BEKOMAT 32iU Translation Of Original Installation And Operation Manual Download | Manualshive

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3. Product information

3.1 Product overview

F

D

A

E

C

B

Item

Description / explanation

Item

Description / explanation

[A]

Control unit, complete

[D]

Condensate discharge

[B]

Control panel

[E]

Right cable gland

[C]

Condensate inlet

[F]

Left cable gland

BEKOMAT

®

32iU

Original installation and operation manual

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Summary of Contents for 32iU

Page 1: ...EN BEKOMAT 32iU 01 4209 Original installation and operation manual BM32iU ...

Page 2: ... 5 4 Transport and storage 11 2 5 5 Installation 11 2 5 6 Maintenance 12 2 5 7 Handling hazardous substances 12 2 5 8 Use of spare parts accessories or materials 13 2 6 Warning notices 13 3 Product information 14 3 1 Product overview 14 3 2 Exploded drawing 15 3 3 Function description 16 3 4 Modbus function 17 3 4 1 Default interface parameters 17 3 4 2 Byte sequence 17 3 4 3 Implemented functions...

Page 3: ...stallation 34 7 1 Warning notices 34 7 2 Connection work 35 7 2 1 Single device connection 36 7 2 2 Connecting multiple Modbus devices series connection 38 8 Commissioning 40 8 1 Warning notices 40 8 2 Commissioning work 41 9 Operation 42 9 1 Warning notices 42 9 2 Operating states 43 10 Maintenance 45 10 1 Warning notices 45 10 2 Maintenance schedule 46 10 3 Maintenance work 46 10 3 1 Changing th...

Page 4: ...missioning work 57 13 Dismantling 58 13 1 Warning notices 58 13 2 Dismantling work 58 14 Disposal 60 14 1 Warning notices 60 14 2 Disposal of operational materials and components 61 15 Troubleshooting 62 16 Appendices 63 16 1 Approval certificates and declarations of conformity 63 16 2 Declaration of Conformity 64 17 Notes 66 BEKOMAT 32iU Original installation and operation manual 4 68 ...

Page 5: ...ngs diagrams and other representations are protected by the copyright of the manufacturer This applies especially to duplication reproduction microfilming and storage as well as processing in electronic systems Publication date Revision Version Reason for amendment Scope of amendment 18 May 2021 01 00 Editorial revision Spelling mistakes corrected and spare part information added 30 June 2021 02 0...

Page 6: ...imum possible water exposure that can occur The splash water must be free of corrosive components Only use the product and accessories in areas which are free of toxic and corrosive chemicals and gases Only use the product and accessories within the piping system designed for the technical data with appropriate connections pipe diameters and assembly clearance Only use the product and accessories ...

Page 7: ...ware of any inappropriate use of the product or accessories which are not listed here the manufacturer must be informed immediately 2 2 Responsibility of the operating company The responsible operating company must ensure the following to prevent accidents incidents and adverse effects on the environment Before all actions check to ensure that the manual available does in fact belong to the produc...

Page 8: ...as technology are people who due to their training professional experience and qualification possess all the necessary capabilities to safely execute actions and instruct all actions related to pressurised fluids and systems to independently foresee potential hazardous situations and implement appropriate measures to avert any danger The capabilities include in particular experience in handling Me...

Page 9: ...timum operation Symbol Description explanation General warning symbol danger warning caution Warning pressurised system Warning electric voltage Note the installation and operating manual General note Wear safety footwear Use protective gloves cut proof and liquid resistant Wear safety goggles with side shields i General information Original installation and operation manual BEKOMAT 32iU 9 68 ...

Page 10: ...cessories may lead to serious personal injuries or death To guarantee safe operation of the product and accessories observe the following points Use suitable protective equipment during all work on the product or accessories Adhere to the limits and operating parameters specified on the type plate and in the manual Adhere to the assembly conditions and ambient conditions Check whether the permissi...

Page 11: ...dle packaging the product and accessories carefully Transport and handle the packaged product and accessories according to the markings on the packaging note lifting gear attachment points the centre of gravity and alignment e g keep vertical do not throw etc Only use proper means of transport and lifting equipment that is in proper working order Always adhere to the permissible transport and stor...

Page 12: ... maintenance and repair work Prevent contamination from entering the opened product or accessories Store the disassembled components and accessories directly in a safe place After completing maintenance and repair work remove all of the tools and cleaning media used as well as all parts that are no longer needed from the work area Only dispose of the product and accessories when cleaned and freed ...

Page 13: ... notices Warning notices warn against dangers when handling the product and accessories In order to prevent accidents personal injury and damage to property as well as impairments during operation it is essential to adhere to the warning notices Structural set up SIGNAL WORD Type and source of danger Symbol Possible consequences if the danger is ignored Measure to prevent the danger Signal words D...

Page 14: ...A E C B Item Description explanation Item Description explanation A Control unit complete D Condensate discharge B Control panel E Right cable gland C Condensate inlet F Left cable gland BEKOMAT 32iU Original installation and operation manual 14 68 ...

Page 15: ...g 20 x 2 mm 3 Moulded seal 13 Intermediate adapter 4 Sensor board 14 Cylinder head screw hexagon socket M6 x 12 5 Bottom cover 15 O ring 15 6 x 1 78 mm 6 Screw fitting 16 Angle adapter G1 2 7 Plug 17 Cylinder head screw hexagon socket M6 x 12 8 Design shell optional 18 Plug G1 2 9 Hose connection 19 Sealing mat 10 Plug Original installation and operation manual BEKOMAT 32iU 15 68 ...

Page 16: ...lve M activates and the area above the membrane N is depressurised The membrane N lifts off of the valve seat and the excess pressure in the collecting tank K presses the condensate into the condensate discharge D M N L D When the sensor in the sensor tube L is no longer covered by condensate the controller of the pilot valve M activates and pressure builds up above the membrane N The membrane N i...

Page 17: ...able via Modbus 10 seconds after start up with the following interface parameters Value Parameter Baud rate 19200 Data bits 8 Stop bits 1 Parity even Client address 247 3 4 2 Byte sequence Data type Modbus register Division float 2 Register ABCD u32 2 Register ABCD u16 1 Register AB u8 1 Register A u8 B 3 4 3 Implemented functions The following Modbus functions are supported 1 Read Input Registers...

Page 18: ... u16 1701 Status ERROR LED LED off 0 LED 100 1 LED 50 2 u16 1760 Main Button State Status TEST button On 1 Off 0 u16 3103 Remaining Time Hi Word Remaining service time float 3104 Remaining Time Lo Word 3105 Remaining Counts Hi Word Remaining switching cycles float 3106 Remaining Counts Lo Word 3200 Error Flags All Error Flags Bit 1 Error1 Flag Bit 2 Error2 Flag Bit 3 Error3 Flag Bit 4 Error4 Flag ...

Page 19: ...APP V2 3 0 BBS V3 4 0 CFG V1 0 0 ASCII 0x03 VendorUrl BEKO website http www beko technologies com ASCII 0x04 ProductName BEKO product name BEKOMAT ASCII 0x05 ModelName BEKO circuit board designation KA2C OL11 2044 ELV P i4 0 ASCII 0x06 UserApplicationName BEKO serial number circuit board 1912720040 ASCII 0x80 n a Production Circuit board test date 03 01 2018 14 53 16 01 01 01 ASCII 0x81 n a Produc...

Page 20: ...wByte Modbus Client address 1 246 Example value 0x070A decimal 1802 For interface parameters see table index 0x07 decimal 7 Client Address 0x0A decimal 10 3 To save the settings write the value 0xBA5E decimal 47710 to Holding Register 0x139C Decimal 5020 4 Switch the product off and switch it back on again 0 The changes will go into effect approx 10 seconds after the restart Parameter HighByte Par...

Page 21: ...If you contact the manufacturer or supplier always have this data ready for system identification 4046022 1 70 C 34 158 F IP67 24 VDC 10 3 W BM32iUP 0 8 16 barg 12 230 psig Made in Germany Manufacturer BEKO TECHNOLOGIES GMBH 4046022 14345535 14345535 6 6 9 7 5 8 1 2 3 5 Type 13 4 Example illustration Item Description explanation 1 Product name 2 Operating temperature 3 IP degree of protection 4 Ho...

Page 22: ...ery of the BEKOMAT Illustration Description explanation BEKOMAT 32iU DE BEKOMAT 32iU 01 1596 Original Installations und Betriebsanleitung BM32iU Original installation and operation manual 1 x connector BEKOMAT 32iU Original installation and operation manual 22 68 ...

Page 23: ...G1 4 exterior hose connection for hose diameter 8 10 mm 0 31 0 39 in interior Media Condensate oil contaminated or oil free Empty weight 1 0 kg 2 22 lbs Operating voltage 24 VDC 10 see type plate Power consumption P 0 6 3 VA W Degree of protection IP67 Housing class UL50E Type 13 Overvoltage category IEC 61010 1 III Degree of pollution IEC 61010 1 3 Recommended cable diameter 5 10 mm 0 23 0 33 in ...

Page 24: ...ion 1 70 C 34 158 F 4 3 Materials BEKOMAT 32iU Housing Aluminium and plastic glass fibre reinforced Membrane FKM 4 4 Dimensions mm inch 117 6 4 63 TEST 73 2 87 164 7 6 48 G1 2 NPT 1 2 179 7 05 88 6 3 49 130 5 12 G1 2 NPT 1 2 G1 4 Ø 8 10 0 32 0 39 BEKOMAT 32iU Original installation and operation manual 24 68 ...

Page 25: ...inlet 4 8 Nm 3 6 ft lb Z3 Screws top cover 0 9 Nm 0 5 Nm 0 66 ft lb 0 37 ft lb 4 6 Installation dimensions Illustration Description explanation ca 100 mm approx 3 93 in Allow sufficient assembly space above the top cover at the place of installation so that the LEDs are visible and the TEST button can be pressed Original installation and operation manual BEKOMAT 32iU 25 68 ...

Page 26: ...4 7 Terminal diagram Illustration ON OFF GND 0V RS485 B RS485 A 24 V GND 0V RS485 B RS485 A 24 V Modbus termination BEKOMAT 32iU Original installation and operation manual 26 68 ...

Page 27: ... outside of areas exposed to direct sunlight and heat sources NOTE Handling packaging material Inappropriate disposal of packaging materials can cause environmental damage Dispose of the packaging material in accordance with the applicable legal requirements and provisions of the country and place of use 5 1 Transport After transporting and removing the packaging material inspect the product for p...

Page 28: ...e working area during assembly installation maintenance and repair work Before pressurisation check all system pipe connections for leak tightness and tighten if necessary Slowly pressurise the system Avoid pressure blows and high differential pressures Assemble all pipes free of mechanical stress Install the feed lines and drain lines as fixed pipes WARNING Insufficient qualification Insufficient...

Page 29: ... ft 5 m 16 25 ft Drain line version Do not use shut off valves in the drain line Only connect the BEKOMAT to the drain line using a hose 0 The hose compensates for assembly tolerances vibrations and thermal expansion Do not install the drain line on storage or transportation surfaces The drain line may be a maximum of 10 m 32 8 ft long and installed at a maximum of 5 m 16 25 ft rise 0 The minimum ...

Page 30: ...slope 3 Diameters of the connected lines The minimum diameter of the feed line and the drain line must be at least 1 2 interior diameter at least 13 mm 0 5 in Do not fit any reductions in the line e g using reducing nipples or fittings Bypassing filters Drain each condensate collection point with a separate BEKOMAT Do not create any filter bypass points BEKOMAT 32iU Original installation and opera...

Page 31: ...ork to be carried out the following prerequisites must be fulfilled and the preparatory tasks must have been completed Prerequisites Tools Material Protective equipment Spanner or adjustable end wrench Sealants e g PTFE Feed line Drain line Hose interior diameter 8 10 mm 0 31 0 39 in Length approx 30 cm 1 ft Always to be worn Preparatory tasks 1 Depressurise the pressurised system or the respectiv...

Page 32: ...e the plugs 18 10 on the condensate inlet C and condensate discharge D 9 D 2 Screw the enclosed hose connection 9 to the condensate discharge D 3 Tighten the hose connection 9 with a torque of 3 4 Nm 2 21 2 95 ft lb BEKOMAT 32iU Original installation and operation manual 32 68 ...

Page 33: ...r the condensate inlet line X1 apply sealant to the end of a pressure resistant pipe and screw this in at the condensate inlet C X3 X4 9 5 For the condensate discharge push the hose provided X3 onto the hose connection 9 and use a hose clamp for fixation 6 Connect the other end of the hose X3 with the condensate drain line X4 Original installation and operation manual BEKOMAT 32iU 33 68 ...

Page 34: ... and repair work Adhere to all applicable regulations e g VDE 0100 IEC 60364 ATEX during installation Connect the protective conductor earth connection according to regulations WARNING Insufficient qualification Insufficient qualification of the personnel carrying out work on the product and accessories can lead to accidents personal injury and damage to property as well as impair operation All wo...

Page 35: ...t angle 90 over high voltage cables Only use shielded connection cables for signal transmission Connect the shielding of the connection cables at least to the ground potential or shielding connection of the Modbus server device 7 2 Connection work For connection work to be carried out the following prerequisites must be fulfilled and the preparatory tasks must have been completed Prerequisites Too...

Page 36: ... 6 E 7 3 Unscrew the counter nut 6 from the right cable gland E 4 Remove the plugs 7 from the counter nut 6 6 mm 50 mm 1 97 in 0 23 in 5 Prepare the connection cable X6 E 6 6 Fit the counter nut 6 over the connection cable X6 7 Insert the connection cable X6 into the right cable gland G BEKOMAT 32iU Original installation and operation manual 36 68 ...

Page 37: ...minal diagram 4 7 Terminal diagram on Page 26 6 E X6 9 Draw the connection cable X6 taut 10 Screw the counter nut 6 onto the right cable gland E 2 1 11 Set the top cover 2 in place and insert the screws 1 12 Tighten the screws 1 with a torque of 0 9 Nm 0 5 Nm 0 66 ft lb 0 37 ft lb Original installation and operation manual BEKOMAT 32iU 37 68 ...

Page 38: ...land F and right cable gland E 4 Remove the plugs 7 from the counter nuts 6 6 mm 50 mm 1 97 in 0 23 in 5 Prepare connection cable X5 and connection cable X6 X5 F 6 X6 E 6 6 Fit the counter nuts 6 over the connection cable X5 and insert connection cable X6 7 Insert the connection cable X5 into the left cable gland F 8 Insert the connection cable X6 into the right cable gland E BEKOMAT 32iU Original...

Page 39: ...erminal diagram 4 7 Terminal diagram on Page 26 6 E X6 6 F X5 10 Draw cable X5 and connection cable X6 taut 11 Screw the counter nuts 6 on the left cable gland F and right cable gland E 2 1 12 Set the top cover 2 in place and insert the screws 1 13 Tighten the screws 1 with a torque of 0 9 Nm 0 5 Nm 0 66 ft lb 0 37 ft lb Original installation and operation manual BEKOMAT 32iU 39 68 ...

Page 40: ...onnections for leak tightness and tighten if necessary Slowly pressurise the system Avoid pressure blows and high differential pressures DANGER Electric voltage There is a danger of death or serious injuries as well as malfunction and device failure following contact with components which are in contact with electric voltage Only operate the product with the cover complete and closed or the housin...

Page 41: ...ly 0 The BEKOMAT carries out the power on self test 2 Slowly pressurise the system e g by slowly opening the recommended shut off valve X2 in the condensate inlet line X1 3 Carry out a functional test see 10 3 2 Functional test on Page 52 Original installation and operation manual BEKOMAT 32iU 41 68 ...

Page 42: ...n amended or restricted by the use of accessories Adhere to the maintenance intervals DANGER Electric voltage There is a danger of death or serious injuries as well as malfunction and device failure following contact with components which are in contact with electric voltage Only operate the product with the cover or housing complete and closed NOTE Operating personnel Insufficient knowledge of th...

Page 43: ...oid valve is not cycling 0 The BEKOMAT switches to normal operation Power Alarm Service TEST Power Alarm Service TEST Power Alarm Service TEST Power Alarm Service TEST n 20 n Negative power on self test number of repetitions n 20x The red ALARM LED is on The green POWER LED is on 100 brightness while the solenoid valve is cycling quickly The green POWER LED is on 50 brightness while the solenoid v...

Page 44: ...inutes The red ALARM LED is on The green POWER LED is on 50 brightness Power Alarm Service TEST n Power Alarm Service TEST Alarm mode malfunctioning of condensate discharge The red ALARM LED flashes The green POWER LED is on 50 brightness 0 The solenoid valve is cycling every 4 minutes After the malfunction has been eliminated the BEKOMAT automatically switches to normal operation Power Alarm Serv...

Page 45: ... back on again unintentionally Set up a safety area around the working area during all maintenance and repair work Only operate the product with the cover complete and closed or the housing closed DANGER Use of incorrect spare parts accessories or materials The use of incorrect spare parts accessories or materials as well as auxiliary and operating materials may result in death or serious injury M...

Page 46: ...ied out the following prerequisites must be fulfilled and the preparatory tasks must have been completed Prerequisites Tools Material Protective equipment Screwdriver flat head size 2 5 mm 0 09 Spanner or adjustable end wrench Sealants Lubricant for greasing the O rings Mild detergent Cotton or disposable cloth Always to be worn 10 3 1 Changing the Service Unit Exchange work Illustration Descripti...

Page 47: ...ss the TEST button briefly multiple times 0 The BEKOMAT is depressurised 0 The condensate remaining in the BEKOMAT is drained X7 A 3 Release the control unit A by pressing the locking hook X7 A 4 Remove the control unit A Original installation and operation manual BEKOMAT 32iU 47 68 ...

Page 48: ...Remaining service time counter Modbus address 3103 3104 is reset 0 The Remaining switching cycles counter Modbus address 3105 3106 is reset 7 Lay the control unit A carefully to one side 8 8 If a design shell 8 is attached carefully lift the design shell 8 to the marked positions using a flat head screwdriver 9 Carefully remove the design shell 8 X3 9 10 Remove the hose connection 9 with the hose ...

Page 49: ... 14 Grease and insert the new O ring 12 15 Dispose of the old Service Unit and the old O ring properly For more information see 14 Disposal on Page 60 11 22 13 16 Check to ensure the new Service Unit 11 fits the control unit A 0 Model designation 0 The colour of the locking hook X7 is identical to the colour of the control unit 17 Push the new Service Unit 11 with the rails 22 onto the connection ...

Page 50: ... 19 Tighten the hexagon socket screws 14 with a torque of 4 8 Nm 3 6 ft lb X3 9 20 Fit the hose connection 9 with the hose X3 8 11 21 Attach the demounted design shell 8 to the new Service Unit 11 BEKOMAT 32iU Original installation and operation manual 50 68 ...

Page 51: ...ol unit A into the sensor tube opening A 11 24 Insert the hooks on the control unit A 25 Press the control unit A against the Service Unit 11 and lock into place X2 X1 26 Carry out a leakage test on all screw fittings 27 Carefully open the condensate feed via the condensate inlet lines X1 e g by opening the recommended shut off valve X2 Original installation and operation manual BEKOMAT 32iU 51 68...

Page 52: ...damaged components immediately 10 3 4 Leakage test The leakage test is a non destructive test method and is used to prove leak tightness in vacuum and overpressure systems The leakage test can be carried out in different ways BEKO TECHNOLOGIES provides no recommendations for selecting a testing process The operator of the pressurised system is responsible for the selection and specification of the...

Page 53: ...ice with hard or pointed implements Use an anti static damp cloth for cleaning the outside Immediately replace any product markings pictograms markings that have become illegible NOTE Local hygiene regulations In addition to the cleaning instructions listed any regionally applicable hygiene regulations must be observed Preparatory tasks 1 Proper shutdown of the BEKOMAT is completed Cleaning work 1...

Page 54: ... delivered The contact data for the BEKO TECHNOLOGIES customer services responsible are listed in chapter 1 1 Contact on Page 5 11 2 Accessories Illustration Description explanation Material no Mounting bracket for wall and floor 4010105 Trace heater 230 VAC 4041657 Drain kit 2000045 Integrator Hardware Kit 4052710 Software Integrator The software can be downloaded from the BEKO TECHNOLOGIES homep...

Page 55: ...11 3 Spare parts Illustration Description explanation Material no Service Unit 4023571 Design shell 4010167 Connection adapter 4010155 Original installation and operation manual BEKOMAT 32iU 55 68 ...

Page 56: ...ice failure following contact with components which are in contact with electric voltage Only carry out maintenance and repair work on the product when it has been disconnected and secured against being switched back on again unintentionally Set up a safety area around the working area during all maintenance and repair work WARNING Insufficient qualification Insufficient qualification of the perso...

Page 57: ... e g by closing the recommended shut off valve X2 Power Alarm Service TEST 2 Press the TEST button briefly multiple times 0 The BEKOMAT is depressurised 0 The condensate remaining in the BEKOMAT is drained 3 Disconnect the BEKOMAT from the voltage supply and switch off all power Original installation and operation manual BEKOMAT 32iU 57 68 ...

Page 58: ...entionally Set up a safety area around the working area during all maintenance and repair work WARNING Insufficient qualification Insufficient qualification of the personnel carrying out work on the product and accessories can lead to accidents personal injury and damage to property as well as impair operation All work on the product and the accessories may only be carried out by skilled technical...

Page 59: ...9 1 Remove the hose X3 from the hose connection 9 and disassemble 2 Remove the condensate inlet line X1 and the recommended shut off valve X2 from the condensate inlet C and disassemble 3 Disassemble all power supplies Original installation and operation manual BEKOMAT 32iU 59 68 ...

Page 60: ...y Electrical and electronic equipment are marked by the crossed out rubbish bin The crossed out rubbish bin symbolises that electrical and electronic equipment must be collected separately and must not be disposed of together with unsorted domestic waste For this purpose all communities have set up collecting systems where waste from electronic equipment or electrical and equipment can be handed i...

Page 61: ...tion materials filter materials cleaning wipes and protective clothing contaminated by oils or other hazardous substances 15 02 02 Adsorption materials filter materials cleaning wipes and protective clothing with the exception of those classified by 15 02 02 15 02 03 Packaging paper and cardboard 15 01 01 Packaging plastic material 15 01 02 Electric and electronic devices with the exception of tho...

Page 62: ... voltage supply and reconnect after 5 seconds Inspect the circuit board for potential damage Power Alarm Service TEST No condensate is drained after pressing the TEST button Check the feed line and the drain line Replace the Service Unit Check the valve function by pressing the TEST button 0 Valve switching can be heard clearly clicking sound Check the connection terminals on the control board Pow...

Page 63: ... of TÜV Rhineland for the Canadian and US American market and that basic safety and health requirements were met during manufacturing of the product The product may be sold on the Canadian and US American market EAC marking The EAC marking indicates that a product fulfils all the Eurasian directives applicable for this product and that basic safety and health requirements were met during manufactu...

Page 64: ...16 2 Declaration of Conformity BEKOMAT 32iU Original installation and operation manual 64 68 ...

Page 65: ...ssure 16 bar g Product description and function Condensate drain for electronically level controlled discharge of condensate in the compressed air system Low Voltage Directive 2014 35 EU Applied harmonised standards EN 61010 1 2010 The devices with a working voltage of 24 48 VAC and 18 72 VDC are not governed by the scope of the Low Voltage Directive EMC Directive 2014 30 EU Applied harmonised sta...

Page 66: ...17 Notes BEKOMAT 32iU Original installation and operation manual 66 68 ...

Page 67: ...Original installation and operation manual BEKOMAT 32iU 67 68 ...

Page 68: ...4 610 780 639 info es beko technologies es BEKO TECHNOLOGIES LIMITED Room 2608B Skyline Tower No 39 Wang Kwong Road Kwoloon Bay Kwoloon Hong Kong Tel 852 2321 0192 Raymond Low beko technologies com BEKO TECHNOLOGIES INDIA Pvt Ltd Plot No 43 1 CIEEP Gandhi Nagar Balanagar Hyderabad IN 500 037 Tel 91 40 23080275 91 40 23081107 Madhusudan Masur bekoindia com service bekoindia com BEKO TECHNOLOGIES S ...

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