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Summary of Contents for Igema Green-Red - BU Plus
- Page 1 Bicolour level gauge Type Green-Red - BU Plus Version 04/2025 D-04-B-56602-EN-00 Installation and operating instructions (English translation)
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Page 2: Table Of Contents
Table of Contents About this document Introduction __________________________________________________ 1 Product identification and rating plate ______________________________ 2 Related documents ____________________________________________ 3 Marking of safety precautions ____________________________________ 4 Copyright ____________________________________________________ 4 Safety Instructions Requirements for personnel ______________________________________ 5 Safety at work ________________________________________________ 5 Intended use of the gauge _______________________________________ 8 Damage to the product _________________________________________ 8 Contents of the packaging... - Page 3 Commissioning Before commissioning _________________________________________ 21 Commissioning at the same time as the boiler_______________________ 22 Commissioning under pressure and temperature loads ________________ 22 Servicing Preventive maintenance _______________________________________ 24 Cleaning the gauge / depressurising ______________________________ 25 Blowing through the gauge for further cleaning ______________________ 26 Cleaning the mica shields ______________________________________ 27 Changing the glass and mica ____________________________________ 28 Case of damage...
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Page 5: About This Document
If the gauge is passed on to a third party, these 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 Bicolour level gauge is not possible without precise knowledge of the individual components. -
Page 6: Product Identification And Rating Plate
Bicolour level gauge. The Installation and operating instructions belongs to the Bicolour level gauge of the device type Type Green-Red - BU Plus. Additions that are entered after the designation and describe the design of the Bicolour level gauge (e.g. -
Page 7: Related Documents
In addition to these Installation and operating instructions, the operating instructions of the shut-off and drain valves as well as the lighting system must be observed. Document number/ Product QR-Code Link 62826 Shutoff valve www.igema.com/document/62826 62825 Drain valves www.igema.com/document/62825 Lighting system LED 50226 Secure SOLPlus www.igema.com/document/50226... -
Page 8: 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 Antwerpener Str. 1 48163 Münster Germany Violations oblige you to pay compensation. -
Page 9: Safety Instructions
Only qualified persons who are familiar with the systems are allowed to carry out work Only trained electricians may commission electrical components and carry out maintenance work on them. Igema GmbH can be commissioned for work. AUTION Risk of injury due to external influences External influences can lead to injuries in the absence of protective equipment •... - Page 10 AFETY NSTRUCTIONS ARNING 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 leaking medium Inflammatory, irritating and harmful substances can escape from the gauge and lead to skin injuries and burns.
- Page 11 AFETY NSTRUCTIONS AUTION Risk of injury due to unsecured working area An unsecured working area can endanger working and bystanders. • Ensure safe access. • Delimit and mark the secured working area. • Sufficiently illuminate the working area. Risk of injury due to heavy loads There is a risk of injury when handling large and/or heavy gauges.
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Page 12: Intended Use Of The Gauge
AFETY NSTRUCTIONS 2.3 Intended use of the gauge Property damage caused by irregular use • Use gauges exclusively as a gauge of filling levels on containers. • Maintain maximum pressure and temperature ranges of all components. • Ensure the suitability of the gauge for the planned use/application. •... -
Page 13: Contents Of The Packaging
ONTENTS OF THE PACKAGING 3 Contents of the packaging 3.1 Included 1. Type Green-Red - BU Plus The Bicolour level gauge will be delivered as 2 pre-assembled units, unless otherwise contractually agreed: Unit A • Gauge • Upper shutoff valve •... -
Page 14: System Description
YSTEM ESCRIPTION 4 System Description 4.1 Function The LED illumination on the back of the display unit emits red and green light. If there is water in the display area, then the light rays in the display body will be diverted in such a way that the green light Water beam falls on to the slit dazzling body. -
Page 15: Different Variants
YSTEM ESCRIPTION 4.2 Different variants Standard version With stabilising section With expansion arch Split version D-04-B-56602-EN-00 Page / 11... -
Page 16: Construction
ONSTRUCTION 5 Construction Example: Standard version Screw plug G 1/2" Cover Soft iron seal Cover screw Seal Washer Hexagon nut Hexagon nut Threaded bolt Lighting module Sealing ring Dazzling box Mica packet Upper shutoff valve Mica protection Lower shutoff valve Glass Drain valve Glass insert... -
Page 17: Technical Data
ECHNICAL DATA 6 Technical data 6.1 Limitations of use BU Plus application limits Permissible pressure [PS] Permissible temperature [TS] 200 bar 367 °C 2900 psig 693 °F The maximum permissible operating pressure of the gauge is determined by the lowest permissible pressure of the attached component. - Page 18 ECHNICAL DATA With expansion arch Split version For versions with expansion bend, dimension J may be 135 Shown as a left-hand model. mm long, depending on the alignment. The position of the dead space T can be freely selected. Sight length calculation: E = (n-1) x 76.2 + 21 With a connection dimension A>2000mm, a porthole is omitted and a dead space T of 100 mm is created, the position of which can be freely selected.
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Page 19: Basic Version
ECHNICAL DATA 6.4 Basic version The bicolour level gauges are equipped with an A240 shut-off valve and an AV320 drain valve. Secure SOLPlus 6 or 8 LEDs are installed as light sources. Customised equipment is possible. Shut-off valve A240 Drain valve AV320 Example: LED Secure SOLPlus 6 Type Data sheet... -
Page 20: Optional Versions
ECHNICAL DATA 6.5 Optional versions For versions with other shut-off and drain valves, the documents for the installed valves must also be observed. Examples of optional versions Customised drain valves Customised shut-off valves Example: AV520 Example: A190 Type Data sheet Item number Shut-off valve AV520 Cutting ring fitting DS12 D-09-D-50513-DE... -
Page 21: 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 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 22: Lighting Device On The Gauge
Property damage caused by incorrect installation, commissioning, maintenance and operation Only trained electricians may commission electrical components and carry out maintenance work on them. Igema GmbH can be commissioned for work on electronic components. Included LED Secure SOLPlus 6 LED Secure SOLPlus 8 Before installation, check that the scope of delivery shown is complete. - Page 23 SSEMBLY Assembly instructions Only install the lighting device after the device has been heated up once and then cooled down again. Fig.1 Fig.2 Fig.3 Fig.4 D-04-B-56602-EN-00 Page / 19...
- Page 24 SSEMBLY Figure 1: ▪ The first wing screws must be fitted on the opposite side of the mounting bracket. • Attach dazzling box to the display body • Observe the concentric position of the holes in the dazzling box and display body. Figure 2: •...
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Page 25: Commissioning
OMMISSIONING 8 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 26: Commissioning At The Same Time As The Boiler
OMMISSIONING 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. Fig.1 Fig.2 Figure 1: • Close the drain valve (pos.14) Figure 2: • Open the shut-off valves as far as they will go. - Page 27 OMMISSIONING Fig.3 Fig.4 Fig.5 Figure 1: ▪ The gauge must be depressurised (chap.9.2) • Slowly open the upper shutoff valve (pos. 12) The gauge is heated to operating temperature by the steam flowing through it within 5-10min. Figure 2: ▪ The operating temperature must be reached •...
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Page 28: 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. AUTION Cuts caused by sharp objects During the maintenance of the device, sharp-edged parts may cause injuries. -
Page 29: Cleaning The Gauge / Depressurising
It should be noted that shorter maintenance intervals extend the service life of the level gauge. To ensure a trouble-free process, Igema GmbH recommends replacing the glasses, mica and seals annually. Certain operating conditions shorten the recommended intervals. -
Page 30: Blowing Through The Gauge For Further Cleaning
ERVICING 9.3 Blowing through the gauge for further cleaning Fig.1 Fig.2 Figure 1: ▪ The gauge must be depressurised (chap.9.2) • Slowly open the upper shutoff valve (pos. 12) The steam flowing through cleans the glasses. Figure 2: • Close the upper shutoff valve (pos. -
Page 31: Cleaning The Mica Shields
ERVICING 9.4 Cleaning the mica shields Fig.1 Fig.2 Figure 1 ▪ The gauge must be depressurised (chap.9.2) • Unscrew the screw plug (pos. 1) • Clean glasses and channel in the display body with a round brush (Article number 40-00775) Figure 2 •... -
Page 32: Changing The Glass And Mica
ERVICING 9.5 Changing the glass and mica Property damage caused by damaged components Apparently intact components can be damaged and lead to damage to the device when reinstalled or reused. • After loosening the clamping tabs, install completely new seals. •... - Page 33 ERVICING Figure 3: • Grease hexagon head screws with suitable lubricant (e.g. Fuchs Lubritech PBC 1574) • Install the sealing ring , mica pack , mica protection (pos. 4.1) (pos. 4.2) (pos. 4.3) glass and glass insert in the specified order. (pos.
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Page 34: Case Of Damage
ASE OF DAMAGE 10 Case of damage Fault Cause Remediation Leakage between the seal and Tighten cover screws Wear and tear the display body (chap.10.1) Tighten the flange Leakage at flange connection Wear, stresses connection / replace the seal (chap.10.2) Tighten the screw, replace Leakage at screw plug Wear and tear... -
Page 35: Leakage At Flange Connection
ASE OF DAMAGE 10.2 Leakage at flange connection Fig.1 Fig.2 Figure 1 • Install the flange connection between the gauge and the boiler/pressure vessel according to the applicable standard and torque. If there is no improvement: • Dismantling the display body (chap.12.2) Figure 2: •... -
Page 36: Leakage Between The Screw Plug And The Display Body
ASE OF DAMAGE 10.3 Leakage between the screw plug and the display body These working instructions apply to both the G " screw plug and the G " screw plug, which are screwed into the connection piece on offset versions of the gauges. Fig.1 Fig.2 Fig.3... -
Page 37: Spare Parts And Technical Accessories
PARE PARTS AND TECHNICAL ACCESSORIES 11 Spare parts and technical accessories 11.1 Spare parts pos. Designation Pressure level Item no. Quantity Screw plug G " 40-10481 to 200 bar Sealing ring 40-00099 n.d. Screw plug " 40-03794 n.d. Sealing ring Ø13.5 x Ø19 x 1.5mm 40-00114 PN 40... -
Page 38: 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 / 34 D-04-B-56602-EN-00... -
Page 39: Decommissioning And Disposal
ECOMMISSIONING AND DISPOSAL 12 Decommissioning and disposal 12.1 Dismantling the lighting system Dismantling the lighting system is carried out in reverse order to installation. (Chap. 7.3) 12.2 Dismantling the display body Fig.1 Fig.2 Figure 1 ▪ The gauge must be depressurised (chap. -
Page 40: 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 Muenster Germany info@igema.com www.igema.com...
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