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881 HERSEY STREETST. PAUL, MN 55114
PHONE (651) 646-1177FAX (651) 646-1676
Algas SDIDIRECT FIREDLPG Vaporizers
Vaporizer Repair
and Maintenance Guide
Installation Example
Vapor BypassRegulator
Liquid
OilSeparator
First StageRegulator
Burner SupplyLine
SupplementalRelief Valve
VaporTo Load
StorageTank
600 W
OG
600 WOG
600 WOG
Vaporizer Installation Best Practices
Distances from vaporizer
Storage tankStorage shutoffsPoint of transferBuildings
10 feet15 feet15 feet25 feet
Notes
All piping must follow the guidelines of NFPA 58.
The liquid tank opening shows an internal valveallowing two-way liquid flow. The boiling liquid andexpanding vapor in the vaporizer chamber requiresthis two-way flow capability.
The system has a first stage regulator on the dis-charge of the vaporizer and a vapor bypass regulatoron the tank vapor outlet valve. The bypass regulatoris normally set slightly lower and only delivers vaporto the system if the vaporizer quits functioning.
The vaporizer burner supply line is optional buthighly recommended. Pulling cold vapor directly from the storage tank greatly alleviates clogged controls,pilots etc. in the vaporizer from oily heavy ends.
The oil separator shown piped in after the first stageregulator removes the oily mist from the vapor streambefore it can enter the load piping. To avoid reconden-sation of the propane vapor, the separator must bepiped after the first stage regulator.
The supplemental relief valve shown is requiredto protect the downstream system from over-pressure conditions and liquid formation in the firststage piping. Because most industrial first stageregulators do not provide adequate relief protection,this relief is nearly always mandatory.
Vaporizer Repair and Maintenance Guide
The following sketch depicts a typical vaporizer installation. The vaporizer system, when piped as shown, will provide long trouble free vapor service. The vaporizer can be isolated for maintenence or repair without interrupting the load.
Although some of the components such as the vapor bypass regulator, the burner supply line and the oil separator are optional, they are all highly recommended as "Best Practice Piping" for direct fired vaporizers.
Remove screen and clean.
Inspect pilot for proper flame.
Inspect for proper flame.
Check for signs of corrosion and replaceany missing caps.
Check entire enclosure, louvers andvent cap for debris.
Strainer
Pilot Burner Assembly
Main Burner Assembly
Relief Valves
Enclosure
Service to PerformItems to Service Monthly
Monthly Check List
Check thermostat for proper operation.Replace if needed.
Check thermocouple position in pilotand verify proper millivolt output.
Replace valve seat, spring and O-ringusing Kit # 3-0016.
Clean piston and replace the spring andO-ring using Kit # 3-0017.
Check flues for holes or excessive scale.Remove debris. Check bottom of theheat exchanger for pitting. Replace if thepitting is in excess of 0.125".
Check for proper flame. Clean debris andcheck air supply. Clean orifices as needed.
Thermostat
Thermocouple
Liquid Inlet Valve
Capacity Control Valve
Heat Exchanger
Main Burner
Service to PerformItems to Service Annually
Annual Check List
Maintenance Schedule
Vaporizer Repair and Maintenance Guide
FLAMMABLE GAS
Vaporizers and ancillary equipment should be serviced ONLY by trained and fully qualified personnel. This equipment operates with LP gas which is flammable and under pressure. Inherent hazards exist and a thorough understanding of the equipment is required for safe maintenance.
Regular scheduled maintenance on vaporizers is a must for trouble free operation. The suggested schedules listed above should be used as a guide. Certain installations and situations will require more stringent inspection and repair.
40/40 Parts
Vaporizer Repair and Maintenance Guide
VaporizersBuiltTo Oct 200240C6840C663-0017
3129G3129-40P
3-0776
41045920V
3-35401501-5015-02
3-0787
3-0782
3-0777
1980-36
3-0631BA-718 .018
40C39A
40C14
3-0529
40C37
3-41503-0016
3-0778
3-0549
DescriptionCapacity Control ValveCapacity Control PistonCapacity Control Kit
Relief ValveRelief Valve Cap
Regulator Supply Tube
Burner Regulator KitRegulator Only
ThermostatThermostat Cover
Thermostat Supply Tube
Burner Supply Tube
Pilot Tube
Thermocouple
Pilot AssemblyPilot Orifice
Burner Manifold
Burner Jet
Flue
Inlet Valve Gasket
Liquid Inlet ValveInlet Valve Kit
Loading Tube
Vapor Out Nipple
Key111
22
3
44
55
6
7
8
9
1010
11
12
13
14
1515
16
17
VaporizersBuiltPost Oct 200240C6840C663-0017
T3131G3131-54
3-0776
41045920V
3-35401501-5015-02
3-0787
41022
41024
1980-36
3-0631BA-718 .018
1502-4006
33581
451-506-01
40C37
3-41503-0016
3-0778
3-0549
Repair Parts for Algas 40/40 Vaporizer
1
2
3
4
5
6
7
8
91011
12
13
14
15
1716
New Burner ArrangementPost October 2002
New Burner Regulator Assy41045 Kit - Upgrades to 920Vregulator with shutoffs, tubingassemblies and drip leg.
920V - Regulator only.
Old Burner ArrangementPre October 2002
RO WAB HE TSRRO WAB HE TSR
HGIH
HGIHLO
WLO
W
WARNINGWARNINGREAD ALL INSTRUCTIONSBEFORE LIGHTINGREAD ALL INSTRUCTIONSBEFORE LIGHTING
The Algas 40/40 vaporizer has undergone major improvements and revisions since 2002. The burner assembly, burner regulator and associated supply lines as well as the thermostat control have been updated for more reliable and better performance. Most of these improvements can readily be incorporated to existing models in the field during maintenence and repair servicing.
The following parts breakdown lists the Pre 2002 and Post 2002 parts with graphics to depict the differences.
80/40 Parts
Vaporizer Repair and Maintenance Guide
VaporizersBuiltTo Oct 20023-0549
40C6840C663-0017
3-0779
41045920V
3-35401501-5015-02
3-0788
3-0782
3-0781
1504-5009
1980-36
80C99
DescriptionVapor Out Nipple
Capacity Control ValveCapacity Control PistonCapacity Control Kit
Regulator Supply Tube
Burner Regulator KitRegulator Only
ThermostatThermostat Cover
Thermostat Supply Tube
Burner Supply Tube
Pilot Tube
Right Flue
Thermocouple
Right Burner Manifold
Key1
222
3
44
55
6
7
8
9
10
11
VaporizersBuiltPost Oct 20023-0549
40C6840C663-0017
3-0779
41045920V
3-35401501-5015-02
1504-5005
41019
40404
1504-5009
1980-36
1504-4005
VaporizersBuiltTo Oct 20023-0644BA-718 .023
3-0783
40C39
40C14
452-505-01
40C37
3-41503-0016
3-0786
T3131G3131-54
3-0792
DescriptionPilot AssemblyPilot Orifice
Burner Manifold Tube
Left Burner Manifold
Burner Jet
Left Flue
Inlet Valve Gasket
Liquid Inlet ValveInlet Valve Kit
Loading Tube
Relief ValveRelief Valve Cap
Connector Tube
Key1212
13
14
15
16
17
1818
19
2020
21
VaporizersBuiltPost Oct 200241021BA-718 .023
3-0783
1504-4004
33581
452-505-01
40C37
3-41503-0016
3-0786
T3131G3131-54
3-0792
2 3
4
6
7
8
9
1011121314
15
16
17
18
1920
21 5
1
New Burner ArrangementPost October 2002
Old Burner ArrangementPre October 2002
RO WAB HE TSRRO WAB HE TSR
HG
H I
HG
H ILO
WLO
W
WARNINGWARNINGREAD ALL INSTRUCTIONSBEFORE LIGHTINGREAD ALL INSTRUCTIONSBEFORE LIGHTING
New Burner Regulator Assy41045 Kit - Upgrades to 920Vregulator with shutoffs, tubingassemblies and drip leg.
920V - Regulator only.
Repair Parts for Algas 80/40 Vaporizer
The Algas 80/40 vaporizer has undergone major improvements and revisions since 2002. The burner assembly, burner regulator and associated supply lines as well as the thermostat control have been updated for more reliable and better performance. Most of these improvements can readily be incorporatedto existing models in the field during maintenance and repair servicing.
The following parts breakdown lists the Pre 2002 and Post 2002 partswith graphics to depict the differences.
Kits and Service
Liquid Inlet ValveRemove the plug from the inlet valve and wipe away debris.Use kit # 3-0016 to replace the valve seat, spring andO-ring on the plug.
Thermostat CheckAt ambient temperatures, rotating the temperature control knob from LOWthrough HIGH will energize the main seat of the control producing a loudaudible click.
The burner gas pressure must be at least 9" W.C. when checked at thepressure tap with the main burner operating. Set the pressure with theadjusting screw located beneath the cap on the Pilot-On-Off knob.
Using a suitable junction block tester, check the thermocouple millivoltoutput. A reading of 13 to 30 millivolts is acceptable. Turn the gas valveoff and observe the millivolt reading at the point when the internal safetymagnet drops out with a click. The millivolt drop out should be appreciablylower (at least 5 Mv) than the running millivolt reading.
Pilot FlameThe pilot flame should envelope 3/8" to 1/2" of the thermocouple tip. Clean or replace the pilot if it is too small.
Main BurnerThe burner flame should be a non blowing blue flame andevenly distributed over the burner ring. If uneven, cleanindividual burner jets (#66 drill for new style jet. # 64 drill forold style jet).
Capacity Control KitDisassemble and clean the valve assembly inside the body.Use kit # 3-0017 to replace the spring and O-rings onthe piston and plug. Use powdered graphite as a lubricanton the piston and use grease on the plug O-ring.
66
WARNING
UNITROL
READ ALL INSTRUCTIONSBEFORE LIGHTING
ALGAS - SDI
HIGH
LO
W
ON PILOT
10-038ADAPTER
TO MILLIVOLTMETER
6
INCHES
8
10
12
15
4
2
40/40Pilot
New Style Jet
OldStyleJet
80/40Pilot
Pressure Adjustment Below
Vaporizer Repair and Maintenance Guide
FLAMMABLE GAS
CAUTIONThe vaporizer must be completely blown down before performing service. Be sure all sources of ignition are extinguished within 25 feet of the work area.