Algas SDI 160H, Operation & Maintenance Manual

Page 1: ...8108 Tel 206 789 5410 Fax 206 789 5414 Web www algas sdi com This manual covers units built after August 2009 After S N 09160185 FILE MANUAL PN 54000 rev 12 8 21 Innovative liquid vaporizing and gas m...

Page 2: ...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 TR...

Page 3: ...ack 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 Internationa...

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Page 5: ...s a potential hazard which can result in severe personal injury or death Use extreme care and follow the instructions given ELECTRICAL DISCONNECT REQUIRED Indicates a potentially dangerous situation w...

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Page 7: ...m Vaporizer 2 4 Figure 2 Vaporizer Dimensions 2 5 Figure 3 Vaporizer Dimensions 160H Vaporizer 2 5 Liquid Supply Line 2 6 Table 2 Recommended Liquid Supply Line Size 2 5 Vapor Distribution Line 2 6 Ta...

Page 8: ...e battery 4 20 Adjusting burner input pressure 4 21 Figure 10 Adjusting burner input pressure 4 21 Liquid inlet valve maintenance procedure 4 22 Capacity control valve maintenance procedure 4 24 5 Tro...

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Page 10: ...tal connected load and high pressure first stage regulator setting See Page 2 8 for Details Economy Valve Kit Economy Valve Kit P N 41051 Quantity 1 per unit See Page 2 9 for Details Inlet and Outlet...

Page 11: ...me directly applied to the heat exchange surface which in turn contacts the LP Gas liquid that is to be vaporized The Algas SDI Direct Fired vaporizers consist of seven 7 main components Liquid inlet...

Page 12: ...t exchanger and the temperature sensor will sense the cool liquid and cycle the main burner s on During continuous operation the burner s will cycle on and off to maintain the required supply of vapor...

Page 13: ...kW THERMOSTAT SUPPLY REGULATOR PRESSURE 15 18 W C 37 3 44 8 mbar BURNER PRESSURE 9 W C 22 4 mbar PILOT BURNER 2 200 BTU hr 0 64 kW NOMINAL OPERATING TEMPERATURE 140 to 160 F 60 to 71 C Regulator Gas P...

Page 14: ...g Carefully open package inspect unit for damage and remove all plastic shipping material and wood shipping base from the vaporizer INITIAL ASSEMBLY Install the Flue cap s on the top of the unit with...

Page 15: ...Installation Algas SDI Operation and Maintenance Manual P N 54000 2 5 Figure 2 Vaporizer Dimensions shown in inches MM Figure 3 Installation 160H vaporizers...

Page 16: ...acity with a maximum pressure drop of less than the hydrostatic head pressure see NFPA 54 4 Connect the vaporizer to the storage tank LIQUID SUPPLY LINE see Figure 3 The liquid supply line should be a...

Page 17: ...0 14 to 0 3 bar below the setting of the vaporizer regulator Then if the vaporizer is overloaded or its output pressure drops off the regulator on top of the storage tank will automatically take over...

Page 18: ...onomy Valve is correctly installed Verify the flow direction on the rating plate during installation Contact Algas SDI for set point information CONTAMINANT SEPARATOR FILTAIRE OPTIONAL FILTAIRETM is a...

Page 19: ...ST STAGE REGULATOR VAPOR FROM VAPORIZER INLET VALVE 2 VAPOR LINE FILTAIRE OIL DEMISTER OUTLET VALVE BYPASS VALVE NORMALLY CLOSED 3 1 5 DRAIN VALVE PIPE STAND 6 4 VAPOR TO LOAD To properly size the FIL...

Page 20: ...LEAK TEST CAUTION The entire installation must be leak tested prior to operating the system 1 Close outlet valve 2 Slowly open inlet valve and allow pressure to equalize in the vaporizer 3 Apply a lib...

Page 21: ...for vent location and thread size Always pipe away regulator vents to a safe location with no source of ignition Ensure vents are not blocked with debris NOTE For installations or locations in Canada...

Page 22: ...aporizer see page 2 7 open the valve supplying gas to the burner supply regulator 4 Turn the temperature control dial on the thermostatic gas control valve counterclockwise to the RUN position RUN pos...

Page 23: ...y cycle off 8 Make sure all the valves on consuming equipment are closed and slowly open the valve in the vapor distribution line Open all consuming equipment valves Direct Fired Vaporizer setpoint ad...

Page 24: ...the thermostat pilot and main burner Figure 7 Vaporizer shut down procedure Direct Fired Vaporizer purge procedure If the vaporizer is not going to be used for a long period of time it should be purge...

Page 25: ...the liquid line 6 Now open vaporizer outlet valve and flare or allow attached equipment to consume the remaining gas in the line 7 After verifying the pressure in the lines is zero and no sources of...

Page 26: ...ork area When flaring the contents of the vaporizer be sure that the burners are on to prevent freezing during the flaring operation Table 5 Initial Installation Operation Inspections Required 30 60 d...

Page 27: ...nings for debris insects and or dirt Clean any plugged or obstructed orifices Liquid Inlet Valve Use repair kit to replace internal components of the liquid inlet valve See detailed Liquid Inlet Valve...

Page 28: ...drain the drip leg to prevent it from filling with contaminants and passing them into the thermostat NOTE In areas where LPG quality is poor it may be necessary for drip legs to be checked for heavy...

Page 29: ...apacity Control Valve Repair Kit Installed Piston and valve body cleaned 8 Strainer Screen inspected for tears or holes and or cleaned 9 Relief Valve Inspected for corrosion Is rain cap present Manufa...

Page 30: ...battery access door on the bottom right corner of the thermostat housing Figure 8 Opening the battery access door 2 Pull out the battery disconnect it and replace with new 9VDC battery Push the batter...

Page 31: ...should now engage 5 With the main burner operating check the gas pressure at the burner pressure port using a manometer see No 2 above For the required burner input pressure for each model refer to pa...

Page 32: ...h a scotch brite type material to remove any debris and or oils from the orifice surface 8 Replace the O ring under the orifice use smallest O ring from kit Lightly grease new O ring before replacing...

Page 33: ...erly 16 Remove any remnants of the old inlet valve flange gasket from the surface of the flange on the inlet valve itself and on the flange at the heat exchanger Inspect surfaces for marks or other da...

Page 34: ...the top center of the piston This will allow you to have leverage and grasp the screw with a pair of pliers to remove the piston from the valve 4 Remove the old O ring from the piston and replace it...

Page 35: ...Maintenance Algas SDI Operation and Maintenance Manual P N 54000 4 25 This page intentionally left blank...

Page 36: ...t greater than 1 8 3 mm Check if the spark electrode is saturated with moisture water Wipe any moisture water or light the vaporizer manually with a torch to dry it Check the rocker switch by removing...

Page 37: ...ON DOWN PRESSURE IS OK PRESSURE IS HIGH LOW ADJUST REGULATOR VERIFY YOU HAVE A MINIMUM OF 6 PSIG INPUT TO REGULATOR DETERMINE CAUSE OF LOW PRESSURE AND REPAIR NO PRESSURE REPLACE REGULATOR PRESSURE IS...

Page 38: ...THE PILOT IS IMPINGING ON THE THERMOCOUPLE BULB APPROXIMATELY 3 8 TO 1 2 9 to 13 mm CHECK THE THERMOCOUPLE SIGNAL TO THERMOSTAT CONTROL VALVE SIGNAL SHOULD BE 13 TO 30 mV DC WHEN THERMOCOUPLE IS HOT R...

Page 39: ...Y BATTERY OK BATTERY DEAD REPLACE BATTERY CHECK IF ELECTRODE IS CONTACTING HOOD OR FURTHER THAN 1 8 3 mm ADJUST AND CHECK OPERATION OUT OF POSITION OK CHECK ROCKER SWITCH BY REMOVING LEADS AND TOUCHIN...

Page 40: ...THAT THE PILOT IS IMPINGING ON THE THERMOCOUPLE BULB APPROXIMATELY 3 8 TO 1 2 9 to 13 mm TURN THE THERMOSTATIC GAS VALVE TEMPERATURE CONTROL DIAL UP TO THE HIGHEST SETTING DID THE CONTROL CLICK CHECK...

Page 41: ...ATOR REPLACE REGULATOR REPAIR PRESSURE SOURCE PRESSURE OK CHECK THE THERMOSTAT PORT OUTLET PRESSURE REFER TO PAGE 1 3 OK LOW HIGH SET THERMOSTAT FOR HIGHER TEMPERATURE CHECK IF BURNER TIPS CLOGGED ORA...

Page 42: ...Algas SDI Operation and Maintenance Manual P N 54000 5 32 APPENDIX A TECHNICAL INFORMATION...

Page 43: ...Figure 11 160H Vaporizer Replacement Parts 3 11 13 5 6 1 2 7 4 14 10 12 8 9...

Page 44: ...rol Valve LIQUID INLET VALVE CAPACITY CONTROL VALVE 17 Inlet valve cap o ring 17 Inlet valve spring 17 Inlet valve gasket 17 Pivot arm gasket 17 Inlet valve orifice o ring 17 Inlet valve seat 15 Pisto...

Page 45: ...Relief valve NPT UL CE ASME P N 34876 9 Thermocouple P N THE0001 00 3 10 Thermostat Thermowell w 9VDC igniter P N 41082 11 Tube kit thermostat supply P N 40408 12 Tube kit burner supply P N 40475 13...

Page 46: ...Mach Screw pan head 8 32 LG zinc plated 2 TER0011 00 3 TRL lug wire 22 18GA nylon 1 40450 Drip Leg Kit Components Description Qty 1508 5020 Thermostat supply tube 1 30040 Z Nipple SCH 80 NPT 5 LG 1 3...

Page 47: ...thermocouple and pilot Components Description Qty 3 1035 3 8 Brass tee 1 30022 Z Nipple SCH 80 3 8 NPT 1 LG zinc plated 1 30130 Z Bushing FS 2000 x 3 8 NPT zinc plated 1 30221 Z Plug 3 8 FS zinc plat...

Page 48: ...inlet valve pin gasket installation procedure 1 Clean pivot screw hole opening from any residue 2 Apply blue medium strength Locktite 243 or Permatex to threads on the liquid inlet valve body or pivot...

Page 49: ...3 Slide pin gasket P N 8135 101 over the pivot screw P N 3 4169 threads as shown in the picture 4 Screw in pivot screw to the inlet valve body and apply 8 in lbs of torque approximately 1 8 full turn...

Page 50: ...ite to properly dry before reinstalling valve assembly back on the vaporizer 7 Re install valve in vaporizer with new flange gasket and uniformly torque bolts to 30 35 ft lbs 40 7 47 5 Nm 8 Re connect...

Page 51: ...ply tube fitting nut pull out the tubing and allow for space to rotate thermostat 9 Rotate thermostat counterclockwise while ensuring that thermowell stays attached to the heat exchanger 10 Remove the...

Page 52: ...ITY AT 0 F AND 100 PSIG PROPANE INLET 6 CONDITION 160 GPH 320 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES 7 ON ABOVE GROUND LEVEL SOLID NON COMBUSTIBLE BASE HEAT INPUT 180 000 BTU HR...

Page 53: ...VED 4 CE MARKED PED 5 VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET 6 CONDITION 320 GPH 640 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES 7 ON ABOVE GROUND LEVEL SOLID NON COMBU...

Page 54: ...us APPROVED 4 CE MARKED PED 5 VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET 6 CONDITION 480 GPH 960 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES 7 ON ABOVE GROUND LEVEL SOLID N...

Page 55: ...3 cULus APPROVED 4 CE MARKED PED 5 VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET 6 CONDITION 640 GPH 1 280 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES 7 ON ABOVE GROUND LEVEL...

Page 56: ...ROVED 4 CE MARKED PED 5 VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE 6 INLET CONDITION 800 GPH 1 600 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR 7 MOUNTING HOLES ON ABOVE GROUND LEVEL SOLID NON C...

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Page 58: ...Algas SDI International LLC 151 South Michigan Street Seattle Washington 98108 Ph 1 206 789 5410 Fax 1 206 789 5414 www algas sdi com...