Algas SDI Direct Fired 40/40H Manual

Operations & Maintenance
Manual
151 South Michigan Street, Seattle, Washington, USA 98108
Tel: [phone] Fax: [phone] Web: www.algas-sdi.com
FILE: MANUAL PN 52642 DIRECT FIRED 5-10-21
...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H
Samuel Oyen
2021.05.07 17:33:46 -07'00'

WARNING
Read the OPERATION MANUAL before operating this equipment.
■ NOTE: Algas-SDI reserves the right to use alternate manufacturers’
components as vendor delivery applicability dictates. Literature
contained in the Operation Manual has been supplied by
vendors. Please check to be sure supplied data matches your
configuration. Contact Algas-SDI if any questions exist.
■ 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 TRAINED and FULLY QUALIFIED PERSON to service this
equipment.
■ Any time a component must be replaced, use the same type, model,
etc. DO NOT SUBSTITUTE! The consequence from such actions are
unpredictable and may lead to dire consequences. When components
are replaced with components not approved for use in our UL listed
equipment, the UL listing becomes void for that unit.

Warranty Registration
A Warranty Registration Card is located on the last page of this manual. Fill it
out and send a copy either by mail to the address shown at the bottom of the
form or submit via email to s[email protected].
Warranty, Copyrights and Approvals
WARRANTY
Algas-SDI International, LLC (ASDI) warrants that the equipment is free of
defects in materials and workmanship under normal use and service. ASDI
agrees to repair or replace, at our option, without charge f.o.b. factory, any part
which has proven defective to the satisfaction of Algas-SDI International, LLC
within one (1) year from the date of the original installation or within 18 months
from the date of shipment, whichever is earlier. Equipment, which in the opinion
of ASDI, has been damaged by improper installation or operation, or has been
abused or tampered with in any way, will not be accepted for return under
warranty.
Algas-SDI International, LLC will not accept back 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
International, LLC will not be liable by reason of shutdown, non-operation or
increased expense of operation of other equipment, or any other loss or damage
of any nature, whether direct or consequential, arising from any cause
whatsoever.
Algas-SDI International, LLC makes NO other warranty of any kind, whatsoever
expressed or implied; and all warranties of merchantability and fitness for a
particular purpose are hereby disclaimed by Algas-SDI International, LLC and
excluded from these terms of sale. No person has any authority to bind Algas-
SDI International, LLC to any representation or warranty other than this warranty.
COPYRIGHT
Copyright 2021 by Algas-SDI International, LLC, Seattle, Washington 98108. All
rights reserved. No part of this manual may be reproduced or copied in any form
or by any means, photographic, electronic, or mechanical, without the prior
express written consent from Algas-SDI International, LLC, Seattle, Washington,
USA.
APPROVALS

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Symbols and Conventions
Special symbols are used to denote hazardous or important information. You
should familiarize yourself with their meaning and take special notice of the
indicated information.
Please read the following explanations thoroughly.
GENERAL WARNING OR CAUTION
Indicates hazards or unsafe practices which can result in damage to
the equipment or cause personal injury. Use care and follow the
instructions given.
FLAMMABLE GAS HAZARD
Indicates a potential 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 result in
severe personal injury or death or damage to equipment. Use great
care and follow the instruction given.
PARTS AND PRICES
For parts and prices contact your Algas-SDI distributor.
ASDI CONTACT NUMBERS
If you have questions, need help with your equipment, or want
information on other products, contact your distributor or
Algas-SDI Global Support Center at:
Telephone: [phone]
Facsimile: [phone]
Email: [e-mail]
Internet: http://www.algas-sdi.com

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Table of Contents
Direct Fired Vaporizer Options
Auto Reigniter
Contaminant Separator / Filtaire
Economy Valve Kit
Inlet and Outlet Hand Valves
Pipe away Adapter
1st Stage Regulator
1. Introduction
Description/Overview 1-1
Figure 1 –Direct Fired Vaporizer System - Basic Features 1-1
How the vaporizer works 1-2
Direct Fired vaporizer specifications 1-3
2. Installation
General 2-4
Unpacking and Initial Assembly 2-4
Unpacking 2-4
Initial Assembly 2-4
Table 1 –Distance from Vaporizer 2-4
Figure 2 –Vaporizer Dimensions 2-5
Figure 3 –Installation –40/40H, 80/40H, and 120/60H vaporizers 2-6
Liquid Supply Line 2-6
Table 2 –Recommended 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
Liquid Pump (Optional) 2-8
Economy Installation (Optional) 2-8
Contaminant Separator –Filtaire (Optional) 2-8
Figure 4 –Filtaire Operation 2-9
Installing Multiple Units in Parallel 2-9
Figure 5 –Installing Multiple Units in Parallel 2-9
Figure 6a –Installing Multiple Units in Parallel, Oversized Manifold, side inlet/outlet 2-10
Figure 6b –Installing Multiple Units in Parallel, Oversized Manifolds, center inlet/outlet 2-11
Air Requirements for Installation in an Enclosure 2-11
Table 4 –Cross-Sectional Inlet/Outlet Air Requirements 2-11
Leak Test 2-11
Check Burner Input Pressure 2-11
Installation Safety Requirements 2-12

3. Operation
Direct Fired Vaporizer start up procedure 3-13
Figure 7 –Temperature control dial in “RUN” position 3-13
Figure 8 –Pilot button pressed down and igniter switch on 3-14
Direct Fired Vaporizer setpoint adjustment 3-14
Direct Fired Vaporizer shutdown procedure 3-15
Figure 9 –Vaporizer shut down procedure 3-15
Direct fired vaporizer purge procedure 3-15
Automatic Re-Ignition Operation 3-16
4. Maintenance
Service and Maintenance 4-17
Table 5 –Initial Installation and Operation inspections 4-17
Table 6 –Recommended annual maintenance and inspections 4-18
Direct Fired vaporizer inspection checklist 4-20
Replacing reigniter battery 4-21
Figure 10 –Opening the battery access door 4-21
Figure 11 –Replacing the battery 4-21
Adjusting 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
Igniter Will Not Spark 5-26
Main Burner Will Not Ignite 5-26
If Vapor Pressure Drops 5-26
Troubleshooting Tree #1: Pilot Will Not Light 5-27
Troubleshooting Tree #2: Pilot Lights But Will Not Hold 5-28
Troubleshooting Tree #3: Igniter Will Not Spark 5-29
Troubleshooting Tree #4: Main Burner Will Not Light 5-30
Troubleshooting Tree #5: Vapor Service Pressure Drops 5-31
Appendix A: Technical Information
Figure 13 –40/40H Vaporizer Replacement Parts
Figure 14 –80/40H and 120/60H Vaporizer Replacement Parts
Figure 15 –Inlet Valve and Capacity Control Valve
Table 7 –Repair kits and other available replacement parts
Liquid Inlet valve pin gasket installation procedure
40/40H Equipment drawing
80/40H Equipment drawing
120/60H Equipment drawing

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Direct Fired Vaporizer Options
Electronic Auto Reigniter
Auto Reigniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit
FILTAIRETM Contaminant Separator
A contaminant separator is recommended for all Direct Fired Vaporizer installations. To properly
size the FILTAIRETM contact 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 Details
Inlet and Outlet Isolation Valves
3/4" inlet valve use P/N 33803, Quantity 1 per unit
1" outlet valve use P/N 33814, Quantity 1 per unit
Pipeaway Adapter
Pipeaway Adapter 3/4", P/N: 34877, Quantity 1 per unit
1st Stage Regulator
1" 5-20 PSIG (0.35-1.4 bar), Use P/N: 33725, Quantity 1 per unit

Algas-SDI Operation and Maintenance Manual –P/N –52642 1-1
Introduction 1
Description/Overview
Algas-SDI is an ISO 9001 registered company. Direct Fired Vaporizers are
manufactured under strict accordance with ASME, UL and PED requirements
and carry the associated marks and the ASME "U" stamp.
A Direct Fired vaporizer, as the name implies, is one in which heat is furnished
by an open flame 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 valve and float assembly
◼Liquid reservoir or heat exchanger
◼Burner supply regulator
◼Thermostat
◼Burners
◼Capacity control valve
◼Relief valve
Figure 1 –Direct Fired Vaporizer System - Basic Features
Vapor
Liquid
Liquid
Inlet
Valve
Vessel
Pressure
Liquid
Burner Pilot Assembly
Float Ball
Burner
Regulator
Excess Flow
Valve
Relief Valve
Vapor Distribution
Line
Regulator
Heat Load
Thermostat

Introduction
1-2 Algas-SDI Operation and Maintenance Manual –P/N - 52642
HOW THE VAPORIZER WORKS
When the shut-off valve in the liquid supply line is opened, liquid is forced into the
heat exchanger by the pressure in the storage tank. As the liquid level rises,
some of the liquid boils off until it matches the pressure coming from the tank.
The flow of liquid into the heat exchanger will stop when the rising liquid forces
the float ball upward, closing the liquid inlet valve, or when the pressure in the
heat exchanger is the same as the pressure coming from the storage tank.
When the burner(s) is lit, the heat will boil off the liquid in the heat exchanger.
During periods of low or no demand, the pressure will build up to the storage tank
pressure. Whenever pressure in the heat exchanger starts to increase above the
tank pressure, the pressure differential will cause the LP gas to flow back through
the inlet valve to the tank.
Due to the boiling action and the flow back to the tank, the liquid level in the heat
exchanger will drop. When the liquid level drops, the temperature sensor
(thermostat) will sense the warmer vapor and cycle off the main burner(s).
As the demand increases, the pressure in the heat exchanger will drop. As a
result, liquid will 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 supply of vapor. As long as the rate of vaporization exceeds the
demand, the heat exchanger will contain a very small amount of liquid. The only
time the heat exchanger will contain a large amount of liquid is when the demand
is equal to or above the capacity of the vaporizer.
Whenever the demand exceeds the capacity of the vaporizer, the capacity
control valve is engaged, which limits the withdrawal rate from the exchanger to
the maximum capacity of the vaporizer.
The capacity control valve is a spring-loaded valve mounted on the outlet of the
exchanger. Liquid LP gas is supplied to the top of the valve and vapor from the
exchanger to the bottom of the valve. During normal operation, the valve is held
open by the force of the spring.
When the liquid/vapor pressure differential exceeds the spring force, the liquid
pressure will begin to close the valve. This restricts the flow out of the vaporizer.
Any increase in demand will create greater pressure drop. In turn, the valve will
further restrict the flow of vapor from the unit. This throttling action will cause the
gas outlet pressure to drop, allowing the pressure in the heat exchanger to build
back up and maintain proper gas supply to the vaporizer’s burner(s) and keep
the vaporizer in operation.

Introduction
Algas-SDI Operation and Maintenance Manual –P/N –52642 1-3
DIRECT FIRED VAPORIZER SPECIFICATIONS:
BURNER INPUT
40/40H 51,360 BTU/hr (15 kW) per burner
80/40H 51,360 BTU/hr (15 kW) per burner
120/60H 77,040 BTU/hr (22.5 kW) per burner
GAS CONSUMPTION: Approximately 1,000 BTU/hr (0.3 kW) per gallon (3.79 liters) of propane vaporized
TOTAL BURNER INPUT
40/40H: 51,360 BTU/hr (15 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 (45 kW) THERMOSTAT PORT PRESSURE*: 14” W.C. (34.9 mbar)
BURNER PRESSURE: 12” W.C. (29.9 mbar)
PILOT BURNER: 2,200 BTU/hr (0.64 kW)
NOMINAL OPERATING TEMPERATURE**: 140 to 160 F (60 to 71ºC)
* Thermostat Port Pressure measured at the pressure port at the outlet of the thermostat on the main burner
line.
** Operating Temperature depends on ambient temperature, thermostat setting, and operating pressure.

2-4 Algas-SDI Operation and Maintenance Manual –P/N –52642
Installation 2
GENERAL
•Install the system so it complies with all governing codes and regulations.
•Make up all threaded pipe connections with a sealing compound that is
approved and listed for LP gas service.
•All above ground lines should be adequately supported.
•Any underground piping should be properly protected against corrosion.
•Vapor outlet piping should be installed such that the first stage regulator is
placed higher than the vaporizer outlet. This allows condensation in the
vapor line to flow back to the vaporizer.
•Clean all foreign material from all pipes prior to making final connections.
•Test all joints as specified in the applicable codes for leaks before placing the
piping system in service.
Unpacking and Initial Assembly
UNPACKING Upon receiving the vaporizer inspect package for any damage that may have
occurred during shipping. Carefully 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 supplied hardware.
Install the vaporizer a minimum of 15 feet (4.6 m) from the storage tank valves
(see Table 1 below).
Secure vaporizer through the four (4) ½ inch holes (see Figure 2) on above
ground level, solid, non-combustible base,
The vaporizer should be adequately protected against damage by moving
vehicles.
If the vaporizer is to be installed in any building or enclosure, a relief valve pipe
away and regulator relief pipe away must be installed. The relief valve and
regulator relief must be able to relieve outside of any enclosure or building.
Table 1 –Distance from Vaporizer
Exposure
Minimum Distance From
Vaporizer Required
Storage Tank
10 feet (3 m)
Storage tank shutoff valves
15 feet (4.6 m)
Point of transfer
15 feet (4.6 m)
Nearest important building or group of buildings or
line of adjoining property which may be built upon
(except buildings in which vaporizer is installed).
25 feet (7.6 m)
Reference NFPA58

Installation
Algas-SDI Operation and Maintenance 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 ¼” (1.12 m)
37 ¾” (0.96 m)
28 ¾” (0.75 m)
40/40H Vaporizer
80/40H and 120/60H Vaporizers

Installation
2-6 Algas-SDI Operation and Maintenance Manual –P/N - 52642
Figure 3 –Installation –40/40H, 80/40H, and 120/60H vaporizers
CAUTION
The entire installation must be leak tested prior to operating the
system.
NOTE
Do not connect this vaporizer to a storage tank that has been used
in vapor withdrawal service until the tank has been emptied and all
sediment and heavy ends have been cleaned from it.
LIQUID SUPPLY LINE (see Figure 3)
The liquid supply line should be 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)
80/40H Vaporizers
3/4”(DN20)
1” (DN25)
1-1/4” (DN32)
120/60H Vaporizers
1” (DN25)
1-1/4”(DN32)
1-1/2” (DN40)
VAPOR DISTRIBUTION LINE (see Figure 3)
The vapor distribution line should be adequately sized for the service.
Table 3 –Recommended Vapor Distribution Line Size (Nominal Pipe Size)
Gas Line Length Ft. (m)
Up to 50 (15)
50-150 (15-36)
150-250 (36-76)
40/40H Vaporizers
1” (DN25)
1-1/2” (DN40)
2” (DN50)
80/40H Vaporizers
1-1/4” (DN32)
1-1/2” (DN40)
2” (DN50)
120/60H Vaporizers
1-1/2” (DN40)
2” (DN50)
2-1/2” (DN80)

Installation
Algas-SDI Operation and Maintenance Manual –P/N –52642 2-7
1. Install a UL listed shut-off valve with a minimum 250 psig (17.24 bar) gas
pressure rating.
2. Install a 0-300 psig (0-20.7 bar) pressure gauge (or provisions for one) ahead
of the 1st stage regulator.
3. Install the first stage regulator as close to the vaporizer as possible, but not
further than 24” (0.6 m) from the outlet of the vaporizer. The outlet pressure
of the regulator should be set at 4 to 6 psig (0.3 to 0.4 bar) lower than tank
saturated vapor pressure at lowest expected temperature; this may require
periodic adjustment.
4. The second stage (or low pressure) regulator should be installed as close to
the consuming equipment as practical.
5. A line relief valve may be installed (optional) to protect the regulators from
excessively high pressure. If a line relief valve is used, set the blow pressure
at approximately 10 PSI (0.7 bar) above the first stage regulator delivery
pressure.
LIQUID INLET NOTE
Do not install a check valve in the supply line between the tank and
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-off valve with a minimum 250 psig (17.24 bar) gas
pressure rating.
3. Install a 0-300 psig (0-20.7 bar) pressure gauge (or provisions for one) ahead
of the liquid inlet valve.
4. The liquid line from the storage tank to the vaporizer should be of sufficient
size to supply the vaporizer at full capacity with a maximum pressure drop of
less than the hydrostatic head pressure (see NFPA 54).
5. Connect the vaporizer to the storage tank.
VAPOR BYPASS LINE - see Figure 3
1. Install a primary (first stage) regulator at the vapor outlet on top of the
storage tank. Set this regulator to deliver gas at a pressure of 2 to 4 psig
(0.14 to 0.3 bar) below the setting of the vaporizer regulator. Then, if the
vaporizer is overloaded or its output pressure drops off, the regulator on top
of the storage tank will automatically take over.
2. Run a line from the regulator and tie it into the vapor service line downstream
of the vaporizer first stage regulator.
3. Although vapor bypass line is not required for proper operation, it is
recommended for all installations.

Installation
2-8 Algas-SDI Operation and Maintenance Manual –P/N - 52642
BURNER REGULATOR SUPPLY LINE (OPTIONAL)
Vaporizer burners are supplied with vapor from the outlet of the vaporizer where
the least possibility of condensation will take place. In regions where there is a
problem with a high content of heavy ends in the LP gas, a separate vapor
supply line to the burner regulator on the vaporizer may be installed. If a
separate burner supply line is used, the following is recommended:
1. Disconnect the ¼” line at the burner regulator inlet.
2. Disconnect the ¼” line at the tee on top of the heat exchanger and plug it
with ¼ NPT plug.
3. Install a first stage regulator as close to the tank vapor outlet as possible. A
manual shut-off valve should be installed ahead of the regulator.
4. Connect the supply line from the first stage regulator to the burner regulator
at the vaporizer. Make sure that the supply is sized properly to handle
maximum input rating of the vaporizer burner(s).
LIQUID PUMP (OPTIONAL)
The liquid pressure to the inlet of the vaporizer must be a minimum of 6 psig (0.4
bar) higher than desired discharge pressure. If tank pressure cannot meet this
requirement, install a pump in the liquid line under the storage tank to maintain
the minimum pressure.
ECONOMY 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 operation and eliminate energy waste. For the Economy Valve
field installation kit, use P/N 41051. The valve modulates open and closed as the
tank pressure rises and falls. The Economy Valve is a mechanical device and
requires no electricity to operate. Make sure the Economy Valve is correctly
installed. Verify the flow direction on the rating plate during installation. Contact
Algas-SDI for set-point information.
CONTAMINANT SEPARATOR –FILTAIRE (OPTIONAL)
FILTAIRE is a filtering device designed to trap heavy hydrocarbons commonly
present in LPG gas vapor. It also traps other materials, which may be in the gas
due to storage conditions and internal condition of the equipment.
Impurities are collected in the system and periodically removed through the
system blow down drain. Residual heavy end hydrocarbons with boiling points
higher than pure LPG are trapped by the filter and fall to the bottom for removal.
A complete FILTAIRE system consists of inlet and outlet connections, 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 FILTAIRE is removed for cleaning (see
Figure 4).
Note: Items 4, 5 and 6 are included with FILTAIRE assemblies.

Installation
Algas-SDI Operation and Maintenance Manual –P/N –52642 2-9
Figure 4 –Filtaire Operation
1ST STAGE
REGULATOR
VAPOR FROM
VAPORIZER
INLET VALVE
2
VAPOR LINE
“FILTAIRE”OIL DEMISTER
OUTLET VALVE
BYPASS VALVE
(NORMALLY CLOSED)
3
1
5 DRAIN
VALVE
PIPE
STAND
64
VAPOR
TO LOAD
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, piping should have equal
distance from the main liquid line to each vaporizer inlet and from the
outlet of each vaporizer to the main vapor distribution line. Only same
model vaporizers shall be manifolded and installed together.
Figure 5 –Installing Multiple Units in Parallel

Installation
2-10 Algas-SDI Operation and Maintenance Manual –P/N - 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 Multiple Units in Parallel, Oversized Manifolds with center inlet/outlet