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

...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H
Operations & Maintenance
Manual
151 South Michigan Street, Seattle, Washington, USA 98108
Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com
This manual covers units built after August 2009
FILE: MANUAL PN 52642 DIRECT FIRED 11_12_13.DOC
After S/N:
2013.11.1
2 09:47:39
-08'00'
40/40H – A13J20003627
80/40H – A13J40007352
120/60H – A13J60002719
WARNING
Read the OPERATION MANUAL before operating this equipment.
■ NOTE: Algas-SDI reserves the right to use alternate manufacturers’
components as vendor delivery applicability dictates. Literature
contained in the Operation Manual has been supplied by
vendors. Please check to be sure supplied data matches your
configuration. Contact Algas-SDI if any questions exist.
■ This equipment uses LPG-a flammable fuel, handled under pressure.
Inherent hazards exist and a thorough understanding of the equipment
is required to allow safe operation and maintenance.
■ Allow only a TRAINED and FULLY QUALIFIED PERSON to service this
equipment.
■ Any time a component must be replaced, use the same type, model,
etc. DO NOT SUBSTITUTE! The consequence from such actions are
unpredictable and may lead to dire consequences. When components
are replaced with components not approved for use in our UL listed
equipment, the UL listing becomes void for that unit.
Warranty, 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 AlgasSDI International, LLC to any representation or warranty other than this warranty.
COPYRIGHT
Copyright 2013 by Algas-SDI International, LLC, Seattle, Washington 98108. All
rights reserved. No part of this manual may be reproduced or copied in any form
or by any means, photographic, electronic, or mechanical, without the prior
express written consent from Algas-SDI International, LLC, Seattle, Washington,
USA.
APPROVALS
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IMPORTANT WARRANTY NOTICE:
The Algas-SDI warranty period for equipment is 18 months after
shipment from our facility or 12 months after installation. See our
warranty statement at the beginning of this manual for the complete
text. A warranty registration card has been provided with this manual
so that you may register the date of installation for warranty purposes.
If you do not return the warranty registration card, the warranty term will
be 12 months after the equipment has been shipped to you, the end
user. If you do not install it immediately, your warranty may expire
earlier than necessary. The warranty registration also gives us
information to contact you if we need to send you important information
about the equipment later on.
Please register your equipment.
Symbols and Conventions
Special symbols are used to denote hazardous or important information. You
should familiarize yourself with their meaning and take special notice of the
indicated information.
Please read the following explanations thoroughly.
GENERAL WARNING OR CAUTION
Indicates hazards or unsafe practices which can result in damage to
the equipment or cause personal injury. Use care and follow the
instructions given.
FLAMMABLE GAS HAZARD
Indicates a potential hazard which can result in severe personal
injury or death. Use extreme care and follow the instructions given.
ELECTRICAL DISCONNECT REQUIRED
Indicates a potentially dangerous situation which can result in
severe personal injury or death or damage to equipment. Use great
care and follow the instruction given.
PARTS AND PRICES
For parts and prices contact your Algas-SDI distributor.
ASDI CONTACT NUMBERS
If you have questions, need help with your equipment, or want
information on other products, contact your distributor or
Algas-SDI at:
Telephone: 206.789.5410
Facsimile: 206.789.5414
Email:
[email protected]
Internet:
http://www.algas-sdi.com
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Table of Contents
Options
Auto Re-igniter
Contaminant Separator / Filtaire
Economy Kit
Inlet and Outlet Hand Valves
Pipe away Adapter
1st Stage Regulator
1.
2.
Introduction
Description/Overview
1-1
Figure 1 – Direct Fired Vaporizer System - Basic Features
1-1
How the vaporizer works
1-2
Direct fired vaporizer specifications
1-3
Installation
General
2-4
Unpacking and Initial Assembly
2-4
Unpacking
2-4
Initial Assembly
2-4
Table 1 – Distance from Vaporizer
2-4
Figure 2 – Vaporizer Dimensions
2-5
Figure 3 – Installation – 40/40H, 80/40H, and 120/60H vaporizers
2-6
Vapor Distribution Line
Table 2 – Recommended Vapor Distribution Line Size
2-6
2-6
Liquid Inlet
2-7
Vapor Bypass Line (Optional)
2-7
Burner Supply Line (Optional)
2-7
Liquid Pump (Optional)
2-8
Economy Installation (Optional)
2-8
Figure 4 – Economy Option
2-8
Contaminant Separator – Filtaire (Optional)
Figure 5 – Filtaire Operation
Installing Multiple Units in Parallel
2-9
2-9
2-10
Figure 6 – Installing Multiple Units in Parallel
2-10
Figure 7 – Installing Multiple Units in Parallel, Oversized Manifolds
2-10
Leak Test
2-11
Check Burner Input Pressure
2-11
3.
Operation
Direct Fired Vaporizer start up procedure
Figure 8 – Temperature control dial in “RUN” position
3-13
Figure 9 – Pilot button pressed down and ignitor switch on
3-14
Direct Fired Vaporizer setpoint adjustment
Figure 10 – Rotating temperature control dial counter-clockwise to desired setpoint
Direct Fired Vaporizer shutdown procedure
Figure 11 – Vaporizer shut down procedure
4.
3-14
3-14
3-15
3-15
Direct fired vaporizer purge procedure
3-16
Automatic Re-Ignition Operation
3-16
Economy Operation
3-16
Maintenance
Service and Maintenance
4-18
Table 3 – commended periodic maintenance and inspections
4-18
Table 4 – Recommended annual maintenance and inspections
4-19
Direct Fired vaporizer inspection checklist
4-21
Replacing reignitor battery
4-22
Figure 12 – Opening the battery access door
4-22
Figure 13 – Replacing the battery
4-22
Adjusting burner input pressure
Error! Reference source not found.
5.
3-13
4-23
4-23
Liquid inlet valve maintenance procedure
4-24
Capacity control valve maintenance procedure
4-26
Troubleshooting
Pilot
5-28
Main Burner Will Not Ignite
5-28
If Vapor Pressure Drops
5-28
Troubleshooting Tree #1: Pilot Will Not Light
5-29
Troubleshooting Tree #2: Pilot Lights But Will Not Hold
5-30
Troubleshooting Tree #3: Main Burner Will Not Light
5-31
Troubleshooting Tree #4: Vapor Service Pressure Drops
5-32
Appendix A: Technical Information
Figure 14 – 40/40H Vaporizer Replacement Parts
A-36
Figure 15 – 80/40H and 120/60H Vaporizer Replacement Parts
A-37
Figure 16 – Inlet Valve and Capacity Control Valve
A-38
Table 5 – Repair kits and other available replacement parts
A-40
Liquid Inlet valve pin gasket installation procedure
A-43
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Options
Auto Re-igniter
40/40H, 80/40H & 120/60H, Auto Re-igniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683,
Quantity 1 per unit
See Page 3-16 for Details
Contaminant Separator / Filtaire
40/40H, 80/40H, Filtaire Model F4, Use P/N: 20536 or 20536-ASME, Quantity 1 per unit
120/60H, Filtaire Model F6, Use P/N: 20540 or 20540-ASME, Quantity 1 per unit
See Page 2-9 for Details
Economy Kit
40/40H, 80/40H & 120/60H, Economy Option Kit P/N: 80793, Quantity 1 per unit,
See Page 2-8 and 3-16 for Details
Inlet and Outlet Isolation Valves
40/40H, 80/40H & 120/60H, 3/4" inlet valve use P/N 33803, Quantity 1 per unit
40/40H, 80/40H & 120/60H, 1" outlet valve use P/N 33814, Quantity 1 per unit
Pipeaway Adapter
40/40H, 80/40H & 120/60H, Pipeaway Adapter 3/4", Quantity 1 per unit
Use P/N 1501-5016 for Cavagna/Omeca relief valve
Use P/N 34877 for REGO relief valve
1st Stage Regulator
40/40H, 80/40H & 120/60H, 1" 5-20 PSIG, Use P/N: 33725, Quantity 1 per unit
1
Introduction
Description/Overview
Congratulations on your purchase of an Algas-SDI Direct Fired vaporizer. AlgasSDI is an ISO 9001 registered company and your new vaporizer was
manufactured under strict accordance with ASME and UL requirements and
carries the associated marks and the ASME "U" stamp.
A Direct Fired vaporizer, as the name implies, is one in which heat is furnished
by an open flame directly applied to the heat exchange surface, which in turn
contacts the LP Gas liquid that is to be vaporized. The Algas-SDI Direct Fired
vaporizers consist of seven (7) main components:







Liquid inlet valve & float assembly
Liquid reservoir or heat exchanger
Thermostat supply regulator
Thermostat
Burners
Capacity control valve
Relief valve
Figure 1 – Direct Fired Vaporizer System - Basic Features
Excess Flow
Valve
Relief Valve
Distribution
Line
Regulator
Vapor
Vapor
Float Ball
Liquid
Heat Load
Liquid
Inlet
Valve
Pressure
Vessel
Burner
Regulator
Liquid
Burner
Algas-SDI Operation and Maintenance Manual – P/N – 52642
Thermostat
Pilot Assembly
1-1
Introduction
HOW THE VAPORIZER WORKS
When the shut-off valve in the liquid supply line is opened, liquid is forced into the
heat exchanger by the pressure in the storage tank. As the liquid level rises,
some of the liquid boils off until it matches the pressure coming from the tank.
The flow of liquid into the heat exchanger will stop when the rising liquid forces
the float upward, closing the liquid inlet valve, or when the pressure in the heat
exchanger is the same as the pressure coming from the storage tank.
When the burner(s) is lit, the heat will boil off the liquid in the heat exchanger.
During periods of low or no demand, the pressure will build up to the storage tank
pressure. Whenever pressure in the heat exchanger starts to increase above the
tank pressure, the pressure differential will cause the LP gas to flow back through
the inlet valve to the tank.
Due to the boiling action and the flow back to the tank, the liquid level in the
exchanger will drop. When the liquid level drops, the temperature sensor will
sense the warmer vapor and cycle off the main burner(s).
As the demand increases, the pressure in the heat exchanger will drop. As a
result, liquid will flow into the exchanger, and the temperature sensor will sense
the cool liquid, and cycle the main burner(s) on.
During continuous operation, the burner(s) will cycle on and off to maintain the
required supply of vapor. As long as the rate of vaporization exceeds the
demand, the exchanger will contain a very small amount of liquid. The only time
the exchanger will contain a large amount of liquid is when the demand is equal
to or above the capacity of the vaporizer.
Whenever the demand exceeds the capacity of the vaporizer, the capacity
control valve is engaged, which limits the withdraw rate from the exchanger to
the maximum capacity of the vaporizer.
The capacity control valve is a spring loaded valve mounted on the outlet of the
exchanger. Liquid LP gas is supplied to the top of the valve and vapor from the
exchanger to the bottom of the valve. During normal operation, the valve is held
open by the force of the spring.
When the liquid/vapor pressure differential exceeds the spring force, the liquid
pressure will begin to close the valve. This restricts the flow out of the vaporizer.
Any increase in demand will create greater pressure drop. In turn, the valve will
further restrict the flow of vapor from the unit. This throttling action will cause the
gas outlet pressure to drop, allowing the pressure in the heat exchanger to build
back up and maintain proper gas supply to the vaporizer’s burner(s) and keep
the vaporizer in operation.
1-2
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Introduction
Direct Fired Vaporizer specifications:
BURNER INPUT
40/40H
53,792 BTU/hr per burner
80/40H
47,440 BTU/hr per burner
120/60H
61,854 BTU/hr per burner
GAS CONSUMPTION: 1000 BTU’s per gallon of propane vaporized
TOTAL BURNER INPUT
40/40H:
REGULATOR GAS PRESSURE*: 11” W.C.
53,792 BTU/hr
THERMOSTAT PORT PRESSURE**: 10” W.C.
BURNER PRESSURE: 9” W.C.
80/40H:
REGULATOR GAS PRESSURE*: 10” W.C.
94,880 BTU/hr
THERMOSTAT PORT PRESSURE**: 9” W.C.
BURNER PRESSURE: 7” W.C.
120/60H:
REGULATOR GAS PRESSURE*: 18” W.C.
123,708 BTU/hr
THERMOSTAT PORT PRESSURE**: 14” W.C.
BURNER PRESSURE: 12” W.C.
PILOT BURNER:
2200 BTU’s/hr
NOMINAL OPERATING TEMPERATURE***: 140 to 160 F
* Regulator Gas Pressure measured between burner regulator and thermostat at the drip leg.
** Thermostat Port Pressure measured at the pressure port at the outlet of the thermostat.
*** Operating Temperature depends on ambient temperature, thermostat setting, and operating pressure.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
1-3
2
Installation
GENERAL

Install the system so it complies with all governing codes and regulations.

Make up all threaded pipe connections with a sealing compound that is
approved and listed for LP gas service.

All above ground lines should be adequately supported.

Any underground piping should be properly protected against corrosion.

Vapor outlet lines up to the first stage regulator should be sloped toward the
vaporizer to allow condensation in the vapor line to flow back to the
vaporizer.

Clean all foreign material from all pipes prior to making final connections.

Test all joints as specified in the applicable codes for leaks before placing the
piping system in service.
Unpacking and Initial Assembly
UNPACKING
Upon receiving your new vaporizer inspect package for any damage that may
have occurred during shipping. Then carefully open package and inspect unit for
damage. Remove all plastic shipping material from the vaporizer.
INITIAL ASSEMBLY
Install the Flue cap(s) on the top of the unit with the supplied hardware.
Install the vaporizer a minimum of 15 feet from the storage tank valves
(see Table 1 below).
Secure vaporizer through the four (4) ½ inch holes (see Figure 2) on above
ground level, solid, non-combustible base,
The vaporizer should be adequately protected against damage by moving
vehicles.
If the vaporizer is to be installed in any building or enclosure, a relief valve pipe
away and a regulator relief pipe away must be installed. The relief valve and
regulator relief must be able to relieve outside of any enclosure or building.
Table 1 – Distance from Vaporizer
Exposure
Storage Tank
Storage tank shutoff valves
Point of transfer
Nearest important building or group of buildings or
line of adjoining property which maybe built upon
(except buildings in which vaporizer is installed).
Minimum Distance From
Vaporizer Required
10 feet
15 feet
15 feet
25 feet
Reference NFPA58
2-4
Algas-SDI Operation and Maintenance Manual – P/N – 52642
Installation
Figure 2 – Vaporizer Dimensions (shown in inches)
40/40H Vaporizer
80/40H and 120/60H Vaporizers
Model
40/40H
80/40H
120/60H
“A”
35”
35”
44 ¼”
Algas-SDI Operation and Maintenance Manual – P/N – 52642
“B”
29”
29”
37 ¾”
“C”
20”
20”
28 ¾”
2-5
Installation
Figure 3 – Installation – 40/40H, 80/40H, and 120/60H vaporizers
CAUTION
The entire installation must be leak tested prior to operating the
system.
NOTE
Do not connect this vaporizer to a storage tank that has been used
in vapor withdrawal service until the tank has been emptied and all
sediment and heavy ends have been cleaned from it.
VAPOR DISTRIBUTION LINE (see Figure 3)
The vapor distribution line should be adequately sized for the service.
Table 2 – Recommended Vapor Distribution Line Size
Gas Line Length Ft.
40/40H Vaporizers
80/40H Vaporizers
120/60H Vaporizers
Up to 50
1”
1-1/4”
1-1/2”
50-150
1-1/2”
1-1/2”
2”
150-250
2”
2”
2-1/2”
* Nominal Pipe Size
1. Install a UL listed shut-off valve with a Minimum 250psi gas pressure rating
2. Install a 0-300 psig pressure gauge (or provisions for one) ahead of the 1st
stage regulator.
3. Install the first stage regulator as close to the vaporizer as possible, but not
further than 24” from the outlet of the vaporizer. The outlet pressure of the
regulator should be set at 4 to 6 PSI lower than tank saturated vapor
2-6
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Installation
pressure at lowest expected temperature; this may require periodic
adjustment.
4. The second stage (or low pressure) regulator should be installed as close to
the consuming equipment as practical.
5. A line relief valve may be installed (optional) to protect the regulators from
excessively high pressure. If a line relief valve is used, set the blow pressure
at approximately 10 PSI above the first stage regulator delivery pressure.
LIQUID INLET
NOTE
Do not install a check valve in the supply line between the tank and
the vaporizer. Liquid must be able to flow both ways in that line.
1. Install the 60-mesh 3/4" strainer that is supplied with the unit on the liquid
inlet to the vaporizer.
2. Install a UL listed shut-off valve with a Minimum 250psig gas pressure rating
3. Install a 0-300 psig pressure gauge (or provisions for one) ahead of the liquid
inlet valve.
4. The liquid line from the storage tank to the vaporizer should be of sufficient
size to supply the vaporizer at full capacity with a maximum pressure drop of
less than the hydrostatic head pressure (see NFPA 54).
5. Connect the vaporizer to the storage tank.
VAPOR BYPASS LINE (OPTIONAL) - see Figure 3
1. Install a primary (first stage) regulator at the vapor outlet on top of the
storage tank. Set this regulator to deliver gas at a pressure of 2 to 4 psi
below the setting of the vaporizer regulator. Then if the vaporizer is
overloaded or its output pressure drops off, the regulator on top of the
storage tank will automatically take over.
2. Run a line from the regulator and tie it into the vapor service line downstream
from the vaporizer first stage regulator.
BURNER SUPPLY LINE (OPTIONAL)
The vaporizer burners are supplied with vapor from the outlet of the vaporizer
where the least possibility of condensation will take place. In regions where
there is a problem with a high content of heavy ends in the LP gas, a separate
vapor supply line to the burner control on the vaporizer may be installed. If a
separate burner supply line is used, the following is recommended:
1. Disconnect the ¼” line at the burner regulator inlet.
2. Disconnect the ¼” line at the tee on top of the heat exchanger and plug it
with ¼-NPT plug.
3. Install a first stage regulator as close to the tank vapor outlet as possible. A
manual shut-off valve should be installed ahead of the regulator.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
2-7
Installation
4. Connect the supply line from the first stage regulator to the burner regulator
at the vaporizer. Make sure that the supply is sized properly to handle
maximum input rating of the vaporizer burner(s). See Figure 1.
5. For the 40/40H, 80/40H and 120/60H Thermostat Supply Regulator pressure
adjustments please refer to page 1-3.
LIQUID PUMP (OPTIONAL)
The liquid pressure to the inlet of the vaporizer must be a minimum of 6PSI
higher than desired discharge pressure. If tank pressure cannot meet this
requirement, install a pump in the liquid line under the storage tank to maintain
the minimum pressure.
ECONOMY INSTALLATION (OPTIONAL)
A vaporizer with economy operation draws vapor from tank as primary source
and utilizes the vaporizer only when needed. The intent is to allow the most
economical operation and eliminate energy waste. To accomplish this, install an
Algas-SDI 40/40H, 80/40H, or 120/60H vaporizer, operating on demand,
combined with a primary vapor bypass. To do this you will need an economy kit
that consists of several valves and regulators.
Figure 4 – Economy Option
After installing the vaporizer, install and set the regulators from the economy kit as follows:
1. Install the (1) Primary Vapor Regulator in the vapor line at the tank and set at 10 psig. The
regulator must be installed so that any gas condensing between the regulator and the tank
can run back into the tank.
2. Install the (3) Vaporizer Regulator at the outlet of the vaporizer and set at 13 psig or
approximately 3 psig higher than the (1) Primary Vapor Regulator.
3. Between the (3) Vaporizer Regulator and the vaporizer outlet install the (2) Economy
Regulator in reverse direction such that the outlet side of the regulator faces the vaporizer.
This regulator should be set at 30 psig or just high enough to allow enough pressure in the
tank to supply the full flow through the (3) Vaporizer Regulator when needed.
2-8
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Installation
CONTAMINANT SEPARATOR – FILTAIRE (OPTIONAL)
The FILTAIRE is a filtering device designed to trap heavy hydrocarbons
commonly present in LPG gas vapor. It also traps other materials, which may be
in the gas due to storage conditions and internal condition of the equipment.
Impurities are collected in the system and periodically removed through the
system blow down drain. Residual heavy end hydrocarbons with boiling points
higher than pure LPG are trapped by the filter and fall to the bottom for removal.
A complete FILTAIRE system consists of inlet and outlet connections, a blowdown drain (5), a pressure gauge (4), a vent which is normally plugged (6), and a
bypass valve system for cleaning (1, 2, and 3). The bypass valves enable the
system to continue operating when the FILTAIRE is removed for cleaning (see
Figure 5).
At 20 psig, recommend using Algas-SDI FILTAIRE Model F4 ASDI PN: 20536 or
20536-ASME for Direct Fired Models 40/40H, and 80/40H. At 20 psig
recommend using Algas-SDI FILTAIRE Model F6 ASDI PN: 20540 or 20540ASME for Direct Fired Model 120/60H.
Note: Items 4, 5 and 6 are included with FILTAIRE assemblies.
Figure 5 – Filtaire Operation
BYPASS VALVE 1
(NORMALLY CLOSED)
OUTLET VALVE
1ST STAGE
REGULATOR
3
“FILTAIRE” OIL DEMISTER
VAPOR FROM
VAPORIZER
VAPOR LINE
6
4
2 INLET VALVE
PIPE
STAND
5
DRAIN
VALVE
VAPOR
TO LOAD
Algas-SDI Operation and Maintenance Manual – P/N – 52642
2-9
Installation
INSTALLING MULTIPLE UNITS IN PARALLEL
Piping should be equal distance on both inlet and outlet piping for
balanced performance.
Figure 6 – Installing Multiple Units in Parallel
AN OVERSIZED INLET AND OUTLET MANIFOLD MAY BE USED TO BALANCE THE FLOW.
Figure 7 – Installing Multiple Units in Parallel, Oversized Manifold
LEAK TEST
2-10
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Installation
CAUTION
The entire installation must be leak tested prior to operating the
system.
1. Close outlet valve.
2. Slowly open inlet valve and allow pressure to equalize in the vaporizer.
3. Apply a liberal amount of soap/water solution to ALL internal and external
flanged, threaded and tubing connections.
4. Check for any leaks by observing new bubble formation in the soap/water
solution.
5. Repair any leaks before continuing. Leak test until system has no leak
present.
NOTE
If using direct fired vaporizers in mobile or temporary applications,
leak test must be performed each time vaporizer has been moved or
re-located.
CHECK BURNER INPUT PRESSURE
See Adjust burner input pressure on page 4-22.
NOTE
For installations or locations in Canada it may be required to vent
the integral pressure relief of the burner supply regulator. Venting
must be installed in accordance with all requirements defined by
CSA B149.1 Natural Gas and Propane Installation code latest
revision.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
2-11
Installation
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2-12
Algas-SDI Operation and Maintenance Manual – P/N - 52642
3
Operation
Direct Fired Vaporizer start up procedure
1. Before starting the vaporizer, close the outlet valve in the vapor service
line.
2. Fill the vaporizer with LP gas liquid by slowly opening the liquid supply
line valve between the storage tank and the vaporizer. If this valve is
opened too quickly, the excess flow valve in the tank may close. If this
occurs, close the liquid supply line valve and allow the excess flow valve
to equalize and re-open.
3. If the vaporizer is installed with a separate burner supply line not
connected to the vaporizer (see page. 2-7), open the valve supplying gas
to the Thermostat Supply Regulator.
4. Turn the temperature control dial on the thermostatic gas control valve
counter-clockwise to the "RUN" position (“PILOT” on first version).
“RUN” position (“PILOT” on first version) indicates that the pilot and main
burner can start operating.
Figure 8 – Temperature control dial in “RUN” position
5. Turn the igniter switch to “ON”. Press the pilot button. Continue to hold
the pilot button for 30 to 60 seconds and release. Pilot should remain lit.
NOTE: If the ambient temperature is below 10°F (-12°C) when the pilot
button is released it is likely that the main burner will immediately cycle on.
As soon as the LP gas inside the heat exchanger heats up above this
temperature the main burner will cycle off. This is normal operation for the
new Algas-SDI thermostatic gas valves and is different than previous gas
valves used.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
3-13
Operation
Figure 9 –Pilot button pressed down and ignitor switch ON
WARNING
If pilot light goes off after releasing dial, turn control dial to "OFF",
wait 5 minutes and repeat step 4.
6. Turn temperature control dial counter clockwise until burner(s) cycle on.
7. Allow burner(s) to heat the vaporizer until they cycle off.
8. Make sure all the valves on consuming equipment are closed and slowly
open the valve in the vapor distribution line. Open all consuming
equipment valves.
Direct Fired Vaporizer setpoint adjustment
On initial startup, set the temperature control dial to a setpoint between 5 and
7. If there is a drop in downstream pressure, it means that capacity control
valve is beginning to close due to the actual heat input not being able to
satisfy system capacity. Rotate the dial to a higher setpoint to increase heat
input until pressure at the outlet has stabilized.
Figure 10 – Rotating temperature control dial counter-clockwise to the desired setpoint
3-14
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Operation
Direct Fired Vaporizer shut down procedure
1. Turn temperature control dial to “OFF” position. Pilot flame should
immediately extinguish.
2. Once the pilot flame has extinguished turn the ignitor switch to “OFF.
3. If the vaporizer is below -10°F (-12°C) the main burner may continue to
operate for an additional 30-40 seconds until thermocouple cools down.
4. Close the isolation valve ahead of the burner regulator on the side of the
vaporizer. This will prevent any fuel from going downstream to the
thermostat, pilot and main burner.
5. If required, it is not safe to disconnect the vaporizer or service the
thermostat and the burner.
Figure 11 – Vaporizer shut down procedure
Isolation valve
Regulator
Thermostatic gas valve
Algas-SDI Operation and Maintenance Manual – P/N – 52642
3-15
Operation
Direct Fired Vaporizer purge procedure
If the vaporizer is not going to be used for a long period of time, it should
be purged. The information contained below is a step by step procedure on
how to purge Algas-SDI direct fired vaporizer. This procedure should be
followed anytime a vaporizer needs to be maintained, serviced, relocated
or shut down for any other reason.
WARNING
Prior to purging the vaporizer, ensure that there are no closed ball
valves or back check valves restricting the flow of liquid to the tank.
1. Close outlet valve at exit of the vaporizer.
2. If the vaporizer is not operating, start the vaporizer per “Starting the
Vaporizer” procedure.
3. After the burner cycles off, shut down the vaporizer per “Direct Fired
vaporizer shut down procedure”.
4. Before proceeding validate that the burner flame, pilot flame, ignitor spark
and any other sources of ignition are completely extinguished.
5. Close the tank liquid outlet valve.
6. Open the vaporizer outlet valve and flare or allow attached equipment to
consume remaining gas in the line.
AUTOMATIC RE-IGNITION OPERATION
Lighting or re-lighting of the pilot flame is accomplished by a spark across a gap
of approximately 5/32" from the electrode tip to the grounded surface of the pilot
burner or to the thermocouple tip. When the flame is established, the pilot flame
conducts a current to the grounded pilot burner and a solid state switch in the
unit turns off the spark. If the pilot flame is extinguished, current to ground is
interrupted and the solid state switch turns on the spark, which sparks at a
nominal timing of 100 times per minute, re-lighting the pilot flame well before the
thermocouple cools enough to drop out the thermostat safety system.
ECONOMY OPERATION
During normal operation and while the tank pressure is above 30 psig the
primary vapor regulator supplies vapor to the load. During this time the economy
regulator on the discharge side of the vaporizer remains closed, until the tank
pressure drops below 30 psig. Low ambient temperatures may cause this low
pressure in the fall or winter or by excessive demand such that the natural
vaporization cannot maintain the tank pressure. When the tank pressure drops
below 30 psig, the economy regulator opens allowing flow through the vaporizer
and subsequently the higher discharge pressure from the vaporizer regulator (3)
overcomes the lower setting of the primary vapor regulator. This allows flow only
through the vaporizer thus preventing the tank pressure from being drawn down.
3-16
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Operation
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Algas-SDI Operation and Maintenance Manual – P/N – 52642
3-17
4
Maintenance
Maintenance Recommendations
Vaporizers, just like any other LP gas equipment, should be maintained
periodically. The following maintenance scheduled may be used as a guideline.
This maintenance schedule includes items that must be inspected and the type
and frequency of maintenance to be performed. Although the following schedule
is the minimum recommended type and frequency of maintenance, the
conditions in your area and quality of the LP gas liquid may dictate a more
stringent maintenance program. It is important to remember that maintenance is
of paramount importance for trouble free and safe operation of the vaporizer.
See Appendix A for a list of the most common spare parts and repair kits for
proper maintenance.
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.
Table 3 – Recommended periodic maintenance and inspections
Strainer
Pilot Burner Assembly
Flame Spreader Bar
Models 80/40H & 120/60H
Main Burner Assembly
Relief Valves
Drip Leg
Vaporizer Cabinet
4-18
Periodic maintenance inspections
After initial installation inspect strainer 30-60 days for debris and
contaminants. Remove the plug and clean the screen. Replace screen if
necessary. If oils or contaminants are present, it may be necessary to
use a cleaner to remove all of the contaminants.
Inspect pilot flame to ensure flame is enveloping 3/8” to ½” of the
thermocouple tip. If flame is yellow or too small to envelope the
thermocouple tip properly, clean pilot orifice.
Upon initial installation and during periodic maintenance inspections,
check flame spreader bar position to ensure both burners light
simultaneously and smoothly. Straighten spreader bar if it is positioned at
an angle or not positioned on top of the pilot properly.
Inspect burner tips to ensure each tip has proper flame. Check orifices
and air supply openings for debris, insects and/or dirt. If needed, clean
any plugged or obstructed orifices. For easy access to clean the burner
tips, disconnect burner supply line and remove the burner from the unit.
Direct Fired vaporizers built after October 2002 have #66 burner orifices.
Inspect all relief valves on the vaporizer, liquid and vapor lines for signs of
corrosion and rain caps. Replace rain cap if it is damaged or missing.
In new installations check and drain the drip leg approximately 30 days
after installation to establish if there are LPG quality issues. If poor
quality LPG is present, establish a frequency schedule to drain the drip
leg to prevent it from filling with contaminants and passing them into the
thermostat.
Inspect the door, inside enclosure, inlet louvers and vent caps for debris
and/or combustible material. If needed, clean areas so they are free of all
debris.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
Maintenance
Table 4 – Recommended annual maintenance and inspections
Strainer
Thermostat
Thermocouple
Pilot Assembly
Main Burner Assembly
Flame Spreader Bar
Models 80/40H & 120/60H
Liquid Inlet Valve
Capacity Control Valve
Vaporizer Tubing
Relief Valves
Burner Regulator
Heat Exchanger
Annual Maintenance Items
Remove the plug and clean the screen. Replace screen if tears or holes
are present. If oils or contaminants are present, it may be necessary to
use a cleaner to remove all of the contaminants.
Check thermostat for proper operation per the Start-up procedure.
Establish pilot and turn the thermostat dial counter-clockwise to high,
burners should cycle on. Turn the dial clockwise to the “off” position,
main burner and pilot should both extinguish in a short period of time.
Replace the thermostat if not operating properly (thermostat cannot be
serviced). NOTE: Before replacing the thermostat, be sure the
thermocouple is delivering the proper voltage to the thermostat (see
below).
Check electrical output of the thermocouple with a millivolt meter. The
thermocouple output (when hot) should be 13 - 30 mV. Lower than 13
mV reading indicates the thermocouple should be replaced. NOTE: Be
careful not to over tighten the thermocouple! First hand tighten and then
turn 1/8th turn with wrench.
Inspect pilot flame to ensure flame is enveloping 3/8” to ½” of the
thermocouple tip. Clean pilot orifice. If pilot assembly is corroded or
significantly deteriorated, replace complete pilot assembly.
Inspect burner tips to ensure each tip has proper flame. Check orifices
and air supply openings for debris, insects and/or dirt. If needed, clean
any plugged or obstructed orifices. For easy access to clean the burner
tips, disconnect burner supply line and remove the burner from the unit.
Direct Fired vaporizers built after October 2002 have #66 burner orifices.
Upon initial installation and during periodic maintenance inspections,
check flame spreader bar position to ensure both burners light
simultaneously and smoothly. Straighten spreader bar if it is positioned at
an angle or not positioned on top of the pilot properly.
Use repair kit p/n: 3-0016 to replace internal components of the liquid inlet
valve. See detailed Liquid Inlet Valve Maintenance Instructions for further
information.
Use repair kit p/n: 3-0017 to replace internal components of the capacity
control valve. See detailed Capacity Control Valve Maintenance
Instructions for further information.
Inspect all tubing for pitting or flaking - run hands along the underside of
each of the tubes to check for signs of corrosion. Replace tubes is
corroded. Check and tighten all fittings.
Inspect all relief valves on the vaporizer, liquid and vapor lines for signs of
corrosion and rain caps. Replace rain cap if it is damaged or missing.
Replace relief valves per manufacturer’s recommended replacement
period. Also replace relief valve if it shows significant corrosion on the
outlet or has relieved.
Check regulator delivery pressure at the drip leg or at the burner pressure
port to ensure proper pressure is delivered to the thermostat and burners.
See page 1-3.
1. Check heat exchanger flue for holes or excessive scale.
2. Remove debris, soot build-up and any obstructions from the
outside surface of the heat exchanger between the fins and in the
area between the heat exchanger and flue. High pressure air or
a wire brush may be used for removal. A large amount of buildup on the outside of the heat exchanger can lead to a reduced
capacity from your vaporizer.
3. Check bottom head of the heat exchanger for pitting and/or
Algas-SDI Operation and Maintenance Manual – P/N – 52642
4-19
Maintenance
Drip Leg
Vaporizer Cabinet
scaling. Should heat exchanger head thickness be less than
0.156” (5/32”) the heat exchanger should be removed from
service. Nominal wall thickness 0.250” (¼”). An Ultrasonic
thickness tester can be used to determine wall thickness.
4. Check heat exchanger for heavy ends accumulation inside the
vessel. Remove the liquid inlet valve and tilt the vaporizer on its
side to drain the heavy ends. Re-install liquid inlet valve and
uniformly torque bolts to 30-35 ft.-lbs using a star/cross pattern.
NOTE: In areas where LPG quality is poor it may be necessary for heat
exchangers to be checked for heavy ends more frequently (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.
Remove plug below the “T” on the drip leg and drain the drip leg to
prevent it from filling with contaminants and passing them into the
thermostat.
Inspect the door, inside enclosure, inlet louvers and vent caps for debris
and/or combustible material. If needed, clean areas so they are free of all
debris.
CAUTION
1. When servicing a component in the liquid or vapor line, BE
SURE that the LP-gas supply is shut off to that component
before it is removed or disassembled. The vaporizer must be
completely purged before performing service. Be sure that ALL
sources of ignition are extinguished within 25 feet of the work
area.
2. When flaring the contents of the vaporizer, be sure that the
burners are on to prevent freezing during the flaring operation.
4-20
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Maintenance
Use the Direct Fired Vaporizer Inspection & Maintenance Checklist included in this manual to record and keep
track of your annual maintenance and inspections.
DIRECT FIRED VAPORIZER INSPECTION CHECKLIST
Model:_________________
Serial Number:___________________
Maintenance Checklist Items
Inspected
Yes/No
Replaced or
Kit Installed?
1. Thermostat Operation:
‐ Did burner(s) cycle on?
‐ Did the burner(s) & pilot extinguish after a short period of time when turned
off?
2. Thermocouple: Was the millivolt output between 13 -30 mV.?
3. Pilot Assembly:
‐ Pilot assembly inspected for corrosion?
‐ Pilot orifice cleaned?
4. Burner Assembly: Burner tips and orifices cleaned?
5. Flame Spreader Bar: Is it present and positioned properly on 80/40H & 120/60H?
6. Liquid Inlet Valve:
‐ Repair Kit 3-0016 Installed?
‐ Inlet orifice cleaned?
‐ Did valve pass “water test” to ensure seat is sealing properly?
7. Capacity Control Valve:
‐ Repair Kit 3-0017 Installed?
‐ Piston cleaned?
8. Strainer: Screen inspected for tears or holes and/or cleaned?
9. Relief Valve:
‐ Inspected for corrosion?
‐ Is rain cap present?
‐ Manufacture date checked for replacement?
10. Drip Leg: Drained of all contaminants and oils?
11. Burner Regulator: Pressure setting verified?
12. Vaporizer Tubing:
‐ All tubing checked for pitting or flaking?
‐ All Fittings tightened?
13. Heat Exchanger:
‐ Flue inspected?
‐ Debris removed from and around heat exchanger?
‐ Heat exchanger head thickness tested?
‐ Heat exchanger drained of heavy ends?
14. Vaporizer Cabinet: Are door, enclosure, inlet louvers and rain caps cleared of
debris and combustible materials?
Once the above items have been maintained and/or inspected, leak test all fittings and connections inside
and outside the cabinet, including the inlet valve flange and bolts, to ensure there are no leaks.
Connect LPG Supply and light the pilot and engage main burners. Ensure pilot is strong and main
burners are igniting and burning properly.
INSPECTED BY:__________________________________
Algas-SDI Operation and Maintenance Manual – P/N – 52642
INSPECTION DATE:_________________
4-21
Maintenance
Replacing reigniter battery
1. Turn the reigniter switch OFF. Use Phillips screwdriver to open the battery
access door on the bottom right corner of the thermostatic gas control valve
housing.
Figure 12 – Opening the battery access door
2. Pull out the battery, disconnect it and replace with new 9VDC battery. Push
the battery back in the thermostatic gas valve housing and close the battery
access door prior to turning the reignitor switch ON.
Figure 13 – Replacing the battery
4-22
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Maintenance
Adjusting burner input pressure
1. Close the supply valve to the Thermostat Supply Regulator and vent lines.
2. Using a 3/8” FNPT barb fitting and hose, connect a 0-30” manometer (or
similar pressure indicating device) to the pressure tap port at the outlet of the
thermostat. You will have to remove the 3/8” plug. If your vaporizer does not
come equipped with the port at the outlet of the thermostat then connect your
manometer to drip leg ahead of the thermostat.
3. Open the supply valve to the Thermostat Supply Regulator.
4. Turn the reignitor switch “ON”. Establish pilot by turning temperature control
dial to "RUN" (“PILOT on previous version) position. Push down the "PILOT"
button while igniting pilot (hold button down for 30 - 60 seconds). After pilot
flame is established, rotate the temperature control dial counter-clockwise.
The main burner(s) should now engage.
5. With the main burner operating, check the Thermostat outlet pressure port
gas pressure or thermostat supply regulator outlet pressure (see No. 2
above) using the manometer. For the desired Thermostat outlet pressure
port pressure or Thermostat supply regulator pressure for each model please
refer to page 1-3. To adjust the pressure, remove the cap on the Supply
Regulator (See Figure below) and turn the adjustment screw clockwise with a
standard screwdriver to increase the pressure. Return Thermostat Supply
Regulator cap when complete.
6. Close the supply valve to the Thermostat Supply Regulator and wait until
the pilot and main burner have extinguished. Turn the temperature
control dial to “OFF" position. Remove the manometer and fittings. Replace
all plugs before proceeding and perform leak test.
THERMOSTAT SUPPLY
REGULATOR ADJUSTMENT
SCREW
ROTATE GAS CONTROL DIAL
COUNTER CLOCKWISE FOR
BURNER TO ENGAGE
ALTERNATE PRESSURE
PORT – INSERT
MANOMETER HERE
PRESSURE PORT
– INSERT MANOMETER
HERE
Algas-SDI Operation and Maintenance Manual – P/N – 52642
4-23
Maintenance
Liquid inlet valve maintenance procedure
Use Repair Kit P/n: 3-0016 (see repair kit section for kit details)
NOTE: Vaporizer must be purged and empty of all liquid and vapor prior to performing maintenance on the liquid
inlet valve.
1. Loosen the four bolts to remove liquid inlet valve cover on the outside of the
vaporizer cabinet.
2. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity
control valve sensing line fitting on the top of the inlet valve.
3. With a 1-1/2” box end wrench (suggest using 6 point), loosen the large nut on
the top of the inlet valve (inlet valve cap)
4. Loosen the 6 inlet valve flange bolts and remove the inlet valve from the
vaporizer through the hole in the cabinet.
5. Once the valve is removed from the vaporizer, remove the inlet valve cap
(large nut on top) and remove the spring from the valve.
6. Remove the valve seat and stem from the valve body and orifice.
7. After the seat and stem have been removed, using a socket, remove the inlet
valve orifice and wipe the top of the inlet valve orifice with a rag/cloth (one
that does not leave lint on surface) or lightly with a scotch-brite type material
to remove any debris and/or oils from the orifice surface.
8. Replace the O-ring under the orifice (use smallest O-ring from kit). Lightly
grease new O-ring before replacing it.
9. Once the inlet valve orifice O-ring has been replaced, return the orifice to the
valve and tighten accordingly.
10. Compare the length of the new stem from the repair kit to the only one that
was removed from the vaporizer to make sure they are the same. It is
important to make sure the new valve stem isn’t longer than the original stem
because it might prevent the valve from sealing properly. If needed, use a
metal file to shorten the stem to match the original stem length. New
vaporizers are fitted correctly and tested at the factory to make sure the seat
and stem assemblies have the proper length. If the seat and stem
assemblies have been changed in the field without checking the length
against the original stem or the valve was not tested in the shop to ensure it
is sealing (see “Water test” procedure below) there is a chance the stem
could be too long and not allow the inlet valve to close properly. If you are
uncertain about the prior replacement history of the valve stem you should
ensure the valve is tested in water to make sure the new stem and seat
assembly close fully before returning the inlet valve to the vaporizer.
11. Insert the new valve seat and stem assembly into the valve body lining up
the stem with the hole in the inlet orifice.
12. Replace the spring making sure it is centered on the top of the inlet valve
seat.
4-24
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Maintenance
13. Lightly grease and replace the O-ring around the inlet valve cap (large flange
nut).
14. Install inlet valve cap (large flange nut) and tighten into valve body. You may
apply NEVER-SEEZ compound to the flange nut to allow for easy removal of
the flange nut in the future.
15. Once the internal components of the valve are replaced perform a “water
test” to ensure your inlet valve is sealing properly. To perform this test:
apply a 1/8” plug in the top of the inlet valve cap using Teflon tape to ensure
it is leak-proof. Using an air hose, apply 80-100 psi of air pressure at the
inlet of the valve and completely submerge the valve in a bucket or sink full
of water. Wait approximately 5-10 seconds and observe for air bubbles
exiting the valve around valve stem that protrudes from the middle of the inlet
valve. If not bubbles are present, the valve is sealing properly.
16. Remove any remnants of the old inlet valve flange gasket from the surface of
the flange on the inlet valve itself and on the flange at the heat exchanger.
17. Lightly spray new inlet valve flange gasket with a dry lubricant (graphite)
before installing it on the unit.
18. When re-installing the inlet valve on the vaporizer, place flange gasket on the
gasket surface and slide the stem under the float ball inside the heat
exchanger. Slightly tighten the bottom two flange bolts allowing the flange
gasket to be supported by the two bottom bolts. Working your way around
the valve, hand tighten the remainder of the bolts inspecting as you tighten
them to ensure the position of the inlet valve flange gasket is correct.
19. To tighten the inlet valve bolts, torque the 6 bolts to 30-35 ft.-lbs. in a
cross/star pattern.
20. Leak test inlet valve flange bolts prior to re-starting the vaporizer.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
4-25
Maintenance
Capacity control valve maintenance procedure
Use Repair Kit p/n: 3-0017 (see repair kit section for kit details)
1. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity
control valve sensing line fitting on the top of the capacity control valve and
carefully slide tube out of the way in order to remove the large flange nut
(capacity control valve cap). Note: you may need to loosen the tube on the
other end at the top of the inlet valve to remove the tube completely.
2. With a 1-1/2” box end wrench (suggest using 6 point), loosen the large flange
nut on the top of the capacity control valve (capacity control valve cap).
3. Remove the piston from the valve and wipe the piston with a rag/cloth (one
that does not leave lint on surface) or lightly with a scotch-brite type material
to remove any debris and/or oils from the piston surface.
4. If the piston is stuck in the valve, insert a screw into the screw tap at the top
center of the piston. This will allow you to be able to grasp the screw with a
pair of pliers to be able to pull the piston from the valve.
5. Remove the old O-ring from the piston and replace it with the smallest O-ring
from the kit. Lightly grease new O-ring before installing it on the piston.
6. Remove spring from the capacity control valve.
7. Thoroughly wipe the inside of the valve body with a rag/cloth (again, one that
does not leave lint on surface) to remove any debris or oils from the valve
body.
8. Insert new spring into the Capacity Control Valve.
9. Lightly spray the surface of the capacity control valve piston with a dry
lubricant (graphite) and insert piston into the valve moving it up and down
thereby lubricating the body of the valve and ensuring the piston is moving
up and down freely.
10. Lightly grease and replace the O-ring around the capacity control valve cap
(large flange nut).
11. Install the capacity control valve cap (large flange nut) and tighten into valve
body. You may apply NEVER-SEEZ compound to the flange nut to allow for
easy removal of the flange nut in the future.
12. Re-install capacity control valve sensing line and tighten fittings.
4-26
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Maintenance
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Algas-SDI Operation and Maintenance Manual – P/N – 52642
4-27
5
Troubleshooting
1. PILOT - TROUBLESHOOTING TREES #1 & #2

The pilot flame is adjusted at the factory to provide a non-blowing blue flame.
If the flame is not adequate or the pilot does not stay lit, check the pilot
burner to see if it is clear of any obstructions.

Flame should envelope 3/8” to 1/2" of the thermocouple tip. If the pilot flame
is too low, the thermocouple will not generate sufficient voltage to hold the
main burner’s valve open. If the pilot flame is too small, clean the pilot
burner orifice, or replace the pilot. The 40/40H vaporizers use #18 pilot
orifices, while the 80/40H and 120/60H use #23 pilot orifices.
2. MAIN BURNER WILL NOT IGNITE - TROUBLESHOOTING TREE #3

Check the pilot burner as per 1. above.

Check burner regulator. Disconnect tube from outlet side of regulator and
check output pressure.

If pilot burner and burner regulator check out OK, the problem is in the
thermostat. Replace thermostat (the main burner will not come on unless the
temperature in the heat exchanger drops).
3. IF VAPOR PRESSURE DROPS - TROUBLESHOOTING TREE #4
5-28

Check burner; check pilot as per 1. and 2. above.

If vapor pressure drops, but main burner(s) is working, vapor demand
exceeds vaporizer capacity.

Check liquid excess flow valve and shut off valve; make sure they are open.

Close liquid inlet valve upstream of strainer. Bleed down system and clean
strainer filter.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
Troubleshooting
TROUBLESHOOTING TREE #1
PILOT WILL NOT LIGHT
PRESSURE IS OK
CHECK THE BURNER
INPUT PRESSURE
REFER TO PAGE 1-3
PRESSURE IS HIGH/LOW
NO PRESSURE
REPLACE REGULATOR
PRESSURE IS OK
PRESSURE
IS OK
DISCONNECT THE PILOT
FUEL LINE FROM THE
THERMOSTAT AND
CHECK PRESSURE AT
THE THERMOSTAT PILOT
CONNECTION BY
PRESSING THE PILOT
BUTTON DOWN
PRESSURE WILL
NOT ADJUST
ADJUST
REGULATOR
NO PRESSURE
LIGHT PILOT
AND CHECK
OPERATION
INLET PRESSURE
IS LOW
CHECK FOR
OBSTRUCTIONS
REPLACE
THERMOSTAT
REPAIR OR
REPLACE PILOT
ASSEMBLY
RETEST THE
VAPORIZER
Algas-SDI Operation and Maintenance Manual – P/N – 52642
VERIFY YOU HAVE
A MINIMUM OF 6
PSIG INPUT TO
REGULATOR
DETERMINE CAUSE OF LOW
PRESSURE AND REPAIR
INLET PRESSURE
IS OK
REPLACE THE
REGULATOR
RETEST THE
VAPORIZER
5-29
Troubleshooting
TROUBLESHOOTING TREE #2
PILOT LIGHTS BUT WILL NOT HOLD
PILOT IS OK
CHECK THE THERMOCOUPLE SIGNAL TO
THERMOSTAT CONTROL VALVE. SIGNAL
SHOULD BE 13 TO 30 MILLIVOLTS WHEN
THERMOCOUPLE IS HOT
SIGNAL OK
REPAIR OR
REPLACE PILOT
ASSEMBLY
5-30
CHECK TO SEE THAT THE
PILOT IS IMPINGING ON THE
THERMOCOUPLE BULB,
APPROXIMATELY 3/8” TO 1/2”
PILOT IS LOW
SEE TROUBLESHOOTING TREE
#1: PILOT WILL NOT LIGHT
SIGNAL LOW
REPLACE
THERMOCOUPLE
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Troubleshooting
TROUBLESHOOTING TREE #3
MAIN BURNER WILL NOT LIGHT
NO
CHECK TO SEE THAT THE
PILOT IS IMPINGING ON THE
THERMOCOUPLE BULB,
APPROXIMATELY 3/8” TO 1/2”
SEE TROUBLESHOOTING TREE
#1 OR #2
YES
TURN THE THERMOSTATIC GAS VALVE
TEMPERATURE CONTROL DIAL UP TO
THE HIGHEST SETTING. DID THE
CONTROL “CLICK”?
YES
CHECK FOR
PLUGGED GAS
LINE TO THE
BURNER
Algas-SDI Operation and Maintenance Manual – P/N – 52642
NO
REPLACE
THERMOSTAT
5-31
Troubleshooting
TROUBLESHOOTING TREE #4
VAPOR SERVICE PRESSURE DROPS
NOTE: SERVICE PRESSURE WILL DROP IF THE
DEMAND EXCEEDS VAPORIZER’S CAPACITY: 40/40H
3.6 MBTU/hr, 80/40H 7.3 MBTU/hr, 120/60H 10.9 MBTU/hr.
THE FOLLOWING TROUBLESHOOTING TREE ASSUMES
THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS
MAXIMUM CAPACITY.
YES
OK
CHECK THE
THERMOSTAT PORT
OUTLET PRESSURE
REFER TO PAGE 1-3
OK
SET
THERMOSTAT
FOR HIGHER
TEMPERATURE
OR REPLACE
THERMOSTAT
IS THE BURNER
OPERATING?
NO
SEE TROUBLESHOOTING TREE #3:
MAIN BURNER WILL NOT LIGHT
LOW/HIGH
ADJUST BURNER
PRESSURE
REGULATOR
WILL NOT ADJUST
CHECK
OPERATION
PRESSURE OK
CHECK FOR
MINIMUM OF 6PSI
AT REGULATOR
INLET
PRESSURE LOW
REPAIR PRESSURE
SOURCE
REPLACE
REGULATOR
5-32
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Troubleshooting
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Algas-SDI Operation and Maintenance Manual – P/N – 52642
5-33
APPENDIX A
TECHNICAL INFORMATION
A-34
Algas-SDI Operation and Maintenance Manual – P/N – 52642
Appendix A
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Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-35
Appendix A
Figure 14 – 40/40H Vaporizer Replacement Parts
16
3, 22
9
12
14
8
11
5, 23
4
13
1
6
10
15
2
24
A-36
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Appendix A
Figure 15 – 80/40H and 120/60H Vaporizer Replacement Parts
NOTE
Drawing shown for a 80/40H Vaporizer.
14
16
9
12
3, 22
8
11
5, 23
26
4
17
20
19
18
13
25
15
2
Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-37
Appendix A
Figure 16 –Inlet Valve and Capacity Control Valve
LIQUID INLET VALVE
23 Capacity control valve o-ring
23 Inlet valve spring
23 Inlet valve seat
23 Inlet valve orifice o-ring
23 Inlet valve gasket
Pivot arm gasket
CAPACITY CONTROL VALVE
22 Cap o-ring
22 Piston o-ring
21 Piston
22 Spring
A-38
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Appendix A
Figure 14, 15 and 16 Descriptions
1.
Burner Manifold 40/40H, 60/60H new burner post 10/02
P/N: 1502-4006
2.
Burner tip all models – New burner post 10/02
P/N: 33581
3.
Capacity control valve 1” – All models
P/N: 1508-4001
4.
Drip leg kit 40/40H, 60/60H, 80/40H, 120/60H
P/N: 40403
5.
Liquid inlet valve – All models
P/N: 1501-4001
6.
Pilot assembly kit 40/40H, 60/60H, snap in style w/ignitor
P/N: 42008
7.
Pilot flame Guide 40/40H, 60/60H
P/N: 1502-5010
8.
Regulator, Burner Supply All Models
P/N: 34800
9.
Relief valve, ¾”NPT UL/CE/ASME w/Cap 250psig (Rego)
P/N: 34876
10.
Thermocouple 40/40H & 80/40H
P/N: 46-4
Thermocouple 120/60H
P/N: 37050
11.
Thermostat/Thermowell w/9VDC ignitor 40/40H-120/60H
P/N: 41073
12.
Tube, burner regulator supply Kit 40/40H-120/60H
P/N: 40542
13.
Tube, burner supply kit 40/40H-120/60H
P/N: 42012
14.
Tube, capacity control kit 40/40H-120/60H
P/N: 42013
15.
Tube, pilot supply kit 40/40H-120/60H
P/N: 42014
16.
Vent cap assembly, removable – convex style
P/N: 1501-4015
17.
Burner manifold left 80/40H, 120/60H - new bnr. post 10/02 P/N: 1504-4004
18.
Burner manifold right 80/40H, 120/60H - new bnr. post 10/02 P/N: 1504-4005
19.
Pilot assembly kit 80/40H-120/60H – new bnr. post 10/02
P/N: 41021
20.
Pilot flame guide 80/40H,120/60H – new bnr. post 10/02
P/N: 1501-5086
21.
Piston, Capacity control valve 1” outlet
P/N: 1508-5005
22.
Repair kit, Capacity control valve all models
P/N: 3-0017
*See Capacity Control valve in Figure 15
23.
Repair kit, Liquid Inlet valve all models
P/N: 3-0016
*See Liquid Inlet valve in Figure 15
24.
Strainer, ¾” NPT
P/N: 30655
25.
Tube, burner manifold connector kit 80/40H, 120/60H
P/N: 3-0783
26.
Tube, heat exchanger connector 80/40H, 120/60H
P/N: 3-0792
Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-39
Appendix A
Table 5 – Repair Kits and Other Available Replacement Parts
81111: Master rebuild kit 40/40H (#66 orifice)
Part number
3-0034
33581
34800
Description
40/40H Master repair kit (new burner)
Burner tip #66 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
40631: Master rebuild kit 40/40H (#69 orifice)
Part number
3-0034
34323
34800
Description
40/40H Master repair kit (new burner)
Burner tip #69 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
41032: Master rebuild kit 60/60H (#66 orifice)
Part number
41030
33581
34800
Description
Kit, 60/60H repair
Burner tip #66 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
40632: Master rebuild kit 60/60H (#69 orifice)
Part number
41030
34323
34800
Description
Kit, 60/60H repair
Burner tip #69 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
81112: Master rebuild kit 80/40H (#66 orifice)
Part number
3-0035
33581
34800
Description
80/40H master repair kit (new burner)
Burner tip #66 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
40633: Master rebuild kit 80/40H (#69 orifice)
Part number
3-0035
34323
34800
Description
80/40H master repair kit (new burner)
Burner tip #69 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
41042: Master rebuild kit 120/60H (#66 orifice)
Part number
41040
33581
34800
A-40
Description
Kit, 120/60H repair
Burner tip #66 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Appendix A
40634: Master rebuild kit 120/60H (#69 orifice)
Part number
41040
34323
34800
Description
Kit, 120/60H repair
Burner tip #69 orifice
Pressure relief valve ¼” inlet x ½” outlet, twin stage
3-0034: Repair kit 40/40H – new burner post 10/02
Part number
3-0014
3-0016
3-0017
41073
42008
Description
Repair kit , 40/40H pilot and thermocouple
Repair kit 3-4150 & 1501-4001 liquid inlet valve
Repair kit 40C68 & 1508-4001 Capacity Control Valve
RS to ASDI thermostat/Thermowell
Pilot assembly kit, 40/40H and 60/60H (new burner)
41030: Repair kit 60/60H
Part number
3-0016
3-0017
41031
41073
42008
Description
Repair kit 3-4150 & 1501-4001 liquid inlet valve
Repair kit 40C68 & 1508-4001 Capacity Control Valve
Kit, 60/60H thermocouple and pilot
RS to ASDI thermostat/Thermowell
Pilot assembly kit, 40/40H and 60/60H (new burner)
41040: Repair kit 120/60H
Part number
3-0016
3-0017
41021
41041
41073
Description
Repair kit 3-4150 & 1501-4001 liquid inlet valve
Repair kit 40C68 & 1508-4001 Capacity Control Valve
Pilot assembly kit, 80/40H & 120/60H (new bnr)
Kit, 120/60H thermocouple & pilot orifice
RS to ASDI thermostat/Thermowell
3-0035: Repair kit 80/40H- new burner post 10/02
Part number
3-0013
3-0016
3-0017
41073
41021
Description
Repair kit, 80/40H pilot and thermocouple
Repair kit 3-4150 & 1501-4001 liquid inlet valve
Repair kit 40C68 & 1508-4001 Capacity Control valve
RS to ASDI thermostat/Thermowell
Pilot assembly kit, 80/40H & 120/60H (new bnr)
Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-41
Appendix A
3-0014: Repair kit 40/40H Pilot orifice and thermocouple
Part number
46-4
46-6
Description
Thermocouple for 40/40H and 80/40H – snap in
Orifice pilot burner 40/40H and old burner 80/40H
3-0013: Repair kit 80/40H Pilot orifice and thermocouple
Part number
46-4
37510
Description
Thermocouple for 40/40H and 80/40H – snap in
Orifice pilot burner 80/40H and 120/60H
41031: Repair kit 60/60H Pilot orifice and thermocouple
Part number
37050
46-6
Description
Thermocouple for 60/60H and 120/60H
Orifice pilot burner 40/40H and old burner 80/40H
41041: Repair kit, 120/60H Pilot orifice and thermocouple
Part number
37050
37510
Description
Thermocouple, direct fired 60/60H and 120/60H
Orifice pilot burner 80/40H, 120/60H
42015: 40/40H-120/60H Tubing replacement kit
Part number
40403
40542
42012
42013
42014
A-42
Description
Drip leg kit 40/40H-120/60H
40/40H-120/60H Tube kit, Burner regulator supply
40/40H-120/60H Tube kit, Burner supply
40/40H-120/60H Tube Kit, Capacity Control Valve
40/40H-120/60H supply kit
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Appendix A
Liquid inlet valve pin gasket installation procedure
1. Clean pivot screw hole opening from any residue.
2. Apply blue (medium strength) Locktite 243 or Permatex to threads on the liquid inlet valve body or
pivot screw.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-43
Appendix A
3. Slide pin gasket (P/N 8135-101) over the pivot screw (P/N 3-4169) threads as shown in the picture.
4. Screw in pivot screw to the inlet valve body and apply 8 in-lbs of torque (approximately 1/8 full turn).
A-44
Algas-SDI Operation and Maintenance Manual – P/N - 52642
Appendix A
5. Align valve stem with pivot screw and repeat the same step with the pin gasket and pivot screw on
the opposite side of the liquid inlet valve.
6. Verify there is no damage to the pin gasket. Set inlet valve assembly aside for an hour to allow
locktite to properly dry before reinstalling valve assembly back on the vaporizer.
7. Re-install valve in vaporizer with new flange gasket and uniformly torque bolts to 30-35 ft-lbs.
8. Re-connect sensing line to capacity control valve.
9. After assembly pressurize with 125-150 psig compressed air and apply soap solution or leak
detection fluid to both pin gasket areas and to the valve flange area to make sure there are no leaks.
Algas-SDI Operation and Maintenance Manual – P/N – 52642
A-45
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Algas-SDI International, LLC
151 South Michigan Street
Seattle, Washington, 98108
Ph:
1.206.789.5410
Fax: 1.206.789.5414
www.algas-sdi.com.
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