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Summary of Contents for Igema A230
- Page 1 Shutoff valve Single and double shutoff Version: 01/2024 D-09-B-62826-EN-00 Installation and operating instructions (English translation)
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Page 2: Table Of Contents
A110-CS and A115-CS _________________________________________ 9 A120-CS, A140-CS, A145-CS, A150-CS and A155-CS _______________ 10 A190 ______________________________________________________ 11 A210-CS and A220-CS ________________________________________ 12 A230 and A240 ______________________________________________ 13 Technical data Limitations of use _____________________________________________ 14 Dimensions _________________________________________________ 15 Available dimensions __________________________________________ 17... - Page 3 A110-CS and A115-CS ________________________________________ 31 11.2 A120-CS, A140-CS and A145-CS ________________________________ 32 11.3 A150-CS and A155-CS ________________________________________ 33 11.4 A210-CS and A220-CS ________________________________________ 34 11.5 A230 and A240 ______________________________________________ 35 Decommissioning and disposal 12.1 Dismantle valve ______________________________________________ 36 12.2 Disposal ____________________________________________________ 37...
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Page 5: About This Document
If the gauge is passed on to a third party, these Installation and operating instructionsmust also be included in the national language of the third party. Safe and trouble-free operation of Igema GmbH Shutoff valve is not possible without precise knowledge. •... -
Page 6: Marking Of Safety And Warning Information
This operating manual contains texts and drawings that may not be reproduced, distributed or otherwise communicated in whole or in part without the express permission of the manufacturer. The copyright of the operating instructions remains with: Igema GmbH Antwerpener Str. 1 48163 Münster Germany Violations oblige you to pay compensation. -
Page 7: Safety Instructions
Only qualified persons who are familiar with the measurement and control systems are allowed to carry out work Igema GmbH can be commissioned for the installation and maintenance. AUTION Risk of injury due to external influences External influences can lead to injuries in the absence of protective equipment •... - Page 8 AFETY NSTRUCTIONS Risk of injury due to high temperatures Surfaces of the gauges and areas near the gauges heat up to the maximum permissible temperature and can cause severe burns if touched. • Check the danger of the medium. • Wear protective clothing including safety glasses.
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Page 9: Intended Use
AFETY NSTRUCTIONS Risk of health damage due to noise Noise leads to damage to the health of the hearing. • Wear hearing protection. • Avoid or limit noise if possible. 2.3 Intended use Property damage caused by irregular use • Use gauges exclusively as a gauge of filling levels on containers. -
Page 10: Contents Of The Packaging
ONTENTS OF THE PACKAGING 3 Contents of the packaging 3.1 Included In most cases, the valves are supplied as part of a gauge pre-assembled as a unit. Individual valves can also be supplied. 1. Valve in a pre-assembled unit or individual valve 2. -
Page 11: System Description
4 System Description 4.1 General IGEMA shutoff valves are mostly maintenance-free and easy to handle. All IGEMA valves have metal seals; the valve spindle is sealed with a stuffing box packing. The shut-off valve designs range from a simple shut-off to a double shut-off. All main valve spindles are equipped with a quick closure function that ensures that the valve can be opened or closed with a turn. -
Page 12: Self-Closing Ball Safety Function
ESCRIPTION 4.3 Self-closing ball safety function All IGEMA GmbH shutoff valves are equipped with a self-closing ball function. This function is a safety device that automatically closes the valve passage of the shut-off valve in the event of damage to the gauge (e.g. mica breakage). The ball self-closing function is only guaranteed when the valves are fully open. -
Page 13: Construction
ONSTRUCTION 5 Construction 5.1 A110-CS and A115-CS Pos. Designation Quantity Ball Valve seat 1.3.1 Valve cone with ejector pin 1.3.2 Threaded bush M12 x 1.5 1.3.3 Snap ring SW8 Base ring Packing rings Stuffing box Sealing ring Ø8 x Ø17.5 x1.5 Flange with adapter Spindle Handwheel... -
Page 14: A120-Cs, A140-Cs, A145-Cs, A150-Cs And A155-Cs
ONSTRUCTION 5.2 A120-CS, A140-CS, A145-CS, A150-CS and A155-CS Pos. Designation Quantity Ball Valve seat 1.3.1 Valve cone with ejector pin 1.3.2 Threaded bush M12 x 1.5 1.3.3 Snap ring SW8 Base ring Packing rings Stuffing box Sealing ring Ø8 x Ø17.5 x1.5 For A150-CS / A155-CS: Comb profile seal (not included in the scope of delivery) - Page 15 ONSTRUCTION 5.3 A190 Pos. Designation Quantity Ball Valve seat 1.3.1 Valve cone with ejector pin 1.3.2 Threaded bush M12 x 1.5 1.3.3 Snap ring SW8 Base ring Packing rings Stuffing box Sealing ring Ø8 x Ø17.5 x1.5 Sealing ring Ø22 x Ø27.5 quick-closing spindle Hand lever hex bolt M6 x 35...
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Page 16: A210-Cs And A220-Cs
ONSTRUCTION 5.4 A210-CS and A220-CS Pos. Designation Quantity Ball 1.2/ 1.2a Valve seat 2 x 1 1.3.1 Valve cone with ejector pin 1.3.1a Valve cones 1.3.2 / 1.3.2a Threaded bush M12 x 1.5 2 x 1 1.3.3 / 1.3.3a Snap ring SW8 2 x 1 Base ring 2 x 1... -
Page 17: A230 And A240
ONSTRUCTION 5.5 A230 and A240 Pos. Designation Quantity Ball 1.2/ 1.2a Valve seat 2 x 1 1.3.1 Valve cone with ejector pin 1.3.1a Valve cones 1.3.2 / 1.3.2a Threaded bush M12 x 1.5 2 x 1 1.3.3 / 1.3.3a Snap ring SW8... -
Page 18: Technical Data
A210-CS and A220-CS 120 bar 326°C 1740 psig 618°F Limitations of use A190, all. Pressure [PS] all. Temperature [TS] A230 and A240 200 bar 367°C 2900 psig 692°F The application limits vary depending on the connections fitted. Page / 14 D-09-B-62826-EN-00... -
Page 19: Dimensions
ECHNICAL DATA 6.2 Dimensions Single shut-off valves A110-CS A120-CS A140-CS A150-CS A190-CS D-09-B-62826-EN-00 Page / 15... - Page 20 ECHNICAL DATA Double shut-off valves A210-CS A220-CS A230 A240 [mm] [inch] Hand lever height [L1*] A110-CS ~146 A120-CS ~176 A140-CS A150-CS A190-CS ~238 A210-CS ~176 A220-CS A230 ~238 A240 *Dimensions may vary for other versions. Connection dimension L can be found on the next page...
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Page 21: Available Dimensions
M12 x 48 15-18465 PN160 DN25 Flange EN 1092-1 Flange EN 1092-1 A220-CS 15-18567 PN160 DN25 PN160 DN15 Flange EN 1092-1 A230 M14 x 40 15-00140 PN160 DN25 Flange EN 1092-1 Flange EN 1092-1 A240 15-06733 PN250 DN25 PN320 DN15... -
Page 22: Optional Versions
M12 x 48 15-18233 " Class 300 Flange B16.5 A210-CS M12 x 48 15-18523 NPS 1" Class 600 Flange B16.5 A230 M14 x 40 15-17276 NPS 1" Class 1500 Flange B16.5 Flange B16.5 A240 " Class 15-10225 NPS 1" Class 1500 1500 Welding end B16.25... -
Page 23: Assembly
SSEMBLY 7 Assembly 7.1 Version with flange • Observe the orientation of the gauge . • Check sealing surfaces for cleanliness • Install the flange connection between the gauge and the boiler/pressure vessel according to the applicable standard 7.2 Version with welding sleeve ARNING Eye damage due to lack of personal protective equipment Lack of eye protection during welding leads to eye damage in working and bystanders. -
Page 24: Commissioning
OMMISSIONING 8 Commissioning ARNING Risk of injury due to leaking medium Inflammatory, irritating and harmful substances can escape from the gauge and lead to skin injuries and burns. This danger is also to be expected in the case of an unpressurised cooled system. -
Page 25: Commissioning At The Same Time As The Boiler
Ensuring the cleanliness of the medium in the best possible way 8.2 Commissioning at the same time as the boiler This type of commissioning is recommended by Igema GmbH due to the lower stress on the components. Commissioning at the same time as the boiler must be carried out in the same way for all gauge types. -
Page 26: Commissioning Under Pressure And Temperature Loads
OMMISSIONING 8.3 Commissioning under pressure and temperature loads With this type of commissioning, the action steps of the gauges must be followed. Other commissioning for double shut-off valves If there are double shut-off valves on the gauge, other things must be ensured before commissioning. -
Page 27: Servicing
Replaced spare parts that do not correspond to the characteristics of the original spare parts may cause damage to the gauge. • Only use original parts from Igema GmbH for replacement. Material damage due to insufficient or incorrect lubrication Lubrication of components with inadequate or incompatible lubricants can lead to material damage. -
Page 28: Replacement Of Seat, Cone Fitting And Ball
ERVICING AUTION Cuts caused by sharp objects During the maintenance of the device, sharp-edged parts may cause injuries. • Always expect sharp-edged parts and shards due to glass breakage. • Wear work gloves 9.1 Replacement of seat, cone fitting and ball On double shut-off valves, the following steps relating to the spindle must be carried out on the quick-closing spindle and on the angled spindle. - Page 29 ERVICING Fig.5 Fig.6 Fig.7 Fig.8 Figure 1/2: • Unscrew the valve upper part from the valve body. • Unscrew and remove the valve upper part from the valve body by loosening the nuts. Figure 3: • Unscrew the cone fitting from the spindle. For double shut-off valves, use an SW19 spanner on both plug sets.
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Page 30: Replacement Of Packing Set
ERVICING 9.2 Replacement of packing set Fig.1 Fig.2 Fig.3 Fig.4 Fig.5 Fig.6 Page / 26 D-09-B-62826-EN-00... - Page 31 ERVICING Fig.7 Fig.8 Fig.9 Fig.10 Fig.11 Fig.12 Fig.13 Fig.14 D-09-B-62826-EN-00 Page / 27...
- Page 32 ERVICING Figure 1/2: • Unscrew the valve upper part (pos. 11) and remove it from the valve body (pos. 9). Figure 3/4: • Loosen the hexagon nut (Pos.8) on the hexagon screw (Pos.7) of the handle (Pos.6). • Remove the handle from the valve spindle (pos. 5). For version with handwheel: •...
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Page 33: Assembly After Replacing Components
ERVICING 9.3 Assembly after replacing components Fig.1 Fig.2 Fig.3 Fig.4 Fig.5 Fig.6 Figure 1/2: • Replace old sealing rings with new ones. Figure 3/4: ▪ The previously assembled assemblies must be professionally pre-assembled. Shut-off valves without flange on valve upper part. •... -
Page 34: Case Of Damage
ASE OF DAMAGE 10 Case of damage Fault Cause: Remediation Leaks at spindle/stuffing box Insufficient preload on Increase the torque on the packing union nut union nut (Chap.10.1) Permanent leakage at Wear and tear Replace the stuffing box spindle/stuffing box packing packing (Chap. -
Page 35: Spare Parts
Property damage caused by incorrect spare parts Replaced spare parts that do not correspond to the characteristics of the original spare parts may cause damage to the gauge. • Only use original parts from Igema GmbH for replacement. 11.1 A110-CS and A115-CS Pos. Designation Item no. -
Page 36: A120-Cs, A140-Cs And A145-Cs
PARE PARTS 11.2 A120-CS, A140-CS and A145-CS Item no. Quantit Pos. Designation A140-CS / A120-CS A145-CS Cone fitting, seat, ball 15-00116 Packing set 15-00113 Spindle 25-00553 Sealing ring ø 22 x ø 27.5 x 1.5 mm 40-00117 Hand lever 25-00102 Sealing ring ø... -
Page 37: A150-Cs And A155-Cs
PARE PARTS 11.3 A150-CS and A155-CS Quantit Pos. Designation Item no. Cone fitting, seat, ball 15-00116 Packing set 15-00113 Spindle 25-00553 Sealing ring ø 22 x ø 27.5 x 1.5 mm 40-00117 Hand lever set 25-00102 Grooved metal gasket 40-00206 D-09-B-62826-EN-00 Page / 33... -
Page 38: A210-Cs And A220-Cs
PARE PARTS 11.4 A210-CS and A220-CS Quantit Pos. Designation Item no. Cone set, seat and ball 15-00115 Cone set and seat 15-00114 Packing set 15-00113 quick-closing spindle 25-00126 Spindle 25-00652 Sealing ring 40-00117 Hand lever set 15-00338 Handwheel set 15-00237 Sealing ring 40-00109 Page / 34... -
Page 39: A230 And A240
PARE PARTS 11.5 A230 and A240 Quantit Pos. Designation Item no. Cone set, seat and ball 15-00115 Cone set and seat 15-00114 Packing set 15-00113 quick-closing spindle 25-00126 Spindle 25-00652 Sealing ring 40-00117 Hand lever set 15-00338 Handwheel set 15-00237... -
Page 40: Decommissioning And Disposal
ECOMMISSIONING AND DISPOSAL 12 Decommissioning and disposal 12.1 Dismantle valve Flange connections During the following work, the individual components hang freely and must be secured against falling. • Loosen nuts on flange connections. • Removing bolts from flanges • Secure the seal between the flanges against falling off Fig.1 Welded connections... -
Page 41: Disposal
Residues of hazardous substances pose a health hazard. • Indicate possible dangers and take precautionary measures. This high-quality IGEMA product was designed, manufactured and tested with the application of the QM System guidelines in accordance with DIN EN ISO 9001:2015. - Page 44 Direct Download Product page on the Internet Igema GmbH Antwerpener Str. 1 Phone: +49 2501 924 24 0 Fax: +49 2501 924 24 99 48163 Münster Germany info@igema.com www.igema.com...
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