CGS SAM-1000 DPS User manual

SAM-1000
Operating instructions
Language: English
Revision: Version 1.0
Issue: June 2021
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_E_B_SAM-1000.pdf
MDZ_E_B_SAM-1000_1.0

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Table of contents
Table of contents .....................................................................3
1 General information .................................................................5
1.1 Device version and validity ......................................................5
1.2 Information for our customers ...................................................5
1.3 General .....................................................................5
1.4 Warnings and explanatory texts..................................................5
1.5 Intended use .................................................................6
1.6 Qualified personnel............................................................6
1.7 Warranty information ..........................................................6
1.8 Delivery information ...........................................................7
1.9 Norms and regulations .........................................................7
1.10 Disclaimer ..................................................................8
1.11 Disposal ....................................................................8
2 Warnings and safety instructions.......................................................9
3 Packaging and transport ............................................................10
3.1 Packaging material ...........................................................10
3.2 Shipping labels ..............................................................10
3.3 Transport inspection ..........................................................11
3.4 Storage ....................................................................11
4 Installation, assembly information ....................................................12
5 Setup and function.................................................................13
5.1 Functional description.........................................................13
5.2 Mechanical design ...........................................................15
5.3 Front drawing ...............................................................15
5.4 Connection drawing ..........................................................16
5.4.1 SAM-1000 4 HU ........................................................16
5.4.2 SAM-1000 6 HU ........................................................17
5.5 Gas flow schematic ...........................................................18
5.5.1 SAM-1000 4 HU ........................................................18
5.5.2 SAM-1000 6 HU ........................................................19
5.6 Electrical connection..........................................................20
7 Maintenance &repair ..............................................................22
7.1 Replacing the solenoid valves / replacing the filter..................................22
8 Cleaning .........................................................................23
8.1 Cleaning the surface ..........................................................23
8.2 Cleaning the interior ..........................................................23
8.3 Cleaning the control panel .....................................................23
9 Technical data.....................................................................24
10 Device configuration (order code) ....................................................25
11 Delivery contents .................................................................27
12 Spare part list ....................................................................28
13 Appendix A (EU Declaration of Conformity) .............................................29
14 Appendix B (Inspection protocols) ....................................................30

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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.
1.11 Disposal
This product comes from an environmentally conscious manufacturer and complies with the
2012/19/EU directive on waste electrical and electronic equipment (WEEE).
This product may contain substances which, if improperly disposed of (landfills, incinerators), are
potentially environmentally harmful. It must therefore not be disposed of in this way.
Therefore, behave environmentally conscious:
• Arrange for this product to be recycled at the end of its life cycle via the relevant on-site facilities!
• Observe the relevant regulations for your country!

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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
• Made for indoor use only. For installation in cabinets or housings
• Protect from moisture
Technical prerequisites (supply voltage, gas pressures, etc.) can be found in the Technical Data section.
Warning
Electrical safety
Certain parts of this device are under dangerous voltage. Before switching on the device,
the housing must be closed and grounded.
Failure to do so may result in death, personal injury and/or damage to property.
The analyzer must not be operated in potentially explosive atmospheres.
The supply of gases with flammable components in concentrations above the lower explosion limit (LEL)
must be clarified with the responsible ex-expert and is ultimately the responsibility of the operator.
Warning
Electric connection
For the electrical installation, observe VDE 0100 or an equivalent international standard for
setting up high-voltage systems having nominal voltages under 1000 V.
Failure to comply with these regulations can result in death, personal injury and/or damage
to property.
Mains connection
The device comes with an appliance plug which may only be connected to the mains supply line by
qualified personnel. The mains supply line must comply with the valid regulations and conditions for
the place of installation and be provided with a protective conductor which lies at the potential of the
enclosure. The cross-section of each wire must be ≥ 1 mm². Connect the phase conductor to the marked
position in the plug.
Install the mains line separately from the signal lines.
Provide a mains disconnection device in the direct vicinity of the device (for load rating, see rating plate).
It must be readily accessible and marked.
Check whether the existing mains voltage agrees with the mains voltage specified on the rating plate.

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5 Setup and function
5.1 Functional description
The cabinet override module series SAM-1000 is used to connect different measuring points to analysers.
Because of its modular design, the cabinet override module can be used for various applications in the
chemical and petrochemical industries for gaseous high-purity gases.
The SAM-1000 is particularly characterised by the following features:
• Compact design
• Low dead volume
• Modular design
• High tightness
• Diverse range of applications
The SAM-1000 can be connected to multiple analysers with up to 8 sample gases (S1-S8). The inlets and
outlets of the sample gas are equipped with clamping ring fittings at the rear by default.
One sample gas valve and one bypass valve are actuated for every measuring point. The sample gas
valve channels the gas to be measured to the line of the respective analysis equipment. In automatic
mode (DCS operation), ensure that there is at least one open measurement gas valve, so that the analysis
equipment is supplied with gas. The bypass valve acts as a quick purge of the measurement gas line
and should be opened to be flushed before each measurement task. The flow is adjusted by means of a
mechanical needle valve and displayed by mechanical flow meters (BP quick purge). The duration and
amount of measurement gas purge is pre-calculated based on line length, cross section and product type.
Different versions are available for the SAM-1000. In principle, they differ with regard to the number of
sample gas inlets.
Information about the different versions can be found in the following table:
Version Number of sample
gas inlets
1 2 Sample gas module as 4 HU version
2 4 Sample gas module as 4 HU version
3 6 Sample gas module as 6 HU version
4 8 Sample gas module as 6 HU version
510 Sample gas module as 9 HU version
612 Sample gas module as 9 HU version
714 Sample gas module as 9 HU version
816 Sample gas module as 9 HU version
Depending on the configurations of the SAM-1000, the measuring points can be equipped with a
mechanical flow meter for continuous flushing of the measurement gas line. The flow rate is controlled
by means of a needle valve and displayed in the inspection glass.
The sample gas pressure can be adjusted by means of a mechanical back pressure regulator. An Allen key
(size 4) is required for this. The adjusting screw is accessible via a hole in the front plate.
The actual value is monitored via a pressure switch, and displayed by a red LED on the board. The flow at

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the back-pressure regulator's outlet can be read via a mechanical flow meter (BP-BPR).
The gas override module SAM-1000 is equipped with a relay board. The valves can either be controlled
in “Local” mode via the LED pressure switches, or in “DCS” mode via 24 V inputs.
Using filter frits protects downstream gas-carrying components and analysers.
Using a compact solenoid valve block minimises dead volume, and achieves fast response times of the
analytical system. This system is best implemented in gas trace analysis.
The cabinet override module is equipped with 11 controls and feedback.
- 8 for valve control and feedback
- 1 for service release and feedback
- 2 for alarm display and feedback
The connections of the signals to be wired are located at the rear of the module and are connected by
means of a 37-pin sub-D socket.
The 24 VDC power supply is connected via a 2-pin Phoenix connector.
Options:
Installation of solenoid valves for measuring contaminations in O2:
The solenoid valves which will switch the measurement gas onto the analysers are replaced with
O2-purified valves here. The design and function of the valves remains unchanged.
Installation of solenoid valves for measuring H2O ppm:
The solenoid valves which will switch the measurement gas onto the analysers are replaced with H2O-
suitable valves here. The design and function of the valves remains unchanged, but the components are
adjusted accordingly in the gas-bearing part.
The above mentioned criteria are selected in terms of the measuring task and application of the analysers.

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5.2 Mechanical design
The SAM-1000_DP2 is designed as a 19“ slide-in module for installation in a 19“ rack or a 19“ cabinet.
The height is 4 HU, 6 HU or 9 HU.
• Housing with screwed on front panel
• Control unit
• Valve block
• Outlet block
• Depending on the configuration of the bulkhead connector fittings, the flow meters
and the pressure regulator
5.3 Front drawing
Picture 5-1: SAM-1000 4HE
Picture 5-2: SAM-1000 6HE

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5.4 Connection drawing
The following figure shows the rear side of the SAM-1000 (4 HU):
Designation Function
S1-S4 Sample gas inlet 1-4
P1 Sample gas outlet valve block to pump or sample gas inlet SAM (P2)
P2 Sample gas outlet from pump or valve block outlet
A1 Sample gas outlet to analyzers
ATM Outlet to exhaust gas line, 12 mm tube connection
X1 Power supply 24 VDC
X2 37-pole Sub-D plug signal transmission
5.4.1 SAM-1000 4 HU

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The following figure shows the rear side of the SAM-1000 (4 HU):
Designation Function
S1-S8 Sample gas inlet 1-4
SG-OUT1 Sample gas outlet valve block to pump or sample gas inlet SAM (P2)
P2 Sample gas outlet from pump or valve block outlet
A1 Sample gas outlet to analyzers
ATM Outlet to exhaust gas line, 12 mm tube connection
C1-C3 Gas connections for installation of flow meter displays of external analyzers
or valve blocks
X1 Power supply 24 VDC
X2 37-pole Sub-D plug signal transmission
5.4.2 SAM-1000 6 HU

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5.5 Gas flow schematic
5.5.1 SAM-1000 4 HU

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5.5.2 SAM-1000 6 HU

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5.6 Electrical connection
SUB-D (37-pole connector):
Contact load
max. 1A / 24VDC
for shown
relay point status
relay is deenergized