Algas SDI Direct Fired 80/40H Operation & Maintenance Manual

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...Innovative liquid vaporizing and gas mixing solutions

LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H

Operations & Maintenance

Manual

151 South Michigan Street, Seattle, Washington, USA 98108

Tel: +1 206-789-5410 Fax: +1 206-789-5414 Web: www.algas-sdi.com

FILE: MANUAL PN 52642 DIRECT FIRED 5-10-21

Samuel Oyen

2021.05.07 17:33:46 -07'00'

WARNING

Read the OPERATION MANUAL before operating this equipment.

■ NOTE: Algas-SDI reserves the right to use alternate manufacturers’ components as vendor delivery applicability dictates. Literature contained in the Operation Manual has been supplied by vendors. Please check to be sure supplied data matches your configuration. Contact Algas-SDI if any questions exist.

■ This equipment uses LPG-a flammable fuel, handled under pressure.

Inherent hazards exist and a thorough understanding of the equipment is required to allow safe operation and maintenance.

■ Allow only a TRAINED and FULLY QUALIFIED PERSON to service this equipment.

■ Any time a component must be replaced, use the same type, model, etc. DO NOT SUBSTITUTE! The consequence from such actions are unpredictable and may lead to dire consequences. When components are replaced with components not approved for use in our UL listed equipment, the UL listing becomes void for that unit.

Warranty Registration

A Warranty Registration Card is located on the last page of this manual. Fill it out and send a copy either by mail to the address shown at the bottom of the form or submit via email to [email protected].

Warranty, Copyrights and Approvals

WARRANTY

Algas-SDI International, LLC (ASDI) warrants that the equipment is free of defects in materials and workmanship under normal use and service. ASDI agrees to repair or replace, at our option, without charge f.o.b. factory, any part which has proven defective to the satisfaction of Algas-SDI International, LLC within one (1) year from the date of the original installation or within 18 months from the date of shipment, whichever is earlier. Equipment, which in the opinion of ASDI, has been damaged by improper installation or operation, or has been abused or tampered with in any way, will not be accepted for return under warranty.

Algas-SDI International, LLC 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 Algas-SDI International, LLC purchase order. Algas-SDI

International, LLC 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.

Algas-SDI International, LLC 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 Algas-SDI International, LLC and excluded from these terms of sale. No person has any authority to bind Algas-

SDI International, LLC to any representation or warranty other than this warranty.

COPYRIGHT

Copyright 2021 by Algas-SDI International, LLC, Seattle, Washington 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 Algas-SDI International, LLC, Seattle, Washington,

USA.

APPROVALS

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Symbols and Conventions

Special symbols are used to denote hazardous or important information. You should familiarize yourself with their meaning and take special notice of the indicated information.

Please read the following explanations thoroughly.

GENERAL WARNING OR CAUTION

Indicates hazards or unsafe practices which can result in damage to the equipment or cause personal injury. Use care and follow the instructions given.

FLAMMABLE GAS HAZARD

Indicates a potential hazard which can result in severe personal injury or death. Use extreme care and follow the instructions given.

ELECTRICAL DISCONNECT REQUIRED

Indicates a potentially dangerous situation which can result in severe personal injury or death or damage to equipment. Use great care and follow the instruction given.

PARTS AND PRICES

For parts and prices contact your Algas-SDI distributor.

ASDI CONTACT NUMBERS

If you have questions, need help with your equipment, or want information on other products, contact your distributor or

Algas-SDI Global Support Center at:

Telephone: +1 206 762 4357

Facsimile: +1 206 789 5414

Email: [email protected]

Internet: http://www.algas-sdi.com

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Direct Fired Vaporizer Options

Auto Reigniter

Contaminant Separator / Filtaire

Economy Valve Kit

Inlet and Outlet Hand Valves

Pipe away Adapter

1st Stage Regulator

Introduction

Description/Overview

Figure 1 – Direct Fired Vaporizer System - Basic Features

How the vaporizer works

Direct Fired vaporizer specifications

Installation

General

Unpacking and Initial Assembly

Unpacking

Initial Assembly

Table 1 – Distance from Vaporizer

Figure 2 – Vaporizer Dimensions

Figure 3 – Installation – 40/40H, 80/40H, and 120/60H vaporizers

Liquid Supply Line

Table 2 – Recommended Liquid Supply Line Size

Vapor Distribution Line

Table 3 – Recommended Vapor Distribution Line Size

2-4

Liquid Inlet

Vapor Bypass Line (Optional)

Burner Supply Line (Optional)

Liquid Pump (Optional)

2-8

Economy Installation (Optional)

Contaminant Separator – Filtaire (Optional)

Figure 4 – Filtaire Operation

2-8

2-9

Installing Multiple Units in Parallel 2-9

Figure 5 – Installing Multiple Units in Parallel

Figure 6a – Installing Multiple Units in Parallel, Oversized Manifold, side inlet/outlet

2-9

2-10

Figure 6b – Installing Multiple Units in Parallel, Oversized Manifolds, center inlet/outlet 2-11

2-11 Air Requirements for Installation in an Enclosure

Table 4 – Cross-Sectional Inlet/Outlet Air Requirements

Leak Test

2-11

Check Burner Input Pressure

Installation Safety Requirements

2-11

2-12

2-6

2-7

2-5

2-6

2-6

1-1

1-2

1-3

Operation

Direct Fired Vaporizer start up procedure

Figure 7 – Temperature control dial in “RUN” position

Figure 8 – Pilot button pressed down and igniter switch on

Direct Fired Vaporizer setpoint adjustment

Direct Fired Vaporizer shutdown procedure

Figure 9 – Vaporizer shut down procedure

Direct fired vaporizer purge procedure

Automatic Re-Ignition Operation

Maintenance

Service and Maintenance

Table 5 – Initial Installation and Operation inspections

Table 6 – Recommended annual maintenance and inspections

Direct Fired vaporizer inspection checklist

Replacing reigniter battery

Figure 10 – Opening the battery access door

Figure 11 – Replacing the battery

Adjusting burner input pressure

Figure 12 – Adjusting burner input pressure

Liquid inlet valve maintenance procedure

Capacity control valve maintenance procedure

Troubleshooting

Pilot

Igniter Will Not Spark

Main Burner Will Not Ignite

If Vapor Pressure Drops

Troubleshooting Tree #1: Pilot Will Not Light

Troubleshooting Tree #2: Pilot Lights But Will Not Hold

Troubleshooting Tree #3: Igniter Will Not Spark

Troubleshooting Tree #4: Main Burner Will Not Light

Troubleshooting Tree #5: Vapor Service Pressure Drops

Appendix A: Technical Information

Figure 13 – 40/40H Vaporizer Replacement Parts

Figure 14 – 80/40H and 120/60H Vaporizer Replacement Parts

Figure 15 – Inlet Valve and Capacity Control Valve

Table 7 – Repair kits and other available replacement parts

Liquid Inlet valve pin gasket installation procedure

40/40H Equipment drawing

80/40H Equipment drawing

120/60H Equipment drawing

4-17

4-18

4-20

4-21

4-22

4-23

4-25

3-13

3-14

3-15

3-16

5-26

5-27

5-28

5-29

5-30

5-31

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Direct Fired Vaporizer Options

Electronic Auto Reigniter

Auto Reigniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit

FILTAIRE

Contaminant Separator

A contaminant separator is recommended for all Direct Fired Vaporizer installations. To properly size the FILTAIRE TM contact Algas-SDI with total connected load and high pressure (first stage) regulator setting.

See Page 2-9 for Details

Economy Valve Kit

Economy Valve Kit P/N: 41051, Quantity 1 per unit See Page 2-8 for Details

Inlet and Outlet Isolation Valves

3/4" inlet valve use P/N 33803, Quantity 1 per unit

1" outlet valve use P/N 33814, Quantity 1 per unit

Pipeaway Adapter

Pipeaway Adapter 3/4", P/N: 34877, Quantity 1 per unit

1st Stage Regulator

1" 5-20 PSIG (0.35-1.4 bar), Use P/N: 33725, Quantity 1 per unit

Introduction

Description/Overview

Algas-SDI is an ISO 9001 registered company. Direct Fired Vaporizers are manufactured under strict accordance with ASME, UL and PED requirements and carry the associated marks and the ASME "U" stamp.

A Direct Fired vaporizer, as the name implies, is one in which heat is furnished by an open flame directly applied to the heat exchange surface, which in turn contacts the LP Gas liquid that is to be vaporized. Algas-SDI Direct Fired vaporizers consist of seven (7) main components:

◼ Liquid inlet valve and float assembly

◼ Liquid reservoir or heat exchanger

◼ Burner supply regulator

◼ Thermostat

◼ Burners

◼ Capacity control valve

◼ Relief valve

Figure 1 – Direct Fired Vaporizer System - Basic Features

Excess Flow

Valve

Relief Valve

Distribution

Line

Regulator

Vapor

Liquid

Vapor

Float Ball

Liquid

Inlet

Valve

Pressure

Vessel

Liquid

Burner

Regulator

Thermostat

Heat Load

Burner

Algas-SDI Operation and Maintenance Manual – P/N – 52642

Pilot Assembly

1-1

Introduction

HOW THE VAPORIZER WORKS

When the shut-off valve in the liquid supply line is opened, liquid is forced into the heat exchanger by the pressure in the storage tank. As the liquid level rises, some of the liquid boils off until it matches the pressure coming from the tank.

The flow of liquid into the heat exchanger will stop when the rising liquid forces the float ball upward, closing the liquid inlet valve, or when the pressure in the heat exchanger is the same as the pressure coming from the storage tank.

When the burner(s) is lit, the heat will boil off the liquid in the heat exchanger.

During periods of low or no demand, the pressure will build up to the storage tank pressure. Whenever pressure in the heat exchanger starts to increase above the tank pressure, the pressure differential will cause the LP gas to flow back through the inlet valve to the tank.

Due to the boiling action and the flow back to the tank, the liquid level in the heat exchanger will drop. When the liquid level drops, the temperature sensor

(thermostat) will sense the warmer vapor and cycle off the main burner(s).

As the demand increases, the pressure in the heat exchanger will drop. As a result, liquid will flow into the heat exchanger, and the thermostat will sense the cool liquid and cycle the main burner(s) on.

During continuous operation, the burner(s) will cycle on and off to maintain the required supply of vapor. As long as the rate of vaporization exceeds the demand, the heat exchanger will contain a very small amount of liquid. The only time the heat exchanger will contain a large amount of liquid is when the demand is equal to or above the capacity of the vaporizer.

Whenever the demand exceeds the capacity of the vaporizer, the capacity control valve is engaged, which limits the withdrawal rate from the exchanger to the maximum capacity of the vaporizer.

The capacity control valve is a spring-loaded valve mounted on the outlet of the exchanger. Liquid LP gas is supplied to the top of the valve and vapor from the exchanger to the bottom of the valve. During normal operation, the valve is held open by the force of the spring.

When the liquid/vapor pressure differential exceeds the spring force, the liquid pressure will begin to close the valve. This restricts the flow out of the vaporizer.

Any increase in demand will create greater pressure drop. In turn, the valve will further restrict the flow of vapor from the unit. This throttling action will cause the gas outlet pressure to drop, allowing the pressure in the heat exchanger to build back up and maintain proper gas supply to the vaporizer’s burner(s) and keep the vaporizer in operation.

1-2 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Introduction

DIRECT FIRED VAPORIZER SPECIFICATIONS:

BURNER INPUT

40/40H

80/40H

120/60H

51,360 BTU/hr (15 kW) per burner

77,040 BTU/hr (22.5 kW) per burner

GAS CONSUMPTION: Approximately 1,000 BTU/hr (0.3 kW) per gallon (3.79 liters) of propane vaporized

TOTAL BURNER INPUT

40/40H: 51,360 BTU/hr (15 kW) THERMOSTAT PORT PRESSURE*: 10” W.C. (24.9 mbar)

BURNER PRESSURE: 9 ” W.C. (22.4 mbar)

80/40H: 102,720 BTU/hr (30 kW) THERMOSTAT PORT PRESSURE*:

9” W.C. (22.4 mbar)

BURNER PRESSURE: 7 ” W.C. (17.4 mbar)

120/60H: 154,080 BTU/hr (45 kW) THERMOSTAT PORT PRESSURE*: 14” W.C. (34.9 mbar)

BURNER PRESSURE: 12 ” W.C. (29.9 mbar)

PILOT BURNER: 2,200 BTU/hr (0.64 kW)

NOMINAL OPERATING TEMPERATURE**: 140 to 160



F (60 to 71ºC)

* Thermostat Port Pressure measured at the pressure port at the outlet of the thermostat on the main burner line.

** Operating Temperature depends on ambient temperature, thermostat setting, and operating pressure.

Algas-SDI Operation and Maintenance Manual

– P/N – 52642 1-3

Installation

GENERAL

•

Install the system so it complies with all governing codes and regulations.

•

Make up all threaded pipe connections with a sealing compound that is approved and listed for LP gas service.

•

All above ground lines should be adequately supported.

•

Any underground piping should be properly protected against corrosion.

•

Vapor outlet piping should be installed such that the first stage regulator is placed higher than the vaporizer outlet. This allows condensation in the vapor line to flow back to the vaporizer.

•

Clean all foreign material from all pipes prior to making final connections.

•

Test all joints as specified in the applicable codes for leaks before placing the piping system in service.

Unpacking and Initial Assembly

UNPACKING

Upon receiving the vaporizer inspect package for any damage that may have occurred during shipping. Carefully open package, inspect unit for damage, and remove all plastic shipping material and wood shipping base from the vaporizer.

INITIAL ASSEMBLY

Install the Flue cap(s) on the top of the unit with the supplied hardware.

Install the vaporizer a minimum of 15 feet (4.6 m) from the storage tank valves

(see Table 1 below).

Secure vaporizer through the four (4) ½ inch holes (see Figure 2) on above ground level, solid, non-combustible base,

The vaporizer should be adequately protected against damage by moving vehicles.

If the vaporizer is to be installed in any building or enclosure, a relief valve pipe away and regulator relief pipe away must be installed. The relief valve and regulator relief must be able to relieve outside of any enclosure or building.

Table 1 – Distance from Vaporizer

Exposure

Storage Tank

Storage tank shutoff valves

Point of transfer

Nearest important building or group of buildings or line of adjoining property which may be built upon

(except buildings in which vaporizer is installed).

Reference NFPA58

Minimum Distance From

Vaporizer Required

10 feet (3 m)

15 feet (4.6 m)

25 feet (7.6 m)

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-4

Figure 2 – Vaporizer Dimensions (shown in inches)

Installation

40/40H Vaporizer

80/40H and 120/60H Vaporizers

Model

40/40H

80/40H

120/60H

“A”

35” (0.89 m)

44 ¼” (1.12 m)

Algas-SDI Operation and Maintenance Manual – P/N – 52642

“B”

29” (0.74 m)

37 ¾” (0.96 m)

“C”

20” (0.51 m)

28 ¾” (0.75 m)

2-5

Installation

Figure 3 – Installation – 40/40H, 80/40H, and 120/60H vaporizers

CAUTION

The entire installation must be leak tested prior to operating the system.

NOTE

Do not connect this vaporizer to a storage tank that has been used in vapor withdrawal service until the tank has been emptied and all sediment and heavy ends have been cleaned from it.

LIQUID SUPPLY LINE ( see Figure 3 )

The liquid supply line should be adequately sized for the service.

Table 2 – Recommended Liquid Supply Line Size (Nominal Pipe Size)

Liquid Line Length Ft. (m) Up to 50 (15) 50-150 (15-36) 150-250 (36-76)

40/40H Vaporizers

80/40H Vaporizers

120/60H Vaporizers

3/4 ” (DN20)

1 ” (DN25)

1” (DN25) 1-

1 ” (DN25)

1/4” (DN32)

1” (DN25) 1-1/4 ” (DN32) 11/2” (DN40)

VAPOR DISTRIBUTION LINE ( see Figure 3 )

The vapor distribution line should be adequately sized for the service.

Table 3 – Recommended Vapor Distribution Line Size (Nominal Pipe Size)

Gas Line Length Ft. (m)

40/40H Vaporizers

80/40H Vaporizers

120/60H Vaporizers

Up to 50 (15) 50-150 (15-36) 150-250 (36-76)

1” (DN25) 11/2” (DN40) 2” (DN50)

11/4” (DN32) 1-1/2” (DN40)

11/2” (DN40) 2” (DN50) 2-

2” (DN50)

1/2” (DN80)

2-6 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Installation

1. Install a UL listed shut-off valve with a minimum 250 psig (17.24 bar) gas pressure rating.

2. Install a 0-300 psig (0-20.7 bar) pressure gauge (or provisions for one) ahead of the 1 st stage regulator.

3. Install the first stage regulator as close to the vaporizer as possible, but not further than 24” (0.6 m) from the outlet of the vaporizer. The outlet pressure of the regulator should be set at 4 to 6 psig (0.3 to 0.4 bar) lower than tank saturated vapor pressure at lowest expected temperature; this may require periodic adjustment.

4. The second stage (or low pressure) regulator should be installed as close to the consuming equipment as practical.

5. A line relief valve may be installed (optional) to protect the regulators from excessively high pressure. If a line relief valve is used, set the blow pressure at approximately 10 PSI (0.7 bar) above the first stage regulator delivery pressure.

LIQUID INLET

NOTE

Do not install a check valve in the supply line between the tank and the vaporizer. Liquid must be able to flow both ways in that line.

1. Install the 60-mesh 3/4" strainer that is supplied with the unit on the liquid inlet to the vaporizer.

2. Install a UL listed shut-off valve with a minimum 250 psig (17.24 bar) gas pressure rating.

3. Install a 0-300 psig (0-20.7 bar) pressure gauge (or provisions for one) ahead of the liquid inlet valve.

4. The liquid line from the storage tank to the vaporizer should be of sufficient size to supply the vaporizer at full capacity with a maximum pressure drop of less than the hydrostatic head pressure ( see NFPA 54 ).

5. Connect the vaporizer to the storage tank.

VAPOR BYPASS LINE - see Figure 3

1. Install a primary (first stage) regulator at the vapor outlet on top of the storage tank. Set this regulator to deliver gas at a pressure of 2 to 4 psig

(0.14 to 0.3 bar) below the setting of the vaporizer regulator. Then, if the vaporizer is overloaded or its output pressure drops off, the regulator on top of the storage tank will automatically take over.

2. Run a line from the regulator and tie it into the vapor service line downstream of the vaporizer first stage regulator.

3. Although vapor bypass line is not required for proper operation, it is recommended for all installations.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-7

Installation

BURNER REGULATOR SUPPLY LINE (OPTIONAL)

Vaporizer burners are supplied with vapor from the outlet of the vaporizer where the least possibility of condensation will take place. In regions where there is a problem with a high content of heavy ends in the LP gas, a separate vapor supply line to the burner regulator on the vaporizer may be installed. If a separate burner supply line is used, the following is recommended:

1. Disconnect the ¼” line at the burner regulator inlet.

2. Disconnect the ¼” line at the tee on top of the heat exchanger and plug it with ¼ NPT plug.

3. Install a first stage regulator as close to the tank vapor outlet as possible. A manual shut-off valve should be installed ahead of the regulator.

4. Connect the supply line from the first stage regulator to the burner regulator at the vaporizer. Make sure that the supply is sized properly to handle maximum input rating of the vaporizer burner(s).

LIQUID PUMP (OPTIONAL)

The liquid pressure to the inlet of the vaporizer must be a minimum of 6 psig (0.4 bar) higher than desired discharge pressure. If tank pressure cannot meet this requirement, install a pump in the liquid line under the storage tank to maintain the minimum pressure.

ECONOMY INSTALLATION (OPTIONAL)

A vaporizer with economy operation draws vapor from the tank as the primary source and utilizes the vaporizer only when needed. The intent is to allow the most economical operation and eliminate energy waste. For the Economy Valve field installation kit, use P/N 41051. The valve modulates open and closed as the tank pressure rises and falls. The Economy Valve is a mechanical device and requires no electricity to operate. Make sure the Economy Valve is correctly installed. Verify the flow direction on the rating plate during installation. Contact

Algas-SDI for set-point information.

CONTAMINANT SEPARATOR – FILTAIRE (OPTIONAL)

FILTAIRE is a filtering device designed to trap heavy hydrocarbons commonly present in LPG gas vapor. It also traps other materials, which may be in the gas due to storage conditions and internal condition of the equipment.

Impurities are collected in the system and periodically removed through the system blow down drain. Residual heavy end hydrocarbons with boiling points higher than pure LPG are trapped by the filter and fall to the bottom for removal.

A complete FILTAIRE system consists of inlet and outlet connections, a blowdown drain (5), a pressure gauge (4), a vent which is normally plugged (6), and a bypass valve system for cleaning (1, 2, and 3). The bypass valves enable the system to continue operating when the FILTAIRE is removed for cleaning ( see

Figure 4).

Note: Items 4, 5 and 6 are included with FILTAIRE assemblies.

2-8 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Figure 4 – Filtaire Operation

OUTLET VALVE 3

“FILTAIRE” OIL DEMISTER

BY PASS VALVE 1

(NORMALLY CLOSED)

VAPOR LINE

1ST STAGE

REGULATOR

VAPOR FROM

VAPORIZER

2 INLET VALVE

PIPE

STAND

5 DRAIN

VALVE

Installation

VAPOR

TO LOAD

To properly size the FILTAIRE TM contact Algas-SDI with total connected load and high pressure (first stage) regulator setting.

INSTALLING MULTIPLE UNITS IN PARALLEL

For balanced performance of the system, piping should have equal distance from the main liquid line to each vaporizer inlet and from the outlet of each vaporizer to the main vapor distribution line. Only same model vaporizers shall be manifolded and installed together.

Figure 5 – Installing Multiple Units in Parallel

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-9

Installation

AN OVERSIZED INLET AND OUTLET MANIFOLD MAY ALSO BE USED TO BALANCE THE FLOW.

Figure 6a – Installing Multiple Units in Parallel, Oversized Manifolds with side inlet/outlet

Figure 6b – Installing Multiple Units in Parallel, Oversized Manifolds with center inlet/outlet

2-10 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Installation

ENCLOSURE AIR REQUIREMENTS

If vaporizer must be housed inside an enclosure or other enclosed area, the following requirements for fresh air intake and exhaust outlet area must be met.

Failure to do so will result in improper operation and damage to the equipment.

Table 4 – Cross-Sectional Inlet/Outlet Air Requirements

Vaporizer

40/40H

Inlet Air, Louver Area in 2 (cm 2 )

25.7 (166)

Outlet Exhaust, Flue

Annular Area in 2 (cm 2 )

7.9 (51)

80/40H 51.4 (332) 15.8 (102)

120/60H 77.1 (497) 23.7 (153)

LEAK TEST

CAUTION

Leak test the entire installation prior to operating the system.

1. Close the outlet valve.

2. Slowly open the inlet valve and allow pressure to equalize in the vaporizer.

3. Apply a liberal amount of soap/water solution to ALL internal and external flanged, threaded, and tubing connections.

4. Check for any leaks by observing new bubble formation in the soap/water solution.

5. Repair any leaks before continuing. Leak test until system has no leaks.

NOTE

If using direct fired vaporizers in mobile or temporary applications, leak test must be performed each time vaporizer has been moved or re-located.

CHECK BURNER INPUT PRESSURE

See Adjusting burner input pressure on page 4-22.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-11

Installation

Installation Safety Requirements

NOTE

Burner supply regulator 1 st and 2 nd stage vents shall be piped away from vaporizer if required by local codes and regulations, or when installed in a building, enclosure, or other situation with potential to accumulate flammable gases.

Ensure that vent piping is adequately supported to prevent damage to regulator. Reference equipment drawing for vent location and thread size. Always pipe away regulator vents to a safe location with no source of ignition. Ensure vents are not blocked with debris.

NOTE

For installations or locations in Canada it may be required to vent the integral pressure relief of the burner supply regulator. For those installations or locations venting must be installed in accordance with all requirements defined by CSA B149.1 Natural Gas and

Propane Installation code latest revision.

NOTE

Pressure relief valve discharge on direct fired vaporizers shall be piped to a point outside the structure or a building and shall point vertically upwards and be unobstructed.

2-12 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Operation

Direct Fired Vaporizer start up procedure

1. Before starting the vaporizer, close the outlet valve in the vapor service line.

2. Fill the vaporizer with LP gas liquid by slowly opening the liquid supply line valve between the storage tank and the vaporizer. If this valve is opened too quickly, the excess flow valve in the tank may close. If this occurs, close the liquid supply line valve and allow the excess flow valve to equalize and re-open.

3. If the vaporizer is installed with a separate burner supply line not connected to the vaporizer ( see page 2-8 ), open the valve supplying gas to the burner supply regulator.

4. Turn the temperature control dial on the thermostatic gas control valve counterclockwise to the "RUN" position. “RUN” position indicates that the pilot and main burner can start operating.

Figure 7 – Temperature control dial in “RUN” position

5. Turn the re igniter switch to “ON” and press the pilot button down (see

Figure 8). Continue to hold the pilot button for 30 to 60 seconds and release. Pilot should remain lit.

NOTE: If the ambient temperature is below 10°F (-12°C) when the pilot button is released it is likely that the main burner will immediately cycle on.

As soon as the LP gas inside the heat exchanger heats up above this temperature the main burner will cycle off. This is normal operation for the thermostatic gas valve.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 3-13

Operation

Figure 8 –Pilot button pressed down and igniter switch ON

WARNING

If pilot light goes off after releasing the pilot button, turn control dial

to "OFF", wait 5 minutes and repeat step 4.

6. Turn temperature control dial counter clockwise until burner(s) cycle on.

7. Allow burner(s) to heat the vaporizer until they cycle off.

8. Make sure all the valves on consuming equipment are closed and slowly open the valve in the vapor distribution line. Open all consuming equipment valves.

Direct Fired Vaporizer setpoint adjustment

On initial startup, set the temperature control dial to a setpoint between 5 and

7. If there is a drop in downstream pressure, it means that the capacity control valve is beginning to close due to the actual heat input not being able to satisfy system capacity. Rotate the dial to a higher setpoint to increase heat input until pressure at the outlet has stabilized.

3-14 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Operation

Direct Fired Vaporizer shut down procedure

(See Figure 9)

1. Turn temperature control dial to “OFF” position. Pilot flame should immediately extinguish.

2. Once the pilot flame has extinguished turn the igniter switch to “OFF”.

3. Close the isolation valve ahead of the burner regulator on the side of the vaporizer. This will prevent any fuel from going downstream to the thermostat, pilot and the main burner.

Figure 9 – Vaporizer shut down procedure

Isolation valve

Regulator

Thermostat

Direct Fired Vaporizer purge procedure

If the vaporizer is not going to be used for a long period of time, it should be purged. The information contained below is a step-by-step procedure on how to purge Algas-SDI direct fired vaporizer. This procedure should be followed anytime a vaporizer needs to be maintained, serviced, relocated, or shut down for any other reason.

WARNING

Prior to purging the vaporizer, ensure that there are no closed ball valves or back check valves restricting the flow of liquid to the tank.

1. Ensure all tank valves are open with no restrictions of flow back to the storage tank. A check valve restricting flow back to the storage tank must never be used in a vaporizer installation.

Algas-SDI Operation and Maintenance Manual

– P/N – 52642 3-15

Operation

2. Close outlet shut-off valve at the exit of the vaporizer.

3. Start burner per Direct Fired Vaporizer startup procedure and turn the thermostat temperature control dial to the highest setpoint (7).

4. After the burner cycles off, turn thermostat temperature control dial to

“OFF” position, shut off reigniter (if installed) and check that the pilot flame is extinguished.

5. After the pilot flame is extinguished, close shut off valve prior to the vaporizer in the liquid line.

6. Now open vaporizer outlet valve and flare or allow attached equipment to consume the remaining gas in the line.

7. After verifying the pressure in the lines is zero and no sources of ignition are present in the area, the vaporizer can now be disconnected.

AUTOMATIC RE-IGNITION OPERATION

Lighting or re-lighting of the pilot flame is accomplished by a spark across a gap of approximately 1/8" (3 mm) from the electrode tip to the grounded surface of the pilot. When the flame is established, the pilot flame conducts a current to the grounded pilot burner and a solid-state switch in the unit turns off the spark. If the pilot flame is extinguished, current to ground is interrupted and the solid-state switch turns on the spark, which sparks at a nominal timing of 100 times per minute, re-lighting the pilot flame well before the thermocouple cools enough to drop out the thermostat safety system.

3-16 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance

Maintenance Recommendations

Direct Fired Vaporizers are designed for trouble free and safe operation.

Because of the nature of their use, and the severe duty they receive, it is important to provide scheduled maintenance. The maintenance schedule, type and frequency, provided in this manual is the minimum maintenance required for proper and safe operation of your vaporizer. Ambient conditions surrounding the vaporizer installation and LPG quality may require a more frequent maintenance schedule. A list of spare parts and repair kits for proper maintenance is located in the Appendix section of this manual.

CAUTION

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

Component

Inlet Strainer

Main Burner

Assembly

Drip Leg

When servicing a component in the liquid or vapor line, BE SURE that the LP-gas supply is shut off to that component before removal or disassembly. Vaporizer must be completely purged before performing service. Be sure that ALL sources of ignition are extinguished within 25 feet (7.6 m) of the work area.

When flaring the contents of the vaporizer, be sure that the burners are on to prevent freezing during the flaring operation.

Table 5 – Initial Installation and Operation Inspections

Required 30-60 days after initial installation

Action Required

Inspect strainer and remove accumulated debris. NOTE: if debris accumulation is heavy check every 3-6 months or more frequent as required.

Check orifices and air supply openings on the burner tips for debris or foreign objects.

If needed, clean any plugged or obstructed orifices before restarting the vaporizer.

NOTE: In some applications vaporizer may be installed in an environment where excessive amounts of dust or debris are present. When vaporizer is located in this type of an environment, it may be necessary to check the burner tips on a frequent basis to ensure proper operation and capacity of the vaporizer.

Check the vaporizer drip leg, and any others present in the installation, for heavy ends and oil build-up. If present, first ensure there are no sources of ignition within 25 feet

(7.6 m), and then drain heavy ends. NOTE: In areas where LPG quality is poor it may be necessary for drip legs to be checked for heavy ends more frequently (monthly or bi-monthly depending on quality of LPG). Once it is verified that no significant quantity of heavy ends is accumulating during vaporizer operation, this maintenance can be performed on an annual basis.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-17

Maintenance

Table 6 – Annual Maintenance Requirements

Strainer

Thermostat

Thermocouple

Pilot Assembly

Main Burner Assembly

Pilot Flame Guide / Flame

Spreader Bar

Liquid Inlet Valve

Capacity Control Valve

Vaporizer Tubing

Relief Valves

Burner Regulator

Heat Exchanger

Annual Maintenance Items

Remove the plug and clean the screen. Replace screen if tears or holes are present (40 – 80 Mesh). If oils or contaminants are present, it may be necessary to use a cleaner to remove all of the contaminants.

Check thermostat for proper operation per the Start-up procedure .

Establish pilot and turn the thermostat dial counterclockwise to high, burners should cycle on. Turn the dial clockwise to the OFF ” position, main burner and pilot should both extinguish in a short period of time.

Replace the thermostat if not operating properly (thermostat cannot be serviced). NOTE: Before replacing the thermostat, be sure the thermocouple is delivering the proper voltage to the thermostat (see below).

Check electrical output of the thermocouple with a multimeter. The thermocouple output (when hot) should be 13 - 30 mV DC. Lower than

13 mV DC reading indicates the thermocouple should be replaced.

NOTE: Be careful not to over tighten the thermocouple! First, hand tighten and then turn 1/8 th turn with wrench.

Inspect pilot flame to ensure flame is enveloping 3/8” to ½” (9-13 mm) of the thermocouple tip. Clean pilot orifice. If pilot assembly is corroded or significantly deteriorated, replace complete pilot assembly.

Inspect burner tips to ensure each tip has proper flame. For easy access to clean the burner tips, disconnect burner supply line and remove the burner from the unit. With compressed air (if possible), blow out main burner ring prior to cleaning the burner tips. Check orifices and air supply openings for debris, insects and/or dirt. Clean any plugged or obstructed orifices.

Upon initial installation and during periodic maintenance inspections, check for corrosion on the ends of the pilot flame guide. If flame diverter(s) are corroded more than 1/8” replace flame guide.

Additionally on 80/40H and 120/60H, check flame spreader bar position to ensure both burners light simultaneously and smoothly. Straighten spreader bar if it is positioned at an angle or not positioned on top of the pilot properly.

Use repair kit to replace internal components of the liquid inlet valve. See detailed Liquid Inlet Valve Maintenance Instructions for further information.

Use repair kit to replace internal components of the capacity control valve.

See detailed Capacity Control Valve Maintenance Instructions for further information.

Inspect all tubing for pitting or flaking - run hands along the underside of each of the tubes to check for signs of corrosion. Replace tubes if corroded. Disconnect all tubing and blow tubes free of debris. Re-install tubing to the vaporizer and check and tighten all fittings.

Inspect all relief valves on the vaporizer, liquid, and vapor lines for signs of corrosion and damaged or missing rain caps. Replace rain cap if it is damaged or missing. Replace relief valves per manufacturer’s recommended replacement period. Also replace relief valve if it shows significant corrosion on the outlet or has relieved.

Check regulator delivery pressure at the drip leg and at the burner pressure port to ensure proper pressure is delivered to the thermostat and burners. See page 1-3 for burner pressure specifications.

1. Check heat exchanger flue for holes or excessive scale.

2. Remove debris, soot build-up and any obstructions from the outside surface of the heat exchanger between the fins and in the

4-18 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance

Drip Leg

Vaporizer Cabinet area between the heat exchanger and flue. High pressure air or a wire brush may be used for removal. A large amount of buildup on the outside of the heat exchanger can lead to a reduced capacity from your vaporizer.

3. Check bottom head of the heat exchanger for pitting and/or scaling. Should heat exchanger head thickness be less than

0.156” (4 mm) the heat exchanger should be removed from service. Nominal wall thickness 0.250” (6.4 mm). An Ultrasonic thickness tester can be used to determine wall thickness.

4. Check heat exchanger for heavy ends accumulation inside the vessel. Remove the liquid inlet valve and tilt the vaporizer on its side to drain the heavy ends. Re-install liquid inlet valve and uniformly torque bolts to 30-35 ft.-lbs (40.7-47.5 Nm) using a star/cross pattern.

NOTE: In areas where LPG quality is poor it may be necessary for heat exchangers to be checked for heavy ends more frequently. Once it is verified that no significant quantity of heavy ends are accumulating during vaporizer operation, this maintenance can be performed on an annual basis.

Remove plug below the tee on the drip leg and drain the drip leg to prevent it from filling with contaminants and passing them into the thermostat. NOTE: In areas where LPG quality is poor it may be necessary for drip legs to be checked for heavy ends more frequently.

Once it is verified that no significant quantity of heavy ends are accumulating during vaporizer operation, this maintenance can be performed on an annual basis.

Inspect the door, inside enclosure, inlet louvers and vent caps for debris and/or combustible material. If needed, clean areas so they are free of all debris.

CAUTION

When servicing a component in the liquid or vapor line, BE SURE that the LP-gas supply is shut off to that component before it is removed or disassembled. The vaporizer must be completely purged before performing service. Be sure that ALL sources of ignition are extinguished within 25 feet (7.6 m) of the work area.

When flaring the contents of the vaporizer, be sure that the burners are on to prevent freezing during the flaring operation.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-19

Maintenance

Use the Direct Fired Vaporizer Inspection & Maintenance Checklist included in this manual to record and keep track of your annual maintenance and inspections.

DIRECT FIRED VAPORIZER INSPECTION CHECKLIST

Model:_________________ Serial Number:___________________

Maintenance Checklist Items Inspected

Yes/No

Replaced or

Kit Installed?

1. Thermostat Operation:

Did burner(s) cycle on?

Did the burner(s) and pilot extinguish after a short period of time when turned off?

2. Thermocouple: Was the millivolt output between 13-30 mV DC?

3. Pilot Assembly:

Pilot assembly inspected for corrosion?

Pilot orifice cleaned or replaced?

4. Burner Assembly: Burner tips and orifices cleaned?

5. Flame Spreader Bar: Is it present and positioned properly or does it have signs of damage/corrosion (applicable to 80/40H and 120/60H)

6. Liquid Inlet Valve:

Repair Kit installed?

Inlet orifice cleaned?

Did valve pass “water test” to ensure seat is sealing properly?

7. Capacity Control Valve:

Repair Kit installed?

Piston and valve body cleaned?

8. Strainer: Screen inspected for tears or holes and/or cleaned?

9. Relief Valve:

Inspected for corrosion?

Is rain cap present?

Manufacture date checked for replacement?

10. Drip Leg: Drained of all contaminants and oils?

11. Burner Regulator: Pressure setting verified? Record pressure setting here.

12. Vaporizer Tubing:

All tubing checked for pitting or flaking and blown free of debris?

All fittings tightened?

13. Heat Exchanger:

Flue inspected?

Debris removed from and around heat exchanger?

Heat exchanger head thickness tested?

Heat exchanger drained of heavy ends?

14. Vaporizer Cabinet: Are door, enclosure, inlet louvers and rain caps cleared of debris and combustible materials?

Once the above items have been maintained and/or inspected, leak test all fittings and connections inside and outside the cabinet, including the inlet valve flange and bolts, to ensure there are no leaks.

Connect LPG Supply and light the pilot and engage main burners. Ensure pilot is strong and main burners are igniting and burning properly.

INSPECTED BY:__________________________________ INSPECTION DATE:_________________

4-20 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance

Replacing reigniter battery

1. Turn the reigniter switch “OFF”. Open the battery access door on the bottom right corner of the thermostat housing.

Figure 10 – Opening the battery access door

2. Pull out the battery, disconnect it and replace with new 9VDC battery. Push the battery back in the thermostat housing and close the battery access door prior to turning the reigniter switch “ON”.

Figure 11 – Replacing the battery

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-21

Maintenance

Adjusting burner input pressure

1. Close the supply valve to the burner supply regulator and vent lines.

2. Using a 3/8” FNPT barb fitting and hose, connect a 0-30” manometer (or similar pressure indicating device) to the pressure tap port at the outlet of the thermostat. You will have to remove the 3/8” plug. If the vaporizer does not come equipped with the port at the outlet of the thermostat then connect the manometer to drip leg ahead of the thermostat.

3. Open the supply valve to the burner supply regulator.

4. Turn the reigniter switch “ON”. Establish pilot by turning temperature control dial to "RUN" position. Push down the "PILOT" button while igniting pilot

(hold button down for 30 - 60 seconds). After pilot flame is established, rotate the temperature control dial counterclockwise. The main burner(s) should now engage.

5. With the main burner operating, check the gas pressure at the thermostat outlet pressure port using a manometer (see No. 2 above). For the required burner input pressure for each model refer to page 1-3. To adjust the pressure, remove the cap on the burner supply regulator (See Figure 12) and turn the adjustment screw clockwise with a standard screwdriver to increase the pressure. Return burner supply regulator cap when complete.

6. Close the supply valve to the burner supply regulator and wait until the pilot and main burner have extinguished . Turn the temperature control dial to

“OFF" position. Remove the manometer and fittings. Replace all plugs

before proceeding and perform a leak test.

Figure 12 – Adjusting burner input pressure

BURNER SUPPLY

REGULATOR ADJUSTMENT

SCREW

ROTATE GAS CONTROL DIAL

COUNTER-CLOCKWISE FOR

BURNER TO ENGAGE

ALTERNATE PRESSURE

PORT INSERT

MANOMETER HERE

4-22

PRESSURE PORT

– INSERT MANOMETER

HERE

Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance

Liquid inlet valve maintenance procedure

Use Repair Kit P/N: 40764 (see Appendix A for kit details)

NOTE: Vaporizer must be purged and empty of all liquid and vapor prior to performing maintenance on the liquid inlet valve.

CAUTION

Follow the below instructions carefully to prevent hazardous conditions. Leak test the entire installation prior to operating the system.

1. Loosen the four bolts to remove liquid inlet valve cover on the outside of the vaporizer cabinet.

2. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity control valve sensing line fitting on the top of the inlet valve.

3. With a 11/2” box end wrench (suggest using 6 point), loosen the large nut on the top of the inlet valve

(inlet valve cap)

4. Loosen the 6 inlet valve flange bolts and remove the inlet valve from the vaporizer through the hole in the cabinet.

5. Once the valve is removed from the vaporizer, remove the inlet valve cap (large nut on top) and remove the spring from the valve.

6. Remove the valve seat and stem from the valve body and orifice.

7. After the seat and stem have been removed, using a socket, remove the inlet valve orifice and wipe the top of the inlet valve orifice with a rag/cloth (one that does not leave lint on surface) or lightly with a scotch-brite type material to remove any debris and/or oils from the orifice surface.

8. Replace the O-ring under the orifice (use smallest O-ring from kit). Lightly grease new O-ring before replacing it.

9. Once the inlet valve orifice O-ring has been replaced, return the orifice to the valve and tighten accordingly.

10. Compare the length of the new stem from the repair kit to the old one that was removed from the vaporizer to make sure they are the same. It is important to make sure the new valve stem isn’t longer than the original stem because it might prevent the valve from sealing properly. If needed, use a metal file to shorten the stem to match the original stem length. New vaporizers are fitted correctly and tested at the factory to make sure the seat and stem assemblies have the proper length. If the seat and stem assemblies have been changed in the field without checking the length against the original stem or the valve was not tested in the shop to ensure it is sealing (see “Water test” procedure below) there is a chance the stem could be too long and not allow the inlet valve to close properly. If you are uncertain about the prior replacement history of the valve stem you should ensure the valve is tested in water to make sure the new stem and seat assembly close fully before returning the inlet valve to the vaporizer.

11. Insert the new valve seat and stem assembly into the valve body lining up the stem with the hole in the inlet orifice.

12. Replace the spring making sure it is centered on the top of the inlet valve seat.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-23

Maintenance

13. Lightly grease and replace the O-ring around the inlet valve cap (large flange nut).

14. Install inlet valve cap (large flange nut) and tighten into valve body. You may apply NEVER-SEEZ compound to the flange nut to allow for easy removal of the flange nut in the future.

15. Once the internal components of t he valve are replaced perform a “water test” to ensure your inlet valve is sealing properly. To perform this test: apply a 1/8” plug in the top of the inlet valve cap using Teflon tape to ensure it is leak-proof. Using an air hose, apply 80-100 psig (6-7 bar) of air pressure at the inlet of the valve and completely submerge the valve in a bucket or sink full of water. Wait approximately 5-10 seconds and observe for air bubbles exiting the valve around valve stem that protrudes from the middle of the inlet valve. If no bubbles are present, the valve is sealing properly.

16. Remove any remnants of the old inlet valve flange gasket from the surface of the flange on the inlet valve itself and on the flange at the heat exchanger. Inspect surfaces for marks or other damage and clean of any other debris.

17. Inspect new inlet valve flange gasket for damage – primarily any tears, bends, or significant scratches.

18. Lightly spray flange gasket with a dry lubricant (graphite) before installing it on the unit.

19. When re-installing the inlet valve on the vaporizer, place flange gasket on the gasket surface and slide the stem under the float ball inside the heat exchanger. Slightly tighten the bottom two flange bolts allowing the flange gasket to be supported by the two bottom bolts. Working your way around the valve, hand tighten the remainder of the bolts inspecting as you tighten them to ensure the position of the inlet valve flange gasket is correct.

20. To tighten the inlet valve bolts, torque the 6 bolts to 30-35 ft.-lbs (40.7-47.5 Nm) in a cross/star pattern.

21. Leak test inlet valve flange bolts prior to re-starting the vaporizer.

4-24 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance

Capacity control valve maintenance procedure

Use Repair Kit p/n: 40764 (see Appendix A for kit details)

1. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity control valve sensing line fitting on the top of the capacity control valve and carefully slide tube out of the way in order to remove the large flange nut (capacity control valve cap). Note: you may need to loosen the tube on the other end at the top of the inlet valve to remove the tube completely.

2. With a 11/2” box end wrench (suggest using 6 point), loosen the large flange nut on the top of the capacity control valve (capacity control valve cap).

3. Remove the piston from the valve and wipe the piston with a rag/cloth (one that does not leave lint on surface) or lightly with a scotch-brite type material to remove any debris and/or oils from the piston surface. If the piston is stuck in the valve or difficult to remove, thread an 8-32 bolt or screw into the screw tap at the top center of the piston. This will allow you to have leverage and grasp the screw with a pair of pliers to remove the piston from the valve.

4. Remove the old O-ring from the piston and replace it with the smallest O-ring from the kit. Lightly grease new O-ring before installing it on the piston.

5. Remove spring from the capacity control valve.

6. Thoroughly wipe the inside of the valve body with a rag/cloth (again, one that does not leave lint on surface) to remove any debris or oils from the valve body.

7. Insert new spring into the Capacity Control Valve.

8. Lightly spray the surface of the capacity control valve piston with a dry lubricant (graphite) and insert piston into the valve moving it up and down thereby lubricating the body of the valve and ensuring the piston is moving up and down freely.

9. Lightly grease and replace the O-ring around the capacity control valve cap (large flange nut).

10. Install the capacity control valve cap (large flange nut) and tighten into valve body. You may apply

NEVER-SEEZ compound to the flange nut to allow for easy removal of the flange nut in the future.

11. Re-install capacity control valve sensing line and tighten fittings.

12. Leak test prior to restarting the vaporizer.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-25

Troubleshooting

1. PILOT - TROUBLESHOOTING TREES #1 & #2

◼ The pilot flame is adjusted at the factory to provide a non-blowing blue flame.

If the flame is not adequate or the pilot does not stay lit, check the pilot burner to see if it is clear of any obstructions.

◼ Flame should envelope 3/8” to 1/2" (9 to 13 mm) of the thermocouple tip. If the pilot flame is too low, the thermocouple will not generate sufficient voltage to hold the main burner’s valve open. If the pilot flame is too small, clean the pilot burner orifice, or replace the pilot. The 40/40H vaporizers use

#18 pilot orifices, while the 80/40H and 120/60H use #23 pilot orifices.

2. IGNITER WILL NOT SPARK – TROUBLESHOOTING TREE #3

◼ Check the reigniter battery and replace if necessary.

◼ Verify that the spark electrode is not in contact with the pilot hood and that spacing from the hood is not greater than 1/8” (3 mm).

◼ Check if the spark electrode is saturated with moisture/water. Wipe any moisture/water or light the vaporizer manually with a torch to dry it.

◼ Check the rocker switch by removing the leads and touching them together.

If the reigniter spark is established, then the rocker switch is faulty.

3. MAIN BURNER WILL NOT IGNITE - TROUBLESHOOTING TREE #4

◼ Check the pilot burner as per 1. above.

◼ Check burner regulator. Disconnect tube from outlet side of regulator and check output pressure.

◼ If pilot burner and burner regulator check out OK, the problem is in the thermostat. Replace thermostat (the main burner will not come on unless the temperature in the heat exchanger drops).

4. IF VAPOR PRESSURE DROPS - TROUBLESHOOTING TREE #5

◼ Check burner; check pilot as per 1. and 2. above.

◼ If vapor pressure drops, but main burner(s) is working, vapor demand exceeds vaporizer capacity.

◼ Check liquid excess flow valve and shut off valve; make sure they are open.

◼ Close liquid inlet valve upstream of strainer. Bleed down system and clean strainer filter.

5-26 Algas-SDI Operation and Maintenance Manual – P/N – 52642

Troubleshooting

TROUBLESHOOTING TREE #1

PILOT WILL NOT LIGHT

PRESSURE IS OK

CHECK THE BURNER

INPUT PRESSURE

REFER TO PAGE 1-3

PRESSURE IS HIGH/LOW

NO PRESSURE

REPLACE REGULATOR

PRESSURE

IS OK

DISCONNECT THE PILOT

FUEL LINE FROM THE

THERMOSTAT AND

CHECK PRESSURE AT

THE THERMOSTAT PILOT

CONNECTION BY

PRESSING THE PILOT

BUTTON DOWN

NO PRESSURE

PRESSURE IS OK

LIGHT PILOT

AND CHECK

OPERATION

ADJUST

REGULATOR

CHECK PILOT

TUBE AND PILOT

ORIFICE FOR

OBSTRUCTIONS

REPLACE

THERMOSTAT

PRESSURE WILL

NOT ADJUST

INLET PRESSURE

IS LOW

VERIFY YOU

HAVE A

MINIMUM OF 6

PSIG INPUT TO

REGULATOR

INLET PRESSURE

IS OK

REPAIR OR

REPLACE PILOT

ASSEMBLY DETERMINE CAUSE OF LOW

PRESSURE AND REPAIR

REPLACE THE

REGULATOR

RETEST THE

VAPORIZER

RETEST THE

VAPORIZER

Algas-SDI Operation and Maintenance Manual – P/N – 52642 5-27

Troubleshooting

PILOT IS OK

TROUBLESHOOTING TREE #2

PILOT LIGHTS BUT WILL NOT HOLD

CHECK TO SEE THAT THE

PILOT IS IMPINGING ON THE

THERMOCOUPLE BULB,

APPROXIMATELY 3/8” TO 1/2”

(9 to 13 mm)

PILOT IS LOW

SEE TROUBLESHOOTING TREE

#1: PILOT WILL NOT LIGHT CHECK THE THERMOCOUPLE SIGNAL TO

THERMOSTAT CONTROL VALVE. SIGNAL

SHOULD BE 13 TO 30 mV DC WHEN

THERMOCOUPLE IS HOT

SIGNAL OK SIGNAL LOW

REPAIR OR

REPLACE PILOT

ASSEMBLY

REPLACE

THERMOCOUPLE

5-28 Algas-SDI Operation and Maintenance Manual – P/N - 52642

BATTERY OK

TROUBLESHOOTING TREE #3

IGNITER WILL NOT SPARK

CHECK

REIGNITER

BATTERY

BATTERY DEAD

Troubleshooting

OUT OF

POSITION

ADJUST AND

CHECK

OPERATION

CHECK IF

ELECTRODE IS

CONTACTING HOOD

OR FURTHER THAN

1/8” (3 mm)

CHECK IF

ELECTRODE

IS WET

YES

WIPE

ELECTRODE

DRY OR LIGHT

MANUALLY

WITH TORCH

REPLACE BATTERY

CHECK ROCKER SWITCH BY

REMOVING LEADS AND

TOUCHING TOGETHER

SPARK

ESTABLISHED

ROCKER

SWITCH IS

FAULTY -

REPLACE

Algas-SDI Operation and Maintenance Manual – P/N – 52642 5-29

Troubleshooting

TROUBLESHOOTING TREE #4

MAIN BURNER WILL NOT LIGHT

CHECK TO SEE THAT THE

PILOT IS IMPINGING ON THE

THERMOCOUPLE BULB,

APPROXIMATELY 3/8” TO 1/2”

(9 to 13 mm)

YES

SEE TROUBLESHOOTING TREE

#1 OR #2 TO CHECK

THERMOCOUPLE AND

REGULATOR

TURN THE THERMOSTATIC GAS VALVE

TEMPERATURE CONTROL DIAL UP TO

THE HIGHEST SETTING. DID THE

CONTROL “CLICK”?

YES NO

CHECK FOR

PLUGGED GAS

LINE TO THE

BURNER

REPLACE

THERMOSTAT

5-30 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Troubleshooting

YES

TROUBLESHOOTING TREE #5

VAPOR SERVICE PRESSURE DROPS

CHECK THE

THERMOSTAT PORT

OUTLET PRESSURE

REFER TO PAGE 1-3

IS THE BURNER

OPERATING?

NOTE: SERVICE PRESSURE WILL DROP IF THE

DEMAND EXCEEDS VAPORIZER’S CAPACITY: 40/40H

3.6 MMBTU/hr (1,055 kW), 80/40H 7.3 MMBTU/hr (2,139 kW), 120/60H 10.9 MMBTU/hr (3,195 kW). THE

FOLLOWING TROUBLESHOOTING TREE ASSUMES

THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS

MAXIMUM CAPACITY.

SEE TROUBLESHOOTING TREE #3:

MAIN BURNER WILL NOT LIGHT

LOW/HIGH

ADJUST BURNER

PRESSURE

REGULATOR

WILL NOT ADJUST

SET THERMOSTAT FOR

HIGHER TEMPERATURE

CHECK

OPERATION

CHECK IF BURNER

TIPS CLOGGED

(ORANGE/NO

FLAME)

PRESSURE

YES

REPLACE

REGULATOR

REPLACE

THERMOSTAT CLEAN

BURNER TIPS

AND ORIFICES

DOES NOT

FUNCTION

REPLACE

THERMOSTAT

CHECK

OPERATION

Algas-SDI Operation and Maintenance Manual – P/N – 52642

CHECK FOR

MINIMUM OF

6psig (0.4 bar) AT

REGULATOR

INLET PRESSURE

LOW

REPAIR PRESSURE

SOURCE

5-31

APPENDIX A

TECHNICAL INFORMATION

Figure 13 – 40/40H Vaporizer Replacement Parts

Figure 14 – 80/40H and 120/60H Vaporizer Replacement Parts

NOTE

Drawing shown for an 80/40H Vaporizer.

17 20

Figure 15 – Inlet Valve and Capacity Control Valve

LIQUID INLET VALVE

23 Inlet valve cap o-ring

23 Inlet valve spring

23 Inlet valve seat

Inlet valve orifice

23 Inlet valve gasket

23 Inlet valve orifice o-ring

23 Pivot arm gasket

CAPACITY CONTROL VALVE

22 Capacity control valve

Cap o-ring

22 Piston o-ring

21 Piston

22 Spring

Figure 13, 14 and 15 Descriptions

1. Burner Manifold – 40/40H

2. Burner tip #69 burner jet orifice – All models

3. Capacity control valve 1” – All models

4. Drip leg kit – All models

5. Liquid inlet valve – All models

6. Pilot assembly with thermocouple – 40/40H

7. Pilot flame Guide – 40/40H

8. Regulator, Burner Supply – All Models

9. Relief valve, ¾” NPT UL/CE/ASME – All models

10. Thermocouple – All models

11. Thermostat/Thermowell w/9VDC igniter – All models

12. Tube kit, burner regulator supply – All models

13. Tube kit, burner supply – All models

14. Tube kit, capacity control – All models

15. Tube kit, pilot supply – All models

16. Vent cap assembly – All models

17. Burner manifold left – 80/40H, 120/60H

18. Burner manifold right – 80/40H, 120/60H

19. Pilot assembly with thermocouple – 80/40H-120/60H

20. Pilot flame guide – 80/40H,120/60H

21. Piston, Capacity control valve – All models

22. Repair kit, Capacity control valve – All models

*See Capacity Control valve in Figure 15

23. Repair kit, Liquid Inlet valve – All models

*See Liquid Inlet valve in Figure 15

24. Strainer, ¾” NPT (ships loose)

25. Tube kit, burner manifold connector – 80/40H, 120/60H

26. Tube, heat exchanger connector – 80/40H, 120/60H

P/N: 1502-4020

P/N: 34323

P/N: 1508-4001

P/N: 40403

P/N: 1501-4001

P/N: 40774

P/N: 1502-5010

P/N: 34800

P/N: 34876

P/N: 37050

P/N: 41073

P/N: 40542

P/N: 42012

P/N: 42013

P/N: 42014

P/N: 1501-4015

P/N: 1501-4020

P/N: 1501-4021

P/N: 40768

P/N: 1501-5086

P/N: 1508-5005

P/N: 40764

P/N: 30655

P/N: 3-0783

P/N: 3-0792

Part number

3-0034

34323-10

34800

Table 7 – Repair Kits and Other Available Replacement Parts

40631: Master rebuild kit 40/40H

Description

40/40H Repair kit

Burner tip #69 orifice (qty 10)

Burner supply regulator

Part number

3-0035

34323-10

34800

40633: Master rebuild kit 80/40H

Description

80/40H Repair kit

Burner tip #69 orifice (qty 10)

Burner supply regulator

Part number

41040

34323-10

34800

40634: Master rebuild kit 120/60H

Description

120/60H Repair kit

Burner tip #69 orifice (qty 10)

Burner supply regulator

Part number

40764

41073

40774

3-0034: Repair kit 40/40H

Description

Repair kit, Liquid inlet valve & Capacity control valve

Thermostat/Thermowell with 9 VDC reigniter

Pilot assembly with thermocouple 40/40H

Part number

40764

41073

40768

3-0035: Repair kit 80/40H

Description

Repair kit, Liquid inlet valve & Capacity control valve

Thermostat/Thermowell with 9 vdc reigniter

Pilot assembly with thermocouple 80/40H & 120/60H

Part number

40764

40768

41073

41040: Repair kit 120/60H

Description

Repair kit, Liquid inlet valve & Capacity control valve

Pilot assembly with thermocouple, 80/40H & 120/60H

Thermostat/Thermowell with 9 vdc reigniter

Part number

37050

46-6

Part number

37050

37510

Part number

37050

37510

3-0014: Repair kit 40/40H Pilot orifice and thermocouple

Description

Thermocouple for all models

Orifice pilot burner 40/40H, #18

3-0013: Repair kit 80/40H Pilot orifice and thermocouple

Description

Thermocouple for all models

Orifice pilot burner 80/40H & 120/60H, #23

41041: Repair kit, 120/60H Pilot orifice and thermocouple

Description

Thermocouple for all models

Orifice pilot burner 80/40H &120/60H, #23

Part number

40403

40542

42012

42013

42014

42015: 40/40H, 80/40H & 120/60H Tubing replacement kit

Description

Drip leg kit

Tube kit, Burner regulator supply

Tube kit, Burner supply

Tube kit, Capacity Control Valve

Tube kit, Pilot supply

Liquid inlet valve pin gasket installation procedure

1. Clean pivot screw hole opening from any residue.

2. Apply blue (medium strength) Locktite 243 or Permatex to threads on the liquid inlet valve body or pivot screw.

3. Slide pin gasket (P/N 8135-101) over the pivot screw (P/N 3-4169) threads as shown in the picture.

4. Screw in pivot screw to the inlet valve body and apply 8 in-lbs (0.9 Nm) of torque (approximately 1/8 full turn).

5. Align valve stem with pivot screw and repeat the same step with the pin gasket and pivot screw on the opposite side of the liquid inlet valve.

6. Verify there is no damage to the pin gasket. Set inlet valve assembly aside for an hour to allow

Locktite to properly dry before reinstalling valve assembly back on the vaporizer.

7. Re-install valve in vaporizer with new flange gasket and uniformly torque bolts to 30-35 ft-lbs (40.7-

47.5 Nm).

8. Re-connect sensing line to capacity control valve.

9. After assembly pressurize with 125-150 psig (8.6-10.3 bar) compressed air and apply soap solution or leak detection fluid to both pin gasket areas and to the valve flange area to make sure there are no leaks

1" MNPT VAPOR OUTLET START/SHUTDOWN INSTRUCTIONS THERMOSTAT AND REIGNITOR ASSEMBLY

PRESSURE RELIEF VALVE

DRIP LEG DRAIN VALVE

HEAT EXCHANGER

1 8

CAPACITY CONTROL

3/4" FNPT LIQUID INLET

3 8

3 16

5 16

7 8

1ST STAGE VENT (1/8" FNPT)

1 2

.XX .XXX

6. 40 GPH [80 KG/HR].

7. ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.

8. 9.

THIRD ANGLE PROJECTION

DO NOT SCALE DRAWING

254 10"

DETAIL B SCALE 1 : 4

2ND STAGE VENT (3/4" FNPT)

RELIEF VALVE

1" MNPT VAPOR OUTLET

START/SHUTDOWN INSTRUCTIONS

THERMOSTAT AND REIGNITOR ASSEMBLY

DRIP LEG DRAIN VALVE

CAPACITY CONTROL HEAT EXCHANGER

6. 80 GPH [160 KG/HR].

7. ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.

.XX .XXX

THIRD ANGLE PROJECTION

DO NOT SCALE DRAWING

1 8

305 12"

5 16

3/4" FNPT LIQUID INLET

1ST STAGE VENT (1/8" FNPT)

7 8

DETAIL B SCALE 1 : 4

2ND STAGE VENT (3/4" FNPT)

RELIEF VALVE

1" MNPT VAPOR OUTLET

START/SHUTDOWN INSTRUCTIONS THERMOSTAT AND REIGNITOR ASSEMBLY

DRIP LEG DRAIN VALVE

CAPACITY CONTROL HEAT EXCHANGER

6. 120 GPH [240 KG/HR].

7. ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.

.XX .XXX

THIRD ANGLE PROJECTION

DO NOT SCALE DRAWING

3/4" FNPT LIQUID INLET

1ST STAGE VENT (1/8" FNPT)

305 12"

SECTION A-A SCALE 1 : 12

DETAIL B SCALE 1 : 4

2ND STAGE VENT (3/4" FNPT)

Algas-SDI International, LLC

151 South Michigan Street

Seattle, Washington, 98108

Ph: 1.206.789.5410

Fax: 1.206.789.5414 www.algas-sdi.com

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Annonce

...Innovative liquid vaporizing and gas mixing solutions

Operations & Maintenance

Manual

WARNING

Read the OPERATION MANUAL before operating this equipment.

■ This equipment uses LPG-a flammable fuel, handled under pressure.

Inherent hazards exist and a thorough understanding of the equipment is required to allow safe operation and maintenance.

■ Allow only a TRAINED and FULLY QUALIFIED PERSON to service this equipment.

Warranty Registration

Warranty, Copyrights and Approvals

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Symbols and Conventions

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Table of Contents

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Direct Fired Vaporizer Options

Electronic Auto Reigniter

FILTAIRE

Contaminant Separator

Economy Valve Kit

Inlet and Outlet Isolation Valves

Pipeaway Adapter

1st Stage Regulator

Introduction

Description/Overview

Installation

Unpacking and Initial Assembly

Installation Safety Requirements

Operation

Direct Fired Vaporizer start up procedure

Direct Fired Vaporizer setpoint adjustment

Direct Fired Vaporizer shut down procedure

(See Figure 9)

Direct Fired Vaporizer purge procedure

Maintenance

Maintenance Recommendations

Replacing reigniter battery

Adjusting burner input pressure

Liquid inlet valve maintenance procedure

Capacity control valve maintenance procedure

Troubleshooting

APPENDIX A

TECHNICAL INFORMATION

Figure 13, 14 and 15 Descriptions

Liquid inlet valve pin gasket installation procedure

1. Clean pivot screw hole opening from any residue.

2. Apply blue (medium strength) Locktite 243 or Permatex to threads on the liquid inlet valve body or pivot screw.

3. Slide pin gasket (P/N 8135-101) over the pivot screw (P/N 3-4169) threads as shown in the picture.

4. Screw in pivot screw to the inlet valve body and apply 8 in-lbs (0.9 Nm) of torque (approximately 1/8 full turn).

5. Align valve stem with pivot screw and repeat the same step with the pin gasket and pivot screw on the opposite side of the liquid inlet valve.

6. Verify there is no damage to the pin gasket. Set inlet valve assembly aside for an hour to allow

Locktite to properly dry before reinstalling valve assembly back on the vaporizer.

7. Re-install valve in vaporizer with new flange gasket and uniformly torque bolts to 30-35 ft-lbs (40.7-

47.5 Nm).

8. Re-connect sensing line to capacity control valve.

9. After assembly pressurize with 125-150 psig (8.6-10.3 bar) compressed air and apply soap solution or leak detection fluid to both pin gasket areas and to the valve flange area to make sure there are no leaks

1" MNPT VAPOR OUTLET START/SHUTDOWN INSTRUCTIONS THERMOSTAT AND REIGNITOR ASSEMBLY

PRESSURE RELIEF VALVE

DRIP LEG DRAIN VALVE

HEAT EXCHANGER

1 8

CAPACITY CONTROL

3/4" FNPT LIQUID INLET

1ST STAGE VENT (1/8" FNPT)

.XX .XXX

6. 40 GPH [80 KG/HR].

7. ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.

8. 9.

THIRD ANGLE PROJECTION

DO NOT SCALE DRAWING

DETAIL B SCALE 1 : 4

2ND STAGE VENT (3/4" FNPT)

RELIEF VALVE

1" MNPT VAPOR OUTLET

START/SHUTDOWN INSTRUCTIONS

THERMOSTAT AND REIGNITOR ASSEMBLY

DRIP LEG DRAIN VALVE

CAPACITY CONTROL HEAT EXCHANGER

6. 80 GPH [160 KG/HR].

7. ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.