AlgasSDI Algas 40/40 Repair And Maintenance Manual

Brand
AlgasSDI
Model
Algas 40/40
Type
Repair And Maintenance Manual

AlgasSDI Algas 40/40 is a direct-fired LPG vaporizer that provides long, trouble-free vapor service. Its features include:

  • Vapor bypass regulator that delivers vapor to the system if the vaporizer quits functioning
  • Vaporizer burner supply line that alleviates clogged controls and pilots by pulling cold vapor directly from the storage tank
  • Oil separator that removes oily mist from the vapor stream
  • Supplemental relief valve that protects the downstream system from overpressure conditions
  • Thermostat, thermocouple, liquid inlet valve, capacity control valve, heat exchanger, and main burner for optimal performance and safety

AlgasSDI Algas 40/40 is a direct-fired LPG vaporizer that provides long, trouble-free vapor service. Its features include:

  • Vapor bypass regulator that delivers vapor to the system if the vaporizer quits functioning
  • Vaporizer burner supply line that alleviates clogged controls and pilots by pulling cold vapor directly from the storage tank
  • Oil separator that removes oily mist from the vapor stream
  • Supplemental relief valve that protects the downstream system from overpressure conditions
  • Thermostat, thermocouple, liquid inlet valve, capacity control valve, heat exchanger, and main burner for optimal performance and safety
881 HERSEY STREET
ST. PAUL, MN 55114
PHONE (651) 646-1177
FAX (651) 646-1676
Algas SDI
DIRECT FIRED
LPG Vaporizers
Vaporizer Repair
and Maintenance Guide
Installation Example
Vapor Bypass
Regulator
Liquid
Oil
Separator
First Stage
Regulator
Burner Supply
Line
Supplemental
Relief Valve
Vapor
To Load
Storage
Tank
600 WOG
600 WOG
600 WOG
Vaporizer Installation Best Practices
Distances from vaporizer
Storage tank
Storage shutoffs
Point of transfer
Buildings
10 feet
15 feet
15 feet
25 feet
Notes
All piping must follow the guidelines of NFPA 58.
The liquid tank opening shows an internal valve
allowing two-way liquid flow. The boiling liquid and
expanding vapor in the vaporizer chamber requires
this two-way flow capability.
The system has a first stage regulator on the dis-
charge of the vaporizer and a vapor bypass regulator
on the tank vapor outlet valve. The bypass regulator
is normally set slightly lower and only delivers vapor
to the system if the vaporizer quits functioning.
The vaporizer burner supply line is optional but
highly 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 stage
regulator removes the oily mist from the vapor stream
before it can enter the load piping. To avoid reconden-
sation of the propane vapor, the separator must be
piped after the first stage regulator.
The supplemental relief valve shown is required
to protect the downstream system from over-
pressure conditions and liquid formation in the first
stage piping. Because most industrial first stage
regulators 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 replace
any missing caps.
Check entire enclosure, louvers and
vent 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 pilot
and verify proper millivolt output.
Replace valve seat, spring and O-ring
using Kit # 3-0016.
Clean piston and replace the spring and
O-ring using Kit # 3-0017.
Check flues for holes or excessive scale.
Remove debris. Check bottom of the
heat exchanger for pitting. Replace if the
pitting is in excess of 0.125".
Check for proper flame. Clean debris and
check 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
Vaporizers
Built
To Oct 2002
40C68
40C66
3-0017
3129G
3129-40P
3-0776
41045
920V
3-3540
1501-5015-02
3-0787
3-0782
3-0777
1980-36
3-0631
BA-718 .018
40C39A
40C14
3-0529
40C37
3-4150
3-0016
3-0778
3-0549
Description
Capacity Control Valve
Capacity Control Piston
Capacity Control Kit
Relief Valve
Relief Valve Cap
Regulator Supply Tube
Burner Regulator Kit
Regulator Only
Thermostat
Thermostat Cover
Thermostat Supply Tube
Burner Supply Tube
Pilot Tube
Thermocouple
Pilot Assembly
Pilot Orifice
Burner Manifold
Burner Jet
Flue
Inlet Valve Gasket
Liquid Inlet Valve
Inlet Valve Kit
Loading Tube
Vapor Out Nipple
Key
1
1
1
2
2
3
4
4
5
5
6
7
8
9
10
10
11
12
13
14
15
15
16
17
Vaporizers
Built
Post Oct 2002
40C68
40C66
3-0017
T3131G
3131-54
3-0776
41045
920V
3-3540
1501-5015-02
3-0787
41022
41024
1980-36
3-0631
BA-718 .018
1502-4006
33581
451-506-01
40C37
3-4150
3-0016
3-0778
3-0549
Repair Parts for Algas 40/40 Vaporizer
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
New Burner Arrangement
Post October 2002
New Burner Regulator Assy
41045 Kit - Upgrades to 920V
regulator with shutoffs, tubing
assemblies and drip leg.
920V - Regulator only.
Old Burner Arrangement
Pre October 2002
R
O
W
A
B
H
E
T
S
R
R
O
W
A
B
H
E
T
S
R
H
G
I
H
H
G
I
H
L
O
W
L
O
W
WARNINGWARNING
READ ALL INSTRUCTIONS
BEFORE LIGHTING
READ ALL INSTRUCTIONS
BEFORE 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
Vaporizers
Built
To Oct 2002
3-0549
40C68
40C66
3-0017
3-0779
41045
920V
3-3540
1501-5015-02
3-0788
3-0782
3-0781
1504-5009
1980-36
80C99
Description
Vapor Out Nipple
Capacity Control Valve
Capacity Control Piston
Capacity Control Kit
Regulator Supply Tube
Burner Regulator Kit
Regulator Only
Thermostat
Thermostat Cover
Thermostat Supply Tube
Burner Supply Tube
Pilot Tube
Right Flue
Thermocouple
Right Burner Manifold
Key
1
2
2
2
3
4
4
5
5
6
7
8
9
10
11
Vaporizers
Built
Post Oct 2002
3-0549
40C68
40C66
3-0017
3-0779
41045
920V
3-3540
1501-5015-02
1504-5005
41019
40404
1504-5009
1980-36
1504-4005
Vaporizers
Built
To Oct 2002
3-0644
BA-718 .023
3-0783
40C39
40C14
452-505-01
40C37
3-4150
3-0016
3-0786
T3131G
3131-54
3-0792
Description
Pilot Assembly
Pilot Orifice
Burner Manifold Tube
Left Burner Manifold
Burner Jet
Left Flue
Inlet Valve Gasket
Liquid Inlet Valve
Inlet Valve Kit
Loading Tube
Relief Valve
Relief Valve Cap
Connector Tube
Key
12
12
13
14
15
16
17
18
18
19
20
20
21
Vaporizers
Built
Post Oct 2002
41021
BA-718 .023
3-0783
1504-4004
33581
452-505-01
40C37
3-4150
3-0016
3-0786
T3131G
3131-54
3-0792
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
5
1
New Burner Arrangement
Post October 2002
Old Burner Arrangement
Pre October 2002
R
O
W
A
B
H
E
T
S
R
R
O
W
A
B
H
E
T
S
R
H
G
H
I
H
G
H
I
L
O
W
L
O
W
WARNINGWARNING
READ ALL INSTRUCTIONS
BEFORE LIGHTING
READ ALL INSTRUCTIONS
BEFORE LIGHTING
New Burner Regulator Assy
41045 Kit - Upgrades to 920V
regulator with shutoffs, tubing
assemblies 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 incorporated
to existing models in the field during maintenance and repair servicing.
The following parts breakdown lists the Pre 2002 and Post 2002 parts
with graphics to depict the differences.
Kits and Service
Liquid Inlet Valve
Remove the plug from the inlet valve and wipe away debris.
Use kit # 3-0016 to replace the valve seat, spring and
O-ring on the plug.
Thermostat Check
At ambient temperatures, rotating the temperature control knob from LOW
through HIGH will energize the main seat of the control producing a loud
audible click.
The burner gas pressure must be at least 9" W.C. when checked at the
pressure tap with the main burner operating. Set the pressure with the
adjusting screw located beneath the cap on the Pilot-On-Off knob.
Using a suitable junction block tester, check the thermocouple millivolt
output. A reading of 13 to 30 millivolts is acceptable. Turn the gas valve
off and observe the millivolt reading at the point when the internal safety
magnet drops out with a click. The millivolt drop out should be appreciably
lower (at least 5 Mv) than the running millivolt reading.
Pilot Flame
The pilot flame should envelope 3/8" to 1/2" of the
thermocouple tip. Clean or replace the pilot if it is too small.
Main Burner
The burner flame should be a non blowing blue flame and
evenly distributed over the burner ring. If uneven, clean
individual burner jets (#66 drill for new style jet. # 64 drill for
old style jet).
Capacity Control Kit
Disassemble and clean the valve assembly inside the body.
Use kit # 3-0017 to replace the spring and O-rings on
the piston and plug. Use powdered graphite as a lubricant
on the piston and use grease on the plug O-ring.
66
WARNING
UNITROL
READ ALL INSTRUCTIONS
BEFORE LIGHTING
ALGAS - SDI
HIGH
LOW
ON
PILOT
10-038
ADAPTER
TO MILLIVOLT
METER
6
INCHES
8
10
12
15
4
2
40/40
Pilot
New Style Jet
Old
Style
Jet
80/40
Pilot
Pressure Adjustment Below
Vaporizer Repair and Maintenance Guide
FLAMMABLE GAS
CAUTION
The vaporizer must be completely blown down before performing service. Be sure
all sources of ignition are extinguished within 25 feet of the work area.
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AlgasSDI Algas 40/40 Repair And Maintenance Manual

Brand
AlgasSDI
Model
Algas 40/40
Type
Repair And Maintenance Manual

AlgasSDI Algas 40/40 is a direct-fired LPG vaporizer that provides long, trouble-free vapor service. Its features include:

  • Vapor bypass regulator that delivers vapor to the system if the vaporizer quits functioning
  • Vaporizer burner supply line that alleviates clogged controls and pilots by pulling cold vapor directly from the storage tank
  • Oil separator that removes oily mist from the vapor stream
  • Supplemental relief valve that protects the downstream system from overpressure conditions
  • Thermostat, thermocouple, liquid inlet valve, capacity control valve, heat exchanger, and main burner for optimal performance and safety
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