropriate precautions are taken.
CAUTION
with warning triangle indicates that minor personal injury can result if no appropriate precautions are
taken.
NOTE
means that an undesirable event or situation can occur if the corresponding information is not observed.
CAUTION
without warning triangle indicates that property damage can result if no appropriate precautions are
taken.

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3 Packaging and transport
3.1 Packaging material
The individual system components and modules are shipped in different packaging. Primary packaging
materials: wood, cardboard and plastics (films, foams), but also including hoop iron (for bundles), for
example. Packing materials include materials which are added to the packages for moisture protection
(e.g. silica gel bags).
If no agreement was reached on returning the packaging material then the packaging material remains
with the customer.
Waste disposal that is environmentally friendly and in accordance with the applicable disposal regulations
must be ensured. If necessary, assign waste disposal companies with the disposal of the packaging
material.
The system components are to be transported as far as possible in the package to the installation site
and kept in the package until assembly.
3.2 Shipping labels
Symbols are attached on the packages which must be observed during all transport phases including
storage.
1. TOP! The package must be stored, handled and transported in such a way that the arrows always point
upwards. Rolling, swinging, severe tipping or walking of goods marked in this way must be avoided.
2. Do not use forklift truck here
3. Do not destroy barrier!
4. Fragile, handle with care! Goods marked with this symbol should be handled carefully and should
never be rolled over or tied tightly.
5. Keep dry. Since goods of this type should also be protected from high levels of humidity, they must be
transported in closed vehicles or containers.
6. Center of gravity. This symbol is intended to provide a clear indication of the position of the center of
gravity.

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3.3 Transport inspection
Important:
Check the entire shipment for completeness and possible transport damage immediately upon arrival.
Failure to observe the following instructions in the event of damage shall cease the obligation of the
insurer to render performance.
•Even in case of suspected damage: Only acknowledge receipt with reservation (e.g. including shipping
documents) by specifying the alleged damage.
•Assert claims for compensation against third parties:
Carriers, freight forwarders, warehouse keepers:
- demand joint damage inspection
- request a certificate of damage
- hold these liable for damages in writing and describe the damage in detail,
namely:
- in case of visible damage prior to accepting delivery of the goods
- in case of no apparent outward damage immediately upon discovery
•Set deadlines for complaints and observe these!
•Ensure mitigation of incurred damage and avoidance of further damage.
•Immediately consult an insurance adjuster to record the damage and provide advice for securing claims
against third parties and for measures to mitigate the damage incurred.
•Never change the status of the consignment and its packaging until the arrival of the adjuster insofar
this is not required to mitigate and prevent further damage.
•Immediately notify the insurer about the insurance case and quickly submit the complete claim
documents to accelerate claims settlement (latest time before any preclusion and/or limitation periods
for claims against third parties).
3.4 Storage
After unloading, the packages must be stored until installation in accordance with the shipping markings.
Packed machine parts and accessories may not be unpacked.
Observe the applicable regulations for storage:
•Store in a cool dry place. Maximum humidity: 60 %.
Make sure the packages are not stored outdoors.
Also ensure that the storage room floor is dry during storage.
•Protect against direct sunlight. Storage temperature 5° C to 35 °C.
•Store in a dust-free location!
•Avoid mechanical shock and damage.
•For longer storage over 3 months, check the conservation measures.
In case of aggressive weather conditions, conservation must be renewed if necessary.

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4 Installation, assembly information
Safety measures:
Installation and assembly must only be performed by specially trained and qualified personnel. The
general accident prevention regulations must thereby be observed.
A formal handover to the operator occurs in case of implementation by CGS or its authorised representatives.
The device can subsequently be properly operated according to the operating instructions and applicable
safety regulations.
Before opening the device, disconnect it from the power supply in any case.
Requirements for the installation site:
•No exposure to direct sunlight
•Low exposure to dust
•Sufficient space for operation and maintenance
•Available and easily accessible escape routes
•No tripping hazards caused by cables that run close to the ground, etc.
•Maximum height: 2000 m above sea level
Technical prerequisites (supply voltage, gas pressures, etc.) can be found in the Technical Data section.

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5 Setup and function
5.1 Functional description
The cabinet sample module series SAM-1000_DP is used to connect different sample points to analysers.
Because of its modular design, it can be used for various applications in the chemical and petrochemical
industries for gaseous high-purity gases.
Special features:
The SAM-3000 especially distinguishes itself through the following features:
• Compactconstruction
• Minordeadvolume
• Modularconguration
• Highleakthightness
• Multi-purposeapplicationspossible
• PROFIBUSconnectivitypossible(optional)
Depending on the expansion stage of SAM-3000 can be switched up to 4 sample gases and 2 calibration
gases to an analyzer. For monitoring the gas ways at a glance LED’s shows the selected way. The LED’s
can be optionally arranged as Pushbuttons. Filter frits at the inlet of the switching module protects the
following analysers. So that impurities are filtered out of the sample gases and avoids pollutions and
damages at the analyzer. Filter frits are available in 20 μm and 50 μm fineness of filtration. With the
solenoid valve manifold concerning purging or no purging the dead volumes are minimized. For high pu-
rity applications the solenoid valves on the manifold are optimally arranged. By activation of a solenoid
valve a potential free contact can be used to send a feedback signal to the DCS. Up to 4 flow indicators
can be used to monitor the flow rate of sample gases. The SAM-3000 optional includes an integrated
pressure transmitter. The estimation of additional attended connectors and tubing connections can be
much reduced and supports a fast installation. A high variety of connectors can be chosen for different
tubing diameters. Depending on application different materials for the tubing inside of SAM-3000 can
be selected. Free configurable bridge circuits on control PCB compliance individual requirements. So for
e.g. the LED’s displays the individual task of function. Optionally the SAM-3000 can be connected to a
Profibus.

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5.2 Design and operating mode
The SAM-3000 is designed as a plug-in module for 19“ racks or 19“ cabinets.
• Aluminiumhousingwithmountedfrontplate
• ControlPCB
• Solenoidvalvemanifold
• Outletmanifold
• Dependingontheexpansionstagebulkheadunions,owmetersandowregulators
Bypass-Outlet Outlet to analyzer Pressure transmitter Solenoid valve manifold
Housing with
front plate
Control PCB
Flow controller
Quick connector
Flow low indicator
Flow meters with
needle valve
In the main case the inner of the module includes a solenoid valve manifold with selectable tubings in
different materials (metal, plastic or mixture of both) available. To control the solenoid valves and to
evaluate the signals is a control PCB integrated. The top of the LED’s the Pushbuttons are implemented in
the front plate of the SAM-3000. Depending on expansion stage there are bulkhead unions, flow meters
and flow regulators monted at the front plate.

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5.3 Dimensional drawing
The following drawing shows the necessary space required:
25-250l/h
bypass
AP4711
bypass
AP4712
25-250l/h 25-250l/h
bypass
AP4713
bypass
AP4714
25-250l/h 6-60l/h
sample
gas
SAM-3000
Manual
Sampling
Sample
Flow
Power/LT
Flow 1
Flow 2
Flow 4
Flow 3
Service
Zero Gas
Sample 1
Span Gas
Sample 2
Sample 4
Sample 3
AP2615
AP4711
AP4712
AP4714
AP4713
Zero Gas
Span Gas
Service
Flow 3
Flow 4
Flow 1
Flow 2

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5.4 Gas flow schematic
A exemplary gas diagram is shown below:
25-250 l/h 25-250 l/h
6-60 l/h
25-250 l/h
SAM-3000
sample gas 1
25-250 l/h
to analyser
ATM
example
sample gas 2
sample gas 3
sample gas 4
zero gas
span gas

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5.5 Control PCB
5.5.1 Design and operating mode of the control PCB with LED v.1.0
The dimensions of control PCB is developed for using in the 19“plug-in device. Via guiding rails the con-
trol PCB gets through the module. On control PCB mounted diodes and Pushbuttons for inspection and
service are implemented in the front plate.
The connection plugs are located at the rear side of control PCB. Power supply plug, the connection to
analyzer and the plug for connection to the DCS. The control PCB is supplied by 24 V DC and protected by
a fuse. For a failure-free operation the voltage is stabilized onboard.
1
2
3
4
1
3
2
4
Pushbuttons
Green LEDs to display sample gases
Yellow LEDs to display service, zero and span gas
Red LEDs for FLOW- Sample gas/ or. costomized display variants
Used to test the lights on the front panel

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5.5.1 Design and operating mode of the control PCB with
button v.2.0
1
2
3
4
5
6
7
Pushbuttons
Used to test the lights on the front panel
Pushbuttons for different sample gases
Switches the sample gases
LED for the service mode
Pushbutton for zero gas
Pushbutton for span gas
LED for FLOW- Sample gas/ or. costomized display variants
Pushbutton for Reset- Sample gas/ span gas
1
2
1
1
1
3
1
4
1
5
1
6
1
7

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Micro-fuse
Power supply 24 VDC
Connection to analyzer SUB-D 9-pin
Connection to DCS SUB-D 37-pin
1
3
2
4
1
3
2
4
5.5.3 Design of both Control PCBs (back view)

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Description of display- and operating controls:
Power/LT (green):
LED is shining permanently, if the module is connected to the power supply. By pressing the button the
function of LEDs can be checked (all LEDs are shining).
Sample 1 (green):
LED is shining permanently, if sample gas 1 is switched to the analyzer.
Sample 2 (green):
LED is shining permanently, if sample gas 2 is switched to the analyzer.
Sample 3 (green):
LED is shining permanently, if sample gas 3 is switched to the analyzer.
Sample 4 (green):
LED is shining permanently, if sample gas 4 is switched to the analyzer.
Service (yellow):
LED is shining permanently, if DCS releases manual service handling.
Zero Gas (yellow):
LED is shining permanently, if zero gas is switched to the analyzer.
Span Gas (yellow):
LED is shining permanently, if span gas is switched to the analyzer.
Flow 1 (red):
LED is shining by individual customer requirements. The LED can shine for instance if the gas flow of
sample gas 1 is in tolerance range or outside of tolerance range.
Flow 2 (red):
See above „Flow 1“.
Flow 3 (red):
See above „Flow 1“.
Flow 4 (red):
See above „Flow 1“.

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Plug connections:
Power supply (2-pin plug):
Pin Function Description
1 24 V DC voltage + 24 VDC
2GND-connection GND
SUB-D 9-pin plug for connection to analyzer:
The left side „functions of device“ of diagram shows the schematic design of the control PCB.
The right side of diagram shows the connections to peripheral devices.
5
9
4
8
6
2
7
3
1binary input sample gas 1
binary input zero gas
analog output pressure transmitter +
analog output pressure transmitter -
binary input span gas
binary output service release
output GND
output 24VDC
binary input flow
functions
of device
PIN-
assign
P
I