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 54629 TORREXX REV 11-2-21
Briana
2021.11.02
11:12:57
-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 Nemko listed
equipment, the Nemko listing becomes void for that unit.
WARRANTY REGISTRATION
A Warranty Registration Card is located on the last page of this manual. Fill it out
and send a copy either by mail to the address shown at the bottom of the form or
submit via email to [email protected].
WARRANTY, COPYRIGHTS AND APPROVALS
WARRANTY
Algas-SDI International, LLC (ASDI) warrants that the equipment is free of
defects in materials and workmanship under normal use and service. ASDI
agrees to repair or replace, at our option, without charge f.o.b. factory, any part
which has proven defective to the satisfaction of Algas-SDI International, LLC
within one (1) year from the date of the original installation or within 18 months
from the date of shipment, whichever is earlier. Equipment, which in the opinion
of ASDI, has been damaged by improper installation or operation, or has been
abused or tampered with in any way, will not be accepted for return under
warranty.
Algas-SDI International, LLC will not accept back charges for work performed by
others upon or in conjunction with ASDI equipment, unless prior authorization is
given by means of an Algas-SDI International, LLC purchase order. Algas-SDI
International, LLC will not be liable by reason of shutdown, non-operation or
increased expense of operation of other equipment, or any other loss or damage
of any nature, whether direct or consequential, arising from any cause
whatsoever.
Algas-SDI International, LLC makes NO other warranty of any kind, whatsoever
expressed or implied; and all warranties of merchantability and fitness for a
particular purpose are hereby disclaimed by Algas-SDI International, LLC and
excluded from these terms of sale. No person has any authority to bind AlgasSDI International, LLC to any representation or warranty other than this warranty.
COPYRIGHT
Copyright 2021 by Algas-SDI International, LLC, Seattle, Washington 98108.
All rights reserved. No part of this manual may be reproduced or copied in any
form or by any means, photographic, electronic, or mechanical, without the prior
express written consent from Algas-SDI International, LLC, Seattle, Washington,
USA.
APPROVALS
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:
+1.206.762.4537
Facsimile:
+1.206.789.5414
Email:
[email protected]
Internet:
http://www.algas-sdi.com
TORREXX TABLE of CONTENTS
1. INTRODUCTION
DESCRIPTION
Figure 1 – TORREXX SSR Dimensional Drawing
TORREXX VAPORIZER OPTIONS
1-1
1-2
1-3
2. MAJOR COMPONENTS
DESCRIPTION
2-6
Figure 2 – Heating System
2-6
Figure 3 – Liquid Passage Prevention System
2-7
MAJOR COMPONENTS LIST
Figure 4 – TORREXX SSR Major Components Drawing
2-8
2-8
3. INSTALLATION
GENERAL
3-10
Figure 5 – Typical TORREXX Installation Drawing with Pump & Vapor Bypass
3-10
Figure 6 – Typical TORREXX Installation Drawing with Vapor Bypass & No Pump
3-11
Figure 7 – Typical TORREXX Installation Drawing with Economy Operation &
Vapor Bypass
3-11
Figure 8 – Typical TORREXX Installation Drawing for Manifolding 2 Vaporizers
3-12
Figure 9 – Typical TORREXX Installation Drawing for Manifolding 3 Vaporizers
3-12
LIQUID LINE
3-13
LIQUID PUMP
3-13
VAPOR LINE
3-13
SAFETY RELIEF VALVE
3-14
ELECTRICAL SERVICE
3-14
GROUNDING
3-14
WIRE SIZE
3-15
Table 1 – Wire Length Chart (#4 AWG, 25 mm2)
3-16
Table 2 – Wire Length Chart (#6 AWG, 16 mm2)
3-16
Table 3 – Wire Length Chart (#8 AWG, 10 mm2)
3-17
Table 4 – Wire Length Chart (#10 AWG, 6 mm2)
3-17
Table 5 – Liquid Temperature vs. Tank Pressure Chart
3-18
Table 6 – LPG Liquid Line Sizing Chart (Minimum Pipe Size)
3-19
Table 7 – Equivalent Pipe Length of Various Valves and Fittings
3-19
TORREXX TABLE of CONTENTS - Continued
4. OPERATION
GENERAL
4-20
OPERATING INSTRUCTIONS
4-20
STARTING THE VAPORIZER
4-20
STOPPING THE VAPORIZER
4-21
PURGING THE VAPORIZER
4-21
5. MAINTENANCE
GENERAL
5-22
INITIAL INSTALLATION AND OPERATION INSPECTIONS
5-22
ANNUAL MAINTENANCE REQUIREMENTS
5-23
Liqui-SAFE VALVE – PERFORMANCE CHECK
5-24
Figure 10 – Steps to check Liqui-SAFE valve operation.
Liqui-SAFE VALVE – SERVICE INSTRUCTIONS
5-24
5-25
Figure 11A – STEP 1 – Be sure the Liqui-SAFE valve
is in the closed position as shown.
5-25
Figure 11B – STEP 2 – Unscrew reset button base and remove the spring.
5-25
Figure 11C – STEP 3 – Replace button post internal O-ring.
5-26
Figure 11D – Full hook O-ring tool
5-26
Figure 11E – STEP 4 – Unscrew valve latch body.
5-26
Figure 11F – STEP 5 – Replace valve body static O-ring.
5-27
Figure 11G – STEP 6 – Replace valve seat and valve stem base O-rings.
5-27
6. TROUBLESHOOTING
TROUBLESHOOTING TREES
6-28
FULL LOAD VOLTAGE CHECK
6-34
Figure 12 – Full Load Voltage Check
FULL LOAD CURRENT CHECK
6-34
6-35
Figure 13 – Full Load Current Check
6-35
TORREXX ELECTRIC VAPORIZER DATA SHEET
6-36
HEATER CORE RESISTANCE
6-37
Figure 14 – Heater Core Resistance Check
SOLENOID VALVE LEAK TEST
Figure 15 – Solenoid Valve Leak Test Components
6-37
6-38
6-38
TORREXX TABLE of CONTENTS - Continued
SOLENOID VALVE ELECTRICAL TEST
Figure 16 – Solenoid Valve Electrical Test
6-39
6-39
7. TORREXX OPTIONS
ECONOMY OPERATION
Figure 17 – TORREXX Economy Valve Installation
TORREXX ECONOMY VALVE MAINTENANCE
7-40
7-40
7-41
Figure 18A – STEP 1 – Unscrew the inlet housing from the outlet housing.
7-41
Figure 18B – STEP 2 – Remove old O-rings and clean all piston surfaces.
7-41
Figure 18C – STEP 3 – Clean all O-ring contact surfaces and the
bottom surface of the outlet housing. Apply excess lithium O-ring grease
to inside of both housings.
7-42
Figure 18D – STEP 4 – Replace the three O-rings contained in the Economy
Valve repair kit. Apply excess lithium O-ring grease to all O-rings.
7-42
Figure 18E – 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. The inlet housing MUST be screwed all the way down
for the valve to accurately function at the set pressure. DO NOT apply sealant
agent or Teflon tape on these threads.
TX REMOTE BOX
Figure 19 – Remote START/STOP Box
7-42
7-43
7-43
VALVE AND STRAINER PACKAGE
7-44
FILTAIRE CONTAMINANT SEPARATOR
7-44
Figure 20 – FILTAIRE Operation
7-44
APPENDIX A – TECHNICAL INFORMATION
TORREXX LPG VAPORIZER DATA SHEETS (CE/NEMKO)
TORREXX ELECTRIC VAPORIZER SPARE PARTS AND ACCESSORIES (CE/NEMKO)
Figure 21 – TORREXX Electric Vaporizer Major Components and Accessories
HEATER BUSSING DIAGRAMS
EQUIPMENT DRAWINGS
INSTALLATION DRAWINGS
TORREXX WIRING SCHEMATIC
REMOTE BOX WIRING SCHEMATICS
ASCO SOLENOID VALVE USED BY ASDI
SOLENOID NOISE
SOLENOID VALVE INSTALLATION AND MAINTENANCE INSTRUCTIONS
WARRANTY REGISTRATION CARD – Refer to the nameplate on the unit to fill out the product
registration.
1
INTRODUCTION
DESCRIPTION
The dimensional drawing (see page 1-2) identifies various components of the
Algas-SDI TORREXXTM SSR model vaporizer. This equipment is intended for
use with liquid propane, butane, or propane-butane mixtures. 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 K-type 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-SAFETM Valve is designed to prevent liquid from passing downstream.
TORREXXTM Vaporizer can be configured for many applications.
♦
1-1
Standard configuration for Zone I for use with Propane and LPG, DNV GL
Nemko Presafe & CE mark. In this configuration the TORREXXTM complies
with the following standards:
o
EN 60079-0:2012/A11:2013 (IEC 60079-0 ed. 6.0)
o
EN 60079-1:2014 (IEC 60079-1 ed. 7.0)
o
EN 60079-18:2015 (IEC 60079-18 ed. 4.0)
♦
TORREXXTM vaporizer can be manifolded together for increased capacity on
a single skid. Consult Algas-SDI for Configuration information.
♦
TORREXXTM vaporizer can be packaged with an Algas-SDI mixing system
on a single skid. Consult Algas-SDI for Configuration information.
♦
For customizing the TORREXXTM vaporizer to your requirements consult
Algas-SDI for information.
ASDI Operations and Maintenance – TX Models – P/N: 54629
Figure 1 – TORREXX SSR Dimensional Drawing
ASDI Operations and Maintenance – TX Models – P/N: 54629
1-2
TORREXX VAPORIZER OPTIONS
Optional items for the TORREXXTM vaporizer are designed to enhance
convenience for the end user and can be applied in the field to all models.
This section provides a brief introduction to the options available for the
TORREXXTM. See SECTION 7 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 TORREXXTM about 1 ft (30 cm) off the ground
for ease of control box access and removes the vaporizer from elements i.e.
snow and mud. Hardware to mount TORREXXTM to the stand is included.
Ships loose.
1-3
ASDI Operations and Maintenance – TX Models – P/N: 54629
4) Economy Valve – Allows use of propane storage tank natural vaporization
when the storage tank can provide enough vaporization and pressure to
satisfy the load requirements.
5) Remote Start/Stop Box – Includes remote start/stop capability and a status
light indicating the vaporizer is ready for operation (solenoid valve open).
IP65 (NEMA 4) enclosure. Must be installed outside Zone 1 and 2 (IP65).
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) FILTAIRETM Contaminant Separator – The Algas-SDI FILTAIRETM is a
filtering device designed to trap heavy hydrocarbons commonly present in
LP-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 installing multiple vaporizers in parallel, balancing
orifices should be installed at the outlet of each vaporizer to properly balance
the load between the vaporizers and achieve full combined capacity.
ASDI Operations and Maintenance – TX Models – P/N: 54629
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: 54629
MAJOR COMPONENTS
2
The TORREXXTM 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 TORREXXTM:
1)
Heating System – Figure 2
2)
Liquid Passage Prevention System – Figure 3
Figure 2 – Heating System
•
•
•
•
SELF REGULATING HEATING SYSTEM
NO START/STOP SWITCHES
ENGAGES AUTOMATICALLY
JUST APPLY POWER TO TURN VAPORIZER ON
POWER DISTRIBUTION BLOCK
UNUSED
ENTRY /
CUSTOMER
ELECTRICAL
CONNECTION
(M32 X 1.5)
SOLID-STATE
RELAYS
TEMPERATURE CONTROLLER
DETECTS HEAT EXCHANGER
TEMPERATURE VIA DUAL K TYPE
THERMOCOUPLE
TEMPERATURE ACTIVATED
CIRCUIT OPENS AT 55°C OR
131°F WITH SOLENOID VALVE
TO ENSURE AUTOMATIC
RESTART AFTER POWER
INTERRUPTION
TX320 SSR SHOWN
ASDI Operations and Maintenance – TX Models – P/N: 54629
2-6
Figure 3 – Liquid Passage Prevention System
RED FLAG INDICATES STATUS
VALVE IS TRIPPED WHEN FLAG
IS UP (AS SHOWN)
•
•
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 THROUGH
THE Liqui-SAFE VALVE CAN
BE MANUALLY TRIPPED TO
VERIFY CLOSING INTEGRITY
FLOAT BALL
2-7
ASDI Operations and Maintenance – TX Models – P/N: 54629
Figure 4 – TORREXX SSR Major Components Drawing
6
2
5
7
3
4
8
1
2
2
1) Liquid Inlet Solenoid Valve
2) Valve, Gauge and Strainer kit components (Optional)
3) Transformer
4) Temperature Controller Board
5) Economy Valve (Optional)
6) Liqui-SAFETM Valve with manual reset
7) Insulation Jacket
8) Solid-State Relays
ASDI Operations and Maintenance – TX Models – P/N: 54629
2-8
3
INSTALLATION
WARNING
The equipment described in this manual is designed to operate with
LP-gas, a flammable fuel under pressure. The nature of the
application involves inherent hazards that could result in injury.
Only a TRAINED and FULLY QUALIFIED person should service this
equipment.
NOTE
Prior to installing your new TORREXXTM vaporizer, check all
relevant codes and standards that apply in your local area to ensure
compliance!
CAUTION
To prevent ignition of hazardous atmospheres:
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.
NOTE
Installer must install a terminal box (connection facility).
Metal Terminal Box (M32x1.5)
Ex d II A Gb, (ATEX certified or equivalent) - marking for Europe
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.
CAUTION
Internal ground connection is provided by factory.
3-9
ASDI Operations and Maintenance – TX Models – P/N: 54629
GENERAL
Install the TORREXXTM vaporizer on a level firm base at least 6” (15 cm) above
grade and secure it through the four ½” (13 mm) holes. Protect the equipment
against damage from 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. Ensure installation environment does not exceed 50°C.
Install in accordance with applicable codes and local regulations as required.
Explosion proof seal off must carry the same approvals as the vaporizer to
maintain the approval of the overall installation.
Figure 5 - Typical TORREXX Installation Drawing with Pump & Vapor Bypass
1.
2.
3.
4.
NOTES
LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK
MUST NOT EXCEED HYDROSTATIC HEAD WHEN THE PUMP IS
SHUT OFF.
INSTALL VAPORIZER 1ST STAGE REGULATOR UPSTREAM OF
VAPOR BYPASS LINE CONNECTION TO MAIN VAPOR LINE.
SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG (0.1-0.3 BAR)
HIGHER THAN TANK VAPOR PRESSURE REGULATOR SETPOINT.
NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO
FLOW IN BOTH DIRECTIONS.
*BY OTHERS
TANK VAPOR
PRESSURE
REGULATOR*
ISOLATION
VALVE*
VAPOR BY-PASS LINE
ISOLATION
VALVE*
VAPORIZER REGULATOR*
(VAPOR)
TO LOAD
STORAGE TANK
PRESSURE GAUGE*
OUTLET ISOLATION
VALVE”
STRAINER WITH
MAGNET FOR IRON
PARTICLE PICK-UP*
LIQUID
SEAL OFF REQUIRED*
OPTIONAL
ELECTRIC SERVICE
REQUIRED*
ISOLATION VALVE
W/HYDROSTATIC
RELIEF*
Note: The vapor bypass line is not required except when you have the Economy Operation option.
However, it is recommended to install a bypass line on all installations because it will provide a backup supply of vapor from the tank to the load in case of vaporizer failure or power interruption.
Vaporizer will operate properly without the bypass.
ASDI Operations and Maintenance – TX Models – P/N: 54629
3-10
Figure 6 - Typical TORREXX Installation Drawing with Vapor Bypass & No Pump
NOTES
1.
LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK
MUST NOT EXCEED HYDROSTATIC HEAD.
INSTALL VAPORIZER 1ST STAGE REGULATOR UPSTREAM OF
VAPOR BYPASS LINE CONNECTION TO MAIN VAPOR LINE.
SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG (0.1-0.3 BAR)
HIGHER THAN TANK VAPOR PRESSURE REGULATOR SETPOINT.
NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO
FLOW IN BOTH DIRECTIONS.
2.
3.
4.
*BY OTHERS
TANK VAPOR
PRESSURE
REGULATOR*
ISOLATION
VALVE*
VAPOR BY-PASS LINE
OUTLET ISOLATION VALVE”
ISOLATION
VALVE*
(VAPOR)
TO LOAD
STORAGE TANK
PRESSURE GAUGE*
VAPORIZER
REGULATOR*
STRAINER WITH
MAGNET FOR IRON
PARTICLE PICK-UP*
SEAL OFF REQUIRED*
LIQUID
ELECTRIC SERVICE
REQUIRED*
ISOLATION VALVE
W/HYDROSTATIC
RELIEF*
ISOLATION VALVE”
Figure 7 - Typical TORREXX Installation Drawing with Economy Operation & Vapor Bypass
1.
2.
3.
4.
NOTES
LIQUID PIPING LOSSES BETWEEN VAPORIZER AND THE TANK
MUST NOT EXCEED HYDROSTATIC HEAD.
INSTALL VAPORIZER 1ST STAGE REGULATOR UPSTREAM OF
VAPOR BYPASS LINE CONNECTION TO MAIN VAPOR LINE.
SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG (0.1-0.3 BAR)
HIGHER THAN TANK VAPOR PRESSURE REGULATOR SETPOINT.
NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO
FLOW IN BOTH DIRECTIONS.
*BY OTHERS
TANK VAPOR
PRESSURE
REGULATOR*
ISOLATION
VALVE*
VAPOR BY-PASS LINE
ISOLATION
VALVE*
OUTLET ISOLATION VALVE*
ASDI ECONOMY VALVE
SENSES UPSTREAM
PRESSURE
(VAPOR)
TO LOAD
STORAGE TANK
PRESSURE GAUGE*
VAPORIZER
REGULATOR*
SEAL OFF REQUIRED*
STRAINER WITH
MAGNET FOR IRON
PARTICLE PICK-UP*
LIQUID
ELECTRIC SERVICE
REQUIRED*
ISOLATION VALVE
W/HYDROSTATIC
RELIEF*
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: 54629
Figure 8 – Typical TORREXX Installation for Manifolding 2 Vaporizers.
BALL VALVE WITH BALANCING ORIFICE
Liqui-SAFE VALVE
OVERSIZED COMMON
HEADER
VAPOR OUT
NOTES:
1. USE 1” UNION AND BALL
VALVE WITH BALANCING
ORIFICES P/N 64004 ON ALL
VAPORIZER OUTLETS
2. USE ONLY ONE COMMON
REGULATOR AT THE OUTLET
3. ONLY VAPORIZERS OF SAME
SIZE AND APPLIED VOLTAGE
SHALL BE MANIFOLDED
TOGETHER
4. HEADERS MUST BE SIZED
APPROPRIATELY FOR THE
ENTIRE CAPACITY OF ALL
VAPORIZERS IN THE SYSTEM
TORREXX VAPORIZER
LIQUID INLET STRAINER
W/MAGNET FOR IRON
PARTICLE PICK-UP
LIQUID IN
Figure 9 – Typical TORREXX Installation for Manifolding 3 Vaporizers.
BALL VALVE WITH BALANCING ORIFICE
Liqui-SAFE VALVE
NOTES:
1. USE 1” UNION AND BALL
VALVE WITH BALANCING
ORIFICES P/N 64004 ON ALL
VAPORIZER OUTLETS
2. USE ONLY ONE COMMON
REGULATOR AT THE OUTLET
3. ONLY VAPORIZERS OF SAME
SIZE AND APPLIED VOLTAGE
SHALL BE MANIFOLDED
TOGETHER
4. HEADERS MUST BE SIZED
APPROPRIATELY FOR THE
ENTIRE CAPACITY OF ALL
VAPORIZERS IN THE SYSTEM
5. IF COMMON HEADERS ARE
USED ON 3 OR MORE
VAPORIZERS, THERE MAY BE A
CAPACITY DE-RATE ON THE
SYSTEM. REFER TO DWG 50018005 IN THE APPENDIX FOR
ILLUSTRATION OF BALANCED
PIPING WITH MULTIPLE
VAPORIZERS.
ASDI Operations and Maintenance – TX Models – P/N: 54629
OVERSIZED COMMON
HEADER
VAPOR OUT
TORREXX VAPORIZER
LIQUID INLET STRAINER
W/MAGNET FOR IRON
LIQUID IN
PARTICLE PICK-UP
3-12
LIQUID LINE
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. Install a liquid line strainer with
magnet for iron particle pickup at the vaporizer inlet. Do not install the
liquid line such that it must pass above the vaporizer to enter the tank. It
is also recommended not to use liquid dip tube withdrawal (top
withdrawal) from the tank as vaporizer may experience difficulty pushing
liquid back at lower capacities.
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 (30 CM) OF LIQUID
PROPANE EQUALS .21 PSI (.014 BAR)! Liquid line frosting
indicates too much pressure drop in the liquid line.
LIQUID PUMP
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 if the storage
pressure will not always exceed the required distribution pressure by 5 PSI (0.35
bar), a pump is necessary. Install an ASDI STABILAIRETM 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 immediately downstream and at or above the
level of the vaporizer 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 bar) inlet pressure rated!
3-13
ASDI Operations and Maintenance – TX Models – P/N: 54629
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 upwards. 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 valve. If
water enters, it may freeze and prevent the relief valve from properly discharging,
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 ATEX/IECEx 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 and with approved connectors.
Internally a ground connection is provided by the factory. Wire size and type
must comply with the applicable codes for the area in which it is being installed.
Tables 1 through 4 list the recommended wire size for the different models and
are to be used as guides only. Provide a fused disconnect or circuit breaker
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. For Zone 1
locations, the unused entry size is 1” NPT with factory supplied M32x1.5 adapter.
Each vaporizer shall have a separate disconnect.
If the installation is prone to surges it is recommended to protect the equipment
by installing a properly sized Semiconductor or “ultra-fast acting” fuse in each
phase upstream of the TORREXXTM that has a total clearing I2t rating of less than
18,000 A2sec.
GROUNDING
INTERNAL
Internal ground connection is required. Use the grounding connection in the
respective enclosure where the power is supplied. A factory provided #8 AWG
(3.26 mm diameter or 8.3 mm2 cross sectional area) wire is permanently secured
to the enclosure. Use a dual rated (Al/Cu) and dual barrel lug connector to make
the connection between the factory and field ground wires. Reference lug
connector manufacturer’s recommendation for tightening moment. Alternatively,
crimp a dual rated (Al/Cu) ring connector to the factory provided ground wire and
make a connection at the provided junction box terminal. Reference ring
connector manufacturer’s recommendation for proper crimping tools and
technique. Reference junction box manufacturer’s recommendations for
tightening moment.
EXTERNAL
External ground connection is optional. At the back of the enclosure base an
external ground hole measuring 0.17 in (4.3 mm) in diameter is provided. Use a
5/32 in (0.156 mm) diameter blind aluminum rivet and a dual rated (Al/Cu) ring
connector to connect the external ground wire to the enclosure attachment.
Verify all ground connections are secure.
ASDI Operations and Maintenance – TX Models – P/N: 54629
3-14
WIRE SIZE
When selecting the type and size of wire used to install the TORREXX series
electric vaporizers, please consider the following environmental information:
■
Maximum enclosure surface temperature: 65ºC (150 ºF).
■
Maximum enclosure ambient temperature: 80ºC (176 ºF).
■
Maximum temperature at relay terminals: 80ºC (176 ºF).
■
Current draw of vaporizer: Indicated on vaporizer rating plate and on the
data sheet.
■
Power distribution block terminal lug wire size range: #2 - 14.
For Zone 1 installations the phase conductor wire must be of the same size as
the factory provided #8 AWG (3.26 mm diameter or 8.3 mm2 cross sectional
area) ground wire. Refer to Table 3 for wire run limitations based on vaporizer
current draw.
For Zone 1 installations the size of the grounding cable shall be in accordance
with the table below. The minimum permitted size of the equipotential bonding
connector is 4 mm2.
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 solid-state relay 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. Always ensure terminals at the heater pins are tight. If not,
torque to 10 in-lbs (1.13 Nm).
3-15
ASDI Operations and Maintenance – TX Models – P/N: 54629
Table 1 – Wire Length Chart [#4 AWG, 25 mm2] – Div. 1 only
Table 2 – Wire Length Chart [#6 AWG, 16 mm2] – Div. 1 only
ASDI Operations and Maintenance – TX Models – P/N: 54629
3-16
Table 3 – Wire Length Chart [#8 AWG, 10 mm2] – Div. 1 and Zone 1
Table 4 – Wire Length Chart [10 AWG, 6 mm2] – Div. 1 only
3-17
ASDI Operations and Maintenance – TX Models – P/N: 54629
Table 5 – Liquid Temperature vs. Tank Pressure Chart
Liquid
Temperature
Propane
Butane
Tank Gauge
Pressure
Tank Gauge
Pressure
°F
°C
PSI
Bar
-43.73
-40
-35
-30
-25
-20
-15
-10
-41.7
-39.6
-36.9
-34.1
-31.4
-28.6
-25.9
-23.1
0
1.4
3.4
5.6
8.0
10.7
13.6
16.7
0
0.10
0.24
0.39
0.56
0.74
0.94
1.15
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
-20.4
-17.6
-14.9
-12.1
-9.35
-6.6
-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
37.4
40.2
42.9
45.7
48.4
51.2
53.9
56.7
59.4
20.0
23.6
27.6
31.7
36.2
41.1
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
173.6
186.1
199.2
213.0
227.4
242.5
258.2
274.7
291.9
1.36
1.63
1.90
2.19
2.50
2.83
3.19
3.57
3.97
4.40
4.86
5.34
5.86
6.40
6.98
7.58
8.22
8.90
9.64
10.36
11.14
11.97
12.83
13.74
14.69
15.68
16.72
17.81
18.94
20.12
ASDI Operations and Maintenance – TX Models – P/N: 54629
PSI
Bar
NOTE:
Below 30°F or -10°C,
Butane is a liquid at normal
atmospheric pressure.
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
0.10
0.20
0.33
0.47
0.62
0.78
0.95
1.14
1.33
1.55
1.78
2.01
2.25
2.53
2.83
3.21
3.47
3.81
4.17
4.56
4.97
5.39
3-18
Table 6 – LPG Liquid Line Sizing Chart (Minimum Pipe Size)
Capacity of
units
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)
Distance from storage to vaporizer - feet (meters)*
Kg
25
50
100
160
240
320
LBS
25
50
75
100 150 200 300
400
(GPH) (8) (15) (23) (31) (36) (61) (92) (122)
55
½”
½”
½”
½”
½”
¾”
¾”
¾”
(12.5) (DN15) (DN15) (DN15) (DN15) (DN15) (DN20) (DN20) (DN20)
110
½”
½”
½”
¾”
¾”
1”
1”
1”
(25) (DN15) (DN15) (DN15) (DN20) (DN20) (DN25) (DN25) (DN25)
220
½”
¾”
¾”
¾”
1”
1”
1”
1¼”
(50) (DN15) (DN20) (DN20) (DN20) (DN25) (DN25) (DN25) (DN32)
352
¾”
¾”
1”
1”
1”
1¼” 1¼” 1¼”
(80) (DN20) (DN20) (DN25) (DN25) (DN25) (DN32) (DN32) (DN32)
530
1”
1”
1¼” 1¼” 1¼” 1½” 1½” 1½”
(120) (DN25) (DN25) (DN32) (DN32) (DN32) (DN40) (DN40) (DN40)
530
1”
1”
1¼” 1¼” 1¼” 1½” 1½” 1½”
(160) (DN25) (DN25) (DN32) (DN32) (DN32) (DN40) (DN40) (DN40)
Table 7 – Equivalent Pipe Length of Various Valves and Fittings
Globe Valve
½”
(1.27 cm)
15.5/4.72
¾”
(1.91 cm)
21/6.40
1”
(2.54 cm)
27/8.23
1 ¼”
(3.18 cm)
36/10.97
1 ½”
(3.81 cm)
43/13.11
Gate Valve
0.6/0.18
0.8/0.24
1/0.30
1.4/0.43
1.6/0.49
Angle Valve
8/2.44
11/3.35
14/4.23
18/5.49
21/6.40
Elbow, 90
1.4/0.43
1.9/0.58
2.4/0.73
3.2/0.98
3.8/1.19
Elbow, 45
0.7/0.21
1/0.30
1.2/0.37
1.6/0.49
2/0.61
Elbow, 90 STR
2.3/0.70
3.1/0.94
4/1.22
5.3/1.62
6.3/1.92
Tee
2.7/0.82
3.7/1.13
4.8/1.46
6.4/1.95
7.5/2.29
Size/Description
3-19
ASDI Operations and Maintenance – TX Models – P/N: 54629
4
OPERATION
GENERAL
TORREXXTM Electric Vaporizer utilizes a finned cast aluminum heater core. The
heater core contains multiple cast-in resistance heating 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 to 175°F (74°C to 79°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 solid-state relay, applying power to
the heating elements.
Prior to startup, always ensure cover plate is torqued to 26.6 Nm (19.6 ft. lbs.).
Improperly installed cover plate compromises the explosion proof rating of the
vaporizer and can lead to water ingress that damages the electrical equipment.
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 to 175°F (74°C to 79°C).
caution when working around vaporizer.
Use
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.
ASDI Operations and Maintenance – TX Models – P/N: 54629
4-20
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. If the upper control box lid is off, the solid-state relay LED lights
should come on. The vaporizer heating elements are now energized. It will
take approximately 60 seconds for the vaporizer to reach operating
temperature. After reaching the operating temperature, the inlet solenoid
valve will open automatically to allow LPG to enter. Wait approximately 2
minutes for excess LPG to be pushed back to the storage tank.
4) Carefully press the Button on top of the Liqui-SAFETM valve all the way down
and SLOWLY release it. A latch mechanism inside the Liqui-SAFETM valve
will keep the red flag in the down position, indicating the valve is open and in
operating position.
5) The TORREXXTM 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.
NOTE
Do not fill tank above 90% full. When the tank is overfilled, the
vaporizer cannot push liquid back to the tank.
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 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.
2) If the vaporizer is not operating, start the vaporizer.
3) Allow 5 minutes for vaporizer to heat up and push most of the remaining
liquid back into the tank.
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: 54629
5
MAINTENANCE
GENERAL
TORREXXTM 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 perform 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:
Required 30-60 days after initial installation
Component
Action Required
Inlet Strainer
Inspect strainer and remove accumulated debris. NOTE: If debris accumulation is
heavy check every 3-6 months.
Electronic wiring and
connections
Check primary terminal lug tension. Inspect electrical connections for loose wires
and any indication of heat build-up.
Heat exchanger &
drip legs
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 ft (7.6 m), 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 no significant quantity of
heavy ends is accumulating during vaporizer operation, this maintenance can be
performed on an annual basis.
ASDI Operations and Maintenance – TX Models – P/N: 54629
5-22
Annual Maintenance Requirements:
Component
Action Required
Inlet strainer
Remove plug and clean the screen. Replace screen if gaps or holes are present
in the screen. If oils or contaminants are present, it may be necessary to use a
cleaner to remove them. If magnetic plug is installed in the strainer, clean any
debris off the plug using a lint-free rag.
Inlet solenoid valve
Perform a leak test of the valve according to procedure on page 6-39. If no leak
is observed, continue to use the valve as-is. If a leak is observed, 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 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 regardless if leak is present.
Liqui-SAFETM valve
Conduct performance check as described on page 5-25. If valve does not pass
leak test, replace all O-rings in the Liqui-SAFETM valve provided in the repair kit.
If valve does not pass latch test, replace Liqui-SAFETM valve assembly. (see
spare parts list for part numbers).
Relief Valve
Visually check and replace if 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.
Electronic wiring and
connections
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.
Heat exchanger &
system drip legs
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 (7.6 m), 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 no significant quantity of heavy ends is accumulating during vaporizer
operation, this maintenance can be performed on an annual basis.
5-23
ASDI Operations and Maintenance – TX Models – P/N: 54629
Liqui-SAFE Valve – Performance Check
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 2 (#5)
when the valve is closed (see Figure 10), follow the “Liqui-SAFETM valve –
Service Instructions” and change all the O-rings. (This service should not be
performed in the field.)
Figure 10 – Steps to check Liqui-SAFE valve operation.
2. PRESS AND RELEASE
QUICKLY TO CLOSE
1. CHECK FOR LEAKS
(AT THE GAP)
3. CHECK FOR LEAKS
(AT PIPE THREADS)
6. PRESS AND RELEASE
SLOWLY TO RE-OPEN
5. CHECK FOR LEAKS
(AT THE GAP)
STEP 1
4. CHECK FOR LEAKS
(AT VALVE THREADS)
7. MAKE SURE VALVE FLAG
IS DOWN. VAVLE IS NOW IN
OPERATING POSITION
STEP 2
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: 54629
5-24
Liqui–SAFE Valve – Service Instructions
There are four (4) o-rings in the Liqui-SAFETM 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-SAFETM 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 0.25 lbf (1.11 N) and 0.5 lbf
(2.22 N).
Figure 11A – STEP 1 – Be sure the Liqui-SAFE valve is in the closed position as shown.
Figure 11B – STEP 2 – Unscrew reset button base and remove the spring.
UNSCREW RESET
BUTTON BASE
REMOVE SPRING
5-25
ASDI Operations and Maintenance – TX Models – P/N: 54629
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 11D)
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
WARNING: BE SURE THAT THE VALVE IS IN THE
CLOSED POSITION BEFORE UNSCREWING
VALVE LATCH BODY. FAILURE TO DO SO MAY
RESULT IN PERMANENTLY DAMAGING THE
LATCH!
ASDI Operations and Maintenance – TX Models – P/N: 54629
5-26
Figure 11F – STEP 5 – Replace valve body static O-ring.
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
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-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
•
5-27
IMPORTANT:
Always perform a functional check and leak test (see Figure 10) 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 11G is sealing along the entire surface on the
bottom face of the valve body.
ASDI Operations and Maintenance – TX Models – P/N: 54629
6
TROUBLESHOOTING
General
Follow the troubleshooting guide below to identify the problem:
NO FLOW OUT OF THE VAPORIZER
YES
IS Liqui-SAFE
VALVE
TRIPPED?
SEE TROUBLESHOOTING TREE 1A
ASDI Operations and Maintenance – TX Models – P/N: 54629
NO
SEE TROUBLESHOOTING TREE 2A
6-28
TREE # 1 A
Liqui-SAFE VALVE TRIPS
YES
IS VAPORIZER WARM
AND UP TO
TEMPERATURE?
PERFORM FULL LOAD CURRENT CHECK.
SEE PAGE 6-36
YES
SEE TROUBLESHOOTING
TREE 1B
NO
IS CURRENT
CHECK GOOD?
PERFORM FULL LOAD VOLTAGE CHECK.
SEE PAGE 6-35
REMOVE LIQUI-SAFE VALVE. SEE PAGE
5-26 FOR SERVICE INSTRUCTIONS.
RE-INSTALL LIQUI-SAFE VALVE
YES
YES
VERIFY LOAD IS NOT
EXCEEDING THE
SYSTEM CAPACITY
VERIFY LIQUID LINE IS
SIZED CORRECTLY
FOR SYSTEM LOAD.
ENSURE THERE ARE
NO RESTRICTIONS IN
LIQUID LINES SUCH AS
PARTIALLY OPENED
VALVES OR A CHECK
VALVE. RESTRICTIONS
CAN BE IDENTIFIED BY
FROSTING ON THE
OUTSIDE OF THE PIPE.
6-29
RESTART
VAPORIZER.
DOES THE
VALVE TRIP?
NO
IS VOLTAGE
CHECK GOOD?
NO
NO
FIX VOLTAGE ISSUE
AND RESTART
VAPORIZER
CHECK FOR OPEN FUSE
LINKS
RESUME OPERATING
THE VAPORIZER
YES
FUSE LINKS
OPEN?
REPLACE OPEN FUSE
LINKS.
CONTACT ASDI
NO
CHECK FOR OPEN
HEATERS.
CONTACT ASDI
ASDI Operations and Maintenance – TX Models – P/N: 54629
TREE # 1 B
Liqui-SAFE VALVE TRIPS
YES
IS VAPORIZER POWER
OFF?
PERFORM SOLENOID VALVE
LEAK TEST (SEE PAGE 6-39).
REPAIR OR REPLACE
SOLENOID VALVE
NO
SEE TROUBLESHOOTING TREE # 2A
PERFORM LEAK TEST
AGAIN TO ENSURE
ISSUE IS CORRECTED.
RESTART VAPORIZER
ASDI Operations and Maintenance – TX Models – P/N: 54629
6-30
TREE # 2A
Liqui-SAFE VALVE DOES NOT TRIP
NO LIGHT
CHECK CONTROL BOARD LIGHT
RED
CHECK
INCOMING
POWER
GREEN
SEE TROUBLESHOOTING
TREE #2C
NO
INCOMING
POWER OK?
SEE TROUBLESHOOTING
TREE #2B
YES
CHECK
TRANSFORMER
WIRING
CORRECT
INCOMING
POWER ISSUE
BAD WIRING
CONNECTIONS.
REPLACE OR REPAIR
ANY DAMAGED WIRING
YES
LOOSE
WIRING?
NO
CHECK
TRANSFORMER FUSE
YES
BLOWN
FUSE?
NO
REPLACE FUSE AND
RESTART
VAPORIZER
YES
PROBLEM CAUSED BY
A BLOWN FUSE.
YES
PROBLEM
FIXED?
NO
REPLACE TRANSFORMER
AND RESTART VAPORIZER.
IS THE PROBLEM
FIXED?
NO
REPLACE
TEMPERATURE
CONTROLLER.
RESTART VAPORIZER
6-31
ASDI Operations and Maintenance – TX Models – P/N: 54629
TREE # 2B
Liqui-SAFE VALVE DOES NOT TRIP
GREEN
YES
NO
IS RELAY
LATCHED?
CHECK FUSE LINKS
NO
FUSE LINKS
OPEN?
PRESS HI-LIMIT
BUTTON TO RESET
YES
YES
SEE HEATER CORE
RESISTANCE ON
PAGE 6-37.
SERVICE INLET
SOLENOID WITH
SERVICING KIT (SEE
SPARE PARTS LIST).
IS THERE A
LOOSE WIRE?
NO
REPLACE OPEN
FUSE LINKS.
CONTACT ASDI
CHECK FOR LOOSE
WIRING
NO
VAPORIZER
STARTS
WORKING?
CHECK IF THERE
IS 24V AT THE
RELAY LEADING
TO THE
TEMPERATURE
CONTROLLER
YES
TIGHTEN WIRES.
RESTART
VAPORIZER.
CHECK:
1. IF THERMOCOUPLE
CONNECTION TO CONTROL
BOARD IS LOOSE
2. CHECK THERMAL GREASE
COATS LAST 2 INCHES OF
THERMOCOUPLE TIP WHEN
REMOVED FROM
THERMOWELL
3. CHECK THERMOCOUPLE IS
FULLY INSERTED IN THE
THERMOWELL. WHEN FULLY
INSERTED THERMOCOUPLE
SHOULD BOTTOM OUT IN THE
THERMOWELL AND
THERMOCOUPLE SHEATHING
SHOULD COMPRESS TO
SECURE BAYONETT FITTING
4. REMOVE DRAIN PLUG AND
CHECK FOR HEAVY ENDS
NO
24V AT THE
RELAY?
YES
REPLACE RELAY
IF THE ABOVE ACTIONS DO
NOT FIX THE PROBLEM THEN
REPLACE TEMPERATURE
CONTROLLER BOARD.
REPLACE
THERMOCOUPLE
ASDI Operations and Maintenance – TX Models – P/N: 54629
6-32
TREE # 2C
Liqui-SAFE VALVE DOES NOT TRIP
RED
NO
IS THERMOCOUPLE
MOLEX PLUG OR
TRANSITION
HARNESS LOOSE
OR
DISCONNECTED?
YES
RECONNECT LOOSE OR
DISCONNECTED MOLEX
OR
REINSTALL WIRES INTO
TRANSITION HARNESS
NO
IS LED LIGHT RED
ON CONTROL
BOARD?
IS FLOAT
SWITCH OR
PRESSURE
SWITCH
OPEN?
PRESS RED RESET BUTTON TO
RESTART VAPORIZER
IF THE ABOVE ACTIONS DO NOT
FIX THE PROBLEM THEN GO TO
THE “NO” STEP
OPTIONAL
NO
YES
YES
PRESS RED RESET BUTTON TO
RESTART VAPORIZER.
IF PROBLEM REOCCURS THEN:
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.
1. CHECK THERMAL GREASE
COATS LAST 2 INCHES OF
THERMOCOUPLE TIP WHEN
REMOVED FROM
THERMOWELL
2. CHECK THERMOCOUPLE IS
FULLY INSERTED IN THE
THERMOWELL. WHEN FULLY
INSERTED THERMOCOUPLE
SHOULD BOTTOM OUT IN THE
THERMOWELL AND
THERMOCOUPLE SHEATHING
SHOULD COMPRESS TO
SECURE BAYONETT FITTING
3. REMOVE DRAIN PLUG AND
CHECK FOR HEAVY ENDS
IF THE ABOVE ACTIONS DO NOT
FIX THE PROBLEM THEN
CONTACT ASDI OR GO TO “NO”
STEP IF FLOAT OR PRESSURE
SWTITCH ARE INSTALLED.
6-33
ASDI Operations and Maintenance – TX Models – P/N: 54629
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.
WARNING
These tests include high voltage. Exercise great caution in making
the following tests. Carelessness could result in severe injury or
death. L1 ALWAYS ENERGIZED. See additional warnings located at
the beginning of this chapter.
FULL LOAD VOLTAGE CHECK
Check heater voltage by measuring voltage at the power distribution block
terminals. See data sheet on page 6-36 or rating plate on the vaporizer to
determine the correct voltage for your vaporizer. Measure voltage between all
poles of the distribution block. The readings should be equal to +5/-10% of the
value on the rating plate.
Figure 12 – Full Load Voltage Check
POWER
DISTRIBUTION
BLOCK
POWER IN
SOLID-STATE RELAYS
MEASURE
VOLTAGE
ASDI Operations and Maintenance – TX Models – P/N: 54629
6-34
Full Load Current Check
NOTE
See fusible link detail below for typical fusible link installation.
WARNING
These tests include high voltage. Exercise great caution when
performing the following tests. Carelessness could result in severe
injury or death. L1 ALWAYS ENERGIZED. 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
on page 6-36 or rating plate on the vaporizer for the correct line current for your
vaporizer. All wires should have readings equal to +10/-18% 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
POWER
DISTRIBUTION
BLOCK
POWER IN
VIEW OF
FUSIBLE LINK
IN NORMAL
CONDITIONS
POWER INPUT
WIRING
COPPER STRIP
MEASURE
CURRENT
AMP CLAMP
VIEW OF
FUSIBLE LINK
IN OPEN
CONDITION
FUSIBLE LINKS
6-35
ASDI Operations and Maintenance – TX Models – P/N: 54629
TORREXX Electric Vaporizer Data Sheet
MODEL
PHASE
VOLTAGE
(VAC)
CURRENT
(A)
TX25
TX25
TX25
TX25
TX50
TX50
TX50
TX50
TX50
TX50
TX50
TX50
TX50
TX100
TX100
TX100
TX100
TX100
TX100
TX100
TX100
TX100
TX100
TX100
TX160
TX160
TX160
TX160
TX160
TX160
TX160
TX160
TX240
TX240
TX240
TX240
TX240
TX320
TX320
TX320
TX320
TX320
TX320
1
1
1
1
1
3
1
3
1
3
3
3
3
1
3
1
3
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
120
208
220
240
208
208
220
220
240
240
380
400
415
208
208
220
220
240
240
380
400
415
440
480
208
220
240
380
400
415
440
480
380
400
415
440
480
380
400
415
440
480
575
32.8
14.2
15.0
16.4
28.5
16.4
30.1
17.4
32.8
19.0
10.0
10.6
10.9
56.9
32.8
60.2
34.7
54.7
37.8
20.0
21.1
21.9
17.4
19.0
45.5
48.1
52.5
27.8
29.3
30.3
24.0
26.2
38.6
40.6
42.1
33.4
36.4
58.7
53.4
55.4
50.8
48.0
39.9
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
22.2
22.2
22.2
22.2
22.2
22.2
22.2
22.2
16
16
16
16
16
16
16
16
11.5
11.5
11.5
11.5
11.5
7.4
8.8
8.8
7.4
8.8
16.9
ASDI Operations and Maintenance – TX Models – P/N: 54629
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
44.3
44.3
44.3
3.7
7.4
3.7
7.4
4.4
7.4
22.2
22.2
22.2
29.6
29.6
5.3
5.3
5.3
16
16
16
21.3
21.3
11.5
11.5
11.5
15.3
15.3
7.7
8.8
8.8
10.3
11.7
16.8
NOMINAL
POWER
(kW)
3.9
3.0
3.3
3.9
5.9
5.9
6.6
6.6
7.9
7.9
6.6
7.3
7.8
11.8
11.8
13.2
13.2
13.1
15.7
13.2
14.6
15.7
13.2
15.8
16.4
18.3
21.8
18.3
20.3
21.8
18.3
21.8
25.4
28.1
30.3
25.5
30.3
38.6
37.0
39.8
38.7
39.9
39.7
6-36
Heater Core Resistance
NOTE
Refer to the data sheet for wire-to-wire resistance of your vaporizer.
CAUTION
Turn off electrical power at the disconnect before performing this
procedure.
Remove the lid on the upper control box. Measure the resistance across each
pair of wires connected to OUTPUT (2) on the relays. An incorrect resistance
reading indicates a faulty heater element, a wiring problem, or an open fusible
link. If a fusible link is open, contact the factory. Do not attempt to repair it.
Figure 14 – Heater Core Resistance Check
SOLID-STATE RELAYS
READ WIRE-TO-WIRE
RESISTANCE
SEE HEATER WIRING
DIAGRAM OR DATASHEET
ON PAGE 6-36
6-37
ASDI Operations and Maintenance – TX Models – P/N: 54629
Solenoid Valve Leak Test
1) Shut 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 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 reinstall the pressure gauge in
the vaporizer and verify 0 pressure.
3) Open the inlet isolation valve. The solenoid valve is closed and you
should not have any pressure build up in the vaporizer. If pressure
increases in the vaporizer, 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
VAPORIZER
PRESSURE
GAUGE
FIRST STAGE
REGULATOR
VAPOR OUT
SOLENOID VALVE
STRAINER
LIQUID INLET
ISOLATION VALVE
LIQUID IN
ASDI Operations and Maintenance – TX Models – P/N: 54629
6-38
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
CONTROL
BOARD
DISCONNECT
MOLEX JUMPER
RESISTANCE SHOULD BE
APPROXIMATELY 3 OHMS
6-39
ASDI Operations and Maintenance – TX Models – P/N: 54629
TORREXX OPTIONS
7
Economy Operation
The Economy Option minimizes the electric power required to meet your vapor demand by shutting off flow at the
outlet of the vaporizer when the natural vaporization rate of the storage tank can supply enough vapor to meet the
demand. The Economy Valve operates by reacting to the pressure in the storage tank. When tank pressure falls
below 22 PSIG (1.5 bar), the valve is fully open allowing the vaporizer to supply vapor to the load. When the tank
pressure rises above 82 PSIG (5.7 bar), the valve is fully closed allowing the storage tank to provide natural
vaporization to the load. The pressure sensing valve is a mechanical device that operates independent of the
electrical controls.
The Economy Option will NOT function if a pump is used. The liquid piping is limited to 10 ft (3 m) of length from
the tank to the Inlet Solenoid.
The pressure set point of the Economy Valve is not adjustable.
The Economy Valve is a field installed component and shall be installed directly at the outlet of the vaporizer prior
to the first-stage regulator. Use field installation kit, ASDI P/N 41051.
Ensure the Economy Valve is correctly installed by verifying the flow direction indicator on the rating plate.
Figure 17 – TORREXX Economy Valve Installation
NOTES
1.
LIQUID PIPING LOSSES BETWEEN THE VAPORIZER AND THE
TANK MUST NOT EXCEED THE HYDROSTATIC HEAD.
INSTALL VAPORIZER 1ST STAGE REGULATOR UPSTREAM OF
VAPOR BYPASS LINE CONNECTION TO MAIN VAPOR LINE.
SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG (0.1-0.3 BAR)
HIGHER THAN TANK VAPOR PRESSURE REGULATOR SETPOINT.
NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE ABLE TO
FLOW IN BOTH DIRECTIONS.
2.
3.
4.
*BY OTHERS
TANK VAPOR
PRESSURE
REGULATOR*
ISOLATION
VALVE*
VAPOR BY-PASS LINE
ISOLATION
VALVE*
OUTLET ISOLATION VALVE*
ASDI ECONOMY VALVE
SENSES UPSTREAM
PRESSURE
(VAPOR)
TO LOAD
STORAGE TANK
PRESSURE GAUGE*
VAPORIZER
REGULATOR*
SEAL OFF REQUIRED*
STRAINER WITH
MAGNET FOR IRON
PARTICLE PICK-UP*
LIQUID
ELECTRIC SERVICE
REQUIRED*
ISOLATION VALVE
W/HYDROSTATIC
RELIEF*
ISOLATION VALVE”
Note: Economy Option cannot be used on an installation that requires a pump.
ASDI Operations and Maintenance – TX Models – P/N: 54629
7-40
TORREXX Economy Valve Maintenance
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 to perform maintenance on the Economy Valve once every two years using the
Economy Valve repair kit ASDI P/N 40869.
Figure 18A – STEP 1 – Unscrew the inlet housing from the outlet housing.
Figure 18B – STEP 2 – Remove old O-rings and clean all piston surfaces.
7-41
ASDI Operations and Maintenance – TX Models – P/N: 54629
Figure 18C – STEP 3 – Clean all O-ring contact surfaces and the bottom surface of the outlet housing.
Apply excess lithium O-ring grease to inside of both housings.
Figure 18D – STEP 4 – Replace the three O-rings contained in the Economy Valve repair kit. Apply excess
lithium O-ring grease to all O-rings.
Figure 18E – STEP 5 – Make sure the pin hole is clear and the spring is undamaged. Carefully reassemble
all parts. Apply lubrication grease on the straight threads if necessary. 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.
ASDI Operations and Maintenance – TX Models – P/N: 54629
7-42
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. Must be installed outside Zone 1 and 2 (IP65).
FIGURE 19 – Remote START/STOP Box
7-43
ASDI Operations and Maintenance – TX Models – P/N: 54629
Valve and Strainer Package
For TX25 and TX320
ASDI P/N 36923 ¾” NPT inlet, 1” NPT outlet
FILTAIRE Contaminant Separator
The FILTAIRETM 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 FILTAIRETM 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 not included with
FILTAIRETM). The bypass valves enable the system to continue operating when the FILTAIRETM is removed for
cleaning.
FIGURE 20 – FILTAIRE Operation
Leak Test
1.
2.
3.
4.
Close outlet valve.
Slowly open inlet valve and allow pressure to equalize in the vaporizer.
Apply a small amount of soap/water solution to ALL pipe connections around the FILTAIRETM.
Check for any leaks by observing new bubble formation in the soap/water solution.
Repair any leaks before continuing.
ASDI Operations and Maintenance – TX Models – P/N: 54629
7-44
APPENDIX A
TECHNICAL
INFORMATION
TORREXX Vertical Electric Vaporizer Data Sheet
CE / NEMKO LPG Vaporizer
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 ºC
131 ºF
Operating Temperature: 71-79 ºC
160-175 ºF
High Temperature Limit: 171 ºC
340 ºF
Connections:
¾” FNPT – Inlet; 1” FNPT – Outlet
Conduits:
M32, Conduit Seal-Off by others
Type of Service:
Propane Vaporization
ASME Pressure Vessel: 250 PSIG MAWP @ 250ºF (17.2 BAR MAWP @ 121ºC)
-20ºF MDMT @ 250 PSIG (-29ºC MDMT @ 17.2 BAR)
Heat Exchanger Area: 5.4 ft2 / 0.503 m2
TX240
7.1 ft2 / 0.660 m2
TX320
266 lbs / 120.9 kg
TX240
284 lbs / 129.1 kg
TX320
Dry Weight:
Hazardous Area Rating:
TO AVOID POTENTIAL ELECTROSTATIC CHARGING HAZARD, ALWAYS USE A DAMP CLOTH FOR
CLEANING THE INSULATION JACKET. AVOID DRY RUBBING OF THE INSULATION JACKET.
“TORREXX” is a trademark of Algas-SDI International LLC.
EU marking description
CE (2460)
CE Conformity Marking:
Identification
Number of Notified
Body involved in production control stage:
2460
Explosion Protection marking:
Equipment Group:
Equipment Category:
-/II
2G
The equipment is intended for Zone 1 and Zone 2. The space inside the process vessel and process
lines are considered as non-hazardous area therefore (-/II) in the marking code.
Equipment Category Definition
Gas atmospheres "high level of
protection"
Gas atmospheres "normal level of
protection"
No Ex protection.
EU
Equipment
Category
Group
Typical Zone of
application
2G
3G
-
1
II
-
2
Out of hazardous zone
Specific Conditions of Use
“X” - The flameproof joints not intended to be repaired.
“X” – Ambient temperature -20ºC to +60ºC
“X” – Minimum yield stress of the fastening screws used for enclosure is 646 MPa.
“X” – To avoid potential electrostatic charging hazard, always use a damp cloth for cleaning the
insulation jacket. Avoid dry rubbing of the insulation jacket.
“X” – The cable glands provided are suitable only for fixed applications and the cable must be
effectively clamped and cleated to prevent pulling and twisting.
Applicable Standards
EN 60079-0:2012/A11:2013 (IEC 60079-0 ed.6.0)
EN 60079-1:2014 (IEC 60079-1 ed.7.0)
EN 60079-18:2008 (IEC 60079-18 ed. 4.0)
TORREXX Alternate Configuration
Refer to Nameplate on unit for the model and voltage information then look up specific information on the tables
below. Alternate configuration arises from use of alternate conduit assembly. Functionality is identical.
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 ºC
131 ºF
Operating Temperature: 71-79 ºC
160-175 ºF
High Temperature Limit: 171 ºC
340 ºF
Connections:
¾” FNPT – Inlet; 1” FNPT – Outlet
Conduits:
M32, Conduit Seal-Off by others
Type of Service:
Propane Vaporization
ASME Pressure Vessel: 250 PSIG MAWP @ 250ºF (17.2 BAR MAWP @ 121ºC)
-20ºF MDMT @ 250 PSIG (-29ºC MDMT @ 17.2 BAR)
Heat Exchanger Area: 5.4 ft2 / 0.503 m2
TX240
7.1 ft2 / 0.660 m2
TX320
266 lbs / 120.9 kg
TX240
284 lbs / 129.1 kg
TX320
Dry Weight:
Hazardous Area Rating:
TO AVOID POTENTIAL ELECTROSTATIC CHARGING HAZARD, ALWAYS USE A DAMP CLOTH FOR
CLEANING THE INSULATION JACKET. AVOID DRY RUBBING OF THE INSULATION JACKET.
“TORREXX” is a trademark of Algas-SDI International LLC.
EU marking description
CE (2460)
CE Conformity Marking:
Identification
Number of Notified
Body involved in production control stage:
2460
Explosion Protection marking:
Equipment Group:
Equipment Category:
-/II
2G
The equipment is intended for Zone 1 and Zone 2. The space inside the process vessel and process
lines are considered as non-hazardous area therefore (-/II) in the marking code.
Equipment Category Definition
Gas atmospheres "high level of
protection"
Gas atmospheres "normal level of
protection"
No Ex protection.
EU
Equipment
Category
Group
Typical Zone of
application
2G
3G
-
1
II
-
2
Out of hazardous zone
Specific Conditions of Use
“X” - The flameproof joints not intended to be repaired.
“X” – Ambient temperature -20ºC to +60ºC
“X” – Minimum yield stress of the fastening screws used for enclosure is 646 MPa.
“X” – To avoid potential electrostatic charging hazard, always use a damp cloth for cleaning the
insulation jacket. Avoid dry rubbing of the insulation jacket.
“X” – The cable glands provided are suitable only for fixed applications and the cable must be
effectively clamped and cleated to prevent pulling and twisting.
Applicable Standards
EN 60079-0:2012/A11:2013 (IEC 60079-0 ed.6.0)
EN 60079-1:2014 (IEC 60079-1 ed.7.0)
EN 60079-18:2008 (IEC 60079-18 ed. 4.0)
IEC 60079-7:2017, Edition: 5.1
EN IEC 60079-7:2015/A1:2018
TORREXX VERTICAL ELECTRIC VAPORIZER DATA SHEET
(CE / NEMKO CONFIGURATIONS)
MODEL
PHASE
VOLTAGE
TX240
TX240
TX240
TX320
TX320
TX320
3
3
3
3
3
3
380
400
415
380
400
415
EQUIPMENT
DRAWING
5001 - 6003
5001 - 6003
5001 - 6003
5001 - 6003
5001 - 6003
5001 - 6003
ELECTRICAL
DRAWING
5001-7010
5001-7010
5001-7010
5001-7010
5001-7010
5001-7010
BUSSING
DIAGRAM
0620 - 7010
0620 - 7010
0620 - 7010
0620 - 7010
0620 - 7010
0620 - 7010
TORREXX Electric Vaporizer Spare Parts and Accessories (CE / NEMKO)
REFERENCE
KEY
SPARE PARTS
1
2
3
4
5
6
7
8
9
TEMPERATURE CONTROL BOARD KIT
TRANSFORMER
SOLID-STATE RELAY KIT
THERMOCOUPLE KIT
Liqui-SAFE VALVE
PRESSURE RELIEF VALVE
RAIN CAP
FUSIBLE LINK
INLET SOLENOID
10
11
12
13
14
15
16
17
18
19
20
21
22
FUSE KIT
ECONOMY VALVE FIELD INSTALL KIT
ECONOMY VALVE MAINTENANCE 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
40888
54575
40969
41143
5001-3003
34876
35379
33139
33418
TX240
440V
480V
40888
54576
40969
41143
5001-3003
34876
35379
33139
33418
TX320
380V
400V
415V
40888
54575
40969
41144
5001-3003
34876
35379
33139
33418
TX320
440V
480V
40888
54576
40969
41144
5001-3003
34876
35379
33139
33418
52222
41051
40869
52222
41051
40869
52222
41051
40869
52222
41051
40869
34877
36923
5010-3003
20437
53820
60806
40249
40421
41067
64004
34877
36923
5010-3003
20437
53820
60806
40249
40421
41067
64004
34877
36923
5010-3003
20437
53820
60806
40249
40421
41067
64004
34877
36923
5010-3003
20437
53820
60806
40249
40421
41067
64004
FIGURE 21 – TORREXX Electric Vaporizer Major Components and Accessories
7
5
8
6
2
18
17
3
1
9
18
3
248 9 4 "
2
1 +1/8"
+3
672 - 3 26 2 " - 1/8"
3 PHASE
ELECTRICAL
SERVICE
(BY OTHERS)
1
231 9 8 "
TX240 1320 [52"]
TX320 1500 59"
1" FNPT
VAPOR
OUTLET
NOTES:
1.
ALL DIMENSIONS ARE IN mm [INCHES].
2.
NEMKO APPROVED FOR USE IN ZONE 1 AREAS.
3.
DNV APPROVED FOR CONFORMANCE WITH PRESSURE EQUIPMENT DIRECTIVE.
4.
CE COMPLIANT.
5.
VAPORIZER PRESSURE VESSEL RATED AT 250 PSIG [17.6 KG/CM ] MAWP.
6.
RELIEF VALVE SETTING 17.24 BARG (250PSIG).
7.
VAPORIZER CAPACITY RATED 0 F AND 100 PSIG PROPANE INLET CONDITION.
8.
SUITABLE FOR INDOOR/OUTDOOR INSTALLATION.
9.
VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON ABOVE GROUND,
LEVEL, SOLID, NON-COMBUSTIBLE BASE.
10.
AVOID DRY RUBBING OF THE INSULATION JACKET TO PREVENT ELECTROSTATIC CHARGING
HAZARD. ALWAYS USE DAMP CLOTH FOR CLEANING.
11. ECONOMY VALVE OPTION AVAILABLE UPON REQUEST.
12. APROXIMATE SHIPPING WEIGHT: TX240 (121kg) TX320 (130kg).
OPTIONAL
DRAIN
PORT
TX240 1441 [56 3/4"]
3
TX320 1610 63 8 "
PRESSURE
RELIEF
VALVE
(4) 1/2"
MOUNTING
HOLES
Part #
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
RATING
PLATE
3/4" FNPT LIQUID
INLET VALVE
PRESSURE
GAUGE
10/29/2020
BZ
Dwg. #
5001-6011
RWP
ASDI STD
Job #
Sht. No.:
1of 1
Rev.:
A
1:16 AND NOTED
Scale:
Date:
Approved By:
Checked By:
Drawn By:
TORREXX SOLID STATE RELAY VAPORIZER - NEMKO
B
.X
.XX
.XXX
ANGLE 1
FRACTIONS 1/4"
UNLESS OTHERWISE
SPECIFIED
TOLERANCES
TEMPERATURE
CONTROL
SENSOR
HEATING
ELEMENT
CORE
FLOAT
BALL
Title:
INTERPRET THIS DRAWING IN ACCORDANCE
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
USED IN ANY MANNER DETRIMENTAL TO ITS
Size:
INTERESTS. ALL RIGHTS RESERVED.
© COPYRIGHT ALGAS-SDI
DO NOT
SCALE
DRAWING
THIRD ANGLE
PROJECTION
10 GA WIRE
MESH OR
DEFORMED
REBAR
CONTROL
HOUSING
COVER 311+3 12 1 "+1/8"
-3
4 - 1/8"
SOLID STATE
RELAY CONTROL
COVER
INSULATION
JACKET
Liqui-SAFE
VALVE
152 6"
PRESSURE GAUGE
HYDROSTATIC RELIEF VALVE
ISOLATION VALVE WITH HYDROSTATIC RELIEF
VAPOR BY-PASS LINE
ISOLATION VALVE
(VAPOR)
TO LOAD
VAPORIZER
REGULATOR
OUTLET ISOLATION VALVE
ELCTRICAL SERVICE
WITH SEAL OFF
REQUIRED
STRAINER WITH MAGNET FOR
IRON PARTICLE PICK UP
LIQUID
PUMP
THIRD ANGLE
PROJECTION
TANK VAPOR PRESSURE REGULATOR
ISOLATION VALVE
ISOLATION VALVE
DO NOT
SCALE
DRAWING
PIPEAWAY ADAPTER
PRESSURE RELIEF VALVE
STORAGE TANK
RWP
BZ
11/12/10
A.S.D.I. STD.
Job #
1:20 AND NOTED
Scale:
Date:
Approved By:
Checked By:
Drawn By:
NOTES:
1. LIQUID PIPING LOSSES BETWEEN VAPORIZER AND
THE TANK MUST NOT EXCEED HYDROSTATIC HEAD
WHEN THE PUMP IS SHUT OFF.
2. INSTALL VAPORIZER 1ST STAGE REGULATOR
UPSTREAM OF THE TANK VAPOR PRESSSURE
CONNECTION POINT.
3. SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG
HIGHER THAN TANK VAPOR PRESSURE REGULATOR
SET-POINT.
4. NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE
ABLE TO FLOW IN BOTH DIRECTIONS.
5. VAPORIZER REGULATOR MUST BE INSTALLED ABOVE
VAPORIZER OUTLET.
TOLERANCES
UNLESS OTHERWISE
SPECIFIED
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
Part #
Dwg. #
TORREX INSTALLATION DRAWING WITH PUMP
AND VAPOR BYPASS
Sht. No.:
Rev.:
5001-8001
1of 1
D
B
.X 0.1
.XX 0.06
.XXX 0.030
ANGLE 0 30'
FRACTIONS 1/16"
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
USED IN ANY MANNER DETRIMENTAL TO IT'S
Size:
INTERESTS. ALL RIGHTS RESERVED.
© COPYRIGHT ALGAS-SDI
ELCTRICAL SERVICE
WITH SEAL OFF
REQUIRED
VAPORIZER
REGULATOR
(VAPOR)
TO LOAD
ISOLATION VALVE
LIQUID
ISOLATION VALVE
STRAINER WITH MAGNET FOR
IRON PARTICLE PICK UP
OUTLET ISOLATION VALVE
ISOLATION VALVE WITH HYDROSTATIC RELIEF
PRESSURE GAUGE
B
Part #
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
11/18/10
BZ
RWP
A.S.D.I. STD.
Job #
1:20 AND NOTED
Scale:
Date:
Approved By:
Checked By:
Drawn By:
TORREXX INSTALLATION WITH VAPOR BYPASS
AND NO PUMP
Sht. No.:
Rev.:
Dwg. #
D
5001-8002
1of 1
.X 0.1
.XX 0.06
.XXX 0.030
ANGLE 0 30'
FRACTIONS 1/16"
UNLESS OTHERWISE
SPECIFIED
TOLERANCES
NOTES:
1. INSTALL VAPORIZER 1ST STAGE REGULATOR
UPSTREAM OF THE TANK VAPOR PRESSSURE
CONNECTION POINT.
2. SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG
HIGHER THAN TANK VAPOR PRESSURE REGULATOR
SET-POINT.
3. NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE
ABLE TO FLOW IN BOTH DIRECTIONS.
4. VAPORIZER REGULATOR MUST BE INSTALLED ABOVE
VAPORIZER OUTLET.
STORAGE TANK
PRESSURE RELIEF VALVE
PIPEAWAY ADAPTER
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
USED IN ANY MANNER DETRIMENTAL TO IT'S
Size:
INTERESTS. ALL RIGHTS RESERVED.
© COPYRIGHT ALGAS-SDI
DO NOT
SCALE
DRAWING
THIRD ANGLE
PROJECTION
ISOLATION VALVE
TANK VAPOR PRESSURE REGULATOR
VAPOR BYPASS LINE
PRESSURE GAUGE
ISOLATION VALVE WITH HYDROSTATIC RELIEF
OUTLET ISOLATION VALVE
ISOLATION VALVE
(VAPOR)
TO LOAD
VAPORIZER
REGULATOR
ASDI ECONOMY VALVE SENSES
UPSTREAM PRESSURE (OPEN AT
30PSIG CLOSED AT 60PSIG)
ELECTRICAL SERVICE
WITH SEAL OFF
REQUIRED
STRAINER WITH MAGNET FOR
IRON PARTICLE PICK UP
ISOLATION VALVE
LIQUID
VAPOR BYPASS LINE
PIPEAWAY ADAPTER
PRESSURE RELIEF VALVE
STORAGE TANK
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
Dwg. #
Drawn By:
Checked By:
RWP
BZ
11/18/10
Approved By:
Date:
1:20 AND NOTED
Scale:
A.S.D.I. STD.
Job #
TORREXX INSTALATION WITH ECONOMY
OPERATION AND VAPOR BYPASS
Sht. No.:
Rev.:
D
5001-8003
1of 1
Part #
NOTES:
1. INSTALL VAPORIZER 1ST STAGE REGULATOR
UPSTREAM OF THE TANK VAPOR PRESSSURE
CONNECTION POINT.
2. SET 1ST STAGE VAPORIZER REULATOR 2-4 PSIG
HIGHER THAN TANK VAPOR PRESSURE REGULATOR
SET-POINT.
3. NO CHECK VALVES IN LIQUID LINE. LIQUID MUST BE
ABLE TO FLOW IN BOTH DIRECTIONS.
4. VAPORIZER REGULATOR MUST BE INSTALLED ABOVE
VAPORIZER OUTLET.
B
.X 0.1
.XX 0.06
.XXX 0.030
ANGLE 0 30'
FRACTIONS 1/16"
UNLESS OTHERWISE
SPECIFIED
TOLERANCES
TANK VAPOR PRESSURE REGULATOR
ISOLATION VALVE
THIRD ANGLE
PROJECTION
DO NOT
SCALE
DRAWING
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
USED IN ANY MANNER DETRIMENTAL TO IT'S
Size:
INTERESTS. ALL RIGHTS RESERVED.
© COPYRIGHT ALGAS-SDI
FULL SIZED GLOBE ISOLATION
VALVES EQUAL TO PIPE SIZE,
TO ENSURE NO RESTRICTIONS
IN LIQUID INLET LINE.
PROPERLY SIZED LIQUID PIPING IN
ACCORDANCE WITH O&M MANUAL,
ALLOWING LIQUID TO BE PUSHED
BACK TO TANK
(TOO SMALL LINE MAY CAUSE TRIPPING OF
LIQUI-SAFE VALVE).
S
STRAINER WITH MAGNETIC PLUG
P/N 40776 INSTALLED AT THE LIQUID
INLET OF EACH VAPORIZER, TO PROTECT
SOLENOID VALVE AND VAPORIZER
FROM IMPURITIES.
BALANCING ORIFICE P/N 64004 INSTALLED
IN UNION AT OUTLET OF EACH VAPORIZER
NECESSARY TO BALANCE MULTIPLE
VAPORIZER INSTALLATIONS.
REGULATOR LINE POSITIONED ABOVE VAPORIZER
TO RE-CONDENSE LIQUID BACK INTO HEAT EXCHANGER.
DO NOT
SCALE
DRAWING
INTERPRET THIS DRAWING IN ACCORDANCE
Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING IS PROPRIETARY AND CONFIDENTIAL
AND SHALL NOT BE REPRODUCED OR USED IN ANY
MANNER DETRIMENTAL TO ALGAS-SDI'S INTERESTS. Size:
ALL RIGHTS RESERVED.© COPYRIGHT ALGAS-SDI
.X 0.10
.XX 0.030
.XXX 0.010
ANGLE 1
FRACTIONS 1/4"
UNLESS OTHERWISE
SPECIFIED
TOLERANCES
THIRD ANGLE
PROJECTION
B
Job #
Dwg. #
5001-8005
Sht. No.:
1of 2
Rev.:
A
1:4 AND NOTED
1/3/2018
DN
RWP
ASDI STD
5001-8005
TORREXX MULTI INSTALLATION P&ID
Part #
Scale:
Date:
Approved By:
Checked By:
Drawn By:
FILTAIRE/ OIL DEMISTER. INSTALL
AFTER 1ST STAGE REGULATOR TO
DRAIN OILS/HEAVY ENDS.
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
INSTALL DRAIN VALVE KIT P/N 5010-3003
IN EACH VAPORIZER TO REGULARLY
DRAIN OILS/HEAVY ENDS
P
BY-PASS VALVE TO ALLOW
CONTINUED OPERATION DURING
SERVICING OF FILTER/OIL DEMISTER.
SINGLE SYSTEM REGULATOR SIZED PROPERLY
FOR DEMAND. INSTALL AT THE
IMMEDIATE OUTLET OF THE HEADER.
NOTE:
1
S
S
TORREXX X 2 INSTALLATION IN PARALLEL
S
S
S
1
TORREXX X 3 INSTALLATION IN PARALLEL
FIRST STAGE REGULATOR SHALL BE POSITIONED
ABOVE THE OULET HEADER TO RE-CONDENSE LIQUID
BACK INTO HEAT EXCHANGER
S
S
S
S
TOLERANCES
UNLESS OTHERWISE
SPECIFIED
.X 0.10
.XX 0.030
.XXX 0.010
ANGLE 1
FRACTIONS 1/4"
B
151 S. Michigan St., Seattle, Washington. USA 98108
Tel: (206) 789-5410 Fax: (206) 789-5414
Dwg. #
5001-8005
1
Drawn By:
Checked By:
RWP
DN
1/3/2018
Approved By:
Date:
2of 2
Rev.:
A
1:4 AND NOTED
Scale:
Job #
Sht. No.:
ASDI STD
5001-8005
TORREXX MULTI INSTALLATION P&ID
Part #
TORREXX X 4 INSTALLATION IN PARALLEL
1
THIRD ANGLE
PROJECTION
DO NOT
SCALE
DRAWING
INTERPRET THIS DRAWING IN ACCORDANCE
Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING IS PROPRIETARY AND CONFIDENTIAL
AND SHALL NOT BE REPRODUCED OR USED IN ANY
MANNER DETRIMENTAL TO ALGAS-SDI'S INTERESTS. Size:
ALL RIGHTS RESERVED.© COPYRIGHT ALGAS-SDI
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
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:
parts.
Inspect valve internals and exterior. Replaced damaged
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 reassemble.
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.
Installation & Maintenance Instructions
SERIES
OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS
Form No.V6584R8
8003G
8202G
INSTALLATION
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.
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.
FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY
DESCRIPTION
Catalog numbers 8003G and 8202G are epoxy encapsulated pull-type
solenoids. The green solenoid with lead wires and 1/2Ăconduit 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.
50 Hanover Road, Florham Park, New Jersey 07932
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 180C. 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 90C. 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
None, FB, KF, KP
SC, SD, SF, & SP,
F
125F (51.7C)
10.1 & 17.1
HB, HT, KB, KH,
SS, ST, SU,
H
140F (60C)
11.6 & 22.6
None, FB,KF, KP,
SC, SD, SF, & SP.
F
104F (40C)
11.6 & 22.6
HP, HT, KB, KH,
SS, ST, SU, & SV
H
104F (40C)
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.
www.ascovalve.com
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 90C 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 90C or greater for connections. For
steam service use 105C rated wire up to 50 psi or use 125C 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 90C or greater for
connections. Strip wire leads back approximately 1/4 for 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.
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.
Page 2 of 4
Form No.V6584R8
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Torque Chart
Part Name
solenoid base sub-assembly & adapter
pipe adapter
Torque Value Inch-Pounds
175 ± 25
90 maximum
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
red cap
nameplate/
retainer
grounding wire green or green with
yellow stripes
solenoid
with 1/2 NPT
finger washer
.062 to .093 maximum
thickness of panel
for mounting
core
(AC)
Torque Value Newton-Meters
19,8 ± 2,8
10,2 maximum
0.69 diameter
mounting hole
core
(DC)
Side View
finger
washer
solenoid base
sub-assembly
Tapped hole in core
0.250-28 UNF-2B
0.63 minimum full thread (AC)
0.38 minimum full thread (DC)
collar to face
valve body
0.9375-26 UNS -2A
thread
Alternate
Construction
Panel Mount
Figure 1. Series 8003G solenoids
red cap
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
nameplate/
retainer
pipe adapter
spacer
plugnut gasket
grounding wire green or green with
yellow stripes
solenoid
with 1/2 NPT
spring washer
solenoid base
sub-assembly
bonnet washer
core(small end up)
solenoid base gasket
plugnut assembly
cutaway view to
show positioning
of retainer in
gasket recess
Without
Adapter
retainer gasket
retainer
adapter
gasket
stem
disc
disc holder
assembly
disc spring
disc holder
spring
Figure 2. Series 8202G solenoids
adapter
Air Only Construction
Vent to Atmosphere
With
Adapter
Figure 3. 3-Way Construction
Form No.V6584R8
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
Torque Chart
Part Name
terminal block screws
socket head screw
center screw
Torque Value in Inch-Pounds
10 ± 2
15 - 20
5±1
Open-Frame Solenoid
with Screw Terminals.
Socket head screw is
used for grounding.
Open-Frame Solenoid
with 1/4 Spade Terminals
See
torque chart
above
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
gasket screw terminal adapter
terminal block
screw
tapped hole for
#10-32 grounding screw
(not included)
DIN terminal adapter
socket head
grounding screw
(5/32 hex key wrench)
socket head screw (5/32 hex key wrench)
Figure 4. Open-frame solenoids
Junction Box Solenoid
with 1/4 Spade Terminals
or Screw Terminals
screw terminal block
(see note)
cover screw
See
torque chart
above
cover
cover gasket
grounding screw
and cup washer
junction box gasket
Note:
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
socket head screw
(5/32 hex key wrench)
Figure 5. Junction box (optional feature)
Open-Frame Solenoid
with DIN Terminal
Plug Conector
DIN terminal
adapter
See
torque chart
above
connector
gland nut
gasket
gland gasket
socket head screw
(5/32 hex key wrench)
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.
Page 4 of 4
Indicates that these parts are included
in DIN plug connector Kit No. K236034
gasket
DIN connector
terminal block
(see note 2)
washer
center screw
connector cover
(see note 1)
Figure 6. DIN plug connector kit No. K236034 (optional feature)
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Form No.V6584R8
50 Hanover Road
Florham Park, New Jersey 07932
Tel. (973) 966-2000
Fax (973) 966 2628
1561 Columbia Highway
Aiken, South Carolina 29801
Tel. (803) 641-9200
Fax (803) 641-9290
SCIENTIFIC
50 Hanover Road
MMIl
All Rights Reserved. Printed in U.S.A. Form No. V6950R5
Florham Park, New Jersey 07932
Tel. (973) 236-6160
Fax (973) 966 6461
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)
Brantford, Ontario N3T 5M8
Tel: (519) 758-2700
Fax: (519)758-5540
ASCOTECH S.A. de C.V.
Circuito Del Progreso No.27
Parque Industrial Progreso
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:
Serial Number:
ASDI Sales Order #:
Order Date:
Purchased By:
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:
Tel:
City:
Fax:
State:
Zip:
Name of individual to contact for follow up information:
Title:
Usage - Circle one:
Base Load
Standby System
Peak Shaving
Other:
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,
Tel: 206.789..5410
E-mail: [email protected]
Seattle, Washington, 98108, USA
Fax: 206.789.5414
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
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