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
This manual covers units built after August 2009 After S/N: 40/40H – A13J20003627
80/40H – A13J40007352
120/60H – A13J60002719
FILE: MANUAL PN 52642 DIRECT FIRED 11_12_13.DOC
...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Va
p
orizer: 40/40H, 80/40H & 120/60H
2013.11.1
2 09:47:39
-08'00'

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, 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 2013 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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IMPORTANT WARRANTY NOTICE:
The Algas-SDI warranty period for equipment is 18 months after
shipment from our facility or 12 months after installation. See our
warranty statement at the beginning of this manual for the complete
text. A warranty registration card has been provided with this manual
so that you may register the date of installation for warranty purposes.
If you do not return the warranty registration card, the warranty term will
be 12 months after the equipment has been shipped to you, the end
user. If you do not install it immediately, your warranty may expire
earlier than necessary. The warranty registration also gives us
information to contact you if we need to send you important information
about the equipment later on.
Please register your equipment.

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 at:
Telephone:[phone]
Facsimile: 206.789.5414
Email: [email protected]
Internet: http://www.algas-sdi.com

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Table of Contents
Options
Auto Re-igniter
Contaminant Separator / Filtaire
Economy 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
Vapor Distribution Line 2-6
Table 2 – Recommended Vapor Distribution Line Size 2-6
Liquid Inlet 2-7
Vapor Bypass Line (Optional) 2-7
Burner Supply Line (Optional) 2-7
Liquid Pump (Optional) 2-8
Economy Installation (Optional) 2-8
Figure 4 – Economy Option 2-8
Contaminant Separator – Filtaire (Optional) 2-9
Figure 5 – Filtaire Operation 2-9
Installing Multiple Units in Parallel 2-10
Figure 6 – Installing Multiple Units in Parallel 2-10
Figure 7 – Installing Multiple Units in Parallel, Oversized Manifolds 2-10
Leak Test 2-11
Check Burner Input Pressure 2-11

3. Operation
Direct Fired Vaporizer start up procedure 3-13
Figure 8 – Temperature control dial in “RUN” position 3-13
Figure 9 – Pilot button pressed down and ignitor switch on 3-14
Direct Fired Vaporizer setpoint adjustment 3-14
Figure 10 – Rotating temperature control dial counter-clockwise to desired setpoint 3-14
Direct Fired Vaporizer shutdown procedure 3-15
Figure 11 – Vaporizer shut down procedure 3-15
Direct fired vaporizer purge procedure 3-16
Automatic Re-Ignition Operation 3-16
Economy Operation 3-16
4. Maintenance
Service and Maintenance 4-18
Table 3 – commended periodic maintenance and inspections 4-18
Table 4 – Recommended annual maintenance and inspections 4-19
Direct Fired vaporizer inspection checklist 4-21
Replacing reignitor battery 4-22
Figure 12 – Opening the battery access door 4-22
Figure 13 – Replacing the battery 4-22
Adjusting burner input pressure 4-23
Error! Reference source not found. 4-23
Liquid inlet valve maintenance procedure 4-24
Capacity control valve maintenance procedure 4-26
5. Troubleshooting
Pilot 5-28
Main Burner Will Not Ignite 5-28
If Vapor Pressure Drops 5-28
Troubleshooting Tree #1: Pilot Will Not Light 5-29
Troubleshooting Tree #2: Pilot Lights But Will Not Hold 5-30
Troubleshooting Tree #3: Main Burner Will Not Light 5-31
Troubleshooting Tree #4: Vapor Service Pressure Drops 5-32
Appendix A: Technical Information
Figure 14 – 40/40H Vaporizer Replacement Parts A-36
Figure 15 – 80/40H and 120/60H Vaporizer Replacement Parts A-37
Figure 16 – Inlet Valve and Capacity Control Valve A-38
Table 5 – Repair kits and other available replacement parts A-40
Liquid Inlet valve pin gasket installation procedure A-43

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Options
Auto Re-igniter
40/40H, 80/40H & 120/60H, Auto Re-igniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683,
Quantity 1 per unit
See Page 3-16 for Details
Contaminant Separator / Filtaire
40/40H, 80/40H, Filtaire Model F4, Use P/N: 20536 or 20536-ASME, Quantity 1 per unit
120/60H, Filtaire Model F6, Use P/N: 20540 or 20540-ASME, Quantity 1 per unit
See Page 2-9 for Details
Economy Kit
40/40H, 80/40H & 120/60H, Economy Option Kit P/N: 80793, Quantity 1 per unit,
See Page 2-8 and 3-16 for Details
Inlet and Outlet Isolation Valves
40/40H, 80/40H & 120/60H, 3/4" inlet valve use P/N 33803, Quantity 1 per unit
40/40H, 80/40H & 120/60H, 1" outlet valve use P/N 33814, Quantity 1 per unit
Pipeaway Adapter
40/40H, 80/40H & 120/60H, Pipeaway Adapter 3/4", Quantity 1 per unit
Use P/N 1501-5016 for Cavagna/Omeca relief valve
Use P/N 34877 for REGO relief valve
1st Stage Regulator
40/40H, 80/40H & 120/60H, 1" 5-20 PSIG, Use P/N: 33725, Quantity 1 per unit

Algas-SDI Operation and Maintenance Manual – P/N – 52642 1-1
Introduction 1
Description/Overview
Congratulations on your purchase of an Algas-SDI Direct Fired vaporizer. Algas-
SDI is an ISO 9001 registered company and your new vaporizer was
manufactured under strict accordance with ASME and UL requirements and
carries 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. The Algas-SDI Direct Fired
vaporizers consist of seven (7) main components:
Liquid inlet valve & float assembly
Liquid reservoir or heat exchanger
Thermostat 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 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
exchanger will drop. When the liquid level drops, the temperature sensor 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 exchanger, and the temperature sensor 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 exchanger will contain a very small amount of liquid. The only time
the 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 withdraw 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 53,792 BTU/hr per burner
80/40H 47,440 BTU/hr per burner
120/60H 61,854 BTU/hr per burner
GAS CONSUMPTION: 1000 BTU’s per gallon of propane vaporized
TOTAL BURNER INPUT
40/40H: 53,792 BTU/hr REGULATOR GAS PRESSURE*: 11” W.C.
THERMOSTAT PORT PRESSURE**:10” W.C.
BURNER PRESSURE: 9” W.C.
80/40H: 94,880 BTU/hr REGULATOR GAS PRESSURE*: 10” W.C.
THERMOSTAT PORT PRESSURE**: 9” W.C.
BURNER PRESSURE: 7” W.C.
120/60H: 123,708 BTU/hr REGULATOR GAS PRESSURE*: 18” W.C.
THERMOSTAT PORT PRESSURE**: 14” W.C.
BURNER PRESSURE: 12” W.C.
PILOT BURNER: 2200 BTU’s/hr
NOMINAL OPERATING TEMPERATURE***: 140 to 160 F
* Regulator Gas Pressure measured between burner regulator and thermostat at the drip leg.
** Thermostat Port Pressure measured at the pressure port at the outlet of the thermostat.
*** 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 lines up to the first stage regulator should be sloped toward the
vaporizer to allow 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 your new vaporizer inspect package for any damage that may
have occurred during shipping. Then carefully open package and inspect unit for
damage. Remove all plastic shipping material 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 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 a 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
Storage tank shutoff valves 15 feet
Point of transfer 15 feet
Nearest important building or group of buildings or
line of adjoining property which maybe built upon
(except buildings in which vaporizer is installed). 25 feet
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” 29” 20”
80/40H 35” 29” 20”
120/60H 44 ¼” 37 ¾” 28 ¾”
40/40H Va
p
orize
r
80/40H and 120/60H Va
p
orizers

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.
VAPOR DISTRIBUTION LINE (see Figure 3)
The vapor distribution line should be adequately sized for the service.
Table 2 – Recommended Vapor Distribution Line Size
Gas Line Length Ft. Up to 50 50-150 150-250
40/40H Vaporizers 1” 1-1/2” 2”
80/40H Vaporizers 1-1/4” 1-1/2” 2”
120/60H Vaporizers 1-1/2” 2” 2-1/2”
* Nominal Pipe Size
1. Install a UL listed shut-off valve with a Minimum 250psi gas pressure rating
2. Install a 0-300 psig 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” from the outlet of the vaporizer. The outlet pressure of the
regulator should be set at 4 to 6 PSI lower than tank saturated vapor

Installation
Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-7
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 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 250psig gas pressure rating
3. Install a 0-300 psig 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 (OPTIONAL) - 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 psi
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
from the vaporizer first stage regulator.
BURNER SUPPLY LINE (OPTIONAL)
The 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 control 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.

Installation
2-8 Algas-SDI Operation and Maintenance Manual – P/N - 52642
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). See Figure 1.
5. For the 40/40H, 80/40H and 120/60H Thermostat Supply Regulator pressure
adjustments please refer to page 1-3.
LIQUID PUMP (OPTIONAL)
The liquid pressure to the inlet of the vaporizer must be a minimum of 6PSI
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 tank as primary source
and utilizes the vaporizer only when needed. The intent is to allow the most
economical operation and eliminate energy waste. To accomplish this, install an
Algas-SDI 40/40H, 80/40H, or 120/60H vaporizer, operating on demand,
combined with a primary vapor bypass. To do this you will need an economy kit
that consists of several valves and regulators.
Figure 4 – Economy Option
After installing the vaporizer, install and set the regulators from the economy kit as follows:
1. Install the (1) Primary Vapor Regulator in the vapor line at the tank and set at 10 psig. The
regulator must be installed so that any gas condensing between the regulator and the tank
can run back into the tank.
2. Install the (3) Vaporizer Regulator at the outlet of the vaporizer and set at 13 psig or
approximately 3 psig higher than the (1) Primary Vapor Regulator.
3. Between the (3) Vaporizer Regulator and the vaporizer outlet install the (2) Economy
Regulator in reverse direction such that the outlet side of the regulator faces the vaporizer.
This regulator should be set at 30 psig or just high enough to allow enough pressure in the
tank to supply the full flow through the (3) Vaporizer Regulator when needed.