Algas-SDI Electric Vaporizer User Manual
Below you will find brief information for Z50, Z40, Z37, Z34, Z31, Z28, Z26, Z23, Z20, Z17. These electric LPG or Propane vaporizers add energy to vaporize liquid fuel when natural energy is insufficient. The device allows greater capacities from smaller amounts of stored LPG, overcoming space limitations. Vaporizers are manufactured under a certified ISO 9001 quality system. They help control inlet flow to ensure only superheated vapor leaves the unit.
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...Innovative liquid vaporizing and gas mixing solutions ZIMMER Electric Vaporizer Operations & Maintenance Manual 151 S. Michigan Street, Seattle, Washington, USA 98108 Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com FILE: MANUAL PN 52690 REV 10-17-12 ZIMMER ELECTRIC VAPORIZER.doc 2012.10.17 14:34:23 -07'00' TM DISCLAIMER and COPYRIGHT DISCLAIMER Read this Operations and Maintenance Manual before operating the ZIMMER TM! Algas-SDI International, LLC shall not be liable for technical and/or editorial errors or omissions in this manual. Algas-SDI makes no warranties, express or implied, including the implied warranties of merchantability and fitness for a particular purpose with respect to this manual. In no event shall Algas-SDI be liable for any special or consequential damages including, but not limited to, loss of production time or loss of profits. Product names used in this manual are for the manufacturer or supplier identification only and may be trademarks, or registered trademarks, of these companies. In accordance with the manufacturer’s policy of continual product improvement, Algas-SDI reserves the right to use alternate manufacturer’s components as vendor availability dictates. For further information please contact Algas-SDI. COPYRIGHT Copyright 2012 by Algas-SDI International, LLC Seattle, Washington, USA 98108 All rights reserved. No part of this manual may be reproduced or copied in any form or by any means, photographic, electronic, or mechanical without the prior express written consent from AlgasSDI International, LLC. 2 WARRANTY and CONTACT INFORMATION WARRANTY REGISTRATION Fill out the Warranty Registration information on the last page of this manual. Refer to the nameplate on the unit to fill out the product registration. Then make a photocopy and mail to the address shown at the bottom. WARRANTY Algas-SDI International, LLC (ASDI) warrants that the equipment is free from defects in materials and workmanship under normal use and service. ASDI agrees to repair or replace, at its option, without charge F.O.B. factory, any part which has proven defective to the satisfaction of ASDI within one (1) year from the date of the original installation or with 18 months from the date of shipment, whichever is earlier. Equipment, which in the opinion of ASDI, has been damaged in shipment or by improper installation or operation, or has been abused or tampered with in any way, will not be accepted for return under warranty. ASDI will not accept back charges for work performed by others upon or in conjunction with ASDI equipment, unless prior authorization is given by means of an ASDI purchase order. ASDI will not be liable by reason of shutdown, non-operation or increased expense of operation of other equipment, or any other loss or damage of any nature, whether direct or consequential, arising from any cause whatsoever. ASDI makes NO other warranty of any kind, whatsoever expressed or implied; and all warranties of merchantability and fitness for a particular purpose are hereby disclaimed by ASDI and excluded from these terms of sale. No person has any authority to bind ASDI to any representation or warranty other than this warranty. ASDI CONTACT INFORMATION If you have questions or need help with your equipment, or want information on other products, contact your distributor or Algas-SDI at: Telephone: 1.206.789.5410 Facsimile: 1.206.789.5414 E-mail: [email protected] Internet: www.algas-sdi.com 3 TECHNICAL SPECIFICATIONS Capacity, kg/hr (gal/hr) Model Model Z50 Z40 Z37 Z34 Z31 Z28 LPG 40 (20) Z40L Z40P Z40S Kg/Hr 50 40 37 34 31 28 40 (20) GPH 25 20 18.5 17 15.5 14 kW 5.72 5.28 4.88 4.49 4.09 3.70 Model Z26 Z23 Z20 Z17 Z14 Kg/Hr 26 23 20 17 14 GPH 13 11.5 10 8.5 7 kW 3.41 3.04 2.64 2.27 1.89 17,24 bar (250 psig) MAWP: 17,24 barg @ 343ºC (250 psig @ 650ºF) MDMT: -29ºC @ 17, 24 barg (-20ºF @ 250 psig) Hydrostatic Test Pressure: 25.86 barg (375 psig) PED: Electrical: 50/50 LPG 40 (20) Pressure Relief Valve Set point: Heat Exchanger: Propane SEP (Sound Engineering Practice) Voltage: 100 - 240VAC Phase: 1 Frequency: 50/60Hz Amps: 32, 7 Amps (100V) – 19,5 Amps (240V) Kilowatts: 3,27 - 5,72 kW Load type: Inductive Circuit breaker: Z40 - 208-240V use a UL listed 30 amp high inrush circuit breaker 100-120V use a UL listed 40 amp high inrush circuit breaker Z50 – 208-240V use a UL listed 40 amp high inrush circuit breaker 100-120V use a UL listed 50 amp high inrush circuit breaker Hazardous Area Rating: LPG VAPORIZER FOR HAZARDOUS LOCATIONS 2PA5 0575 II 2 G DEMKO 12 ATEX 1203758X IECEx UL 12.0037X Ex d IIA T3 Gb Class I, Division 1, Group D, T3 Enclosure Rating: Type 4 Quality System: ISO 9001 Lloyd’s Quality Register, Certificate Number: 108266 4 5 6 TABLE of CONTENTS 1. 2. INTRODUCTION 9 Description/Overview 9 How the Vaporizer Works 9 Basic Features 10 Model Selection 10 Propane version (Z40P) 11 Propane version (Z40P) – Table 1 11 LPG version (Z40L) 11 LPG version (Z40L) – Table 2 11 50/50 version (Z40S) 12 50/50 version (Z40S) – Table 3 12 Available Options 13 Safety 14 INSTALLATION 15 Preparing the Site 16 Materials you may need for Installation Mounting the ZIMMER ZIMMER 3. 4. TM TM Tank Mounting Kit Instructions 17 20 21 Piping 25 Installing Multiple Units 28 Common Piping Problems 29 Electrical Service 29 OPERATION 31 Putting Your Vaporizer into Service 31 Shutting Down the System 32 MAINTENANCE 33 Servicing your ZIMMER TM 33 Drip leg and Filter 33 Inlet valve (Cleaning Instructions) 33 Heating System 35 Relief valve 35 7 5. TROUBLESHOOTING 37 Possible problems 37 Inlet valve does not open – Tree #1 37 Inlet valve closes during operation – Tree #2 38 6. REPLACEMENT PARTS 39 7. FREQUENTLY ASKED QUESTIONS 40 ZIMMER TM Current and Power Charts 42 Warranty Registration - Refer to the nameplate on the unit to fill out the product registration. Then photocopy and mail to address shown. 8 1 INTRODUCTION Description / Overview Your new ZIMMER TM is a dry electric LPG or Propane vaporizer that adds energy to vaporize liquid fuel when the amount of energy available from the natural environment is insufficient for vaporization. A primary benefit of this device is that it allows greater capacities from smaller amounts of stored LPG. Often time’s code restrictions limit the number and size of cylinders that can be stored next to a building or in a small space. The ZIMMERTM overcomes this problem and allows loads up to 80 kg/hr (40 gal/hr), or more, with two units in parallel and can be supplied by as few as one cylinder or tank of any size, or as many as can be manifolded together according to local codes. All ZIMMER TM vaporizers are manufactured under a certified ISO 9001 quality system. The inlet control valve and heat exchanger have been proof tested to 172 bar (2500 psig). How the Vaporizer Works 7 4 1 6 2 3 5 Ref. 1 – Liquid LPG enters the inlet valve manifold where the inlet valve screen prevents debris from entering. Ref. 2 – Liquid flows through the inlet valve where it is controlled by a metal-to-metal seat and ball. The infinite seating positions of the ball provide long life, while the inverted seat prevents foreign material from collecting on the valve seat. 9 Ref. 3 – As liquid passes through the tubes energy is transferred, causing the liquid to boil. Steel tubes cast into the aluminum heat sink provide a secure pressure boundary and exceptional heat transfer. Ref. 4 – Energy drawn from the heat sink is replenished by replaceable self-regulating heaters without the need for switches, temperature sensors, relays, or other controls. The heaters cannot overheat by nature of their design and they consume only as much energy as is needed for vaporization. Ref. 5 – Power is supplied to the heaters by a wide range of voltages through a factory-mounted explosion-proof seal. Ref. 6 – As vapor exits the unit, it heats or cools the temperaturesensitive bulb, providing feedback to the inlet valve. Ref. 7 – The inlet control valve receives feedback from the temperature-sensitive bulb and combines it with pressure feedback to ensure only superheated vapor (superheat is the amount of temperature above the dew point) leaves the vaporizer. The valve modulates the inlet flow to control the process. In the event of a power failure the unit will continue to operate until all of the available energy has been used. If the power comes back on before all of the energy has been used, the heat process being served by the LPG should remain engaged. Otherwise the inlet valve will close as the heat stored in the heat exchanger is transferred to the passing fluid. When the power comes back on the vaporizer will automatically re-energize and begin operation. Basic Features The heating elements are self-temperature-regulating and therefore do not have (or need) an external temperature sensor. The heat generating material of the heaters also acts as a high-temperature limit by breaking down if it reaches its critical point. Because of its unique design features, the ZIMMER TM can be operated on power supplies ranging from 100-240 volts AC. When operated on 110V, the maximum continuous capacity rating will be reduced by 25%. Model Selection The ZIMMER TM is available in three versions –propane (Z40P), one model for LPG (Z40L) and one model for LPG (Z40S). 10 The difference between the Z40L, Z40P and the Z40S is in the control valve. The control valve operates on the thermodynamic properties of the specific gas (either LPG or commercial propane). The valve expects to see the vapor exit the vaporizer at 8 C (15 F) higher than the boiling point of the respective gas. The unique function of the valve is that it senses both pressure and temperature to truly predict the boiling point. The valve is clearly marked with a sticker indicating that it is to be used with LPG, Propane or 50/50 (LPG). Propane version (Z40P) – See Table 1 Use with 85% or greater commercial Propane. Never use propane which exceeds 15% Butane. Table 1 - Propane version (Z40P) 100% Butane 0% Propane Never use in this range 15% Butane 85% Propane Full capacity 0% Butane 100% Propane LPG version (Z40L) – See Table 2 Full capacity is based on LPG containing 60-80% Butane. Never use LPG which contains more than 80% Butane. Using the LPG version with LPG containing more than 4060% Propane will decrease the capacity of the vaporizer. *Especially in warmer environments. Contact A.S.D.I. for more details. Table 2 - LPG version (Z40L) 100% Butane 0% Propane Never use in this range 80% Butane 20% Propane Full capacity 60% Butane 40% Propane *Reduced capacity 40% Butane 60% Propane Do not use in this range 0% Butane 100% Propane 11 50/50 version (Z40S) – See Table 3 Full capacity is based on LPG containing 40-60% Butane. Never use LPG which contains more than 60% Butane. Using the 50/50 version with LPG containing more than 60% Propane will decrease the capacity of the vaporizer. *Especially in warmer environments. Contact A.S.D.I. for more details. Table 3 - 50/50 version (Z40S) 100% Butane 0% Propane Never use in this range 60% Butane 40% Propane Full capacity 40% Butane 60% Propane *Reduced capacity 0% Butane 12 100% Propane Relief Valve Inlet Valve Actuator LPG Liquid “IN” Heat Exchanger / Heat Sink LPG Vapor “OUT” Insert 13mm (1/2”) pipe to steady valve when tightening inlet and outlet piping Available Options Ask for the following items from your local Algas-SDI dealer: Algas-SDI P/N: 80885 Wall Mount kit Algas-SDI P/N: 80887 Tank Mount Kit for mounting the ZIMMER TM to any horizontal tank up to 48” diameter. Algas-SDI P/N: 80888 ( includes Kit P/N: 80890 ) Piping Kit for use with Tank Mount Kit Algas-SDI P/N: 80890 Outlet regulator and gauge kit with Fluorocarbon elastomers for high temperature gas Algas-SDI P/N: 80892 Strainer with 40 mesh and piping kit (See page 13 ) Algas-SDI P/N: 20556 FILTAIRE TM - Vapor filter for filtering out heavier hydrocarbons 13 Safety CAUTION Propane Odor can fade. CAUTION Vaporizer may be hot after or during use. Do not remove cover prior to allowing the unit to cool. CAUTION Allow only a TRAINED and FULLY QUALIFIED PERSON to service this equipment. 14 2 INSTALLATION WARNING The equipment described in this manual is designed to operate with LP-gas, a flammable fuel under pressure. The nature of the application involves inherent hazards that could result in injury. ONLY a trained and fully qualified person should service this equipment. NOTE TM Prior to installing your new ZIMMER , check all relevant codes and standards that apply in your local area to ensure compliance! CAUTION To prevent ignition of hazardous atmospheres: 1. 2. Any repairs internal to the flameproof enclosure must be made by the manufacturer or its authorized service center. Keep flameproof enclosure tight, torque to 40,6 Nm ( 30 ft. lbs.) while in service, and disconnect power before installing or removing unit from service. NOTE Installer must install a terminal box (connection facility). Metal Terminal Box (3/4”): Ex d II A Gb or Ex e II, ATEX certified - marking for Europe; or Class I, Division 1, Group D (UL listed or equivalent) - for US and Canada. Electrical wiring must be rated for -20ºC (-4ºF) to 130C (266F). WARNING Potential electrostatic charging hazard. Clean cover with a damp cloth. CAUTION Connect only metal electrical conduit or armored cable to the vaporizer sealing fitting. CAUTION Do not install vaporizer in corrosive environments or expose to corrosive chemicals. CAUTION If flameproof joint dimensions are required by the end user please contact AlgasSDI. 15 Preparing the site When preparing your site, consider local setback limitations for your desired storage container(s). Also give consideration to points of ingress/egress and other openings into buildings, including any air intakes. The ZIMMER TM vaporizer is explosion-proof, which means that it can be mounted next to, on, or near the storage container(s). For portable applications the ZIMMER TM can be mounted on the storage container. Make sure the mount touches the vessel in as small an area as possible to avoid corrosion on the vessel surface. For stationary applications it is best to mount the ZIMMER TM on a wall or support near the container(s). From: NFPA 58, 2004 edition, Annex I 16 From: NFPA 58, 2004 edition, Annex I Materials you may need for installation Storage tank; or cylinder(s) with liquid withdrawal valve(s) also called “dip tube(s)”, are required. Excess flow valve(s) Manifold kit if using multiple cylinders ½” NPT Inlet isolation valve with hydrostatic relief valve approved for liquid LP Gas service ( included with Algas-SDI P/N 80892 ) Piping components including forged steel union or removable compression/flare fittings Schedule 80 pipe for liquid service, or approved tubing and fittings 17 Inlet strainer, ½” NPT, with 40 mesh screen ( included with Algas-SDI P/N 80892 Outlet regulator, REGO model x1584MN or equivalent ( AlgasSDI P/N 80890) (Outlet Range 0.21 – 2.10 Bar [3-30 psig]) Outlet isolation valve, ½” NPT, approved for LP Gas vapor service ( included with Algas-SDI P/N 80892 ) Vaporizer mounting kit ( Algas-SDI P/N 80885 ) Electrical disconnect switch rated for 30 amps at 240VAC or 40 amps at 100VAC for Z40 and 40 amps at 240VAC or 50 amps at 100VAC for Z50 Circuit breaker: Z40: 208-240V use a UL listed 30 amp high inrush circuit breaker 100-120V use a UL listed 40 amp high inrush circuit breaker Z50: 208-240V use a UL listed 40 amp high inrush circuit breaker 100-120V use a UL listed 50 amp high inrush circuit breaker Typical Installation with Stationary Cylinder 18 Typical Tank Mount Installation 19 Mounting the ZIMMER TM 346.0 [13.63] 175.3 [6.90] If mounted outdoors, the ZIMMER TM must be mounted on a vertical or horizontal surface to maintain its enclosure rating. Use AlgasSDI Mounting Kit P/N 80885, or equivalent components, when mounting the ZIMMER TM to a concrete, masonry or wood construction wall. MOUNTING CHANNEL SLEEVE ANCHOR 3/8" WASHER 20 ZIMMER TM Tank Mounting Kit Instructions ZIMMER TM Tank Mounting Kit Instructions – Use with kit 80887 bracket assembly and 80888 piping kit (sold separately). 80887 Tank Mount Kit contents: 1 1 1 2 30’ 4 2 4 8 12 4 Tank Bracket Tension bar Tension rod ½” – 13 threaded Hex nut, ½” – 13 Cable, 1/8” vinyl coated Vinyl pipe cap Top cap for bracket Hex head bolt, 3/8” – 16 x 2-3/4” lg Hex nut, 3/8” – 16 Flat washer, 3/8 Split washer/ 3/8 80888 Piping Kit contents: 1 2 4 4 4 4 1 2 1 1 2 3 1 1 2 2 1 1 1 1 1 Nipple, sch 80, ½” x 2” lg Nipple, sch 80, ½” x 3” lg Nipple, sch 80, ½” x 4” lg Nipple, sch 80, ½” x 6” lg Nipple, sch 80, ¾” x 2” lg Nipple, sch 80, ¾” x 6” lg Nipple, sch 80, ½” x 12” lg Bushing, ¾” x ½” NPT Plug, ½” NPT Tee, ½” NPT Union, ½” NPT Elbow, ½”, 90 deg Elbow, ½”, 45 deg Hydro Relief Valve, ¼” Ball Valve, ½” NPT, brass Pipe Bracket, ½” Press regulator, Rego X1584MN Press Gauge, 0-30 psi, dry Strainer, ¾” NPT, 40 mesh ¾” Check-Lok Adapter Instructions, Tank Mounting Kit This kit is intended for use with all horizontal tanks up to 48” outer diameter. Larger tanks can be accommodated by using longer 1/8” vinyl coated cable. 1. Assemble the 4 vinyl pipe caps onto each end of the bracket. 2. Install the 2 top caps onto the bracket. 3. Locate the (4) 3/8” bolts and fasten the ZIMMER TM (with cover removed) to the bracket as shown. The ZIMMER TM should be mounted to the flat side of the channel. End Caps – 4 places 21 4. Mount as many of the piping components to the ZIMMER TM as possible. Install the ¾” x ½” NPT reducing bushings into each end of the strainer provided. To complete the piping installation you will need to have a shutoff valve located before the ZIMMER TM. This valve should be as close to the outlet of the tank as possible. Always install hydrostatic relief valves between any two points in the liquid piping that can trap liquid. Use schedule 80 pipe or tubing suitably rated for liquid LP-Gas service. ½” x 4” lg 90 deg Elbow ½” x 6” lg Union Isolation valve w/ hydrostatic relief ½” x 3” lg 90 deg Elbow ¾” strainer w/ reducing bushings ½” x 4” lg Excess flow valve Liquid LPG Supply from tank 5. Insert the pressure gauge in one of the ¼” NPT openings provided on the regulator. 6. Wrap the outlet piping around the backside of the ZIMMER TM and use the pipe clamps provided to secure the piping to the open side of the channel. ½” x 6” lg 45 deg Elbow Ball Valve 90 deg Elbow ½” x 4” lg ½” x 6” lg ½” x 3” lg ½” x 4” lg Union ½” Tee ½” x 6” lg Ball Valve & Plug 22 ½” x 2” lg ZIMMER Outlet ½” x 12” lg 7. Paint the piping as needed and allow it to dry. 8. Survey the tank and determine the best mounting site – preferably toward one end of the tank. 9. Starting from the inside of the bracket and the side with the 9/16” diameter hole, place each end of the cable through the two ¼” diameter holes. Feed the cable all the way through so that it is centered at each end. 10. Place the ZIMMER TM and bracket assembly onto the tank in the desired location. 11. Place the cable around the bottom of the tank and feed it through the two ¼” openings on the opposite side of the bracket. 12. Insert the ½” –13 threaded rod through the hole in the bracket and thread on one of the ½” nuts. Tension Rod ½” hex nut 13. Place the tension bar on the other end of the ½” –13 threaded tension rod and thread the other ½” hex nut on. 14. Feed each end of the cable through the outer holes of the tension bar and pull the cable tight. Tension Bar 23 15. Feed the cable back through the inner holes. Save a small amount at the bend. Loop the cable back over the top of the tension rod and weave the cable through the small loop left at the bend. Pull the cable as tight as possible by hand. 16. Tighten the ½” –13 nuts until the cables are tight and the bracket can no longer be moved on the tank. 17. Cut off any excess cable. Outlet Inlet Drip Leg For help with questions contact your dealer or Algas-SDI at: 1.206.789.5410 Or E-Mail: [email protected] 24 Piping CAUTION Teflon tape can clog orifices if not properly used. If a fitting is removed that has Teflon tape, make sure to clean all threads and remove all tape debris before re-installing. The ZIMMER TM is designed for feed-through operation. If you are using cylinders to store the LPG, you will need liquid withdrawal valves in each cylinder (REGO 8556 or equivalent). It is best to use valves that have both vapor and liquid withdrawal ports – this allows you to use vapor when your load is small or when the temperature is high, and then use your vaporizer when the ambient energy is not sufficient. Typical Piping Installation – Dip Tube If you are using a tank to store the LPG, you will need to connect to the bottom of the tank or to a connection that has a “dip tube” extending into the tank for liquid withdrawal. 25 Install an approved isolation valve at the outlet of the tank. If you are using cylinders you should install an isolation valve after the cylinders have been manifolded together. The isolation valve should have a hydrostatic relief valve installed to protect the pipe section between the valves. After the isolation valve, install a ½” or ¾” NPT strainer with a 40 mesh, or smaller, screen. Connect the strainer to the inlet of the ZIMMER pipe, Schedule 80. TM using ½” NOTE Do not install a check valve between the ZIMMER TM and the tank or cylinders! Liquid must be able to back-flow if necessary. At the outlet of the ZIMMER approved for LPG vapor service. TM install an isolation valve Next, install a pressure regulator with Fluorocarbon elastomers such as a Rego X1584MN. Install this regulator as close to the outlet of the vaporizer as possible and always at a higher elevation than the vaporizer outlet to allow any condensed liquid to travel back to the vaporizer. Never install the regulator more than 3 meters (10 feet) from the vaporizer. If you are using PE pipe after the regulator, make sure to install the regulator 2 meters (6-7 feet) after the vaporizer. Install a pressure gauge in the regulator or at the regulator outlet. After the regulator install a “drip-leg” in the piping or a vapor filter to collect any residue or heavy-ends from the LPG. The drip leg should terminate with a valve and a plug for draining. 26 OPTIONAL VAPOR SUPPLY OPTIONAL VAPOR OUTLET REGULATOR SET BELOW VAPORIZER OUTLET REGULATOR "FILTAIRE" GAS TRAP MODEL F.5 (OPTIONAL) LPG STORAGE TANK VAPORIZER OUTLET REGULATOR A.S.D.I. P/N 80890 REGO X584MN OR EQUIVALENT COALESCING FILTER, TRAP OR DRIP LEG TO LOAD ZIMMER LP-GAS VAPORIZER INLET ISOLATION VALVE W/HYDROSTATIC RELIEF A.S.DI. P/N 80892 INLET STRAINER A.S.DI. P/N 80892 ELECTRICAL SERVICE Typical Single Tank Piping Installation – from bottom of tank 27 Installing Multiple Units Multiple ZIMMER TM vaporizers can be manifolded together to increase the total system capacity. Manifold the inlets and outlets together using similar length piping runs. It is best to keep the piping as short as possible. Install an isolation valve at the inlet and outlet of each vaporizer. Install an appropriate sized regulator with Fluorocarbon elastomers after the outlets have been manifolded together. For more than two units a Fisher 627 with a Fluorocarbon diaphragm should be used. Typical Multiple unit Installation 28 Common piping problems Problem: Frost or condensation on the liquid LPG piping. Cause: Vaporizer installed with undersized piping from storage container to vaporizer. Reason: Liquid LPG boils in the pipe before the vaporizer causing a reduction in vaporization capacity. Problem: Moisture or water droplets on the piping before the regulator. Frosting of the regulator. Cause: Outlet regulator installed too far from vaporizer or below vaporizer outlet. Reason: High pressure LPG vapor condenses between the vaporizer outlet and the regulator. Problem: Downstream component failure. Cause: Drip leg or filter is not installed or is too small. Reason: Oils or heavy ends collect in downstream regulators and other components. Electrical Service The ZIMMER TM vaporizer is manufactured as an explosion proof device suitable for hazardous locations. Do not separate the heat exchanger castings to access the electrical enclosure – separating the castings will void the warranty! When connecting the electrical service for the ZIMMER TM you will need a circuit breaker or fuses appropriate for the application (refer to the materials section earlier in this chapter). You will also need a disconnect switch located within sight of the vaporizer. Select the appropriate size conductors based on the current draw and conductor run distance (refer to the Technical Specifications section at the end of this manual). Install a ¾” NPT metal terminal box after the seal-off to make the wiring connections. 29 Metal Terminal Box (3/4”): Ex d II A Gb or Ex e II, ATEX or IECEX certified - marking for Europe; or Class I, Division 1, Group D (UL listed or equivalent) - for US and Canada. Electrical must be rated for 130C (266F). Do not separate the heat exchanger sections to access the wiring. Use wire assembly provided. Connect the green/yellow wire to ground. 30 OPERATION 3 WARNING The equipment described in this manual is designed to operate with LP-gas, a flammable fuel under pressure. The nature of the application involves inherent hazards that could result in injury. ONLY a trained and fully qualified person should service this equipment. CAUTION To avoid electrostatic discharge, clean cover with a damp cloth. Putting your vaporizer into service After completing the piping work, leak check all connections with a soap solution and pressure from the tank or from a pressure tap and compressed air bottle. To initiate operation of the ZIMMER TM vaporizer, engage the electrical supply at the disconnect and open all valves from the container(s) to the vaporizer. Depending on the conditions, it could take up to 30-60 minutes for the vaporizer to be ready for full use. Open the shut-off valve located at the outlet of the vaporizer. Procedure for decreasing startup time: 1. Leave inlet valve closed (no pressure to vaporizer). 2. Start ZIMMER TM and allow unit to heat up for 10-20 minutes. For cold weather conditions allow an additional 20-30 minutes to warm-up. 3. Slowly open inlet valve. 4. Inlet valve should open. 31 If starting the system for the first time; set the first stage regulator at the outlet of the vaporizer to 0.35 bar (5 psig) or at the desired pressure. This pressure should be kept as low as possible to reduce the risk of vapor re-liquification. The system should now be ready for use. The vaporizer is designed to be used continuously or can also be used for just the amount of time necessary. NOTE During the first few days of use it is a good idea to blow-down the drip leg and strainer to remove any debris that may be left over from installation. Shutting down the system For overnight or short time periods: Because the vaporizer uses only a very small amount of electricity (approximately 300-600 watts) when there is no load, it is suitable to leave the power engaged even during periods of non-use. If desired, close the vaporizer outlet shut-off valve when the vaporizer is not being used. For extended periods: Close the vaporizer outlet shut-off valve. Open the disconnect switch to remove power from the vaporizer. Close the inlet valve or tank valve(s) only after the vaporizer has expanded the remaining gas and pushed it back toward the tank. Trapped liquid can expand when heated causing damage or possible rupture to piping and components. Always install hydrostatic relief valves between isolation valves. 32 MAINTENANCE 4 CAUTION To prevent ignition of hazardous atmospheres, 1. Any repairs internal to the flameproof enclosure must be made by the manufacturer. 2. Keep flameproof enclosure tight, torque to 40,6 Nm ( 30 ft. lbs.) while in service, and disconnect power before installing or removing unit from service. Servicing your ZIMMER TM ZIMMER TM vaporizers are designed to need very little maintenance. The amount and frequency of maintenance will depend on the quality of the LPG. The main servicing points for the system will be the drip leg or heavy ends trap, the inlet strainer and the inlet valve screen. Drip Leg and Filter Blow down the inlet strainer and the filter or drip leg each time the LPG tank is refilled (or each time the cylinders are exchanged). Adjust this frequency as required. Inlet Valve (Cleaning Instructions) 1. 2. 3. 4. 5. Remove the inlet valve assembly from the heat exchanger assembly by unscrewing the six M6 bolts on the end of the unit. Unscrew the temperature sensing bulb, and gently slide it out of the valve to minimize capillary bending. Gently unscrew and remove the actuator assembly. (Note: It is extremely important to prevent capillary bending.) Inspect the bulb for pitting or corrosion. Replace if necessary. (Z40L P/N 40425 and Z40P P/N 40424) Unscrew the valve seat assembly and remove the parts enclosed (shaft, ball, ball seat, spring, and spacers). Some of the parts, including the stainless ball, are magnetic, for ease of removal. (Note: Make note of the exact order that the previously mentioned parts are stacked in the unit. This includes counting the number and orientation of the spacers.) 33 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 34 Inspect the valve seat and ball. If the seating surface is smooth and does not show pitting, wipe clean and re-install. If the seat or ball is pitted, replace with a new assembly (usually once a year). Adjust frequency as required. Clean the shaft, spring, spacers and valve seat assembly opening with a solvent. Put the assembly back into the opening in the original order (noted in step 4). Make sure that the rounded (smooth) side of the ball seat (washer that the ball rests on) is facing the ball. Install new "O" rings (2) if needed (P/N 33906 and P/N 33904) Brush the threads of the valve seat assembly and "O" rings with lithium grease. Screw in the valve seat assembly (torque setting: 28-35 ft-lbs or 38-47 N-m). Brush the threads of the actuator assembly with lithium grease. Screw in the actuator assembly without bending the capillary (torque setting: 25-30 ft-lbs or 34-40 N-m). (Note: There is no elastomer/"O" ring in this joint, it is a metal to metal connection) Brush the threads of the temperature sensing bulb with lithium grease. Screw in the temperature sensing bulb. Check the inlet screen to make sure it is not clogged with debris. Clean with a solvent or replace as necessary (screen P/N 0901-5017 and retainer P/N 60310). (Note: Once the screen is removed, it must be replaced with a new part) If the proper strainer is installed upstream, this screen should not become contaminated. Unscrew the brass plug from the "high pressure bypass valve" (located adjacent to and under the actuator). Remove the spring, check valve and "O" ring and clean with a solvent. Also clean inside the opening. Place the "O" ring, check valve and spring back into the opening (See "Inlet Valve Detail" diagram for the order). Brush the threads of the brass plug with appropriate thread sealant. Screw in the brass plug back into the valve body. Replace the four "O" rings between the heat exchanger and valve assembly joint (P/N 33905) and re-attach the inlet valve to the main ZIMMER TM assembly. Conduct a pressure leak test on the unit. Heating System Perform the following test to ensure the Z40 heaters are functioning properly: 1. Let unit cool for 5-6 hours. 2. Attach an ammeter to one leg of the power (black wire). 3. Apply power and record amperage after 20 seconds. Results: 110 VAC current > 32.5 amps 208 VAC current > 20.5 amps 220 VAC current > 19.5 amps 230 VAC current > 18.5 amps 240 VAC current > 17.5 amps Relief Valve Always make certain the safety pressure relief valve cover remains in place. This cover prevents water and foreign materials from collecting in the opening that may inhibit its pressure relieving ability. If this cover has come off the relief valve it usually indicates that the relief valve has opened. Before replacing this cover, leak test the relief valve by applying a soap-water solution to the top portion of the valve. 35 Pressure relief valves have a tendency to leak after they have opened. Additionally, some local regulations require periodic replacement of pressure safety relief valves. If you have reason to believe that this device has opened or is leaking, it should be replaced. CAUTION – HOT! When removing the vaporizer cover always make sure the vaporizer has cooled prior to touching! Actuator assembly with sensing bulb Valve seat assembly with o-rings Shaft Ball Pressure Relief Valve Ball seat Brass Plug Reducing bushing Spring Spring Check Valve Spacers (Generally 2 in the LPG model and 4 and the Propane model) O-ring Inlet valve screen and retainer (only in the Spacer(s) Propane Propaneonly model) models Gauge or Drain port (Temperature sensing bulb) Inlet Valve Detail 36 5 TROUBLESHOOTING The ZIMMER TM is a very simple device with few areas for problems to occur. The main areas of the vaporizer are the inlet valve and the heat exchanger. The heaters used are not ordinary resistance heating elements. The heaters do not have wire filaments that are susceptible to burn-out. Possible problems TREE #1 INLET VALVE DOES NOT OPEN W HEN POW ER IS APPLIED Yes Is aluminum casting heating? Has power been applied for at least 20 min.? No Yes Yes W ait 30-60 min. for valve to open. Is the capillary tube between bulb and actuator broken? Note: May have to replace bulb with known functional assem bly to determine if it is broken. Yes No No Do you have 120-240 VAC at Zimmer wiring assembly? Heater system not functioning. Replace with: P/N 40750 (UL/CE) or P/N 40751 (non approv.) Yes No Is circuit breaker or fusing opening at power start? No Fix wiring. Replace actuator: Z40L: P/N 40541 or Z40P: P/N 40531 Yes Yes W rap insulation around valve. Is it cold and windy at startup? Note: Less than Z40P: -20°F (-29°C) Z40L: 20°F (-7°C) No Heater system not functioning. Replace with: P/N 40750 (UL/CE) P/N 40751 (non approv.) Are high in rush type curcuit protection devices used in circuit and sized appropriately for the Zim mer? 208V-240V 30A High inrush Type 100V-120V 40A High inrush Type Note: Page 36 shows typical high inrush profile. No Change to high in rush type circuit protection Z40L with greater than 40% propane. It will take longer than 20 min. to function. W rapping insulation around valve will im prove performance and startup tim e. 37 TREE #2 INLET VALVE CLOSES DURING OPERATION Measure current as pressure drops. Is alum inum casting less than 130°F (54.4°C) as pressure drops at the outlet? Yes No Is there frosting or water condensation on any of the inlet piping? Yes Is the current m easurem ent greater than 19.5 am ps at 220 VAC or greater than 32.7 am ps at 110 VAC? Yes Correct pressure losses in liquid piping. No Is there debris on inlet screen of the zim m er valve? Yes No Clean the screen. Exceeding vaporizer capacity. Lower capacity or add additional vaporizers. Allow Zim m er to com pletely cool for 5-6 hours. Apply power and m easure current at 20 seconds. 110 VAC current > 32.5 am ps 220 VAC current > 19.5 am ps Yes Heater system not functioning. Replace with: P/N 40750 (UL/CE) P/N 40751 (non approv.) 38 Is it cold and windy during operation? Note: Less than Z40P: -20°F (-29°C) Z40L: 20°F (-7°C) No W rap insulation around valve. Z40L with greater than 40% propane. It m ay take longer than 60 m in. to function. W rapping insulation around valve will im prove perform ance and startup tim e. No REPLACEMENT PARTS ASDI P/N Item 5 Description Heater Assembly - 7 heaters, spacer, buss plate and insulation pad Heater Assembly - 14 heaters, spacer, buss plate and insulation pad Inlet valve rebuild kit (LPG) spring, seat, ball, o-rings Inlet valve actuator assembly (LPG) - actuator, gland nut, o-ring Replacement valve (LPG), complete, (includes O-Ring) Inlet valve rebuild kit (Propane) spring, seat, ball, O-Rings Inlet valve actuator assembly (Propane) - actuator, gland nut, oring Replacement valve (Propane), complete, (includes O-Ring) Inlet valve rebuild kit (50/50 LPG) spring, seat, ball, O-Rings Inlet valve actuator assembly (50/50 LPG) - actuator, gland nut, o-ring Replacement valve (50/50 LPG), complete, (includes O-Ring) Replacement shell - top and bottom, fasteners 6 1 1 2 3 4 2 3 4 2 3 4 6 50/50 70/30 PROPANE Recommended replacement interval 40560 40560 40560 N/A 40565 40565 40565 N/A 40540 2 years 40541 3 years 40545 N/A 40530 2 years 40531 3 years 40535 N/A 40530 2 years 40561 3 years 41052 N/A 40550 40550 40550 only required if damaged Relief valve 33909 33909 33909 After valve opens or as required by local codes 7 O-ring ZIMMERTM Valve 0.070"w x 3/4" ID 33905 33905 33905 N/A 8 Screw, ZIMMERTM Cover Assembly 61053 61053 61053 N/A 61048 61048 61048 N/A 40751 40751 40751 N/A 40750 40750 40750 N/A TM 9 10 10 Washer for ZIMMER Cover use with p/n: 61053 Heat Exchanger Field Replacement Assy. Heat Exchanger Field Replacement Assy. UL/CE 39 FAQ’s 7 Q1: A1: What voltages can the ZIMMER TM operate on? The UL/CE listing is valid for any voltage between 100 – 240VAC. (1 phase only) Q2: A2: Does the ZIMMER TM obtain the same maximum capacity regardless of the supply voltage? No. The 40kg/hr (20 gal/hr) rating is based on 220VAC. The capacity is reduced to 30kg/hr (15 gal/hr) when operated on 110V. Q3: A3: What is the capacity rating based on? The capacity is based on using a 220V power supply and with LPG having a maximum butane percentage as stated per model (Z40P or Z40L) at a temperature of 104F (40 C) and no pump. Q4: A4: Can the ZIMMER TM use any mixture of propane and or butane? There are two versions of the ZIMMER TM - one for commercial propane (Z40P), and one for standard LPG, 70% Butane/ 30% Propane (Z40L). The ZIMMER TM is not designed for use with commercial butanes. The Z40P is designed to operate with a maximum of 15% butane; the Z40L is designed to operate with a maximum of 80% Butane and ideally with 60-80% Butane. Using less than 60% Butane in the Z40L will result in reduced capacity. Specific vapor pressure curves are available upon request. Q5: A5: What is the operating temperature? The ZIMMER TM uses self-regulating heaters that are not fixed resistance. This means that the ZIMMER TM does not have a fixed temperature setting. The ZIMMER TM will reach its peak temperature at idle, at which point it will consume the least amount of energy. As the flow rate increases, heat is drawn from the heaters causing the resistance to decrease and allowing them to produce more energy. Q6: A6: What is the pressure drop at maximum flow? This depends on the pressure. At 100 psig (7kg/cm2) the pressure drop is less than 1 psig (0.07 kg/cm2). Q7: A7: What prevents liquid from passing downstream? The vapor temperature at the exit of the vaporizer in combination with the pressure exerts a specific force against a preset spring and ball assembly. As the temperature drops the resulting decrease in force on the spring causes the ball to modulate closed against the valve seat. The temperature and pressure curves are matched to commercial propane and high butane content LPG. Q8: A8: Can liquid pass downstream when the electricity fails? No. Because the inlet control valve does not require electricity to operate, it is failsafe. The valve operates as stated in A7 to ensure that no liquid passes downstream. Q9: A9: Because there are no switches, what prevents the heaters from overheating? The ZIMMER TM heaters are not traditional filament-type resistance heaters. Instead, the heaters are made from a special ceramic-like silicon material that cannot exceed a certain temperature. If the heaters are subjected to a higher temperature during use the molecular structure will degrade into an infinite resistance form yielding no heat output. Q10: Can I leave my ZIMMER TM on overnight while it is not in use? A10: Yes. Your ZIMMER TM was designed for continuous use. Additionally, the ZIMMER TM will consume very little energy while it is not in use (typically 300-600 watts). 40 Q11: If the power goes out for a brief period of time, will it shut down the gas supply to my burners or pilots? A11: Generally, no. For short power outages the ZIMMER TM will continue operating – even without power. Although no additional heat will be added, the heat sink generally will have enough reserve energy to sustain a short power outage. When the power comes back on the heat-sink will be replenished. Since the inlet control valve does not require electricity for operation, its function is independent of the power supply. Q12: Does the ZIMMER TM have to be horizontally mounted on a wall? A12: If the ZIMMER TM is mounted outdoors it should be mounted horizontally on a wall or structural support. Q13: What is the recommended first stage regulator? A13: Fisher 627-417/V1 or Rego X1584MN. Q14: Can the ZIMMER TM be used in an economy configuration like the XP vaporizers? A14: It is possible, but at present Algas-SDI does not offer an economy kit for the ZIMMER TM. Q15: How many Watts does the ZIMMER TM use when it is at idle? A15: About 300-600 Watts – similar to 2 residential light bulbs. Q16: What is the minimum temperature rating for the ZIMMER TM? A16: The UL/CE approval is valid for –20 degrees F. Q17: Does the capacity need to be de-rated at the minimum temperature? A17: No. In fact the ZIMMER TM will actually vaporize more at lower temperatures. Q18: What is the "maximum current draw"* from the ZIMMER TM and under what conditions does this A18: occur? The maximum current will occur at the maximum capacity, lowest temperature and lowest voltage. The maximum power output will occur at the same conditions, except at the highest voltage. 22.1A @ 240V (-20 F) 25.5A @ 208V (-20 F) 33.3A @ 120V (-20 F) 21.6A @ 220V (40 F) * Maximum current draw is defined as anything after the first five seconds preceding a cold start. 41 ZIMMERTM CURRENT AND POWER CHARTS ZIMMER, MODEL Z40 POWER VS INLET TEMPERATURE AT RATED CAPACITY 5.5 5 POWER - Kw 4.5 LPG @ 220V & PROPANE @ 220V& 220V 4 3.5 LPG @ 3 PROPANE @ 120V 2.5 -20 -10 0 10 20 30 40 50 INLET TEMPERATURE - C ZIMMER, MODEL Z40 CURRENT @ 240V / -20C AMPS 80 1 70 Event 1: Power turned on with no flow through vaporizer. CURRENT - AMPS 60 Event 2: Inlet valve opens and vaporizer is ready for service. Typically 10 to 20 minutes if using the fast start procedure (see procedure on page 27). 50 40 30 20 Event 3: 40 kg/hr flow demand is established through vaporizer. 3 2 10 0 0 10 20 30 40 50 60 TIME ZIMMER, MODEL Z40 CURRENT @ 120V / -20C AMPS 70 Event 1: Power turned on with no flow through vaporizer. 1 60 CURRENT - AMPS 50 Event 2: Inlet valve opens and vaporizer is ready for service. Typically 10 to 20 minutes if using the fast start procedure (see procedure on page 27). 40 30 2 3 20 Event 3: 40 kg/hr flow demand is established through vaporizer. 10 0 0 10 20 30 TIME 42 40 50 60 43 44 Algas-SDI International, LLC 151 S. Michigan Street Seattle, Washington 98108 USA Ph.: 1.206.789.5410 Fax.: 1.206.789.5414 www.algas-sdi.com ">
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Key features
Dry electric LPG or Propane vaporizer
Allows greater capacities from smaller LPG storage
Suitable for hazardous locations
Heat exchanger proof tested to 172 bar (2500 psig)
Wide voltage range operation (100-240 VAC)
Self-regulating heaters
Frequently asked questions
The UL/CE listing is valid for any voltage between 100 – 240VAC. (1 phase only)
No. The 40kg/hr (20 gal/hr) rating is based on 220VAC. The capacity is reduced to 30kg/hr (15 gal/hr) when operated on 110V.
The capacity is based on using a 220V power supply and with LPG having a maximum butane percentage as stated per model (Z40P or Z40L) at a temperature of 104F (40 C) and no pump.
The vapor temperature at the exit of the vaporizer in combination with the pressure exerts a specific force against a preset spring and ball assembly. As the temperature drops the resulting decrease in force on the spring causes the ball to modulate closed against the valve seat. The temperature and pressure curves are matched to commercial propane and high butane content LPG.
No. Because the inlet control valve does not require electricity to operate, it is failsafe. The valve operates as stated in A7 to ensure that no liquid passes downstream.
