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.