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CGS SAM-1000 DPS Operating Instructions Manual

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Operating instructions
SAM-1000_DPS
Language:
Revision:
Issue:
NOTE
Read these operating instructions carefully before assembly,
installation and implementation.
MDZ_E_B_SAM-1000_DPS_2.0
English
Version 2.0 (Software V3.0.1)
June 2022
These operating instructions are also available as a digital document on:
www.cgs-company.de/downloads/MDZ_E_B_SAM-1000_DPS.pdf

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  • Page 1 Operating instructions SAM-1000_DPS Language: English Revision: Version 2.0 (Software V3.0.1) Issue: June 2022 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_DPS.pdf MDZ_E_B_SAM-1000_DPS_2.0...

  • Page 3: Table Of Contents

    Table of contents Table of contents ................3 1 General information .
  • Page 4 10.2 Cleaning the interior ..............37 10.3 Cleaning the control panel .

  • Page 5: General Information

    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.

  • Page 6: Intended Use

    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.

  • Page 7: Delivery Information

    • 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 •...

  • Page 8: Disclaimer

    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.

  • Page 9: Warnings And Safety Instructions

    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 safety 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.

  • Page 10: Packaging And Transport

    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).

  • Page 11: Transport Inspection

    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.

  • Page 12: Installation, Assembly Information

    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.

  • Page 13: Setup And Function

    5 Setup and function 5.1 Functional description The cabinet sample module series SAM-1000_DPS 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-1000_DPS especially distinguishes itself through the following features: •...
  • Page 14 This 3 alternatives are already programmed in the SAM-1000_DPS Software and would be pre-defined be- fore delivery. Depending on the type, the sample streams are equipped with one needle valve and one elec- tronic flow meter for continuously purge of the sample gas tube. The amount can be adjusted by a needle valve and displayed by an electronic flow meter on the touch screen. The regulating screw of the gas flow is accessible via a hole in the front plate and can be adjusted by an Allen key (size 3). The sample gas pressure is adjusted mechanically by the back pressure regulator. The adjusting screw is accessible via the hole in the front plate.

  • Page 15: Mechanical Design

    5.2 Mechanical design The SAM-1000_DPS is designed as an 19“-slide in module to be mounted in a 19“ -cabinet or frame. The heigth is 4 HU. • Double housing with screwed front cover • Control unit • Valve block • Relief block • Bulkhead fitting, flow metere and pressure regulator 5.3 Dimensional drawing The following drawing shows the necessary space required: (Depth without flowmeter and rear screw connections) Product: Revision 2.0 – Issue June 2022 15/55 SAM-1000_DPS...

  • Page 16: Connection Drawing

    5.4 Connection drawing Picture 5-1 Front side and monitor of the SAM-1000_DPS Designation Function NV1 - NV6 Setting of the bypass flow rate for each measuring point Setting of the purge gas flow Setting of the measurement gas pressure An Allen key (size 4) is required for setting. Turning to the right increases the pressure / flow. Turning to the left decreases the pressure / flow. Picture 5-2 Back side and connections of the SAM-1000_DPS Designation Function S1 - S6...

  • Page 17: Gas Flow Schematic

    Picture 5-3 Gas flow schematic 1, without bypass Developed by Developed by Gasschema 1 Gasschema 1 12.01.16 12.01.16 project name project name date date CGS Analysen, Mess- und CGS Analysen, Mess- und ohne Bypässe ohne Bypässe Regeltechnik GmbH Regeltechnik GmbH Wendlik Wendlik Entwicklung SAM1000_XXX Entwicklung SAM1000_XXX name name Keltenstraße 3...

  • Page 18: Gas Flow Schematic Type 2, With Bypass 3/2-Way

    0-60l/h FI10 NV10 0-300l/h FI11 0-300l/h outlet Picture 5-4 Gas flow schematic 2, with bypass 3/2-way Developed by Gasschema 2 12.01.16 project name date CGS Analysen, Mess- und Bypass für alle Messstellen Wendlik Regeltechnik GmbH Entwicklung SAM1000_XXX name Keltenstraße 3 job number D-85095 Denkendorf chkd. date name appr.

  • Page 19: Gas Flow Schematic Type 3, With Bypass

    0-60l/h FI10 NV10 0-300l/h FI11 0-300l/h outlet Picture 5-5 Gas flow schematic 2, with bypass Developed by Gasschema 3 12.01.16 project name date CGS Analysen, Mess- und Bypass je Messstelle Wendlik Regeltechnik GmbH Entwicklung SAM1000_XXX name Keltenstraße 3 job number D-85095 Denkendorf chkd. date name appr. File :...

  • Page 20: Electrical Connection

    46 digital output 35 digital output 47 digital output 36 digital output 48 Developed by 08.12.20 X1-X3 project name date CGS Analysen, Mess- und j.spitz Regeltechnik GmbH name Keltenstraße 3 job number drawing n chkd. D-85095 Denkendorf SAM-1000_DP rev.
  • Page 21 X11 - Power consumption (Amphenol plug): 24V + 24V - PROFIBUS (9-pole plug): profibus 9-pole connector send/receive data send/receive data Erstellt durch 15.11.17 SAM1000-DPS Datum CGS Analysen, Mess- und Einspeisung j.spitz Regeltechnik GmbH Name Keltenstraße 3 D-85095 Denkendorf gepr. SAM-1000_DP Änd. Revision Datum Name geneh.

  • Page 22: Operation Touch-Panel

    6 Operation Touch-Panel 6.1 Main menu The Operation of the SAM-1000_DPS will be done by a Touch-Web-Panel assembled in the front plate of the device. The screen shows the current status of it. Furthermore adjustments can be adapted to each installa- tion through the parameter sheets.

  • Page 23: Device Overview

    6.2 Device overview Picture 6-2 Device overview Overview of displayed devices Label activated devices Measurement value Status description analyzer Status display analyzer a) Green b) Orange c) Red d) Grey Back to main menu Product: Revision 2.0 – Issue June 2022 23/55 SAM-1000_DPS...

  • Page 24: Gas Flow Scheme

    6.3 Gas flow scheme Picture 6-3 Gasflow scheme 1 Flow display bypass back pressure regulator 0 - 300 l/h Back pressure regulator (Schematic display) Pressure value Flow display bypass quick purge 0 - 300 l/h Flow display bypass sample streams 0 - 60 l/h Activation 3/2-way bypass valves, number 1-6 Needle valve bypass (schematic display) Activation bypass valve, Number 1-6...

  • Page 25: Menu

    6.4 Menu Enter user name and password >> Touch title block Cancel and back to main menu Keyboard opens automatically >> User name: user >> Password: 0100 (Operator level) >> User name: it >> Password: 0100 (IT admin level) Picture 6-6 Login To change settings you have to be logged in to „IT admin level“...

  • Page 26: Language

    6.5 Language Language German Language English Log out user Back to main manu Picture 6-8 Language 6.6 Parameter Allow local changeover Auto/Manual in main menu of SAM-1000_DPS Enter Profibus address 1...126 Selection of transmission range in accordance to Siemens S7 protocol Firmware-Version Accept changes and restart device (only for storage of Profibus address necessary) Change password...

  • Page 27: Snmp

    6.8 SNMP Activate SNMP Enter SNMP datas Accept changes and restart device Picture 6-11 SNMP Product: Revision 2.0 – Issue June 2022 27/55 SAM-1000_DPS...

  • Page 28: Profibus Configuration

    7 Profibus/Profinet configuration 7.1 Profibus configuration The control of the SAM-1000_DPS consists of a WAGO control - PFC200. The Profibus interface of the CPU is set up as a slave Before the gas connection module SAM-1000_DPS is connected to the Profibus, the bus address must be set on the touch panel on the parameter page. Otherwise, double addressing can occur on the Profibus. The GSD file „A206_V10.GSD“ must be used for configuration in the DP master. The following modules are to be set up with the GSD file. The order and size of the modules must be observed for correct function 7.2 Profibus Module oversight PROFIBUS SAM-1000_DPS Module Number Data type Direction BYTE Output BYTE Input BYTE Output BYTE Output BYTE Input BYTE Input BYTE Input WORD Input...
  • Page 29 Module Offset Data type Assignment Visualisation 3 3.1: BYTE A1.0 BOOL Activation sample gas valve AP1 A1.1 BOOL Activation bypass valve AP1 A1.2 BOOL Activation sample gas valve AP2 A1.3 BOOL Activation bypass valve AP2 A1.4 BOOL Activation sample gas valve AP3 A1.5 BOOL Activation bypass valve AP3...
  • Page 30 Module Offset Data type Assignment Visualisation 3.6: BYTE A6.0 BOOL Signal to DO41 DO41 A6.1 BOOL Signal to DO42 DO42 A6.2 BOOL Signal to DO43 DO43 A6.3 BOOL Signal to DO44 DO44 A6.4 BOOL Signal to DO45 DO45 A6.5 BOOL Signal to DO46 DO46 A6.6...
  • Page 31 Module Offset Data type Assignment Visualisation 4.4: BYTE A11.0 BOOL Signal to virtual output DO81 DO81 A11.1 BOOL Signal to virtual output DO82 DO82 A11.2 BOOL Signal to virtual output DO83 DO83 A11.3 BOOL Signal to virtual output DO84 DO84 A11.4 BOOL Signal to virtual output DO85...
  • Page 32 Module Offset Data type Assignment Visualisation 5.5: BYTE E5.0 BOOL Feedback from DO33 E5.1 BOOL Feedback from DO34 E5.2 BOOL Feedback from DO35 E5.3 BOOL Feedback from DO36 E5.4 BOOL Feedback from DO37 E5.5 BOOL Feedback from DO38 E5.6 BOOL Feedback from DO39 E5.7 BOOL...
  • Page 33 Module Offset Data type Assignment Visualisation 6.3: BYTE E10.0 BOOL Signal from DI17 DI17 E10.1 BOOL Signal from DI18 DI18 E10.2 BOOL Signal from DI19 DI19 E10.3 BOOL Signal from DI20 DI20 E10.4 BOOL Signal from DI21 DI21 E10.5 BOOL Signal from DI22 DI22 E10.6...

  • Page 34: Activation Of The Profibus Master

    Module Offset Data type Assignment Visualisation 7.4: BYTE E15.0 BOOL Signal from virtual Input DI57 E15.1 BOOL Signal from virtual Input DI58 E15.2 BOOL Signal from virtual Input DI59 E15.3 BOOL Signal from virtual Input DI60 E15.4 BOOL Signal from virtual Input DI61 E15.5 BOOL Signal from virtual Input DI62...
  • Page 35 7.5 Profinet configuration The control of the SAM-1000_DPS consists of a WAGO control - PFC200. The Profibus interface of the CPU is set up as a slave Before the gas connection module SAM-1000_DPS is connected to the Profinet network, the IP address must be set by means of profinet adressing to the SAM-1000_DPS through the master system . Otherwise, double addressing can occur on the Profibus. The current GSDML file „GSDML-V2.32-wago--8215_Sam_1000_DPS_Generic_PROFINET_Controller- xxxxxxxx-xxxxxx.xml“ must be used for configuration in the Profinet-master. The following modules are to be set up with the GSDML file. The order and size of the modules must be observed for correct function. 7.6 Profinet - Module oversight PROFINET SAM-1000_DPS Module Number Data type Direction BYTE...
  • Page 36 Module Offset Data type Assignment Visualisation 2.1: BYTE A1.0 BOOL Activation sample gas valve AP1 A1.1 BOOL Activation bypass valve AP1 A1.2 BOOL Activation sample gas valve AP2 A1.3 BOOL Activation bypass valve AP2 A1.4 BOOL Activation sample gas valve AP3 A1.5 BOOL Activation bypass valve AP3...
  • Page 37 Module Offset Data type Assignment Visualisation 2.6: BYTE A6.0 BOOL Signal to DO41 DO41 A6.1 BOOL Signal to DO42 DO42 A6.2 BOOL Signal to DO43 DO43 A6.3 BOOL Signal to DO44 DO44 A6.4 BOOL Signal to DO45 DO45 A6.5 BOOL Signal to DO46 DO46 A6.6...
  • Page 38 Module Offset Data type Assignment Visualisation 3.4: BYTE A11.0 BOOL Signal to virtual output DO81 DO81 A11.1 BOOL Signal to virtual output DO82 DO82 A11.2 BOOL Signal to virtual output DO83 DO83 A11.3 BOOL Signal to virtual output DO84 DO84 A11.4 BOOL Signal to virtual output DO85...
  • Page 39 Module Offset Data type Assignment Visualisation 4.5: BYTE E5.0 BOOL Feedback from DO33 E5.1 BOOL Feedback from DO34 E5.2 BOOL Feedback from DO35 E5.3 BOOL Feedback from DO36 E5.4 BOOL Feedback from DO37 E5.5 BOOL Feedback from DO38 E5.6 BOOL Feedback from DO39 E5.7 BOOL...
  • Page 40 Module Offset Data type Assignment Visualisation 5.3: BYTE E10.0 BOOL Signal from DI17 DI17 E10.1 BOOL Signal from DI18 DI18 E10.2 BOOL Signal from DI19 DI19 E10.3 BOOL Signal from DI20 DI20 E10.4 BOOL Signal from DI21 DI21 E10.5 BOOL Signal from DI22 DI22 E10.6...
  • Page 41 Module Offset Data type Assignment Visualisation 6.4: BYTE E15.0 BOOL Signal from virtual Input DI57 E15.1 BOOL Signal from virtual Input DI58 E15.2 BOOL Signal from virtual Input DI59 E15.3 BOOL Signal from virtual Input DI60 E15.4 BOOL Signal from virtual Input DI61 E15.5 BOOL Signal from virtual Input DI62...

  • Page 42: Application Example

    8 Application example Product: 42/55 SAM-1000_DPS Revision 2.0 – Issue June 2022...

  • Page 43: Maintenance & Repair

    9 Maintenance & repair Maintenance or repair must only be performed by CGS service technicians. This can also be done by CGS-in- structed / trained technicians. The warranty and liability expires in case of unauthorised maintenance or repair work. The applicable safety and accident prevention regulations must be observed in any case.

  • Page 44: Cleaning

    10 Cleaning 10.1 Cleaning the surface CAUTION Make absolutely sure that no water enters the device while cleaning. Before cleaning the device, disconnect it from the power mains! The front panels are washable. We recommend using a sponge or cloth soaked in a mild detergent. 10.2 Cleaning the interior After opening the device, you can, if necessary, carefully blow out the interior with a compressed air gun.

  • Page 45: Connection Options

    11 Connection options 1. Analyser with Profi bus interface Measuring gas Analyser Valve SAM-1000_DPS Zero gas Profi bus block Profi bus/Profinet Test gas 2. Analyser without Profi bus interface 4-20 mA Measuring/Calibrating SAM-1000_DPS Analyser Maintenance messages Profi bus/Profinet Fault messages Calibration Feedback Measuring gas...

  • Page 46: Technical Data

    12 Technical data • Amount of sample inlets: 6 (standard) • In- and outlet fittings: 3 mm, 6 mm, 1/8“, 1/4“ • Sample conditioning: Back pressure regulator 0,1-4 bar • Pressure display: Pressure transmitter (4-20 mA) • Flow meter: Electronic • Control system: Touch-Web-Panel • Communication: Profibus DP / Profinet • Remote control: Ethernet •...

  • Page 47: Order Numbers

    13 Order numbers TYPE 1: Sample handling module SAM-1000_DPS; 6-fold; without continuous bypass 1032512 TYPE 2: Sample handling module SAM-1000_DPS; 6-fold; with continuous bypass; 3/2-way valve 1034147 TYPE 3: Sample handling module SAM-1000_DPS; 6-fold; with continuous bypass 1034149 Product: Revision 2.0 – Issue June 2022 47/55 SAM-1000_DPS...

  • Page 48: Delivery Contents

    14 Delivery contents Immediately after receipt, check whether the shipment has arrived complete and without damage. • SAM-1000_DPS [1x] • Documentation [1x] • Multipoint connector 16-pole with tension relief [10x] • Multipoint connector 8-pole with tension relief [2x] • Panel jack (6-pole + PE) [1x] •...

  • Page 49: Spare Part List

    15 Spare part list Article Order number 1 Pcs. e!DISPLAY 7300T; Web-Panel; WP 5.7 640x480 PIO1 1033575 1 Pcs. SPS-controller; Profibus; BAN-bus; RS232/485; 2x Ethernet 1027850 1 Pcs. SD memory card; SD-Card; 1 GByte 1028251 3 Pcs. Digital output module; 16-channel; 24 VDC; 0.5 A 1020410 1 Pcs.

  • Page 50: Appendix A (Eu Declaration Of Conformity)

    16 Appendix A (EU Declaration of Conformity) EU-Konformitätserklärung EU Declaration of Conformity Hersteller/Manufacturer: CGS Analysen-, Mess und Regeltechnik GmbH Keltenstraße 3 85095 Denkendorf Hiermit erklären wir, dass unser Produkt, Typ: Hereby, we declare that the product, type: SAM-1000*** / SAM-3000 / SAM-3500 / SAM-1950*** folgenden einschlägigen Bestimmungen entspricht:...

  • Page 51: Appendix B (Inspection Protocols)

    17 Appendix B (Inspection protocols) Qualitätszeugnis Hiermit bestätigen wir, dass unsere Produkte nach aktuellem Stand der Technik produziert und geprüft wurden. Die verwendeten Materialien sind nach den Einsatzspezifikationen ausgesucht und nach handwerklichen Richtlinien verarbeitet. Hierbei kommen maßgebliche nationale und internationale Normen und Standards zur Anwendung. Das fertige Produkt wurde nach technischen Gesichtspunkten in einem Qualitäts- sicherungssystem geprüft und kontrolliert.
  • Page 52 Prüfbescheinigung für Gaskomponenten in Sauerstoff Inspection document for gas components in oxygen Hersteller: CGS Analysen-, Mess- und Verfahren: method: manufacturer: Regeltechnik GmbH Keltenstraße 3 Reinigungsmethode: Ultraschallbad cleaning method: ultrasonic bath D-85095 Denkendorf Aceton acetone Produktreihe: SAM-1000_DPS Spülen der Gaswege: Stickstoff...
  • Page 53 Sauerstoff verwendet werden und mit ihm in Berührung kommen, ist eine extrem saubere Oberfläche erforderlich. CGS Analysen-, Mess- und Regeltechnik GmbH bestätigt, dass die gasführenden Bauteile unserer Analysenanlagen für Sauerstoffanwendungen gemäß den aktuellen Vorschriften gebaut werden. Somit sind die Werkstoffe für Druckregler, Rohr, Manometer… speziell gereinigt und mit Inertgas gespült.

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