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Maintenance

4-20

Algas-SDI Operation and Maintenance Manual

– P/N - 52642

Use the Direct Fired Vaporizer Inspection & Maintenance Checklist included in this manual to record and keep
track of your annual maintenance and inspections.

DIRECT FIRED VAPORIZER INSPECTION CHECKLIST

Model:_________________

Serial Number:___________________

Maintenance Checklist Items

Inspected
Yes/No

Replaced or
Kit Installed?

1. Thermostat Operation:

-

Did burner(s) cycle on?

-

Did the burner(s) and pilot extinguish after a short period of time when turned
off?

2. Thermocouple: Was the millivolt output between 13-30 mV DC?

3. Pilot Assembly:

-

Pilot assembly inspected for corrosion?

-

Pilot orifice cleaned or replaced?

4. Burner Assembly: Burner tips and orifices cleaned?

5. Flame Spreader Bar: Is it present and positioned properly or does it have signs of

damage/corrosion (applicable to 80/40H and 120/60H)

6. Liquid Inlet Valve:

-

Repair Kit installed?

-

Inlet orifice cleaned?

-

Did valve pass “water test” to ensure seat is sealing properly?

7. Capacity 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?

-

Manufacture date checked for replacement?

10. Drip Leg: Drained of all contaminants and oils?

11. Burner Regulator: Pressure setting verified? Record pressure setting here.

12. Vaporizer Tubing:

-

All tubing checked for pitting or flaking and blown free of debris?

-

All fittings tightened?

13. Heat Exchanger:

-

Flue inspected?

-

Debris removed from and around heat exchanger?

-

Heat exchanger head thickness tested?

-

Heat exchanger drained of heavy ends?

14. Vaporizer Cabinet: Are door, enclosure, inlet louvers and rain caps cleared of

debris and combustible materials?

Once the above items have been maintained and/or inspected, leak test all fittings and connections inside
and outside the cabinet, including the inlet valve flange and bolts, to ensure there are no leaks.
Connect  LPG  Supply  and  light  the  pilot  and  engage  main  burners.    Ensure  pilot  is  strong  and  main
burners are igniting and burning properly.

INSPECTED BY:__________________________________

INSPECTION DATE:_________________

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Содержание Direct Fired 120/60H

Страница 1: ...ttle Washington USA 98108 Tel 1 206 789 5410 Fax 1 206 789 5414 Web www algas sdi com FILE MANUAL PN 52642 DIRECT FIRED 5 10 21 Innovative liquid vaporizing and gas mixing solutions LP Gas Vaporizer 4...

Страница 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...

Страница 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...

Страница 4: ...This page left intentionally blank...

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

Страница 6: ...This page left intentionally blank...

Страница 7: ...ecommended Liquid Supply Line Size 2 6 Vapor Distribution Line 2 6 Table 3 Recommended Vapor Distribution Line Size 2 6 Liquid Inlet 2 7 Vapor Bypass Line Optional 2 7 Burner Supply Line Optional 2 8...

Страница 8: ...g burner input pressure 4 22 Figure 12 Adjusting burner input pressure 4 22 Liquid inlet valve maintenance procedure 4 23 Capacity control valve maintenance procedure 4 25 5 Troubleshooting Pilot 5 26...

Страница 9: ...This page left intentionally blank...

Страница 10: ...ntact Algas SDI with total connected load and high pressure first stage regulator setting See Page 2 9 for Details Economy Valve Kit Economy Valve Kit P N 41051 Quantity 1 per unit See Page 2 8 for De...

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

Страница 12: ...flow into the heat exchanger and the thermostat 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 suppl...

Страница 13: ...kW THERMOSTAT PORT PRESSURE 10 W C 24 9 mbar BURNER PRESSURE 9 W C 22 4 mbar 80 40H 102 720 BTU hr 30 kW THERMOSTAT PORT PRESSURE 9 W C 22 4 mbar BURNER PRESSURE 7 W C 17 4 mbar 120 60H 154 080 BTU hr...

Страница 14: ...arefully 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 the...

Страница 15: ...nance Manual P N 52642 2 5 Figure 2 Vaporizer Dimensions shown in inches Model A B C 40 40H 35 0 89 m 29 0 74 m 20 0 51 m 80 40H 35 0 89 m 29 0 74 m 20 0 51 m 120 60H 44 1 12 m 37 0 96 m 28 0 75 m 40...

Страница 16: ...adequately sized for the service Table 2 Recommended Liquid Supply Line Size Nominal Pipe Size Liquid Line Length Ft m Up to 50 15 50 150 15 36 150 250 36 76 40 40H Vaporizers 3 4 DN20 1 DN25 1 DN25...

Страница 17: ...nd the vaporizer Liquid must be able to flow both ways in that line 1 Install the 60 mesh 3 4 strainer that is supplied with the unit on the liquid inlet to the vaporizer 2 Install a UL listed shut of...

Страница 18: ...INSTALLATION OPTIONAL A vaporizer with economy operation draws vapor from the tank as the primary source and utilizes the vaporizer only when needed The intent is to allow the most economical operati...

Страница 19: ...To properly size the FILTAIRETM contact Algas SDI with total connected load and high pressure first stage regulator setting INSTALLING MULTIPLE UNITS IN PARALLEL For balanced performance of the system...

Страница 20: ...52642 AN OVERSIZED INLET AND OUTLET MANIFOLD MAY ALSO BE USED TO BALANCE THE FLOW Figure 6a Installing Multiple Units in Parallel Oversized Manifolds with side inlet outlet Figure 6b Installing Multip...

Страница 21: ...2 120 60H 77 1 497 23 7 153 LEAK TEST CAUTION Leak test the entire installation prior to operating the system 1 Close the outlet valve 2 Slowly open the inlet valve and allow pressure to equalize in t...

Страница 22: ...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...

Страница 23: ...aporizer see page 2 8 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...

Страница 24: ...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...

Страница 25: ...izer purge procedure If the vaporizer is not going to be used for a long period of time it should be purged The information contained below is a step by step procedure on how to purge Algas SDI direct...

Страница 26: ...sume the remaining gas in the line 7 After verifying the pressure in the lines is zero and no sources of ignition are present in the area the vaporizer can now be disconnected AUTOMATIC RE IGNITION OP...

Страница 27: ...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 and Operation Inspections Required 30 60 d...

Страница 28: ...Clean any plugged or obstructed orifices Pilot Flame Guide Flame Spreader Bar Upon initial installation and during periodic maintenance inspections check for corrosion on the ends of the pilot flame...

Страница 29: ...hat no significant quantity of heavy ends are accumulating during vaporizer operation this maintenance can be performed on an annual basis Drip Leg Remove plug below the tee on the drip leg and drain...

Страница 30: ...aling properly 7 Capacity 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...

Страница 31: ...attery access door on the bottom right corner of the thermostat housing Figure 10 Opening the battery access door 2 Pull out the battery disconnect it and replace with new 9VDC battery Push the batter...

Страница 32: ...e the temperature control dial counterclockwise The main burner s should now engage 5 With the main burner operating check the gas pressure at the thermostat outlet pressure port using a manometer see...

Страница 33: ...ype material to remove any debris and or oils from the orifice surface 8 Replace the O ring under the orifice use smallest O ring from kit Lightly grease new O ring before replacing it 9 Once the inle...

Страница 34: ...re present the valve is sealing properly 16 Remove any remnants of the old inlet valve flange gasket from the surface of the flange on the inlet valve itself and on the flange at the heat exchanger In...

Страница 35: ...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...

Страница 36: ...spacing from the hood is not 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 t...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 41: ...ASSUMES THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS MAXIMUM CAPACITY NO ADJUST BURNER PRESSURE REGULATOR OK SEE TROUBLESHOOTING TREE 3 MAIN BURNER WILL NOT LIGHT WILL NOT ADJUST CHECK FOR MINIMUM...

Страница 42: ...APPENDIX A TECHNICAL INFORMATION...

Страница 43: ...Figure 13 40 40H Vaporizer Replacement Parts 1 2 3 4 5 6 10 8 9 11 12 13 14 15 16 24...

Страница 44: ...Figure 14 80 40H and 120 60H Vaporizer Replacement Parts NOTE Drawing shown for an 80 40H Vaporizer 17 18 19 20 25 26 9 16 4 8 11 13 15 2 5 12 3 14...

Страница 45: ...VALVE CAPACITY CONTROL VALVE 21 Piston 23 Inlet valve gasket 23 Inlet valve seat 23 Inlet valve spring 23 Inlet valve cap o ring Inlet valve orifice 23 Pivot arm gasket 22 Piston o ring 22 Capacity co...

Страница 46: ...Tube kit burner supply All models P N 42012 14 Tube kit capacity control All models P N 42013 15 Tube kit pilot supply All models P N 42014 16 Vent cap assembly All models P N 1501 4015 17 Burner mani...

Страница 47: ...ice qty 10 34800 Burner supply regulator 3 0034 Repair kit 40 40H Part number Description 40764 Repair kit Liquid inlet valve Capacity control valve 41073 Thermostat Thermowell with 9 VDC reigniter 40...

Страница 48: ...for all models 37510 Orifice pilot burner 80 40H 120 60H 23 41041 Repair kit 120 60H Pilot orifice and thermocouple Part number Description 37050 Thermocouple for all models 37510 Orifice pilot burne...

Страница 49: ...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...

Страница 50: ...lide 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 0 9 Nm of torque approximately 1 8 full t...

Страница 51: ...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...

Страница 52: ...HEAT INPUT 51 360 BTU HR 54 185 KJ HR 8 9 USE THE 1 8 FNPT PORT TO PIPE AWAY 1ST STAGE VENT IF REQUIRED 10 USE THE 3 4 FNPT PORT TO PIPE AWAY 2ND STAGE VENT IF REQUIRED 11 APPROXIMATE SHIPPING WEIGHT...

Страница 53: ...E FOUR MOUNTING HOLES ON 7 ABOVE GROUND LEVEL SOLID NON COMBUSTIBLE BASE HEAT INPUT 102 720 BTU HR 108 370 KJ HR 8 USE THE 1 8 FNPT PORT TO PIPE AWAY 1ST STAGE VENT IF REQUIRED 9 USE THE 3 4 FNPT PORT...

Страница 54: ...PANE INLET CONDITION 6 120 GPH 240 KG HR VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON 7 ABOVE GROUND LEVEL SOLID NON COMBUSTIBLE BASE HEAT INPUT 154 080 BTU HR 162 555 KJ HR 8 USE THE 1...

Страница 55: ......

Страница 56: ...Algas SDI International LLC 151 South Michigan Street Seattle Washington 98108 Ph 1 206 789 5410 Fax 1 206 789 5414 www algas sdi com...

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