Summary of Contents for Igema Reflex RG200
- Page 1 Reflex level gauge RG200 Version 05/2024 D-02-B-50107-EN-01 Installation and operating instructions (English translation)
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Page 3: Table Of Contents
Table of Contents About this document Introduction __________________________________________________ 1 Product identification and rating plate ______________________________ 2 Related documents ____________________________________________ 2 Marking of safety precautions ____________________________________ 3 Copyright ____________________________________________________ 3 Safety Instructions Requirements for personnel ______________________________________ 4 Safety at work ________________________________________________ 4 Intended use _________________________________________________ 7 Damage to the product _________________________________________ 7 Contents of the packaging... - Page 4 Commissioning Before commissioning _________________________________________ 19 Commissioning at the same time as the boiler_______________________ 20 Commissioning under pressure and temperature loads ________________ 21 Servicing Preventive maintenance _______________________________________ 22 Cleaning the gauge / depressurising ______________________________ 24 Blowing through the gauge for further cleaning ______________________ 25 Cleaning the glass ____________________________________________ 25 Glass replacement ____________________________________________ 26 Case of damage...
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Page 5: About This Document
Installation and operating instructions must also be included in the national language of the third party. Safe and trouble-free operation of the Igema GmbH Reflex level gauge is not possible without precise knowledge of the individual components. -
Page 6: Product Identification And Rating Plate
TAG No. (optional) maximum permissible temperature 1.3 Related documents In addition to these operating instructions, the operating instructions of the shutoff and drain valves must be observed. Operating instruction number/ Product QR-Code Link 62826 Shutoff valve www.igema.com/document/62826 Page 2 D-02-B-50107-EN-01... -
Page 7: Marking Of Safety Precautions
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 D-02-B-50107-EN-01 Page 3... -
Page 8: 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 9 AFETY NSTRUCTIONS Risk of injury due to corrosive liquids Corrosive liquids can cause serious injuries in case of skin contact • Check the danger of the medium. • Wear protective clothing including safety glasses. 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.
- Page 10 AFETY NSTRUCTIONS • Ensure safe access. • Delimit and mark the secured working area. • Sufficiently illuminate the working area. Page 6 D-02-B-50107-EN-01...
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Page 11: Intended Use
AFETY NSTRUCTIONS Risk of injury due to heavy loads There is a risk of injury when handling large and/or heavy gauges. • Observe the load handling regulation. • Use lifting equipment to move heavy and bulky appliances. Risk of health damage due to noise Noise leads to damage to the health of the hearing. -
Page 12: Contents Of The Packaging
ONTENTS OF THE PACKAGING Contents of the packaging 3.1 Included 1 RG200 The Reflex level gauge will be delivered as a pre-assembled unit, unless otherwise contractually agreed: • Gauge • Upper shutoff valve • Lower shutoff valve • Drain valve 2. -
Page 13: System Description
YSTEM ESCRIPTION System Description 4.1 Function Reflex level gauges in different versions are used to detect the water level of steam generators or tanks. The gauge works on the principle of communicating tubes. Steam It is equipped with an elongated, flat glass, which has prismatic grooves on the medium-side surface. - Page 14 YSTEM ESCRIPTION Page 10 D-02-B-50107-EN-01...
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Page 15: Construction
ONSTRUCTION Construction Plug G " Counter plate Sealing ring Display body Cover rail Drain valve Graphite seals Upper shutoff valve Reflective glass Lower shutoff valve Threaded bolt Rating plate (chap. 1.2) Washer Water level mark (chap. 11.2) Hexagon nut D-02-B-50107-EN-01 Page 11... -
Page 16: Technical Data
ECHNICAL DATA Technical data 6.1 Limitations of use Limitations of use RG200 all. Pressure [PS] all. Temperature [TS] Media with glass attack 32 bar -10 to 239 °C (e.g. water vapour) 464 psig -4 to 462 °F 20 bar -10 to 280 °C 290 psig 14 to 536 °F Media without glass attack... -
Page 17: Dimensions
ECHNICAL DATA 6.3 Dimensions One display opening Multiple display openings The displayed gauges are shown as a left-hand model. The dimensions H, J and A are specified customer-specifically minimum maximum [mm] [inch] [mm] [inch] Upper blind space Lower blind space “... - Page 18 ECHNICAL DATA • Provide sufficient support. (e.g. by spring hanger) Page 14 D-02-B-50107-EN-01...
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Page 19: Optional Versions
ECHNICAL DATA 6.4 Optional versions In addition to customer-specific drain and shutoff valves, the gauge can also be customised with other features. These operating instructions also apply to these versions. For versions with other shutoff and drain valves, the documents for the installed valves must also be observed. -
Page 20: Assembly
SSEMBLY 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 end 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 21: Bending And Mounting The Water Level Mark
SSEMBLY 7.3 Bending and mounting the water level mark If the water level mark is not already mounted but is included with the gauge including screws, it must be bent as described below and mounted on the clamping tabs at the specified height. Bending the water level mark Fig.1 Fig.2... - Page 22 SSEMBLY Work steps The work steps on a TG120 transparent gauge are shown below. As the mounting rail for the water level marker is the same and therefore the work steps are also the same, these instructions can also be used for mounting on the RG200 Reflex Level Gauges. Fig.1 Fig.2 Fig.3...
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Page 23: Commissioning
OMMISSIONING Commissioning 8.1 Before commissioning Torque All liquid level gauges are subjected to a pressure test before delivery. In individual cases, material placement may occur due to transport, storage or during assembly. Leaks due to insufficient torques • Check screw connections for appropriate torque and a tight fit. •... -
Page 24: Commissioning At The Same Time As The Boiler
The pH value of the medium has a strong effect on the removal of the reflective glass. 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. -
Page 25: Commissioning Under Pressure And Temperature Loads
OMMISSIONING 8.3 Commissioning under pressure and temperature loads Fig.1 Fig.2 Fig.3 Fig.4 Fig.5 ▪ The gauge must be depressurised (chap.9.2) Figure 1: • Open the upper shutoff valve slowly. The gauge is heated to operating temperature by the steam flowing through it within 5-10min. -
Page 26: Servicing
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. AUTION Cuts caused by sharp objects During the maintenance of the device, sharp-edged parts may cause injuries. - Page 27 ERVICING D-02-B-50107-EN-01 Page 23...
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Page 28: Cleaning The Gauge / Depressurising
ERVICING In order to ensure a trouble-free process, Igema GmbH recommends an annual replacement of the glass and the seals. Shorter maintenance intervals are recommended in extreme operating conditions. Creation of a maintenance plan The operator must determine a maintenance plan suitable for the specific application after evaluating his own operating experience. -
Page 29: Blowing Through The Gauge For Further Cleaning
ERVICING 9.3 Blowing through the gauge for further cleaning Fig.1 Fig.2 ▪ The gauge must be depressurised Figure 1: • Open the upper shutoff valve slowly The steam flowing through cleans the glass. Figure 2: • Close the upper shutoff valve •... -
Page 30: Glass Replacement
ERVICING ▪ The gauge must be depressurised. (chap.9.2) Figure 1: • Unscrew the screw plug. • Clean glasses and channel in the display body with a round brush (Article number 40- 00775) Figure 2: • Screw in the screw plug with a torque Md =120Nm. - Page 31 ERVICING ▪ The gauge must be depressurised. (chap.9.2) Figure 1: • Loosen the hexagon nuts and remove them together with the washers. • Remove the threaded bolt together with the nuts and washers to the other side. • Remove the counter plate. Figure 2: •...
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Page 32: Case Of Damage
ASE OF DAMAGE 10 Case of damage Fault Possible cause Remediation Leakage on the glass holder between the body and the Wear and tear Carry out repair (chap. 10.1) graphite gasket Wear of the sealing Leakage between sealing ring Replacing the seal ring/damage to the sealing and shutoff valve (cap. -
Page 33: Leakage Between Sealing Ring And Shutoff Valve
ASE OF DAMAGE 10.2 Leakage between sealing ring and shutoff valve Fig.1 Fig.2 Fig.3 Fig.4 Figure 1: • Retighten hexagon nuts with Md =65Nm. Figure 2: ▪ If there is no improvement, take the following steps after relieving pressure: • Loosen the hexagon nuts of the valves and remove them using clamps. Property damage due to impacts When handling the gauge, it may be damaged by impacts. -
Page 34: Leakage Between The Screw Plug And The Display Body
ASE OF DAMAGE steps. 10.3 Leakage between the screw plug and the display body Fig.1 Fig.2 Figure 1: • Tighten the torque of the screw plug Figure 2: ▪ If there is no improvement: • Unscrew the screw plug • Replace the gasket. •... -
Page 35: Spare Parts
PARE PARTS 11 Spare parts 11.1 Spare parts Pos. Designation Size Item no. Quantity Screw plug " 40-10481 Sealing ring soft iron 1.0338 40-00099 21 x 26 x 1.5mm Sealing ring stainless steel 40-00128 1.4301 15-13060 n x 1 15-13061 n x 1 15-13062 n x 1... -
Page 36: Accessories
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. Page 32 D-02-B-50107-EN-01... -
Page 37: Decommissioning And Disposal
ECOMMISSIONING AND DISPOSAL 12 Decommissioning and disposal 12.1 Disassembling the display body Fig.1 Fig.2 Figure 1: ▪ The gauge must be depressurised (chap.9.2) • Secure the gauge against falling • Loosen the hexagon nuts of the valves, unscrew and remove together with the clamping brackets. -
Page 38: Disposal
ECOMMISSIONING AND DISPOSAL 12.2 Disposal NVIRONMENT Risk to the environment due to residues Residues on the gauge can pose a danger to the environment. • For returns, observe the applicable safety and environmental laws according to GGVSEB [The Dangerous Goods Ordinance on Roads, Railways and Inland Waterways]. - Page 39 ECOMMISSIONING AND DISPOSAL 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. If the device supplied indicates transport damage or gives cause for complaint in spite of our final quality check, please contact our SERVICE department on telephone +49 2501 92424-0 immediately.
- Page 42 Direct Download Product page on the Internet Igema GmbH Antwerpener Str. 1 Phone: +49 2501 924 24 0 48163 Muenster Fax: +49 2501 924 24 99 Germany info@igema.com www.igema.com...
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