Eclipse Algas-SDI P120, Operation & Maintenance Manual

Page 1: ...nce Manual Innovative liquid vaporizing and gas mixing solutions 151 South Michigan Street Seattle Washington USA 98108 Tel 206 789 5410 Fax 206 789 5414 Web www algas sdi com FILE Manual PN 52632 Rev...

Page 2: ...temperature and controls the heater ON and OFF cycles A second sensor acts as a high temperature safety and shuts the vaporizer off if an over temperature situation occurs A High Liquid Level Safety F...

Page 3: ...Introduction 1 2 Algas SDI Operations Maintenance Manual P N 52632 Figure 1 Typical Configuration Drawing Control System wmf...

Page 4: ...Components 1 dxf 1 Vapor outlet isolation valve 7 Control panel 2 Liquid inlet manifold 8 Relief valve 3 Liquid inlet isolation valve 9 Liquid level safety switch 4 Liquid inlet safety solenoid valve...

Page 5: ...r Major Components Division 2 Models Major Components 2 dxf 1 Vapor outlet isolation valve 7 Control panel 2 Liquid inlet manifold 8 Relief valve 3 Liquid inlet isolation valve 9 Liquid level safety s...

Page 6: ...nance Manual P N 52632 2 5 1 Figure 4 Control Box Major Components Division 1 Models Control Box 1 dxf 1 Start pushbutton momentary 5 Transformer solenoid valve fuses 2 Control board 6 Input power dis...

Page 7: ...l Box Major Components Division 2 Models Control Box 2 dxf 1 Indicator lamps 7 Single float switch PC board 2 ON OFF switch maintained 8 Line power distribution block 3 Start pushbutton momentary 9 He...

Page 8: ...allation of a Power Series Vertical vaporizer can be found below Install the ASDI Power vaporizer on a firm level base Bolt it securely through the four mounting holes in the vaporizer stand base plat...

Page 9: ...lation 3 8 Algas SDI Operations Maintenance Manual P N 52632 Figure 6 Installation Drawing with Pump Installation dxf Figure 6B Typical Installation Drawing with Vapor Bypass and No Pump Installation...

Page 10: ...inimal pressure drop while supplying the vaporizer at capacity operation Table 1 provides a handy guideline to assist in determining the appropriate pipe size for a given size vaporizer over a given d...

Page 11: ...2 2 2 2 2 2 50 0 550 1 2 2 2 2 2 2 2 60 0 660 2 2 2 2 2 2 2 2 80 0 880 2 2 2 2 2 2 2 3 100 0 1100 2 2 2 2 2 2 2 3 150 0 1640 2 2 2 2 2 2 3 3 200 0 2200 2 2 2 2 2 3 3 3 300 0 3300 2 2 2 2 3 3 3 4 400 0...

Page 12: ...4 4 63 825 440 06 2 92 20 133 58 418 402 778 45 7 15 70 455 485 77 4 82 33 233 66 035 455 295 50 9 9 77 49 534 27 6 85 47 229 74 254 511 963 55 12 65 84 945 585 68 9 62 053 83 106 572 996 60 15 4 92 8...

Page 13: ...SECOND stage regulators must be 250 psig 17 58 cm kg2 inlet pressure rated SAFETY RELIEF VALVE If the vaporizer is installed within an enclosure or building VENT THE SAFETY RELIEF VALVE OUTSIDE THE EN...

Page 14: ...rizer 5 6 380V to 575V built in 2007 forward Power distribution terminal lug wire size range 500MCM 2 AWG Branch distribution terminal lug wire size range 4 14 AWG Applies to 2 separate control boxes...

Page 15: ...The liquid LPG that comes in contact with the heated core absorbs the heat vaporizes and cools the core The heaters then come on as necessary to keep the core temperature above 194 F 90 C The amount o...

Page 16: ...ain vaporizer operation for power disturbances less than 5 seconds The Auto Restart Option will restart the vaporizer if there is a loss of power for more than 5 seconds If the vaporizer should shut d...

Page 17: ...me for the power to stabilize and for any externals components to re energize The Display Lamps will remain blank for 2 seconds then will light as the unit starts up If the vaporizer is on and power i...

Page 18: ...ore temperature to match demand CAUTION Make an operational check of the inlet solenoid valve once the vaporizer is started 8 Press the STOP button The valve should stop the flow of liquid as indicate...

Page 19: ...upper left corner of the control board Look up the Operation Fault code on the annunciator to find out why the vaporizer failed Follow the troubleshooting procedures in this manual to determine the ca...

Page 20: ...to the control box The HEAT ON and VAPORIZER OPERATING SAFETY CIRCUIT LATCHED lamps should illuminate 5 The INLET VALVE OPEN lamps will illuminate after approximately 30 seconds of warm up The inlet v...

Page 21: ...N Vaporizers equipped with the Auto Restart option may start the vaporizer operation immediately Vaporizers equipped with the Economy Option may not start immediately due to high tank pressure The vap...

Page 22: ...izer outlet isolation hand valve REPLACING COMPATIBILITY OF CONTROL BOARDS There has been many different part number for the control boards due to obsolete parts and improvements All the control board...

Page 23: ...LLY Liquid Propane Strainer installed by others Visually inspect and clean Visually inspect and clean Safety Relief Valve Visually check Replace if any leakage is observed Inlet Solenoid Inspect and c...

Page 24: ...own the cause of the problem If the vaporizer has been operating and has shut down do not reset until you have opened the control box and recorded the fault indication of the annunciator readout Use t...

Page 25: ...Troubleshooting 6 26 Algas SDI Operations Maintenance Manual P N 52632 Figure 8 High Voltage Areas of Control Box Division 1 Models High Voltage Areas 1 wmf...

Page 26: ...Troubleshooting Algas SDI Operations Maintenance Manual P N 52632 6 27 Figure 9 High Voltage Areas of Control Box Division 2 Models High Voltage Areas 2 wmf...

Page 27: ...l Board Test Points 2 6 Pin Molex Connector for control panel lights J2 3 Typical Board Adjustment Potentiometer 4 Typical Quick Disconnect Board Connector Points 5 Typical Board Lights 6 Operation Fa...

Page 28: ...Control Power 15 VAC into control board Figure 11 Vaporizer Operating Temperature Chart as measured at TP1 on the control board 349 F 176 C 2nd High Temperature Safety Shutdown 320 F 160 C 1st High T...

Page 29: ...ter 90 VDC R9 1 Thermocouple CAUTION FACTORY ADJUSTMENT ONLY DO NOT ADJUST Fixed setpoint on PN 53050 4 R25 2 Thermocouple CAUTION FACTORY ADJUSTMENT ONLY DO NOT ADJUST Fixed setpoint on PN 53050 4 OP...

Page 30: ...e vaporizer off Check your incoming power source Restart the vaporizer The alarm will activate on loss of AC voltage See above note 1 TEMPERATURE SENSOR INOPERATIVE Open or reversed thermocouple leads...

Page 31: ...er is unable to provide enough heat to vaporize the amount required by the load or the liquid level switch is inoperative Do the following tests 1 Attempt to restart the vaporizer If the vaporizer ope...

Page 32: ...point See Operating Temperature Adjustment Procedure 7 DOWNSTREAM PRESSURE SWITCH No longer used But if encountered means that the Economy Options is being used without the Auto Restart Option enabled...

Page 33: ...OFF temperature put the positive meter lead on TP3 and adjust R7 for 0 95 VDC 95 C This reading must always be higher than the reading at TP4 NOTE Clockwise rotation increases temperature setting ON...

Page 34: ...rent All measurements must be made while the heaters are on FULL LOAD VOLTAGE CHECK NOTE Check voltage when heaters are energized Check heater voltage by measuring voltage at the power relay when the...

Page 35: ...Nameplate on the vaporizer for the correct reading line current for your vaporizer All three wires should have equal readings 3 If current readings are uniformly low you have a low voltage If current...

Page 36: ...model number from the Data for important resistance measurements are shown heater resistance wire to wire and individual resistance 1 HEATER RESISTANCE WIRE TO WIRE Perform this procedure from inside...

Page 37: ...e your meter to a high resistance scale and check from each pole to the vaporizer shell or the ground lug in the box The resistance should be 100 mega ohms or more If both checks are good the heaters...

Page 38: ...16 Individual Heater Resistance Tests Individual Heater Tests wmf Using the diagram above check the individual heaters for correct resistance using a low resistance scale See the Bussing Diagram for I...

Page 39: ...fusing 3 Check the two input fuses to the transformer and replace if necessary 4 Check for 15 VAC at the transformer terminals Y1 and Y2 and the control board terminals P13 and P14 A If there is 15 V...

Page 40: ...time However on older vaporizers an incandescent bulb is used Check the bulb and replace if necessary 2 Check for correct voltage on both sides of the mercury relay 3 If the voltage is good go to Tes...

Page 41: ...nect before proceeding Figure 19 Solenoid Valve Electrical Checks A Solenoid Electric Check A dxf Remove cover on conduit T Pull the two red wires and remove the wire nuts Separate the wires and test...

Page 42: ...resistance as indicated If this test is bad repair the wiring If this test is good reconnect the wiring and retest the vaporizer If the display shows 5 again replace the control board See the Electric...

Page 43: ...ssure in the vaporizer and outlet supply piping When the pressure is at 0 psi on the vaporizer pressure gauge shut the outlet hand valve off Open the inlet hand valve The solenoid valve is closed and...

Page 44: ...is good Recheck vaporizer operation If the switch is good and the control board still reads 4 change the control board If the switch reads open OL on the meter perform the following tests Remove the c...

Page 45: ...the conduit cover 1 2 Pull out and separate the wires 2 3 Disconnect the conduit union 3 4 Unscrew the conduit elbow from the liquid level switch 4 5 Remove the liquid level switch 5 The arrow on the...

Page 46: ...power to the vaporizer Check for 15 VAC on the 15 volt input to the card 15 volts OK replace the common liquid carryover board No 15 volts Repair wiring to the transformer or replace the transformer...

Page 47: ...32 Figure 25 Common Liquid Carryover Boards P480 to P1280 NOTE Refer to drawings that came with the vaporizer for wiring changes The configuration shown represents previous versions Vaporizers built a...

Page 48: ...valve and bleed off pressure in the vaporizer before proceeding 1 Remove the conduit cover 1 2 Pull out and separate the wires 2 3 Disconnect the conduit union 3 4 Unscrew the conduit elbow from the...

Page 49: ...r shorted wires due to insulation problems Using the following Figure 27 as a guide check for frayed or loose wiring and correct color coding of the connections Figure 27 Thermocouple Tests Thermocoup...

Page 50: ...nstallation of the thermocouple Figure 28 Thermocouple Position Problem Tests To remove the thermocouple push up on the bayonet fitting and turn it 1 4 turn counter clockwise The thermocouple should n...

Page 51: ...tension wire that matches the thermocouple type K When thermocouple Extension wire is used always be sure that only one end of the shield is grounded to ensure proper operation Typically the extension...

Page 52: ...power has failed at one time or another during operation and it has restarted To reset the display set the toggle switch to OFF and back ON The display will now show an L meaning that the unit is ope...

Page 53: ...ain adequate vapor pressure When set to Manual Operation the tank pressure switch is bypassed and the vaporizer is continuously operating and maintaining operating temperature TESTING YOUR ECONOMY OPE...

Page 54: ...l vaporization from the storage tank through the bypass vapor line When pressure in the storage tank is less than the inlet pressure switch set point the switch CLOSES and the vaporizer is energized T...

Page 55: ...ng the remote box See additional drawings in Appendix ASDI PN 80455 05 Remote box kit Figure 30 Remote Box 1 of 2 Remote Box B dxf REMOTE BOX ALARM INDICATOR BOX There are 2 versions of this remote co...

Page 56: ...______________________________________________________________________________________ Algas SDI Operations Maintenance Manual P N 52632 7 57 Figure 31 Remote Box Division 2 2 of 2 Division 2 Remote B...

Page 57: ...58 Algas SDI Operations Maintenance Manual P N 52632 VALVE AND STRAINER PACKAGE For a P120 P160 use ASDI PN 36930 3 4 NPT inlet 1 NPT outlet For Multiple Vaporizers use ASDI PN 36931 1 NPT inlet 2 NP...

Page 58: ...onnections a blow down drain 5 a pressure gauge 4 a vent which is normally plugged 6 and a bypass valve system for cleaning 1 2 and 3 The bypass valves enable the system to continue operating when the...

Page 59: ...Valve used by Algas SDI 2 9 98 Algas SDI ASCO Valve Draw wmf TORQUE CRISSCROSS TO 110 in Lbs 12 4 N m TORQUE TO 175 in Lbs 19 7 N m WARNING TURN OFF ELECTRICAL POWER AND DE PRESSURIZE VALVE BEFORE MAK...

Page 60: ...e 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...

Page 61: ...Deg F 157 301 3 63 14 4 P160 575 39 4 39 2 225 102 194 203 Deg F 349 Deg F 1 NPT Outlet 7 1ft2 0 66m2 7 1ft2 0 66m2 225 102 P160 480 47 4 39 4 157 302 3 64 14 4 3 4 NPT Inlet 250 PSIG MAWP 157 302 26...

Page 62: ...80 21 3ft2 1 98m2 1050 477 P480 480 142 2 118 1 424 815 38 9 9 83 21 3ft2 1 98m2 21 3ft2 1 98m2 P480 440 118 1 424 815 38 9 9 83 118 0 21 3ft2 1 98m2 21 3ft2 1 98m2 1050 477 P480 415 424 815 38 9 9 8...

Page 63: ...Options Economy Equipment Drawing Electrical Drawing Options Remote Electrical Drawing 0608 7102 0608 7107 0608 7107 POWER P SERIES ELECTRIC VAPORIZER DATA SHEET Continued 0608 7102 0609 6001 0609 70...

Page 64: ...t exchanger Mentioned in this declaration complies with the following standards and or normative documents Requirements Remarks Certificates No 97 23 EC Pressure Equipment Directive PED H 91 Module H...

Page 65: ...7 U S A Phone 206 789 5410 Fax 206 789 5414 POWER VERTICAL SPARE PARTS LIST Locate the replacement parts on the following diagrams then look up the Algas SDI part number on the tables located on the l...

Page 66: ...Innovative Liquid Vaporizing and Gas Mixing Solutions SINGLE VAPORIZER SPARE PARTS Figure 35 View of Division 2 Single Vaporizer Unit...

Page 67: ...Innovative Liquid Vaporizing and Gas Mixing Solutions SINGLE VAPORIZER SPARE PARTS Figure 36 View of Division 1 Single Vaporizer control box...

Page 68: ...Inlet Solenoid 17 Coil Inlet Solenoid 18 Liquid Level Switch Float 19 Pressure Gaurge 0 300 psig 20 Pressure Relief Valve 21 Pipe Away Adapter Relief 22 Fusible Link Manual 24 Thermocouple K Type Opti...

Page 69: ...Innovative Liquid Vaporizing and Gas Mixing Solutions MULTIPLE VAPORIZER SPARE PARTS Figure 37 View of Division 2 Multiple Vaporizer control box...

Page 70: ...ng Cover 13 Corrision Inhibitor Tape 14 Control board 15 Inlet Solenoid Valve 16 Repair Kit Inlet Solenoid 17 Coil Inlet Solenoid 18 Liquid Level Switch Float 19 Pressure Gaurge 0 300 psig 20 Pressure...

Page 71: ...rass Options Alarm Relay 1 per core Economy Pressure Switch Transducer Economy Sw Switch Economy Manual Remote Box Remote Box Alarm only Remote Box Alarm only 60710 36602 35054 50311 80481 Description...

Page 72: ...50 60 50076 60 575 VAC 40 50 52707 50 Drawing Reference Key Description Recommended Spares Multiple Vaporizer Fuse Table Model Voltage P240 P320 P480 P1280 Division 2 Division 2 Division 2 Size Amps 5...

Page 73: ...manner detrimental to our interests All and is not to be reproduced nor used in any This drawing is the property of Algas SDI rights are reserved...

Page 74: ...manner detrimental to our interests All and is not to be reproduced nor used in any This drawing is the property of Algas SDI rights are reserved...

Page 75: ...manner detrimental to our interests All and is not to be reproduced nor used in any This drawing is the property of Algas SDI rights are reserved...

Page 76: ...manner detrimental to our interests All and is not to be reproduced nor used in any This drawing is the property of Algas SDI rights are reserved...

Page 77: ...manner detrimental to our interests All and is not to be reproduced nor used in any This drawing is the property of Algas SDI rights are reserved...

Page 78: ......

Page 79: ......

Page 80: ......

Page 81: ...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...

Page 82: ...St Seattle Washington USA 98107 Tel 206 789 5410 Fax 206 789 5414 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 i...

Page 83: ...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...

Page 84: ...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...

Page 85: ...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...

Page 86: ...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...

Page 87: ...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...