Algas SDI TORREXX TX25 Operation & Maintenance Manual

...Innovative liquid vaporizing and gas mixing solutions

Vertical electric single core vaporizer

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 52368 TORREXX REV 05-05-17

2017.05.0

5

13:47:41

-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. Vendors have supplied literature contained in the Operation Manual. 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 is unpredictable and may lead to dire consequences. When components are replaced with components not approved for use in our FM listed equipment, the FM listing becomes void for that unit.

 

WARRANTY

 

REGISTRATION

 

To register your new equipment: Visit Algas-SDI's web site at: www.algassdi.com, then click on the "Tech Support" button. Select online Registration or print out the Acrobat Warranty Registration.

OR

Fill out the Warranty Registration information on the last page of this manual.

Then make a photocopy and mail to the address shown at the bottom.

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 2014 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

    

*Approvals depending on model

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

 

This symbol 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

 

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

ELECTRICAL

 

DISCONNECT

 

REQUIRED

 

This symbol indicates a potentially dangerous situation, which can result in severe personal injury or death or damage to equipment.

Use great care and follow the instructions given.

ASDI

 

CONTACT

 

NUMBERS

 

If you have questions, need help with your equipment, or want information on other products, contact Algas-SDI at:

Telephone: 206.789.5410

Facsimile:

Email:

Internet:

206.789.5414 [email protected]

http://www.algas-sdi.com

 

 

 

 

 

TORREXX TABLE of CONTENTS

1. INTRODUCTION

DESCRIPTION

Figure 1 – TORREXX Dimensional Drawing (LPG Version)

TORREXX OPTIONS – INTRODUCTION

2. MAJOR COMPONENTS

DESCRIPTION

Figure 2 – Heating system

Figure 3 – Liquid Passage Prevention system

MAJOR COMPONENTS LIST

Figure 4 – TORREXX Major Components Drawing (LPG CONFIGURATION)

1-1

1-2

1-3

3. INSTALLATION

GENERAL

Figure 5 – Typical TORREXX Installation Drawing with Pump & Vapor Bypass

3-9

3-9

Figure 6 – Typical TORREXX Installation Drawing with Vapor Bypass and No Pump 3-10

Figure 7 – Typical TORREXX Installation Drawing with Economy Operation and

Vapor Bypass 3-10

Figure 8 – Typical TORREXX Installation Drawing for Manifolding 2 Vaporizers 3-11

Figure 9 – Typical TORREXX Installation Drawing for Manifolding 3 Vaporizers

LIQUID LINE

3-11

3-12

LIQUID PUMP

VAPOR LINE

SAFETY RELIEF VALVE

ELECTRICAL SERVICE

3-12

3-12

3-13

3-13

DETERMINING WIRE SIZE

Table 1 – Wire Length Chart (#4 AWG)

Table 2 – Wire Length Chart (#6 AWG)

Table 3 – Wire Length Chart (#8 AWG)

Table 4 – Wire Length Chart (#10 AWG)

Table 5 – Liquid Temperature vs. Tank Pressure Chart

Table 6 – LPG liquid line sizing chart (Minimum Pipe Size)

3-13

3-14

3-14

3-15

3-15

3-17

3-18

Table 7 – Equivalent Pipe Length of Various Valves and Fittings

(Length in Feet/Meters) 3-18

2-6

2-6

2-7

2-8

2-8

TORREXX TABLE of CONTENTS - Continued

4. OPERATION

GENERAL

OPERATING INSTRUCTIONS

STARTING THE VAPORIZER

STOPPING THE VAPORIZER

PURGING THE VAPORIZER

5. MAINTENANCE

GENERAL

INITIAL INSTALLATION AND OPERATION INSPECTIONS

ANNAUL MAINTENANCE REQUIREMENTS

CONTACTOR INSPECTION

Liqui-SAFE TM VALVE – PERFORMANCE CHECK (6 MONTHS)

Figure 10 – Steps to check the Liqui-SAFE TM valve operation

Liqui-SAFE TM VALVE – SERVICE INSTRUCTIONS

Figure 11A – STEP 1 – Be sure that the Liqui-SAFE TM valve is at the close position as shown

Figure 11B – STEP 2 – Unscrew reset button base and remove spring

Figure 11C – STEP 3 – Replace button post internal o-ring

Figure 11D – Full hook o-ring tool

Figure 11E – STEP 4 – Unscrew valve latch body

Figure 11F – STEP 5 – Replace valve body static o-ring

Figure 11G – STEP 6 – Replace valve seat and valve stem base o-rings

6. TROUBLESHOOTING

TROUBLESHOOTING TREES

FULL LOAD VOLTAGE CHECK

Figure 12 – Full load voltage check

FULL LOAD CURRENT CHECK

Figure 13 – Full Load Current Check

TORREXX ELECTRIC VAPORIZER DATA SHEET

HEATER CORE RESISTANCE

Figure 14 – Heater Core Resistance Wiring Connections

SOLENOID VALVE LEAK TEST

Figure 15 – Solenoid Valve Leak Test Components

TORREXX TABLE of CONTENTS - Continued

4-19

4-19

4-20

4-20

4-20

6-29

6-35

6-35

6-36

6-36

6-37

6-38

6-38

6-39

6-39

5-26

5-26

5-27

5-27

5-27

5-28

5-28

5-22

5-22

5-23

5-24

5-25

5-25

5-26

 

SOLENOID VALVE ELECTRICAL TEST

Figure 16 – Solenoid Valve Electrical Test

THERMOCOUPLE SENSOR REPLACEMENT

Figure 17 – TORREXX Box showing Thermocouple location

Figure 18 – Thermocouple Sensor with Bayonet Style Retainer

7. TORREXX OPTIONS

ECONOMY OPERATION

Figure 19 – TORREXX Economy valve installation

TORREXX ECONOMY VALVE MAINTENANCE

Figure 20A – STEP 1 – Unscrew the Inlet Housing from the Outlet Housing

Figure 20B – STEP 2 – Replace the two O-rings, apply excess o-ring grease.

7-43

7-43

7-44

7-44

7-44

Figure 20C – STEP 3 – Clean all o-ring contact surfaces and the bottom surface of the Outlet Housing. Apply excess o-ring grease 7-45

Figure 20D – STEP 4 – Clean all piston surfaces. Apply excess grease on o-rings 7-45

Figure 20E – STEP 5 – Make sure that the Pin Hole is clear and The Spring is

6-40

6-40

6-41

6-41

6-42 undamaged. Carefully reassemble all the parts. Apply lubrication grease on straight threads if necessary

MERCURY RELAY

TX REMOTE BOX

VALVE AND STRAINER PACKAGE

FILTAIRE – CONTAMINANT SEPARATOR

Figure 21 – Filtaire Operation

APPENDIX A – TECHNICAL INFORMATION

EC DECLARATION OF CONFORMITY

TORREXX LPG VAPORIZER DATA SHEET (FM)

TORREXX ELECTRIC VAPORIZER SPARE PARTS AND ACCESSORIES (FM)

Figure 23 – TORREXX ELECTRIC VAPORIZER MAJOR COMPONENTS AND

ACCESSORIES

TORREXX LPG VAPORIZER DATA SHEET (NEMKO)

TORREXX ELECTRIC VAPORIZER SPARE PARTS AND ACCESSORIES (NEMKO)

HEATER BUSSING DIAGRAMS

EQUIPMENT DRAWINGS

INSTALLATION DRAWINGS

TORREXX WIRING SCHEMATIC

REMOTE BOX WIRING SCHEMATICS

SOLENOID NOISE

ASCO SOLENOID VALVE USED BY ASDI

SOLENOID VALVE INSTLLATION AND MAINTENANCE INSTRUCTIONS

Warranty Registration – Refer to the nameplate on the unit to fill out the product registration.

Then photocopy and mail to address shown

7-47

7-46

7-46

7-46

7-46

7-46

 

INTRODUCTION

 

DESCRIPTION

 

1  

The dimensional drawing (see page 1-2) identifies various components of the

Algas-SDI TORREXX vaporizer. Multiple resistance heating elements provide thermal energy to the finned aluminum heat exchanger. A solid state controller monitors the heat exchanger temperature and regulates the operating temperature to a predetermined set point. The controls consist of 2 individual Ktype thermocouple sensors with independent high temperature limits. One sensor monitors operating temperature and the other controls the liquid inlet solenoid valve. The liquid inlet solenoid valve does not open until a predetermined warm-up temperature is reached. The vaporizer reaches operating temperature in approximately 60 seconds from a cold start. The vaporized LPG rises into the vapor header and exits through the vapor outlet.

The Liqui-SAFE TM Valve is specially developed to prevent liquid from going downstream.

TORREXX Vaporizer can be configured for many applications.

 Standard configuration for Class I, Division 1, Group D for use with propane and LPG applications, FM and cFM approvals.

 Standard configuration for Zone I for use with propane and LPG, NEMKO &

CE mark.

 Feedback configuration for Class I, Division 1, Group D for Propane and LPG for tank heater applications where adequate tank pressure must be maintained.

 TORREXX TM vaporizer can be manifolded together for increased capacity on a single skid. Consult Algas-SDI for Configuration information.

 TORREXX TM vaporizer can be packaged with an Algas-SDI mixing system on a single skid. Consult Algas-SDI for Configuration information.

 For customizing the TORREXX TM vaporizer to your requirements consult

Algas-SDI for information.

1-1 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Figure 1 – TORREXX Dimensional Drawing (LPG Version)

(4) ½” DIA MOUNTING HOLES

MODEL TX25 TX50 TX100 TX160 TX240

A

41”

1040mm

47”

1190mm

52”

1320mm

TX320

59”

1500mm

PRESSURE

RELIEF

VALVE

Liqui-SAFE

VALVE

1” FNPT

VAPOR

OUTLET

INSULATION

JACKET

FLOAT

HEATER

ELEMENT

TEMPERATURE

CONTROL

SENSOR

CONTROL

HOUSING

ELECTRICAL

SERVICE

REQUIRED

1 1/2”FNPT

PRESSURE

GAUGE

INLET

SOLENOID

VALVE

ASDI Operations and Maintenance – TX Models – P/N: 52368 1-2

 

TORREXX

 

VAPORIZER

 

OPTIONS

 

1-3

Your TORREXX TM vaporizer may be equipped with one or several of the factory options. All the options can be integrated to your TORREXX TM vaporizer and are designed to enhance convenience for the end user.

Below is a brief introduction to the options available for the TORREXX TM vaporizer. See SECTION 8 of this manual or contact Algas-SDI for more information.

1) Valve and Strainer Package – Includes strainer with magnetic plug, inlet shut-off angle valve, hydrostatic relief valve, outlet shut-off ball valve and outlet pressure gauge. Ships loose. All items not shown below.

2) Pipe Away Adapter – Allows the user to pipe the relief valve away from the vaporizer. Fits relief valve P/N 34876. 1”FNPT pipe connection.

3) TORREXX Stand – Elevates TORREXX Vaporizer 1 foot off the ground for ease of control box access and removes the vaporizer from elements i.e. snow and mud. Hardware to mount TX to stand is included. Ships loose.

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

4) Economy – Allows the customer to use propane storage tank vaporization when the storage tank can provide enough vaporization and pressure to satisfy the load requirements.

Control – Includes remote start/stop capability and a status light indicating the vaporizer is ready for operation (solenoid valve open). IP65

(NEMA 4) enclosure.

6) Drain valve kit – Enables the user to drain the oils, heavy ends, and other impurities that can collect over time in the vaporizer heat exchanger. Kit available factory or field installed.

7) Stabilaire Pump Package – Consult factory

8) Contaminant Separator (Filtaire) – The Algas-SDI Filtaire TM is a filtering device design to trap heavy hydrocarbons commonly present in LPG gas vapor. It also traps other materials, which may be in gas due to storage conditions and internal condition of the equipment.

9) Balancing orifice – When manifolding two or more vaporizer together a balancing orifice must be used.

ASDI Operations and Maintenance – TX Models – P/N: 52368 1-4

 

SAFETY

 

 

CAUTION

 

Propane Odor can fade.

 

 

CAUTION

 

Vaporizer may be hot after or during use.

CAUTION

 

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

 

 

 

1-5 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

MAJOR

 

COMPONENTS

 

2

Your New TORREXX TM vaporizer is designed to be reliable and user friendly.

Several features allow you to quickly determine the status of your vaporizer.

 

There are two basic control systems within a TORREXX TM :

1) Heating system – Figure 3

2) Liquid Passage Prevention system – Figure 4

Figure 2 – Heating system

 SELF REGULATING HEATER SYSTEM

 NO START/STOP SWITCHES

 ENGAGES AUTOMATICALLY

 JUST APPLY POWER TO TURN THE

VAPORIZER ON

TEMPERATURE ACTIVATED

CIRCUIT OPENS AT 55ºC OR

131ºF WITH SOLENOID VALVE

TO ENSURE AUTOMATIC

RESTART AFTER POWER

INTERRUPTION

TEMPERATURE CONTROLLER

DETECTS HEAT EXCHANGER

TEMPERATURE VIA A DUAL K

TYPE THERMOCOUPLE

HEAVY DUTY

CONTACTOR

TX100 SHOWN (CE CONFIGURATION) WITH NO OPTIONS

ASDI Operations and Maintenance – TX Models – P/N: 52368 2-6

 

Figure 3 – Liquid Passage Prevention system

 RED FLAG INDICATES STATUS

 VALVE IS TRIPPED WHEN FLAG

IS UP (AS SHOWN)

CLEAR PROTECTIVE BUTTON KEEPS

DEBRIS, WATER OR ICE FROM

IMPEDING PROPER OPERATION

VALVE IS IN OPERATING

POSITION WHEN FLAG IS

DOWN (AS SHOWN)

 FLOAT BALL ACTIVATED

MANUAL RESET Liqui-SAFE

VALVE DETECTS AND

PREVENTS LIQUID FROM

PASSING TROUGH

 THE Liqui-SAFE VALVE CAN

BE MANUALLY TRIPPED TO

VERIFY CLOSING INTEGRITY

FLOAT BALL

TX100 SHOWN (FM/cFM CONFIGURATION) WITH NO OPTIONS

2-7 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Figure 4 – TORREXX Major Components Drawing (LPG CONFIGURATION)

1) Liquid Inlet Solenoid Valve

2) Valve, Gauge and Strainer kit components (Optional)

3) Mercury Relay kit (Optional)

4) Temperature Controller Board

5) Economy Valve (Optional)

6) Liqui-SAFE TM Valve with manual reset

7) Insulation Jacket

8) Contactor

ASDI Operations and Maintenance – TX Models – P/N: 52368 2-8

 

 

INSTALLATION

 

WARNING

 

3

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  

Prior to installing your new TORREXX vaporizer, check all relevant codes and standards that apply in your local area to ensure compliance!

CAUTION  

To prevent ignition of hazardous atmospheres:

 

 

 

 

NOTE  

Keep flameproof enclosure cover tight, torque to 26.6 Nm (19.6 ft. lbs.) while in service and disconnect power before installing or removing unit from service.

Installer must install a terminal box (connection facility).

 

 

 

Metal Terminal Box (M32)

EEx d II A Gb, (ATEX certified or equivalent) - marking for

Europe;

Metal Terminal Box (1”):

Class I, Division 1, Group D (UL listed or equivalent) - for US and Canada.

 

 

WARNING  

Potential electrostatic charging hazard. Clean insulation with a damp cloth.

 

CAUTION  

Connect only metal electrical conduit or armored cable to the vaporizer sealing fitting.

 

 

3-9 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

GENERAL

 

 

Install the ASDI TORREXX vaporizer on a level firm base at least 6” above grade and secure it through the four ½” holes. Protect the equipment against damage by moving vehicles by use of an appropriate barrier. Consult state, provincial, insurance carriers, and local authorities for installation requirements. Clean all foreign material from all pipelines prior to making final connections. All joints require a pipe sealant approved for LPG, depending on type of service. Test for leaks using an inert gas, such as compressed carbon dioxide or nitrogen, at 1½ times the working pressure or as required by applicable codes. Check all connections using an appropriate leak detection solution or device. Even very small leaks are unacceptable. Eliminate all leaks prior to operation.

Install in accordance with applicable codes and local regulations as required.

Explosion proof seal off must carry the same approvals as the vaporizer in order to maintain the approval of the overall installation.

Figure 5 - Typical TORREXX Installation Drawing with Pump & Vapor Bypass

NOTES

1.

2.

3.

LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK

MUST NOT EXCEED HYDROSTATIC HEAD WHEN THE PUMP IS

SHUT OFF.

INSTALL VAPORIZER 1 ST STAGE REGULATOR UPSTREAM OF

THE TANK VAPOR PRESSSURE CONNECTION POINT.

SET 1 ST STAGE VAPORIZER REULATOR 2-4 PSIG HIGHER THAN

4.

TANK VAPOR PRESSURE REGULATOR SET-POINT.

NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO

FLOW IN BOTH DIRECTIONS.

TANK VAPOR

PRESSURE

REGULATOR*

*BY OTHERS

VAPOR BY-PASS LINE ISOLATION

VALVE*

ISOLATION

VALVE*

VAPORIZER REGULATOR*

PRESSURE GAUGE*

(VAPOR)

TO LOAD

OUTLET ISOLATION

VALVE”

STORAGE TANK

STRAINER WITH

MAGNET FOR IRON

PARTICLE PICK-UP*

SEAL OFF REQUIRED*

ELECTRIC SERVICE

REQUIRED*

LIQUID

OPTIONAL

ISOLATION VALVE

W/HYDROSTATIC

RELIEF*

Note: The vapor bypass line is not required except when you have the Economy

Operation option. In other installations, it is recommended because it will provide vapor from the tank to the load in case of vaporizer failure or power failure but it is not required. Vaporizer will operate properly without the bypass.

ASDI Operations and Maintenance – TX Models – P/N: 52368 3-10

 

Figure 6 - Typical TORREXX Installation Drawing with Vapor Bypass and No Pump

1.

NOTES

LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK

2.

3.

MUST NOT EXCEED HYDROSTATIC HEAD WHEN THE PUMP IS

SHUT OFF.

INSTALL VAPORIZER 1 ST STAGE REGULATOR UPSTREAM OF

THE TANK VAPOR PRESSSURE CONNECTION POINT.

SET 1 ST STAGE VAPORIZER REULATOR 2-4 PSIG HIGHER THAN

TANK VAPOR PRESSURE REGULATOR SET-POINT.

4.

*BY OTHERS

NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO

FLOW IN BOTH DIRECTIONS.

VAPOR BY-PASS LINE

TANK VAPOR

PRESSURE

REGULATOR*

ISOLATION

VALVE*

OUTLET ISOLATION VALVE”

ISOLATION

VALVE*

STORAGE TANK

(VAPOR)

TO LOAD PRESSURE GAUGE*

VAPORIZER

REGULATOR*

STRAINER WITH

MAGNET FOR IRON

PARTICLE PICK-UP*

SEAL OFF REQUIRED*

ELECTRIC SERVICE

REQUIRED*

LIQUID

ISOLATION VALVE

W/HYDROSTATIC

RELIEF*

ISOLATION VALVE”

1.

2.

3.

Figure 7 - Typical TORREXX Installation Drawing with Economy Operation and Vapor Bypass

NOTES

LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK

MUST NOT EXCEED HYDROSTATIC HEAD WHEN THE PUMP IS

SHUT OFF.

INSTALL VAPORIZER 1 ST STAGE REGULATOR UPSTREAM OF

THE TANK VAPOR PRESSSURE CONNECTION POINT.

SET 1 ST STAGE VAPORIZER REULATOR 2-4 PSIG HIGHER THAN

TANK VAPOR PRESSURE REGULATOR SET-POINT.

TANK VAPOR

PRESSURE

REGULATOR*

4.

*BY OTHERS

NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO

FLOW IN BOTH DIRECTIONS.

VAPOR BY-PASS LINE

ISOLATION

VALVE*

ISOLATION

VALVE*

OUTLET ISOLATION VALVE*

(VAPOR)

TO LOAD

PRESSURE GAUGE*

ASDI ECONOMY VALVE

SENSES UPSTREAM

PRESSURE (OPEN 30PSIG

CLOSED 60PSIG)

PRESSURE GAUGE*

STORAGE TANK

VAPORIZER

REGULATOR*

STRAINER WITH

MAGNET FOR IRON

PARTICLE PICK-UP*

SEAL OFF REQUIRED*

ELECTRIC SERVICE

REQUIRED*

ISOLATION VALVE

W/HYDROSTATIC

RELIEF*

LIQUID

ISOLATION VALVE”

Note: Economy option cannot be used on an installation that requires a pump.

3-11 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Figure 8 – Typical TORREXX Installation for manifolding 2 vaporizers.

BALL VALVE WITH BALANCING ORIFICE

Liqui-SAFE VALVE

OVERSIZED COMMON

HEADER

VAPOR OUT

TORREXX VAPORIZER

NOTE:

1. USE 1” UNION AND BALL

VALVE WITH BALANCING

ORIFICES ON ALL VAPORIZER

OUTLETS

2. ONLY SAME SIZE VAPORIZERS

SHALL BE MANIFOLDED

TOGETHER

LIQUID IN

Figure 9 – Typical TORREXX Installation for manifolding 3 vaporizers.

BALL VALVE WITH BALANCING ORIFICE

Liqui-SAFE VALVE

OVERSIZED COMMON

HEADER

VAPOR OUT

TORREXX VAPORIZER

NOTE: USE 1” UNION AND BALL

VALVE WITH BALANCING

ORIFICES ON ALL VAPORIZER

OUTLETS

2. ONLY SAME SIZE

VAPORIZERS SHALL BE

MANIFOLDED TOGETHER

LIQUID IN

LIQUID INLET STRAINER

W/MAGNET FOR IRON

PARTICLE PICK-UP

ASDI Operations and Maintenance – TX Models – P/N: 52368 3-12

3-13

 

LIQUID

 

LINE

 

LIQUID

 

PUMP

 

Size the liquid line from the storage tank to the vaporizer to supply the vaporizer at full capacity with a minimal pressure drop. A liquid linesizing chart is provided in Table 6. If liquid line is undersized this may limit vaporizer capacity at low loads due to inability to push liquid back to the tank. Install a liquid line strainer with magnet for iron particle pickup at the vaporizer inlet.

 

CAUTION

 

A liquid pump must be installed if the pressure drop in the liquid line between the vaporizer and the tank exceeds the hydrostatic liquid head in the storage tank. ONE FOOT OF LIQUID PROPANE

EQUALS .21 PSI! Liquid line frosting is a sure indication of too much pressure drop in the liquid line.

 

 

Is a Liquid Pump necessary? What are your vapor pressure requirements?

Pressure in the storage tank depends on temperature See Table 5. A good “rule of thumb” for determining when a Liquid Pump is necessary is this: If the storage pressure will not always exceed the required distribution pressure by 5 psig (0.35 kg/cm2), a pump is necessary. Install an ASDI STABILAIRE Liquid Pump in the liquid line close to the storage tank. To prevent cavitation, place the liquid strainer at least five feet upstream of the pump inlet. Typically a pump is not required unless a mixing system is used or temperature at the installation will be extremely low, causing the pressure to drop below the required process pressure. When using a pump, vaporizer capacity may decrease due to increase in boiling point of LPG. Increasing boiling point requires larger portion of heat exchanger area to be used for liquid heating instead for boiling and vaporization. Please consult ASDI when using a pump.

VAPOR

 

LINE

 

 

Install an appropriate regulator within 3 feet (1m) of the vapor outlet. Connect pipe from the outlet port of the regulator to the distribution system. Further reduction of downstream pressure requires a “Second Stage” regulator close to the consuming equipment. Properly sized piping and regulators will insure satisfactory service.

NOTE

   

For safety reasons both FIRST and SECOND stage regulators must be 250 psig (17.58 cm/kg 2 ) inlet pressure rated!

 

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

SAFETY

 

RELIEF

 

VALVE

 

If the vaporizer is to be installed within an enclosure or building, VENT THE

SAFETY RELIEF VALVE OUTSIDE THE ENCLOSURE AND REDIRECT THE

DISCHARGE UPWARD. A pipe-away adapter must be used at the relief valve.

Always install a rain-cap or similar device to prevent water and other debris from entering the relief discharge. If water enters, it may freeze and prevent the relief valve from proper discharge, creating a potentially hazardous situation.

ELECTRICAL

 

SERVICE

 

The rating plate on the vaporizer and the data sheet provided with the manual provides your specific vaporizer’s electrical power requirements and the drawing numbers of the appropriate wiring diagrams and schematics. This unit is constructed to meet NFPA 70 Class I, Division 1, Group D requirements or ATEX

Zone I requirements (depending on model). All wiring to the unit, including the ground connection, must meet the applicable codes for the area in which it is being installed. Wire size and type must comply with the applicable codes for the area in which it is being installed. The Tables 1 through 4 list the recommended wire size for the different models. Those tables are to be used as guides only.

Provide a fused disconnect outside of the classified area. If it is not within sight of the vaporizer, the fused disconnect must have a locking device. Run wire within rigid conduit, and install a seal-off at the connection of the field conduit to the vaporizer. Use separate breaker for each vaporizer!

WIRE

 

SIZE

 

When selecting the type and size of wire used to install the TORREXX series electric vaporizers, please take into account the following environmental information:

■ Maximum enclosure surface temperature: 65º C (150ºF).

■ Maximum enclosure ambient temperature: 65º C (150ºF).

■ Maximum temperature allowed at contactor terminals: 90º C (195º F).

■ Current draw of vaporizer: Indicated on vaporizer rating plate and on the data sheet.

■ Contactor terminal lug wire size range: #2 - 10.

As the length of the wire run affects the overall wire size requirements, always refer to NFPA 70 (NEC) for proper wire selection. Several wire-sizing charts have been provided for determining the size of wire required due to load and length of wire.

When installing the wire it is important to have a good connection at the terminal lugs. Loose terminals may cause an excessive temperature rise at the terminal lugs, which can lead, to premature contactor failure, transformer failure, and/or overheating and possible destruction of the transformer. For this reason it is strongly recommended that the wire terminations be checked and re-tightened periodically to prevent excessive overheating at the terminals due to loose connections.

ASDI Operations and Maintenance – TX Models – P/N: 52368 3-14

 

Table 1 – Wire Length Chart [#4 AWG]

Table 2 – Wire Length Chart [#6 AWG]

3-15 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Table 3 – Wire Length Chart [#8 AWG]

Table 4 – Wire Length Chart [10 AWG]

ASDI Operations and Maintenance – TX Models – P/N: 52368 3-16

 

°C

37.4

40.2

42.9

45.7

48.4

51.2

53.9

56.7

59.4

-3.

-1.1

1.7

4.4

7.2

9.9

12.7

15.4

18.2

20.9

23.7

26.4

29.2

31.9

34.7

-41.7

-39.6

-36.9

-34.1

-31.4

-28.6

-25.9

-23.1

-20.4

-17.6

-14.9

-12.1

-9.35

-6.6

Table 5 – Liquid Temperature vs. Tank Pressure Chart

Propane

Liquid

Temperature

Tank Gauge

Pressure

°F

100

105

110

115

120

125

130

135

140

45

50

55

60

65

25

30

35

40

70

75

80

85

90

95

-43.73

-40

-35

-30

-25

-20

-15

-10

-5

0

5

10

15

20

PSI

173.6

186.1

199.2

213.0

227.4

242.5

258.2

274.7

291.9

46.2

51.7

57.6

63.8

70.5

77.5

84.9

92.8

101.2

109.9

119.3

129.1

139.7

150.2

161.6

0

1.4

3.4

5.6

8.0

10.7

13.6

16.7

20.0

23.6

27.6

31.7

36.2

41.1

1.2

2.9

4.8

6.9

9

11.3

13.8

16.5

19.3

22.4

25.8

29.2

32.7

36.7

41.0

46.6

50.3

55.3

60.5

66.1

72.1

78.2 kPa

1196.6

1283.1

1373.7

1468.6

1567.9

1671.9

1780.5

1893.9

2012.4

318.7

356.7

397.0

440.1

485.8

534.3

585.7

640.1

697.6

758.3

822.4

889.9

963.5

1035.7

1114.2

0

9.6

23.6

38.9

55.6

73.7

93.5

114.9

136.1

163.1

189.9

218.9

249.9

283.1

Butane

Tank Gauge

Pressure

PSI kPa

NOTE:

Below 30°F or -10°C,

Butane is a liquid at normal atmospheric pressure.

8.6

20.1

33.2

47.2

62.0

78.0

95.3

113.8

133.1

154.7

177.9

201.4

225.3

252.8

282.8

321.1

346.7

381.1

417.3

455.9

497.3

538.9

PSI

196.7

214.2

231.8

251.4

271.0

292.9

314.9

339.2

363.5

39.0

44.9

51.5

58.4

66.0

74.3

83.1

92.6

102.8

113.9

125.5

137.9

151.3

165.5

181.1

1.2

3.5

6.2

8.9

12.2

15.6

19.6

23.7

28.4

33.4

Ammonia

Tank Gauge

Pressure kPa

1356.2

1477.1

1597.9

1733.4

1868.9

2019.9

2171.0

2338.8

2506.5

268.9

309.3

355.1

402.8

455.3

511.9

572.9

638.6

709.1

784.5

865.2

951.4

1043.3

1141.3

1248.8

8.5

24.4

42.6

61.8

84.2

107.7

134.9

163.3

195.9

230.0

3-17 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Table 6 – LPG liquid line sizing chart (Minimum Pipe Size)

Capacity of units

Distance from storage to vaporizer - feet (meters)*

MMBTU

(Kcal)

1.146

(288,792)

2.292

(557,584)

4.584

(1,155,168)

7.280

(1,834,537)

10.920

(2,751,806)

14.665

(3,668,800)

Kg

25

50

100

160

240

320

LBS

(GPH)

55

(12.5)

110

(25)

220

(50)

352

(80)

530

(120)

530

(160)

25

(8)

½”

½”

½”

¾”

1”

1”

50

(15)

½”

½”

¾”

¾”

1”

1”

75

(23)

½”

½”

¾”

1”

100

(31)

½”

¾”

¾”

1”

150

(36)

½”

¾”

1”

1”

200

(61)

¾”

1”

1”

300

(92)

¾”

1”

1”

1¼‘ 1¼‘

400

(122)

¾”

1”

1¼‘

1¼‘

1¼‘ 1¼‘ 1¼‘ 1½ ” 1½ ” 1½ ”

1¼‘ 1¼‘ 1¼‘ 1½ ” 1½ ” 1½ ”

Table 7 – Equivalent Pipe Length of Various Valves and Fittings (Length in Feet/Meters)

½” ¾” 1” 1 ¼” 1 ½”

Size/Description  

(1.27 cm) (1.91 cm) (2.54 cm) (3.18 cm) (3.81 cm)

Globe Valve 15.5/4.72 21/6.40 27/8.23 36/10.97 43/13.11

Gate Valve

Angle Valve

Elbow, 90

Elbow, 45

0.6/0.18 0.8/0.24

8/2.44 11/3.35

1.4/0.43 1.9/0.58

0.7/0.21 1/0.30

1/0.30

14/4.23

2.4/0.73

1.2/0.37

1.4/0.43

18/5.49

3.2/0.98

1.6/0.49

1.6/0.49

21/6.40

3.8/1.19

2/0.61

Elbow, 90 STR

Tee

2.3/0.70 3.1/0.94

2.7/0.82 3.7/1.13

4/1.22

4.8/1.46

5.3/1.62

6.4/1.95

6.3/1.92

7.5/2.29

ASDI Operations and Maintenance – TX Models – P/N: 52368 3-18

 

OPERATION

 

GENERAL

 

4

TORREXX Electric Vaporizer utilizes a finned cast aluminum heater core. The heater core contains multiple cast-in resistance heater elements. Multiple wiring configurations allow a variety of AC input voltages to suit local power supply requirements.

Liquid LPG enters the vaporizer through the Liquid Inlet Solenoid Valve at the base of the pressure vessel.

During operation, a K-type thermocouple temperature sensor and solid state control system maintain the core temperature at 165°F (74°C). As the temperature increases on start, the Liquid Inlet Solenoid Valve opens at 131°F

(55°C), liquid enters the vaporizer and comes in contact with the heater core.

Vaporization results as the liquid extracts energy (heat) from the heater core. As the heater core cools, the Temperature Sensor provides a signal to the control system to energize the heater power contactor, applying power to the heater elements.

OPERATING

 

INSTRUCTIONS

 

 

1) Complete the installation and leak test.

2) Check current and voltage to verify proper operation of the vaporizer.

3) This unit will not be damaged by operating the unit in a “dry” condition. It is not necessary to have liquid in the unit for testing or evaluation.

4) Normal operating temperature is 165°F (74°C). Use caution when working around vaporizer.

4-19 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

 

STARTING

 

THE

 

VAPORIZER

 

CAUTION

 

Power wiring terminals may become loose during shipping. Prior to applying electrical power all power wiring terminals must be retightened. Recheck terminals and retighten as necessary during next service interval.

 

 

CAUTION

 

Do not start the vaporizer when both inlet and outlet isolation valves are closed. Pressure can build in the vaporizer during startup and blow the relief valve.

 

 

1) Close the outlet isolation valve.

2) Open all valves between the storage tank and the vaporizer to allow liquid flow to the vaporizer when the solenoid valve opens.

3) Apply power. A small “click” should be heard immediately afterwards. The vaporizer heater elements are now energized. It will take approximately 60 seconds for the vaporizer to reach operating temperature. After reaches the operating temperature, the Inlet Solenoid Valve will open automatically to allow LPG to enter. Wait approximately 2 minutes so that excess LPG is pushed back to the storage tank.

4) Carefully press the Button on top of the Liqui-SAFE TM valve all the way down and SLOWLY release it. A latch mechanism inside the Liqui-SAFE TM valve will keep the Red Flag at the down position, indicating the valve is open and in operating position.

5) TORREXX vaporizer is now ready to supply vapor. Slowly open the outlet isolation valve to pressurize the supply piping. Then, fully open the outlet isolation valve to allow vapor to flow to the load. Heater will cycle automatically to match the flow conditions.

 

 

 

 

STOPPING

 

THE

 

VAPORIZER

 

1) Close the outlet isolation valve.

2) Disconnect power.

PURGING

 

THE

 

VAPORIZER

 

Purging procedure should be followed anytime a vaporizer needs to be maintained, serviced, relocated or shut down for any other reason.

CAUTION

 

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) Close the valve at the outlet of the vaporizer.

ASDI Operations and Maintenance – TX Models – P/N: 52368 4-20

 

 

 

2) If the vaporizer is not operating, start the vaporizer.

3) Allow at most 5 minutes for vaporizer to heat up and push most of the remaining liquid back into the tank. You should hear the contactor cycle off.

4) Close the tank liquid outlet valve.

5) Open the vaporizer outlet valve and flare or allow attached equipment to consume remaining gas in the line.

4-21 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

MAINTENANCE

 

GENERAL

 

5  

TORREXX vaporizer is designed for long term trouble free 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 operation of the vaporizer. Ambient conditions surrounding the vaporizer installation and LPG quality may require a more frequent maintenance schedule.

A list of RECOMMENDED SPARE PARTS 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

Before performing maintenance on the vaporizer,

Disconnect and lock out power to the vaporizer to prevent electric shock.

Be sure the LP-gas supply is shut off and the vaporizer is completely purged. Ensure ALL sources of ignition are extinguished within 25 feet of the work area.

Initial Installation & Operation Inspections:

Component

Inlet Strainer

Required 30-60 days after initial installation

Action Required

Electronic wiring and connections

Heat exchanger & drip legs

Inspect strainer and remove accumulated debris. Note: if debris accumulation is heavy check every 3-6 months.

Check primary terminal lug tension. Inspect electrical connections for loose wires and any indication of heat build-up.

Check all drip legs and vaporizer for heavy ends and oil build-ups. If present, first ensure there are no sources of ignition within 25 feet, then drain heavy ends.

NOTE: In areas where LPG quality is poor it may be necessary for the drip legs and heat exchanger to be checked for heavy ends more frequently (monthly or bimonthly depending on quality of LPG). 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.

ASDI Operations and Maintenance – TX Models – P/N: 52368 5-22

 

Annual Maintenance Requirements:

Component

Inlet strainer

Action Required

Remove plug and clean the screen. Replace screen if gaps or holes are present

Inlet solenoid valve in the screen. If oils or contaminants are present, it may be necessary to use a cleaner to remove them.

Change solenoid valve diaphragm and internal component using recommended repair kit for the inlet solenoid valve (see spare parts list for proper part number).

Refer to the maintenance and operation information for ASCO 2 way valves

Liqui-SAFE

Contactor

TM valve included in the Appendix section. Replace solenoid valve if the valve body is damaged. NOTE: Install kit if the valve makes unusual noise (chatter or buzzing) during normal operation.

Conduct performance check as described on page 5-25.

If valve does not pass leak test, replace all O-rings in the Liqui-SAFE TM valve provided in the repair kit.

If valve does not latch test, replace Liqui-SAFE TM parts list for proper part numbers). valve assembly. (see spare

Follow the contactor inspection schedule as described in the Contactor

Inspection section. Inspect the contactor for any discoloration, warping, melting, or pitting. These are indications of excessive heat or excessive wear. If these indicators exist, replace the contactor before returning the vaporizer to operation.

If contactor operation is noisy (humming), replace the contactor.

Relief Valve

Electronic wiring and connections

Heat exchanger & system drip legs

Visually check and replace in leaks are observed. Check for excessive corrosion and ensure the relief valve is covered with the appropriate rain cap to prevent rain and debris from entering the valve. Replace rain cap if not present or damaged. Relief valve should be replaced per the manufacturers’ recommended replacement date or if it relieves during normal operation.

Check primary terminal lug tension and visually inspect all electrical connections for corrosion, loose wires, heat build-up and/or charring. Tighten or replace if necessary.

Check the system drip legs and vaporizer for heavy ends and oil build-ups. If present, first ensure there are no sources of ignition within 25 feet, then drain heavy ends. NOTE: In areas where LPG quality is poor it may be necessary for the drip legs and heat exchanger 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 are accumulating during vaporizer operation, this maintenance can be performed on an annual basis.

5-23 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

CONTACTOR

 

INSPECTION

 

WARNING

 

Contactor that powers the heaters produces sparks which may ignite any flammable vapors in the area when the control box cover is removed. If the cover must be removed, shut off the power, remove the cover and check very carefully for fumes, leaks, or any indication of flammable vapors in the atmosphere or in the control enclosure.

Do not re-apply power if fumes are present. They may ignite!

CAUTION

 

Keep a fire extinguisher available in the immediate vicinity before re-applying power when the control cover is removed.

 

TORREXX TM vaporizer utilizes an electro-mechanical contactor to switch power to the heating elements. Since contactors wear out in normal operation, it is prudent industry practice to inspect then on a preventive maintenance basis.

Manufacturers define a cycle life for contactors based upon operations at rated current. The cycle rate of the contactor in vaporizers varies due to liquid temperature/pressure, percent loading of the vaporizer, and installation specifics.

Vaporizer testing has demonstrated that cycle rates are greatest at around 50% of the vaporizer loading and least when vaporizers are energized in a standby mode.

We recommend the following inspection schedule for contactors:

 5000 hours for vaporizers in service

 30,000 hours for vaporizers in standby mode

Remove the incoming and outgoing wires and inspect the individual contacts for signs of excessive heat or wear. If blackening or pitting is present, the contactor should be replaced.

 For vaporizers operating in a combination of service and standby modes, we are providing a simple formula to help determine when contactors should be inspected.

Contactor life factor (LF) can be defined as follows:

LF = X + Y _

When

5000 30000

X = hours of vaporizer operation mode

Y = hours of vaporizer in standby mode

If LF is 1 or greater, the contactor should be replaced.

This data is to be used only as a guide. It is not “fool-proof” as the environment your vaporizer operates in and its load may affect the contactor life span.

ASDI Operations and Maintenance – TX Models – P/N: 52368 5-24

 

 

 

 

Liqui

‐

SAFE

TM  

valve

 

–

 

Performance

 

check

 

(Every

 

6

 

months)

 

I Latch operation. – While the valve is in the open position and the Red Flag is down, press Button and release QUICKLY. This will cause the valve to close and the Red Flag should pop up. Carefully press the Button again all the way down and release SLOWLY. The valve will stay open with red flag down.

II Leak detection. – Follow the instructions in “I” to manually open and close the valve. Perform leak tests in both conditions. If a leak is detected at the Valve

Body (Step 1) when the valve is open, replace the Valve Body O-ring (This can be performed in the field. See below.) If a leak is detected in Step 5 when the valve is closed (see Figure 11), follow the “Liqui-SAFE TM valve –

Service Instructions” and change all the o-rings. (This service should not be performed in the field.)

Figure 10 – Follow 1 to 7 below to check the Liqui-SAFE TM valve operation

2. PRESS AND RELEASE

QUICKLY TO CLOSE

1. CHECK FOR LEAKS

(AT THE GAP)

3. CHECK FOR LEAKS

(AT PIPE THREADS)

7. MAKE SURE VALVE FLAG

IS DOWN. VALE IS NOW IN

OPERATING POSITION

STEP 1

4. CHECK FOR LEAKS

(AT VALVE THREADS)

6. PRESS AND RELEASE

SLOWLY TO RE-OPEN

5. CHECK FOR LEAKS

(AT THE GAP)

STEP 2

5-25

STEP 3

WARNING

 

Extreme caution must be taken due to the potential of flammable vapors being exposed to the atmosphere creating an ignition. Do not operate any equipment that may create a spark from this point.

Do not open the explosion-proof enclosure.

 

 

 

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Liqui–SAFE

TM  

Valve

 

–

 

Service

 

Instructions

 

There are four (4) o-rings in the Liqui-SAFE TM valve; the Button Post o-ring,

Valve Body o-ring, Valve Seat o-ring and Valve Stem Base o-ring. Follow the instructions below to service the Liqui-SAFE TM valve. Clean all the metal parts with WD-40. Re-assemble all the parts. Simulate the tripping action of the valve to ensure proper latch operation before re-installing in the vaporizer. The tripping force applied on the Extension Stem is between 0.2 lbf (0.89 N) and 0.5 lbf (2.22

N).

Figure 11A – STEP 1 – Be sure that the Liqui-SAFE TM valve is in the close position as shown

Figure 11B – STEP 2 – Unscrew reset button base and remove the spring

UNSCREW RESET

BUTTON BASE

REMOVE SPRING

ASDI Operations and Maintenance – TX Models – P/N: 52368 5-26

 

Figure 11C – STEP 3 – Replace button post internal o-ring

COMPRESS SUB-ASSEMBLY TO GAIN BEST ACESS TO

THE O-RING. REMOVE USING FULL HOOK O-RING TOOL

(SEE FIGURE 12D)

REPLACE O-RING. APPLY WHITE LITHIUM GREASE

PRIOR TO INSERTING BACK IN THE O-RING GROOVE.

Figure 11D – Full hook o-ring tool

Figure 11E – STEP 4 – Unscrew valve latch body

UNSCREW VALVE LATCH BODY

5-27

WARNING: BE SURE THAT THE VALVE IS IN THE

CLOSED POSITION BEFORE UNSCREWING

VALVE LATCH BODY. FAILING TO DO SO MAY

RESULT IN PERMANENTLY DAMAGING THE

LATCH!

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Figure 11F – STEP 5 – Replace valve body static o-ring

PULL VALVE STEM

GUIDE UP

Figure 11G – STEP 6 – Replace valve seat and valve stem base o-rings.

USE O-RING HOOK TOOL TO REMOVE O-RING

FROM O-RING GROOVE. SLIDE O-RING OVER

STEM GUIDE.

REPLACE O-RING. APPLY WHITE LITHIUM

GREASE PRIOR TO INSERTING BACK IN

THE O-RING GROOVE

USE O-RING HOOK TOOL TO REMOVE O-RINGS

FROM O-RING GROOVES.

REPLACE O-RING. APPLY WHITE LITHIUM

GREASE TO BOTH O-RINGS PRIOR TO

INSERTING BACK IN THE O-RING GROOVES

IMPORTANT:

 Always perform a functional check and leak test (see Figure 11 ) of the re-assembled valve to ensure that it actuates per design and that valve seat o-ring seals properly against the valve body. A proper seal is present when the large valve seat o-ring shown in Figure 12G is sealing along the entire surface on the bottom face of the valve body.

 Please note that on older versions of the valve (installed on vaporizers built before 8/11/2010) it was necessary to remove the driving magnet in order to access and replace the o-ring below the valve stem guide. When reassembling the old version of the valve after servicing o-rings, make sure that super glue is applied to the inside of the magnet holder and that magnet is firmly pressed in until it bottoms out. Allow sufficient time for glue to dry.

ASDI Operations and Maintenance – TX Models – P/N: 52368 5-28

 

TROUBLESHOOTING

 

General

 

Follow

 

the

 

troubleshooting

 

guide

 

below

 

to

 

identify

 

the

 

problem:

 

6  

YES

NO FLOW OUT OF THE VAPORIZER

IS Liqui-SAFE

VALVE

TRIPPED?

NO

SEE TROUBLESHOOTING TREE 1A SEE TROUBLESHOOTING TREE 2A

6-29 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

TREE # 1 A

Liqui-SAFE VALVE TRIPS

YES

PERFORM FULL LOAD CURRENT CHECK.

SEE PAGE 6-36

REMOVE LIQUI-SAFE VALVE. SEE PAGE

5-26 FOR SERVICE INSTRUCTIONS.

RE-INSTALL LIQUI-SAFE VALVE

YES

IS CURRENT

CHECK GOOD?

IS VAPORIZER WARM

AND UP TO

TEMPERATURE?

NO

SEE TROUBLESHOOTING

TREE 1B

NO

PERFORM FULL LOAD VOLTAGE CHECK.

SEE PAGE 6-35

YES

IS VOLTAGE

CHECK GOOD?

NO

YES

VAPORIZER CAPACITY

EXCEEDED.

REDUCE LOAD

RESTART

VAPORIZER.

DOES THE

VALVE TRIP?

NO

RESUME OPERATING

THE VAPORIZER

CHECK FOR OPEN FUSE

LINKS

FIX VOLTAGE ISSUE

AND RESTART

VAPORIZER

YES

REPLACE OPEN FUSE

LINKS.

CONTACT ASDI

FUSE LINKS

OPEN?

NO

CHECK FOR OPEN

HEATERS.

CONTACT ASDI

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-30

 

YES

PERFORM SOLENOID VALVE

LEAK TEST (SEE PAGE 6-39).

REPAIR OR REPLACE

SOLENOID VALVE

PERFORM LEAK TEST

AGAIN TO ENSURE

ISSUE IS CORRECTED.

RESTART VAPORIZER

TREE # 1 B

Liqui-SAFE TM VALVE TRIPS

IS VAPORIZER POWER

OFF?

NO

SEE TROUBLESHOOTING TREE # 2A

6-31 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

TREE # 2A

Liqui-SAFE VALVE DOES NOT TRIP

CHECK CONTROL BOARD LIGHT

RED GREEN

SEE TROUBLESHOOTING

TREE #2C

SEE TROUBLESHOOTING

TREE #2B

NO

NO LIGHT

CHECK

INCOMING

POWER

INCOMING

POWER OK?

CORRECT

INCOMING

POWER ISSUE

YES

CHECK

TRANSFORMER

WIRING

BAD WIRING

CONNECTIONS.

REPLACE OR REPAIR

ANY DAMAGED WIRING

YES

LOOSE

WIRING?

NO

CHECK

TRANSFORMER FUSE

YES

REPLACE FUSE AND

RESTART

VAPORIZER

BLOWN

FUSE?

YES

PROBLEM

FIXED?

NO

PROBLEM CAUSED BY

A BLOWN FUSE.

REPLACE TRANSFORMER

AND RESTART VAPORIZER.

NO

YES

ASDI Operations and Maintenance – TX Models – P/N: 52368

IS THE PROBLEM

FIXED?

NO

REPLACE

TEMPERATURE

CONTROLLER.

RESTART VAPORIZER

6-32

 

TREE # 2B

Liqui-SAFE VALVE DOES NOT TRIP

GREEN

YES

IS CONTACTOR

LATCHED?

NO

NO

SEE HEATER CORE

RESISTANCE ON

PAGE 6-37.

CHECK FUSE LINKS

NO

FUSE LINKS

OPEN?

YES

CHECK FOR LOOSE

WIRING

IS THERE A

LOOSE WIRE?

YES

TIGHTEN WIRES.

RESTART

VAPORIZER.

PRESS HI-LIMIT

BUTTON TO RESET

YES VAPORIZER

STARTS

WORKING?

NO

REPLACE OPEN

FUSE LINKS.

CONTACT ASDI

CHECK IF THERE

IS 24V AT THE

CONTACTOR

LEADING TO THE

TEMPERATURE

CONTROLLER

CHECK:

1. IF THERMOCOUPLE

CONNECTION IS LOOSE.

2. IF THERMOCOUPLE IS BAD

3. CHECK FOR SUFFICIENT

THERMAL GREASE IN THE

THERMOWELL

4. REMOVE DRAIN PLUG AND

CHECK FOR HEAVY ENDS

IF THE ABOVE ACTIONS DO

NOT FIX THE PROBLEM THEN

REPLACE TEMPERATURE

CONTROLLER BOARD.

NO 24V AT THE

CONTACTOR?

YES

REPLACE

CONTACTOR

6-33 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

TREE # 2C

Liqui-SAFE VALVE DOES NOT TRIP

RED

NO IS THERMOCOUPLE

MOLEX LOOSE OR

DISCONNECTED?

YES

OPTIONAL

NO IS HIGH TEMP.

LIMIT

REACHED?

NO

IS FLOAT

SWITCH OR

PRESSURE

SWITCH

OPEN?

YES

REPLACE TEMP.

CONTROLLER.

RESTART

VAPORIZER

1. ASSESS SYSTEM

CAPACITY

2. PERFORM SOLENOID

VALVE LEAK TEST.

3. CHECK WIRING.

4. CHECK FUSE LINKS.

IF THE ABOVE ACTIONS

DO NOT FIX THE

PROBLEM CONTACT

ASDI.

YES

RECONNECT LOOSE OR

DISCONNECTED MOLEX

PRESS RED RESET BUTTON TO

RESTART VAPORIZER

IF THE ABOVE ACTIONS DO NOT

FIX THE PROBLEM THEN GO TO

THE NEXT STEP

PRESS RED RESET BUTTON TO

RESTART VAPORIZER.

IF PROBLEM REOCCURS THEN:

1. CHECK BOARD SETPOINT

2. CHECK FOR SUFFICIENT

THERMAL GREASE IN

THERMOWELL

3. CHECK THERMOCOUPLE

INSERTION DEPTH

4. REMOVE DRAIN PLUG AND

CHECK FOR HEAVY ENDS

IF THE ABOVE ACTIONS DO NOT

FIX THE PROBLEM THEN

CONTACT ASDI OR GO TO NEXT

STEP IF FLOAT OR PRESSURE

SWTITCH ARE INSTALLED.

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-34

 

Full

 

Load

 

Voltage

 

Check

 

NOTE

 

Current flow depends on the applied voltage. Voltage lower than the specified voltage causes low current and may negatively affect operation. Make all measurements with the heater ON (Contactor closed).

 

WARNING

 

These tests include high voltage. Exercise great caution in making the following tests. Carelessness could result in severe injury or death. See additional warnings located at the beginning of this

Chapter.

FULL

 

LOAD

 

VOLTAGE

 

CHECK

 

 

 

 

Check heater voltage by measuring voltage at the contactor terminals. See Data sheet of your manual or rating plate on the vaporizer to determine the correct voltage reading of your vaporizer. Measure voltage between all connected poles of the contactor. The readings should be equal to +/- 3% of the value on the rating plate.

Figure 12 – Full load voltage check

POWER IN

MEASURE VOLTAGE

CONTROL BOARD

6-35

CONTACTOR

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Full

 

Load

 

Current

 

Check

 

NOTE

 

See fusible link detail below for typical fusible link installation.

WARNING

 

These tests include high voltage. Exercise great caution in making the following tests. Carelessness could result in severe injury or death. See additional warnings located at the beginning of this

Chapter.

 

Measure the current on each of the heater AC power input wires. See Data

Sheet or rating plate provided with your manual for the correct reading (line current) for your vaporizer. All wires should have readings equal to +/- 3% of the value listed on the rating plate.

Low current on all wires indicates low input voltage. Drastically different current readings may indicate a defective heater, defective wiring, or an open fusible link due to overheating. If a fusible link is open, contact the factory. Do not attempt to repair it.

 

Figure 13 – Full Load Current Check

 

 

FUSIBLE LINKS

POWER IN

MEASURE CURRENT

VIEW OF FUSIBLE

LINKS IN NORMAL

CONDITIONS

COPPER STRIP

POWER

INPUT

WIRING

VIEW OF FUSIBLE

LINKS IN OPEN

CONDITIONS

CONTROL

BOARD

AMP CLAMP

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-36

 

TORREXX

 

Electric

 

Vaporizer

 

Data

 

Sheet

 

MODEL PHASE

VOLTAGE

(VAC)

TX240

TX320

TX320

TX320

TX320

TX320

TX 320

6-37

TX160

TX160

TX160

TX160

TX160

TX160

TX160

TX160

TX240

TX240

TX240

TX240

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX25

TX25

TX25

TX25

TX50

TX50

TX50

TX50

TX50

TX50

TX50

TX50

TX50

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

1

3

1

3

1

1

3

3

3

1

3

3

3

1

1

1

1

1

440

480

380

400

415

440

220

240

380

400

415

480

380

400

415

440

480

575

380

400

415

440

480

208

208

208

220

220

240

240

208

220

220

240

240

380

400

415

120

208

220

240

208

CURRENT

(A)

47.6

51.9

27.5

28.9

30.0

23.8

26.0

38.1

40.1

41.6

33.0

36.0

59.7

52.8

54.8

51.7

47.4

39.4

19.8

20.8

21.6

17.1

18.7

45.0

56.2

32.4

59.5

34.3

54.1

37.4

32.4

14.1

14.9

16.2

28.1

16.2

29.7

17.1

32.4

18.7

9.9

10.4

10.8

22.2

22.2

22.2

22.2

22.2

16.0

22.2

22.2

22.2

22.2

22.2

22.2

HEATER

RESISTANCE

(OHMS)

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

22.2

29.6

29.6

5.3

3.7

7.4

3.7

7.4

4.4

7.4

WIRE-TO-WIRE

RESISTANCE

(OHMS)

3.7

14.8

14.8

14.8

7.4

14.8

7.4

14.8

7.4

14.8

44.4

44.4

44.4

POWER

(kW)

13.0

14.4

15.5

13.1

15.5

16.2

11.7

11.7

13.1

13.1

13.0

15.5

5.8

6.5

6.5

7.8

7.8

6.5

7.2

7.8

3.9

2.9

3.3

3.9

5.8

16.0

16.0

16.0

16.0

16.0

16.0

16.0

11.5

11.5

11.5

11.5

5.3

5.3

16.0

16.0

16.0

21.3

21.3

11.5

11.5

11.5

15.4

18.1

21.5

18.1

20.0

21.5

18.1

21.5

25.1

27.8

29.9

25.1

11.5

8.8

8.8

8.8

8.8

8.8

15.4

7.4

8.8

8.8

9.8

11.7

29.9

39.3

36.6

39.3

39.4

39.4

16.9 16.9 39.2

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Heater

 

Core

 

Resistance

 

NOTE

 

Refer to the Bussing diagram in Appendix A for wire to wire resistance for your vaporizer.

CAUTION

 

Turn off electrical power at the disconnect before proceeding.

 

Carefully slide out the control panel for access to the heater wire connections on the contactor. Measure the resistance across each pair of wires. An incorrect resistance reading indicates a faulty heater element, a wiring problem, or an open fusible link.

Figure 14 – Heater Core Resistance Wiring Connections

 

 

 

READ WIRE TO WIRE RESISTANCE.

SEE HEATER WIRING DIAGRAM

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-38

 

Solenoid

 

Valve

 

Leak

 

Test

 

1) Shut off the outlet isolation valve. The inlet isolation valve should be open. Start the vaporizer and allow it to heat up until the heaters shut off.

This allows any accumulated liquid in the vaporizer to be forced back toward the supply tank.

2) Disconnect the vaporizer by shutting off the power at the disconnect.

Shut off the inlet isolation valve. Cautiously bleed off any LPG pressure in the vaporizer and outlet supply piping. When the pressure reaches no pressure in the vaporizer, remove and then reinstall pressure gauge and verify 0 pressure.

3) Turn on the inlet isolation valve. The solenoid valve is closed and you should not have any pressure build up in the vaporizer. If pressure increases, the solenoid valve is leaking and needs to be repaired or replaced.

Figure 15 – Solenoid Valve Leak Test Components

VAPOR DISCHARGE OUTLET

ISOLATION VALVE

VAPOR

PRESSURE

GAUGE

FIRST STAGE

REGULATOR

VAPOR OUT

SOLENOID VALVE

STRAINER

LIQUID INLET

ISOLATION VALVE

LIQUID IN

6-39 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

Solenoid

 

Valve

 

Electrical

 

Test

 

NOTE

 

A multimeter is required for the following test.

CAUTION

 

Turn off electrical power at the disconnect before performing this procedure.

 

Open the electrical housing at the vaporizer base. Disconnect the 2-PIN Molex plug connector and measure resistance between the pins. You should measure approximately 3 ohms. If not, replace the solenoid coil.

Figure 16 – Solenoid Valve Electrical Test

 

 

 

RESISTANCE SHOULD BE

APPROXIMATELY 3 OHMS

1. DISCONNECT

SOLENOID MOLEX

FROM MAIN HARNESS

2. MEASURE

RESISTANCE

3. RECONNECT WHEN

FINISHED

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-40

 

Thermocouple

 

Sensor

 

Replacement

 

CAUTION

 

Always disconnect power to vaporizer before servicing.

 

1) Shut off power at the disconnect.

2) Remove the control box lid.

3) Disconnect the main power wires attached to the contactor and the wires going to the heaters.

4) Slide the circuit panel half way out of the control box.

5) Disconnect the yellow and red thermocouple wires from control board.

6) The thermocouple can now be removed from the center of the core (see

Figure 18 and 19). Two types of locking collars have been used on the sensors.

Figure 17 – TORREXX Box showing Thermocouple location

 

 

THERMOCOUPLE WIRES

6-41 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

FIGURE 18 – Thermocouple Sensor with Bayonet Style Retainer

1) To remove a sensor fitted with the bayonet style retainer, push gently on the retainer while turning to the left. When the retainer is disengaged, pull out the old temperature sensor.

2) Use a short, flat-blade screwdriver to remove the adapter.

3) Install the new spring tab retainer using an appropriately sized open end wrench (1/2” or 13mm).

4) Install the new sensor by applying a small amount of heat transfer grease to the sensor tube and re-inserting in the unit. Squeeze the spring tab while inserting the sensor. Push firmly until the sensor is fully engaged. There should be at least ½” of sheath remaining.

5) When connecting new thermocouple wires back to the control board ensure that the yellow wires are connected to the yellow terminals and red wires to the red terminals. Do not over tighten terminal screws!

Connect the main power wires back to the contactor and re-install the control box lid. Torque lid bolts to 19.5 ft-lb. Failure to properly torque lid bolts may compromise explosion proof enclosure rating and may lead to water entering the enclosure.

6) Restart vaporizer and check operation.

ASDI Operations and Maintenance – TX Models – P/N: 52368 6-42

 

TORREXX

 

OPTIONS

  

TANK VAPOR

PRESSURE

REGULATOR*

ISOLATION

VALVE*

7

 

 

Economy

 

Operation

 

The Economy Option minimizes the electric power required to meet your vapor demand by shutting off the outlet of the vaporizer when the natural vaporization rate of the storage tank is able to supply enough vapor to meet the demand. A pressure sensing valve is specially developed to sense the upstream pressure. The valve opens when the tank pressure falls below 30PSIG, and closes at 60PSIG. The pressure sensing valve is a mechanical device and it operates independently to the electrical controls.

The Economy Option will NOT function if a pump is used.

The pressure set-point of the TORREXX Economy Valve is nonadjustable.

The Economy is normally a factory-installed option. However, a separate Economy valve can be purchased as an add-on in the field.

For the Economy Valve field installation kit, use ASDI PN: 41051.

Make sure that the Economy Valve is correctly installed. Verify the flow direction on the Rating Plate.

Figure 19 – TORREXX Economy valve installation

1.

2.

3.

NOTES

LIQUID PIPING LOSSES BETWEEN THE VAPORIZER AND THE

TANK MUST NOT EXCEED THE HYDROSTATIC HEAD WHEN THE

PUMP IS SHUT OFF

INSTALL VAPORIZER 1 ST STAGE REGULATOR UPSTREAM OF

THE TANK VAPOR PRESSSURE CONNECTION POINT.

SET 1 ST STAGE VAPORIZER REULATOR 2-4 PSIG HIGHER THAN

4.

*BY OTHERS

TANK VAPOR PRESSURE REGULATOR SET-POINT.

NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO

FLOW IN BOTH DIRECTIONS.

VAPOR BY-PASS LINE

OUTLET ISOLATION VALVE* ISOLATION

VALVE*

(VAPOR)

TO LOAD

PRESSURE GAUGE*

ASDI ECONOMY VALVE

SENSES UPSTREAM

PRESSURE (OPEN 30PSIG

CLOSED 60PSIG)

PRESSURE GAUGE*

STORAGE TANK

VAPORIZER

REGULATOR*

STRAINER WITH

MAGNET FOR IRON

PARTICLE PICK-UP*

SEAL OFF REQUIRED*

ELECTRIC SERVICE

REQUIRED*

ISOLATION VALVE

W/HYDROSTATIC

RELIEF*

LIQUID

ISOLATION VALVE”

Note: Economy option cannot be used on an installation that requires a pump.

7-43 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

TORREXX

 

Economy

 

Valve

 

Maintenance  

 

TORREXX Economy Valve operates by sensing the pressure of the Vaporizer and Storage Tank. The Economy

Valve consists of a moving piston which opens and closes the valve’s outlet. The movement of the piston is driven by the pressure force balance between two different sized o-rings and a spring.

Follow the instructions below and perform maintenance on the Economy Valve:

Figure 20A – STEP 1 – Unscrew the Inlet Housing from the Outlet Housing.

Figure 20B – STEP 2 – Replace the two O-rings (ASDI PN 39012 and 39014). Apply excess lithium o-ring grease.

39012

ASDI Operations and Maintenance – TX Models – P/N: 52368 7-44

7-45

 

Figure 20C – STEP 3 – Clean all o-ring contact surfaces and the bottom surface of the Outlet Housing.

Apply excess lithium o-ring grease.

Figure 20D – STEP 4 – Clean all piston surfaces. Apply excess lithium grease on o-rings.

Figure 20E – STEP 5 – Make sure that the Pin Hole is clear and the spring is undamaged. Carefully reassemble all the parts. Apply lubrication grease on the straight threads if necessary.*

ASDI Operations and Maintenance – TX Models – P/N: 52368

 

* - The threads between the Inlet Housing and the Outlet Housing are straight threads and are designed to be hand tightened. Gas will NOT leak through these threads because of the seals from the two o-rings. However, the

Inlet Housing MUST be screwed all the way down for the Valve to accurately function at the set pressure. DO

NOT apply sealing agent or Teflon tape on these threads.

Refer to the table below for any replacement parts in the TORREXX Economy Valve.

QUANTITY ASDI PART NO.

1

1

1

1

1

1

1

2

5001-5023

5001-5025

5001-5024

39012

39014

39038

5001-5026

60204

DESCRIPTION

INLET HOUSING

OUTLET HOUSING

VALVE PISTON

VALVE O-RING (LARGE)

VALVE O-RING (SMALL)

VALVE SPRING

VALVE RATING PLATE

RIVET

Mercury

 

Relay

 

The life of the vaporizer can be further extended by using a Mercury Relay. Compared to a “dry” contactor, a

Mercury Relay reduces the wear and tear each time the heater cycles. A larger explosion-proof enclosure is also used which improves access to the electrical controls.

Mercury Relay is standard on TX240 and TX320 vaporizers in most markets. It is suitable for Class I Division 1

Group D locations and is only available in the NEC configuration. Please contact ASDI if you want to implement this option on TX 160 or want to find out if Mercury Relay option can be used in your market.

The Mercury Relay Option can be integrated with all the other TORREXX options (i.e. Economy, Remote, etc.) In addition, customized options such as external lamps/indicators, on/off switches are also available. Please consult

ASDI for details.

TX

 

Remote

 

Box

 

 

Includes remote start/stop capability and a status light indicating the vaporizer is ready for operation (solenoid valve open). Connection between the box and the vaporizer is established trough the wire harness found on the inside the vaporizer explosion proof enclosure. Remote box is intended for indoor or outdoor installation in general purpose location.

FIGURE 21 – Remote START/STOP box

ASDI Operations and Maintenance – TX Models – P/N: 52368 7-46

 

Valve

 

and

 

Strainer

 

Package

 

For TX25 to TX320

For TX19AA to TX240AA

ASDI PN: 36922 ¾” NPT inlet, 1” NPT outlet

ASDI PN: 36925

Filtaire

 

–

 

Contaminant

 

Separator

 

 

The Filtaire is a filtering device designed to trap heavy hydrocarbons commonly present in LPG 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 blow-down 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.

 

FIGURE 22 – Filtaire Operation

Leak Test

1. Close outlet valve.

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

3. Apply a small amount of soap/water solution to ALL pipe connections.

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

Repair any leaks before continuing.

7-47 ASDI Operations and Maintenance – TX Models – P/N: 52368

 

APPENDIX A

TECHNICAL

INFORMATION

 

TORREXX Vertical Electric Vaporizer Data Sheet

LPG Systems

Refer to Nameplate on unit for the model and voltage information then look up specific information on the tables below.

General Specifications: Applies to all units

Electrical: 50 – 60 Hz, NEMA 4, 1 Phase units are 2 wire, 3 Phase units are 3 wire

Starting Temperature: 55 Deg. C 131 Deg. F

Operating Temperature: 71-79 Deg. C 160-175 Deg. F

High Temperature Limit: 171 Deg. C 340 Deg. F

Connections: ¾” FNPT – Inlet; 1” FNPT – Outlet

1” FNPT, Conduit Seal-Off by others Conduits:

Type of Service: Propane Vaporization

ASME Pressure Vessel: 250 PSIG MAWP @ 250ºF

-20ºF MDMT @ 250 PSIG

Heat Exchanger Area: 2.9 ft 2 / 0.269 m 2 TX25, TX50 and TX100

Dry Weight:

4.3 ft

5.4 ft

7.1 ft

2

2

2

/ 0.399 m

/ 0.503 m

/ 0.660 m

2

2

2

128 lbs / 58.1 kg

TX160

TX240

TX320

TX25, TX50 and TX100

145 lbs* / 65.8 kg*

155 lbs* / 70.3 kg*

TX160

TX240

173 lbs* / 78.5 kg* TX320

* - Add 50 lbs / 22.7 kg if vaporizer if the Mercury Relay option is installed.

Wiring:

Other:

Meets NFPA Pamphlet 70 requirements for Class I Division 1 Group D

Meets NFPA Pamphlet 58 requirements for electric vaporizers and may be installed per indirect fired vaporizers limitations.

“TORREXX” is a trademark of Algas-SDI International LLC.

 

TORREXX VERTICAL ELECTRIC VAPORIZER DATA SHEET FOR LPG SYSTEMS

MODEL PHASE VOLTAGE

TX160

TX160

TX160

TX160

TX160

TX160

TX160

TX240

TX240

TX240

TX-50

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX100

TX160

TX240

TX240

TX320

TX320

TX320

TX320

TX320

TX320

TX-25

TX-25

TX-25

TX-25

TX-50

TX-50

TX-50

TX100

TX100

TX100

TX-50

TX-50

TX-50

TX-50

TX-50

1

1

3

3

3

3

3

1

1

1

1

1

1

1

1

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

220

240

208

220

240

380

400

120

208

220

240

208

220

240

208

415

208

220

240

380

400

415

440

480

415

440

480

380

400

415

440

480

575

208

220

240

380

400

415

440

480

380

400

EQUIPMENT

DRAWING

ELECTRICAL

DRAWING

BUSSING

DIAGRAM

5001 - 6001 5001-7008 0620 - 7007

5001 - 6001 5001-7008 0620 - 7003

5001 - 6001 5001-7008 0620 - 7003

5001 - 6001 5001-7008 0620 - 7003

5001 - 6001 5001-7008 0620 - 7004

5001 - 6001 5001-7008 0620 - 7004

5001 - 6001 5001-7008 0620 - 7004

5001 - 6001 5001-7008 0620 - 7007

5001 - 6001 5001-7008 0620 - 7007

5001 - 6001 5001-7008 0620 - 7008

5001 - 6001 5001-7008 0620 - 7005

5001 - 6001 5001-7008 0620 - 7005

5001 - 6001 5001-7008 0620 - 7005

5001 - 6001 5001-7008 0620 - 7028

5001 - 6001 5001-7008 0620 - 7028

5001 - 6001 5001-7008 0620 - 7028

5001 - 6001 5001-7008 0620 - 7009

5001 - 6001 5001-7008 0620 - 7009

5001 - 6001 5001-7008 0620 - 7009

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7009

5001 - 6001 5001-7008 0620 - 7009

5001 - 6001 5001-7008 0620 - 7012

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7010

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7011

5001 - 6001 5001-7008 0620 - 7010

 

11

12

13

14

8

9

10

15

16

17

18

19

4

5

6

7

1

2

3

20

21

22

23

24

REFERENCE

KEY

10

11

12

6

7

8

9

1

2

3

4

5

13

14

15

16

17

18

19

20

21

22

23

24

REFERENCE

KEY

TORREXX Electric Vaporizer Spare Parts and Accessories

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

MERCURY RELAY CONTACTOR

TRANSFORMER (MERCURY RELAY)

WIRE HARNESS (MERCURY RELAY)

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

BALANCING ORIFICE

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

MERCURY RELAY CONTACTOR

TRANSFORMER (MERCURY RELAY)

WIRE HARNESS (MERCURY RELAY)

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

BALANCING ORIFICE

TX100

380V

400V

415V

53889

52607-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX25

120V

53889

52605-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX100

440V

480V

53889

52608-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX25

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX160

208V

220V

240V

53889

52606-01

53630

5001-4027-02

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX50

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX50

380V

400V

415V

53889

52607-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX160

380V

400V

415V

53899

52607-01

53630

5001-4027-02

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX100

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

TX160

440V

480V

53889

52608-01

53630

5001-4027-02

5001-3003

34876

35379

33139

36111

52222

41051

N/A

N/A

N/A

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

6

 

REFERENCE

KEY

12

13

14

15

9

10

11

16

17

18

19

5

6

7

8

1

2

3

4

20

21

22

23

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

MERCURY RELAY CONTACTOR

TRANSFORMER (MERCURY RELAY)

WIRE HARNESS (MERCURY RELAY)

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

TX240

380V

400V

415V

53889

52607-01

53630

5001-4027-03

5001-3003

34876

35379

33139

36111

52222

41051

53324

52607-01

53823

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

TX240

440V

480V

53889

52608-01

53630

5001-4027-03

5001-3003

34876

35379

33139

36111

52222

41051

53324

52608-01

53823

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

24 BALANCING ORIFICE 64004 64004

FIGURE 22 – TORREXX electric vaporizer major components and accessories

7

5

8

TX320

380V

400V

415V

53889

52607-01

53630

5001-4027-04

5001-3003

34876

35379

33139

36111

52222

41051

53324

52607-01

53823

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

4

TX320

440V

480V

575V

53889

52608-01

53630

5001-4027-04

5001-3003

34876

35379

33139

36111

52222

41051

53324

52608-01

53823

34877

36922

5010-3003

20437

53820

60806

40287

40421

41067

64004

20

3

2

1

19

 

TORREXX Vertical Electric Vaporizer Data Sheet

NEMKO LPG Systems

Refer to Nameplate on unit for the model and voltage information then look up specific information on the tables below.

General Specifications: Applies to all units

Electrical: 50 – 60 Hz, NEMA 4, 1 Phase units are 2 wire, 3 Phase units are 3 wire

Starting Temperature: 55 Deg. C 131 Deg. F

Operating Temperature: 71-79 Deg. C 160-175 Deg. F

High Temperature Limit: 171 Deg. C 340 Deg. F

Connections: ¾” FNPT – Inlet; 1” FNPT – Outlet

Conduits:

Type of Service:

1” FNPT, Conduit Seal-Off by others

Propane Vaporization

ASME Pressure Vessel: 250 PSIG MAWP @ 250ºF

-20ºF MDMT @ 250 PSIG

Heat Exchanger Area: 2.9 ft 2 / 0.269 m 2 TX25, TX50 and TX100

4.3 ft 2 / 0.399 m 2 TX160

5.4 ft 2 / 0.503 m 2 TX240

7.1 ft 2 / 0.660 m 2 TX320

Dry Weight: 128 lbs / 58.1 kg

145 lbs / 65.8 kg

TX25, TX50 and TX100

TX160

155 lbs / 70.3 kg

173 lbs / 78.5 kg

TX240

TX320

Hazardous Area Rating: NEMKO 04 ATEX 1026X Ex d IIB T3

TO AVOID POTENTIAL ELECTROSTATIC CHARGING HAZARD, ALWAYS USE A DAMP CLOTH FOR

CLEANING THE INSULATION JACKET. AVOID DRY RUBBING OF THE INSULATION JACKET.

2460

0496

“TORREXX” is a trademark of Algas-SDI International LLC.

 

TORREXX VERTICAL ELECTRIC VAPORIZER DATA SHEET FOR LPG SYSTEMS

(NEMKO)

MODEL PHASE VOLTAGE

TX-50

TX-50

TX-50

TX100

TX100

TX100

TX100

TX100

TX160

TX-25

TX-25

TX-50

TX-50

TX100

TX100

TX-50

TX-50

TX160

TX160

TX160

TX160

TX240

TX240

TX240

TX320

TX320

TX320

3

3

3

3

3

3

3

3

3

3

1

1

1

1

1

1

3

3

3

3

3

3

3

3

3

3

3

240

380

400

415

220

240

380

400

415

220

220

240

220

240

220

240

220

240

380

400

415

380

400

415

380

400

415

EQUIPMENT

DRAWING

ELECTRICAL

DRAWING

BUSSING

DIAGRAM

5001 - 6003 5001-7008 0620 - 7003

5001 - 6003 5001-7008 0620 - 7003

5001 - 6003 5001-7008 0620 - 7004

5001 - 6003 5001-7008 0620 - 7004

5001 - 6003 5001-7008 0620 - 7007

5001 - 6003 5001-7008 0620 - 7008

5001 - 6003 5001-7008 0620 - 7005

5001 - 6003 5001-7008 0620 - 7005

5001 - 6003 5001-7008 0620 - 7028

5001 - 6003 5001-7008 0620 - 7028

5001 - 6003 5001-7008 0620 - 7028

5001 - 6003 5001-7008 0620 - 7009

5001 - 6003 5001-7008 0620 - 7009

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7009

5001 - 6003 5001-7008 0620 - 7012

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

5001 - 6003 5001-7008 0620 - 7010

 

TORREXX Electric Vaporizer Spare Parts and Accessories (NEMKO)

10

11

12

6

7

8

9

13

14

15

16

1

2

3

4

5

17

18

19

20

21

REFERENCE

KEY

10

11

12

6

7

8

9

13

14

15

16

1

2

3

4

5

17

18

19

20

21

REFERENCE

KEY

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

BALANCING ORIFICE

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

BALANCING ORIFICE

TX100

380V

400V

415V

53889

52607-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX25

120V

53889

52605-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX100

440V

480V

53889

52608-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX25

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX160

208V

220V

240V

53889

52606-01

53630

5001-4027-02

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX50

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX50

380V

400V

415V

53889

52607-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX160

380V

400V

415V

539889

52607-01

53630

5001-4027-02

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX160

440V

480V

53889

52608-01

53630

5001-4027-02

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX100

208V

220V

240V

53889

52606-01

53630

5001-4027-01

5001-3003

34876

35379

33139

33418

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

 

REFERENCE

KEY

10

11

12

13

14

15

16

5

6

7

8

9

1

2

3

4

17

18

19

20

21

SPARE PARTS

TEMPERATURE CONTROL BOARD

TRANSFORMER

CONTACTOR

THERMOCOUPLE

Liqui-SAFE VALVE

PRESSURE RELIEF VALVE

RAIN CAP

FUSIBLE LINK

INLET SOLENOID

FUSE KIT

ECONOMY VALVE FIELD INSTALL KIT

PIPE AWAY ADAPTOR

VALVE, GAUGE AND STRAINER KIT

DRAIN ASSEMBLY

STAND

WIRE HARNESS (MAIN)

CORROSION INHIBITING TAPE

INLET SOLENOID KIT

Liqui-SAFE VALVE O-RING KIT

REMOTE START/STOP BOX

BALANCING ORIFICE

TX240

380V

400V

415V

53889

52607-01

53630

5001-4027-03

5001-3003

34876

35379

33139

36111

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX240

440V

480V

53889

52608-01

53630

5001-4027-03

5001-3003

34876

35379

33139

36111

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX320

380V

400V

415V

53889

52607-01

53630

5001-4027-04

5001-3003

34876

35379

33139

36111

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

TX320

440V

480V

575V

53889

52608-01

53630

5001-4027-04

5001-3003

34876

35379

33139

36111

52222

41051

34877

36922

5010-3003

20437

53820

60806

40249

40421

41067

64004

PRESSURE GAUGE

RATING PLATE

HEATING ELEMENT

.XX .XXX

(4) 1/2" DIA MOUNTING HOLES CONTROL BOX MOUNTING CLAMP

6" 152

Liqui-SAFE VALVE

INSULATION JACKET

MERCURY RELAY CONTROL BOX

3/4" FNPT LIQUID INLET VALVE

CONTROL HOUSING COVER

10 GA WIRE MESH OR DEFORMED REBAR

1 8

THIRD ANGLE PROJECTION

DO NOT SCALE DRAWING

3 4

1 4

1" FNPT VAPOR OUTLET

TX240 52" [1320] TX320 59" [1500]

3 PHASE ELECTRICAL SERVICE (BY OTHERS) 1-1/4" FNPT (THREAD PROTECTOR INSTALLED FOR SHIPPING) FACTORY INSTALLED CONDUIT WITH SEAL OFF

1 4

TX240 56 3/4" [1313] TX320 63 3/4" [1619]

NOTES: 1. ALL DIMMENSIONS ARE IN INCHES [mm]. 2. FM AND FMc APPROVED FOR USE IN CLASS 1 DIVISION 1 GROUP D AREAS. 3. EXPLOSION PROOF CONTROL BOX MEETS NEMA 4 REQUIREMENTS. 4. VAPORIZER PRESSURE VESSEL RATED AT 250 PSIG [17.6 KG/CM 7. SUITABLE FOR INDOOR/OUTDOOR INSTALLATION. 8. VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE. 9. AVOID DRY RUBBING OF THE INSULATION JACKET TO PREVENT ELECTROSTATIC CHARGING HAZARD. ALWAYS USE DAMP CLOTH FOR CLEANING. 10. ECONOMY VALVE OPTION AVAILABLE UPON REQUEST. 11. APROXIMATE SHIPPING WEIGHT: TX240 (205lbs.) TX320 (223lbs.)

SET-POINT. 3.

.XXX .XX

ASCO Valve used by Algas-SDI

SOLENOID NOISE

Solenoid valves emit a sound when operated. When energized, they emit a clicking sound. Also, accompanying the operation of most AC valves, is AC hum.

Whether or not AC hum is objectionable actually depends on the requirements and opinion of the user. Normal AC hum is the result of the constantly reversing magnetic field produced by alternating current. The constantly reversing magnetic field can cause vibrations in the solenoid parts.

1. Solenoid noise due to damage solenoid parts such as bent solenoid base assembly, stretched return springs, loose parts, etc.

Solution: Inspect valve internals and exterior. Replaced damaged

parts.

2. Solenoid noise due to foreign matter between the core and plug-nut. When foreign matter is trapped between the core and plug-nut, the core assembly will rock back and forth at 60 hertz. Eventually, the core and plug-nut face will be distorted, at which time the noise can continue even though the foreign material may have been flushed or removed from the valve.

Solution: Replace damaged parts entirely, clean and reassemble.

3. Solenoid noise due to damaged coil. On rare occasions, a severe voltage spike or over voltage can potentially short a small portion of the coil winding.

This shorting can cause solenoid noise and coil overheating. However, it would normally lead to rapid coil burnout. The solenoid parts, however, could be damaged enough that the noise would continue even after the coil was replaced due to the deformation produced during the peening process.

4. Missing solenoid parts can severely weaken the magnetic circuit. This can produce a solenoid noise condition. As discussed above, it will probably also result in coil burn-out.

Solution: Replace damaged parts, replace lost parts, clean and re-

assemble.

In general, when a noise condition has been encountered, the source of the problem should be determined and eliminated. The valve should then be thoroughly inspected to insure that it is yet repairable. Most times, simple installation of a spare parts kit and a solenoid base sub assembly can restore a valve to like new condition. The restored and reinstalled solenoid valve should be tested to insure proper operation, and a voltage check should be made at the solenoid valve while the valve is energized. In addition, a current reading can be obtained and compared with catalog specifications to verify normal solenoid and coil operation.

Note: The coil may have been damaged due to excessive current draw of at damaged shading coil within the solenoid valve. A partial rebuilding of a valve damaged by a noise condition can prove useless as the noise condition would continue. The entire valve should be dismantled and inspected and cleaned. All parts supplied in a spare parts kit should be installed. Further, and additional solenoid parts damaged by a noise condition such as a solenoid base sub assembly, should be replaced. Examine valve seating, pistons and the valve body to verify that they have not been damaged. Damage to major portions of the valve may make repairing the valve uneconomical.

Should a noise condition be encountered, immediate action may prevent any damage to the solenoid valve itself.

SOLENOID NOISE

Solenoid valves emit a sound when operated. When energized, they emit a clicking sound. Also, accompanying the operation of most AC valves, is AC hum.

Whether or not AC hum is objectionable actually depends on the requirements and opinion of the user. Normal AC hum is the result of the constantly reversing magnetic field produced by alternating current. The constantly reversing magnetic field can cause vibrations in the solenoid parts.

1. Solenoid noise due to damage solenoid parts such as bent solenoid base assembly, stretched return springs, loose parts, etc.

Solution: Inspect valve internals and exterior. Replaced damaged

parts.

2. Solenoid noise due to foreign matter between the core and plug-nut. When foreign matter is trapped between the core and plug-nut, the core assembly will rock back and forth at 60 hertz. Eventually, the core and plug-nut face will be distorted, at which time the noise can continue even though the foreign material may have been flushed or removed from the valve.

Solution: Replace damaged parts entirely, clean and reassemble.

3. Solenoid noise due to damaged coil. On rare occasions, a severe voltage spike or over voltage can potentially short a small portion of the coil winding.

This shorting can cause solenoid noise and coil overheating. However, it would normally lead to rapid coil burnout. The solenoid parts, however, could be damaged enough that the noise would continue even after the coil was replaced due to the deformation produced during the peening process.

4. Missing solenoid parts can severely weaken the magnetic circuit. This can produce a solenoid noise condition. As discussed above, it will probably also result in coil burn-out.

Solution: Replace damaged parts, replace lost parts, clean and re-

assemble.

In general, when a noise condition has been encountered, the source of the problem should be determined and eliminated. The valve should then be thoroughly inspected to insure that it is yet repairable. Most times, simple installation of a spare parts kit and a solenoid base sub assembly can restore a valve to like new condition. The restored and reinstalled solenoid valve should be tested to insure proper operation, and a voltage check should be made at the solenoid valve while the valve is energized. In addition, a current reading can be obtained and compared with catalog specifications to verify normal solenoid and coil operation.

Note: The coil may have been damaged due to excessive current draw of at damaged shading coil within the solenoid valve. A partial rebuilding of a valve damaged by a noise condition can prove useless as the noise condition would continue. The entire valve should be dismantled and inspected and cleaned. All parts supplied in a spare parts kit should be installed. Further, and additional solenoid parts damaged by a noise condition such as a solenoid base sub assembly, should be replaced. Examine valve seating, pistons and the valve body to verify that they have not been damaged. Damage to major portions of the valve may make repairing the valve uneconomical.

Should a noise condition be encountered, immediate action may prevent any damage to the solenoid valve itself.

ASCO Valve used by Algas-SDI

Installation & Maintenance Instructions

SERIES

8003G

8202G

OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS

Form No.V6584R8

Ċ SERVICE NOTICE Ċ

ASCO solenoid valves with design change letter G" or H" in the catalog number (ex. 8210G 1) have an epoxy encapsulated ASCO Red Hat II solenoid. This solenoid replaces some of the solenoids with metal enclosures and open-frame constructions. Follow these installation and maintenance instructions if your valve or operator uses this solenoid.

See separate instructions for basic valve.

INSTALLATION

Check nameplate for correct catalog number, service, and wattage. Check front of solenoid for voltage and frequency.

WARNING: Electrical hazard from the accessibility of live parts. To prevent the possibility of death,Ăserious injury or property damage, install the open - frame solenoid in an enclosure.

DESCRIPTION

Catalog numbers 8003G and 8202G are epoxy encapsulated pull-type solenoids. The green solenoid with lead wires and 1/2 Ăconduit connection is designed to meet Enclosure Type 1-General Purpose, Type 2-Dripproof,

Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. The black solenoid on catalog numbers prefixed EF" or EV" is designed to meet

Enclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6 and 6P-Submersible, Type 7 (A, B, C & D) Explosionproof Class I, Division

1 Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-Ignitionproof Class II,

Division 1 Groups E, F & G. The Class II, Groups F & G Dust Locations designation is not applicable for solenoids or solenoid valves used for steam service or when a class H" solenoid is used. See Temperature Limitations section for solenoid identification and nameplate/retainer for service. When installed just as a solenoid and not attached to an ASCO valve, the core has a 0.250-28 UNF-2B tapped hole, 0.38 or 0.63 minimum full thread.

NOTE: Catalog number prefix EV" denotes stainless steel construction.

Catalog numbers 8202G1, 8202G3, 8202G5 and 8202G7 are epoxy encapsulated push-type, reverse-acting solenoids having the same enclosure types as previously stated for Catalog numbers 8003G1 and

8003G2.

Series 8003G and 8202G solenoids are available in:

Open-Frame Construction: The green solenoid may be supplied with

1/4 spade, screw or DIN terminals. (Refer to Figure 4)

Panel Mounted Construction: These solenoids are specifically designed to be panel mounted by the customer through a panel having a .062 to .093

maximum wall thickness. Refer to Figure 1 and section on Installation of

Panel Mounted Solenoid.

Optional Features For Type 1 - General Purpose

Construction Only

Junction Box: This junction box construction meets Enclosure Types

2,3,3S,4, and 4X. Only solenoids with 1/4 spade or screw terminals may have a junction box. The junction box provides a 1/2 conduit connection, grounding and spade or screw terminal connections within the junction box (See Figure 5).

DIN Plug Connector Kit No.K236034: Ă Use this kit only for solenoids with

DIN terminals. The DIN plug connector kit provides a two pole with grounding contact DIN Type 43650 construction (See Figure 6).

OPERATION

Series 8003G - When the solenoid is energized, the core is drawn into the solenoid base sub-assembly. IMPORTANT: When the solenoid is de-energized, the initial return force for the core, whether developed by spring, pressure, or weight, must exert a minimum force to overcome residual magnetism created by the solenoid. Minimum return force for AC construction is 11 ounces, and 5 ounces for DC construction.

Series 8202G - When the solenoid is energized, the disc holder assembly seats against the orifice. When the solenoid is de-energized , the disc holder assembly returns.

IMPORTANT: Initial return force for the disc or disc holder assembly, whether developed by spring, pressure, or weight, must exert a minimum force to overcome residual magnetism created by the solenoid. Minimum return force is 1 pound, 5 ounces.

MM All Rights Reserved.

F OR B LACK E NCLOSURE T YPES 7 AND 9 O NLY

CAUTION: To prevent fire or explosion, do not install solenoid and/or valve where ignition temperature of hazardous atmosphere is less than 165 C. On valves used for steam service or when a class

H" solenoid is used, do not install in hazardous atmosphere where ignition temperature is less than 180 C. See nameplate/retainer for service.

NOTE: These solenoids have an internal non-resetable thermal fuse to limit solenoid temperature in the event that extraordinary conditions occur which could cause excessive temperatures. These conditions include high input voltage, a jammed core, excessive ambient temperature or a shorted solenoid, etc. This unique feature is a standard feature only in solenoids with black explosionproof/dust-ignitionproof enclosures (Types 7 & 9).

CAUTION: To protect the solenoid valve or operator, install a strainer or filter, suitable for the service involved in the inlet side as close to the valve or operator as possible. Clean periodically depending on service conditions. See ASCO Series 8600, 8601, and

8602 for strainers.

Temperature Limitations

For maximum valve ambient temperatures, refer to chart. The temperature limitations listed, only indicate maximum application temperatures for field wiring rated at 90 C. Check catalog number prefix and watt rating on nameplate to determine maximum ambient temperature. See valve installation and maintenance instructions for maximum fluid temperature.

NOTE: For steam service, refer to Wiring section, Junction Box for temperature rating of supply wires.

Temperature Limitations For Series 8003G or 8202G Solenoids for use on Valves Rated at 10.1, 11.6, 17.1, or 22.6 Watts

Watt

Rating

Catalog

Number Coil Prefix

Class of

Insulation

Maximum

Ambient Temp.

10.1 & 17.1

10.1 & 17.1

None, FB, KF, KP

SC, SD, SF, & SP,

HB, HT, KB, KH,

SS, ST, SU,

F

H

125

140

F (51.7

F (60

C)

C)

11.6 & 22.6

11.6 & 22.6

None, FB,KF, KP,

SC, SD, SF, & SP.

HP, HT, KB, KH,

SS, ST, SU, & SV

F

H

104

104

F (40

F (40

C)

C)

Minimum ambient temperature -40 F (-40 C).

Positioning

This solenoid is designed to perform properly when mounted in any position.

However, for optimum life and performance, the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulating in the solenoid base sub-assembly area.

Wiring

Wiring must comply with local codes and the National Electrical Code. All solenoids supplied with lead wires are provided with a grounding wire which is green or green with yellow stripes and a 1/2 conduit connection. To

Printed in U.S.A.

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Page 1 of 4

facilitate wiring, the solenoid may be rotated 360 . For the watertight and explosionproof solenoid, electrical fittings must be approved for use in the approved hazardous locations.

CAUTION: Cryogenic Applications - Solenoid lead wire insulation should not be subjected to cryogenic temperatures.

Adequate lead wire protection and routing must be provided.

Additional Wiring Instructions For Optional Features:

Open-Frame solenoid with 1/4 spade terminals.

For solenoids supplied with screw terminal connections use #12-18 AWG stranded copper wire rated at 90 C or greater. Torque terminal block screws to 10 ± 2 in-lbs [1,0 ± 1,2 Nm]. A tapped hole is provided in the solenoid for grounding, use a #10-32 machine screw. Torque grounding screw to 15 - 20 in-lbs [1,7 - 2,3 Nm]. On solenoids with screw terminals, the socket head screw holding the terminal block to the solenoid is the grounding screw.

Torque the screw to 15 - 20 in-lbs [1,7 - 2,3 Nm] with a 5/32 hex key wrench.

Junction Box

The junction box is used with spade or screw terminal solenoids only and is provided with a grounding screw and a 1/2 conduit connection. Connect

#12-18 AWG standard copper wire only to the screw terminals. Within the junction box use field wire that is rated 90 C or greater for connections. For steam service use 105 C rated wire up to 50 psi or use 125 C rated wire above

50 psi. After electrical hookup, replace cover gasket, cover, and screws.

Tighten screws evenly in a crisscross manner.

DIN Plug Connector Kit No.K236034

1. The open-frame solenoid is provided with DIN terminals to accommodate the plug connector kit.

2. Remove center screw from plug connector. Using a small screwdriver, pry terminal block from connector cover.

3. Use #12-18 AWG stranded copper wire rated at 90 C or greater for connections. Strip wire leads back approximately 1/4 f or installation in socket terminals. The use of wire-end sleeves is also recommended for these socket terminals. Maximum length of wire-end sleeves to be approximately 1/4 .ĂTinning of the ends of the lead wires is not recommended.

4. Thread wire through gland nut, gland gasket, washer and connector cover.

NOTE: Connector housing may be rotated in 90 increments from position shown for alternate positioning of cable entry.

5. Check DIN connector terminal block for electrical markings. Then make electrical hookup to terminal block according to markings on it. Snap terminal block into connector cover and install center screw.

6. Position connector gasket on solenoid and install plug connector. Torque center screw to 5 ± 1 in-lbs [0,6 ± 1,1 Nm].

NOTE: Alternating current (AC) and direct current (DC) solenoids are built differently. To convert from one to the other, it may be necessary to change the complete solenoid including the core and solenoid base sub-assembly, not just the solenoid. Consult ASCO.

Installation of Solenoid

Solenoids may be assembled as a complete unit. Tightening is accomplished by means of a hex flange at the base of the solenoid.

Installation of Panel Mounted Solenoid (See Figure 1)

1. Disassemble solenoid following instruction under Solenoid Replacement then proceed .

2. Install solenoid base sub-assembly through customer panel.

3. Position spring washer on opposite side of panel over solenoid base sub-assembly.

4. Replace solenoid, nameplate/retainer and red cap.

5. Make electrical hookup, see Wiring section.

Solenoid Temperature

Standard solenoids are designed for continuous duty service. When the solenoid is energized for a long period, the solenoid becomes hot and can be touched by hand only for an instant. This is a safe operating temperature.

MAINTENANCE

WARNING: To prevent the possibility of death, serious injury or property damage, turn off electrical power, depressurize solenoid operator and/or valve, and vent fluid to a safe area before servicing.

Page 2 of 4

Cleaning

All solenoid operators and valves should be cleaned periodically. The time between cleaning will vary depending on medium and service conditions. In general, if the voltage to the solenoid is correct, sluggish valve operation, excessive noise or leakage will indicate that cleaning is required. Clean strainer or filter when cleaning the valve.

Preventive Maintenance

Keep the medium flowing through the solenoid operator or valve as free from dirt and foreign material as possible.

While in service, the solenoid operator or valve should be operated at least once a month to insure proper opening and closing.

Depending on the medium and service conditions, periodic inspection of internal valve parts for damage or excessive wear is recommended.

Thoroughly clean all parts. Replace any worn or damaged parts.

Causes of Improper Operation

Faulty Control Circuit: Check the electrical system by energizing the solenoid. A metallic click signifies that the solenoid is operating. Absence of the click indicates loss of power supply. Check for loose or blown fuses, open-circuited or grounded solenoid, broken lead wires or splice connections.

Burned-Out Solenoid: Check for open-circuited solenoid. Replace if necessary. Check supply voltage; it must be the same as specified on nameplate/retainer and marked on the solenoid. Check ambient temperature and check that the core is not jammed.

Low Voltage: Check voltage across the solenoid leads. Voltage must be at least 85% of rated voltage.

Solenoid Replacement

1. Disconnect conduit, coil leads, and grounding wire.

NOTE: Any optional parts attached to the old solenoid must be reinstalled on the new solenoid. For 3-way construction, piping or tubing must be removed from pipe adapter.

2. Disassemble solenoids with optional features as follows:

Spade or Screw Terminals

Remove terminal connections, grounding screw, grounding wire, and terminal block (screw terminal type only).

NOTE: For screw terminals, the socket head screw holding the terminal block serves as a grounding screw.

Junction Box

Remove conduit and socket head screw (use 5/32 hex key wrench) from center of junction box. Disconnect junction box from solenoid.

DIN Plug Connector

Remove center screw from DIN plug connector. Disconnect DIN plug connector from adapter. Remove socket head screw (use 5/32 hex key wrench), DIN terminal adapter, and gasket from solenoid.

3. Snap off red cap from top of solenoid base sub-assembly. For 3-way construction with pipe adapter (Figure 3), remove pipe adapter, nameplate and solenoid. Omit steps 4 and 5.

4. Push down on solenoid. Then using a suitable screwdriver, insert blade between solenoid and nameplate/retainer. Pry up slightly and push to remove.

NOTE: Series 8202G solenoids have a spacer between the nameplate/ retainer and solenoid.

5. Remove solenoid from solenoid base sub-assembly.

6. Reassemble in reverse order of disassembly. Use exploded views for identification and placement of parts.

7. Torque pipe adapter to 90 inch-pounds maximum [10,2 Nm maximum].

Then make up piping or tubing to pipe adapter on solenoid.

Disassembly and Reassembly of Solenoids

1. Remove solenoid, see Solenoid Replacement .

2. Remove spring washer from solenoid base sub-assembly. For 3-way construction, remove plugnut gasket.

3. Unscrew solenoid base sub-assembly from valve body.

4. Remove internal solenoid parts for cleaning or replacement. Use exploded views for identification and placement of parts.

5. If the solenoid is part of a valve, refer to basic valve installation and maintenance instructions for further disassembly.

6. Torque solenoid base sub-assembly and adapter to 175±25 in-lbs

[19,8±2,8 Nm].

ORDERING INFORMATION FOR ASCO SOLENOIDS

When Ordering Solenoids for ASCO Solenoid Operators or Valves, order the number stamped on the solenoid. Also specify voltage and frequency.

Form No.V6584R8

50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Part Name solenoid base sub-assembly & adapter pipe adapter

Remove red cap and

Then pry here to lift nameplate/retainer and push to remove.

Torque Chart

Torque Value Inch-Pounds

175 ± 25

90 maximum solenoid with 1/2 NPT

.062 to .093 maximum thickness of panel for mounting red cap nameplate/ retainer grounding wire green or green with yellow stripes finger washer

0.69 diameter mounting hole

Torque Value Newton-Meters

19,8 ± 2,8

10,2 maximum

Remove red cap and

Then pry here to lift nameplate/retainer and push to remove.

core

(AC) core

(DC)

Tapped hole in core

0.250-28 UNF-2B

0.63 minimum full thread (AC)

0.38 minimum full thread (DC) red cap nameplate/ retainer spacer solenoid base sub-assembly

0.9375-26 UNS -2A

Panel Mount thread

Figure 1. Series 8003G solenoids

Remove red cap and

Then pry here to lift nameplate/retainer and push to remove.

solenoid with 1/2 NPT grounding wire green or green with yellow stripes spring washer

Side View collar to face valve body

Alternate

Construction finger washer pipe adapter plugnut gasket

Without

Adapter

Form No.V6584R8

bonnet washer core(small end up) solenoid base gasket plugnut assembly retainer gasket retainer stem disc disc spring adapter gasket disc holder assembly disc holder spring

Figure 2. Series 8202G solenoids adapter

With

Adapter

Air Only Construction

Vent to Atmosphere

Figure 3. 3-Way Construction

Page 3 of 4

50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Part Name terminal block screws socket head screw center screw

Open-Frame Solenoid with 1/4 Spade Terminals

See torque chart above tapped hole for

#10-32 grounding screw

(not included)

Junction Box Solenoid with 1/4 Spade Terminals or Screw Terminals

Torque Chart

Torque Value in Inch-Pounds

10 ± 2

15 - 20

5 ± 1

Open-Frame Solenoid with Screw Terminals.

Socket head screw is used for grounding.

Torque Value in Newton-Meters

1,1 ± 0,2

1,7 - 2,3

0,6 ± 0,1

Open-Frame Solenoid with DIN Terminals Indicates parts supplied in Termination Module

Kit No. K256104 screw terminal adapter gasket

DIN terminal adapter block screw socket head grounding screw

(5/32 hex key wrench)

Figure 4. Open-frame solenoids socket head screw

(5/32 hex key wrench) cover screw cover cover gasket

See torque chart above grounding screw and cup washer

Note: junction box gasket

Junction box with screw terminals shown. With screw terminal block removed, remaining parts comprise the junction box for spade terminal construction.

junction box with

1/2 conduit connection and grounding terminal

Figure 5. Junction box (optional feature) socket head screw

(5/32 hex key wrench)

Open-Frame Solenoid with DIN Terminal

Plug Conector

Indicates that these parts are included in DIN plug connector Kit No. K236034

See torque chart above gasket

DIN terminal adapter connector gasket gland nut gland gasket

Notes:

1. Connector cover may be rotated in 90 increments from position shown for alternate position of cable entry.

2. Refer to markings on DIN connector for proper electrical connections.

socket head screw

(5/32 hex key wrench)

DIN connector terminal block

(see note 2) connector cover

(see note 1) washer center screw

Page 4 of 4

Figure 6. DIN plug connector kit No. K236034 (optional feature)

Form No.V6584R8

50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Florham Park, New Jersey 07932

Tel. (973) 966-2000

Fax (973) 966 2628

Aiken, South Carolina 29801

Tel. (803) 641-9200

Fax (803) 641-9290

SCIENTIFIC

50 Hanover Road

Florham Park, New Jersey 07932

Tel. (973) 236-6160

Fax (973) 966 6461

MMIl All Rights Reserved.

Printed in U.S.A. Form No. V6950R5

50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Page 1 of 2

ASCOMATICA S.A. de C.V.

Bosques de Duraznos No. 65-1003A

Fraccionamiento Bosques de las Lomas

Delegacion Miguel Hildago

Mexico, D.F. CP11700

Tel: (52)-55-5596-7741

Fax: (52)-55-5596-7719

ASCO Valve Canada

P.O. Box 160 (Airport Road)

Fax: (519)758-5540

ASCOTECH S.A. de C.V.

Circuito Del Progreso No.27

Mexicali, B.C. Mexico

Tel: (011)-52-686-559-8500

Fax: (011)-52-686-559-8548

MMIl All Rights Reserved.

50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Printed in U.S.A.

Form No. 6950R5

Page 2 of 2

Innovative Liquid Vaporizing and Gas Mixing Solutions

WARRANTY REGISTRATION

Type of Equipment:

ASDI Sales Order #:

Purchased By:

Serial Number:

Order Date:

To help us give you better service, please fill out this warranty registration form and return it to

ASDI to register your purchase and for follow up on the performance of ASDI equipment.

We are dedicated to producing a quality product and if a problem occurs,

ASDI wants to know about it.

Please help us with a small amount of information about your company and how the equipment will be used. When contacting ASDI, please have the type of equipment and the serial number handy so we can give you accurate information. If you have had any kind of problem with this equipment, or you have any comments, please attach a separate sheet to this form. Keep a copy for your records.

End Customer/Company Name:

Address:

City:

State:

Tel:

Fax:

Zip:

Name of individual to contact for follow up information:

Title:

Usage - Circle one:

Other:

Base Load Standby System Peak Shaving

In what application is the equipment being used?

When was the equipment put in service?

Note: If you have more than one piece of ASDI equipment, fill out one warranty sheet and staple the others to it, ASDI will do the rest.

151 South Michigan Street,

Seattle, Washington, 98108, USA

Tel: 206.789..5410

Fax: 206.789.5414

E-mail: [email protected]

Internet: www.algas-sdi.com

Algas-SDI International, LLC

151 South Michigan Street

Seattle, Washington 98108

USA

Ph.: 1.206.789.5410

Fax.: 1.206.789.5414 www.algas-sdi.com