Algas SDI Direct Fired F6-ASME 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: 09160185
FILE: MANUAL PN 54000 rev 09-23-2019
...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 160H - 800H
2019.09.2
6
16:24:07
-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,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 2019 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



TableofContents
Options
Auto Re-igniter
Contaminant Separator / Filtaire
Economy Kit
Inlet and Outlet Hand Valves
Pipeaway Adapter
1st Stage Regulator
1. Introduction
Description/Overview 1
Figure 1 – Direct Fired Vaporizer System - Basic Features 1
How the vaporizer works 2
Direct fired vaporizer specifications 3
2. Installation
General 4
Unpacking and Initial Assembly 4
Unpacking 4
Initial Assembly 4
Table 1 – Distance from Vaporizer 4
Figure 2 – Vaporizer Dimensions 5
Figure 3 – Installation – 160H vaporizers 5
Vapor Distribution Line 6
Table 3 – Recommended Vapor Distribution Line Size 6
Liquid Inlet 6
Vapor Bypass Line (Optional) 7
Burner Supply Line (Optional) 7
Liquid Pump (Optional) 7
Economy Installation (Optional) 7
Figure 4 – Economy Option 8
Contaminant Separator – Filtaire (Optional) 8
Figure 5 – Filtaire Operation 9
Leak Test 9
Check Regulator Pressures 10

3. Operation
Direct Fired Vaporizer start up procedure 11
Figure 6– Temperature control dial in “RUN” position 11
Figure 7 – Pilot button pressed down and ignitor switch on 12
Direct Fired Vaporizer setpoint adjustment 12
Figure 8 – Rotating temperature control dial counter-clockwise to desired setpoint 12
Direct Fired Vaporizer shutdown procedure 13
Figure 9 – Vaporizer shut down procedure 13
Direct fired vaporizer purge procedure 14
Automatic Re-Ignition Operation 14
Economy Operation 14
4. Maintenance
Service and Maintenance 15
Table 3 – Initial Installation & Operation InspectionsError! Reference source not found.15
Table 4 – Annual Maintenance RequirementsError! Reference source not found. 16
Direct fired vaporizer maintenance checklist 18
Replacing Reignitor Battery 19
Figure 10 – Opening the battery access door 19
Figure 11 – Replacing the battery 20
Adjusting the Regulator 21
Figure 12 – Regulator adjustment 21
Liquid inlet valve maintenance 22
Capacity control valve maintenance 23
5. Troubleshooting
Pilot 25
Main Burner Will Not Ignite 25
If Vapor Pressure Drops 25
Troubleshooting Tree #1: Pilot Will Not Light 26
Troubleshooting Tree #2: Pilot Lights But Will Not Hold 27
Troubleshooting Tree #3: Main Burner Will Not Light 28
Troubleshooting Tree #4: Vapor Service Pressure Drops 29
AppendixA:TechnicalInformation
Table 6 – Repair Kits and Other Available Replacement Parts 160H
Liquid inlet valve pin gasket installation procedure
Thermowell leak test procedure

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Options
AutoRe‐igniter
160H, Auto Re-igniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit
See Page 14 for Details

ContaminantSeparator/Filtaire
160H, Filtaire Model F6 - ASME, Use P/N: 20540 or 20540-ASME, Quantity 1 per unit
See Page 9 for Details

EconomyKit
160H, Economy Option Kit P/N: 80793, Quantity 1 per unit,
See Page 8 and 14 for Details

InletandOutletHandValves
160H Inlet, 3/4" Gas Cock, Use P/N: 33803, Quantity 1 per unit
160H Outlet, 1" Gas Cock, Use P/N: 33804, Quantity 1 per unit

PipeawayAdapter
160H, Pipeaway Adapter 3/4", Use P/N: 1501-5016, Quantity 1 per unit

1stStageRegulator
160H, 1” 5-20 PSIG, Use P/N 33725, Quantity 1 per unit
For 320, 480H, 640H and 800H 1st stage regulators please consult factory


Algas-SDI Operation and Maintenance Manual – P/N – 54000 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, UL and PED 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
Algas-SDI Operation and Maintenance Manual – P/N – 54000 2
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 – 54000 3
DirectFiredVaporizerspecifications:
BURNER INPUT: 160H 176,900 BTU’s/Hr (51.8 kW) per
burner
GAS CONSUMPTION: 1,000 BTU’s per gallon of propane
vaporized
THERMOSTAT SUPPLY REGULATOR PRESSURE (BURNER ON)*: 15-18” w.c. (37.3 – 44.8 mbar)
BURNER PRESSURE**: 9” w.c. (22.4 mbar)
PILOT BURNER: 2,200 BTU’s/hr (644 W)
NOMINAL OPERATING TEMPERATURE***: 140 to 160 F (60 to 71ºC)
* Regulator Gas Pressure measured between burner regulator and thermostat at the drip leg.
Regulator supply pressure may vary in order to obtain 9” w.c. at the burner. See “Adjusting the
regulator” on page 21.
** Burner pressure measured at the burner pressure test port. See “Adjusting the regulator” on
page 21.
*** Operating Temperature depends on ambient temperature, thermostat settings, and operating
pressures.


Algas-SDI Operation and Maintenance Manual – P/N – 54000 4
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 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
pipeaway and a regulator relief pipeaway 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

Operation
Algas-SDI Operation and Maintenance Manual – P/N – 54000 5
Figure 2 – Vaporizer Dimensions
Figure 3 – Installation – 160H vaporizers
1” VAPOR OUTLET
3/4 “FNPT LIQUD
INLET CONNECTION
HEAVY ENDS DRAIN

Operation
Algas-SDI Operation and Maintenance Manual – P/N – 54000 6
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 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. Ahead of the vaporizer inlet, install a 60-mesh strainer of equivalent size to
that of the vaporizer inlet connection.
2. Install a UL listed shut-off valve with a Minimum 250psi gas pressure rating
3. 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).
4. Connect the vaporizer to the storage tank.
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)
160H Vaporizers 1” (DN25) 1-1/4” (DN 32) 1-1/2” (DN40)
320H Vaporizers 1-1/4” (DN 32) 1-1/2” (DN40) 2” (DN50)
480H Vaporizers 1-1/4” (DN 32) 1-1/2” (DN40) 2” (DN50)
640H Vaporizers 2” (DN50) 2” (DN50) 2” (DN50)
800H Vaporizers 2” (DN50) 2” (DN50) 2” (DN50)

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)
160H Vaporizers 1-1/4” (DN 32) 1-1/2” (DN40) 2” (DN50)
320H Vaporizers 1-1/4” (DN 32) 1-1/2” (DN40) 2” (DN50)
480H Vaporizers 1-1/4” (DN 32) 1-1/2” (DN40) 2” (DN50)
640H Vaporizers 1-1/2” (DN40) 2” (DN50) 3” (DN80)
800H Vaporizers 1-1/2” (DN40) 2” (DN50) 3” (DN80)

Operation
Algas-SDI Operation and Maintenance Manual – P/N – 54000 7
1. Install a UL listed shut-off valve with a Minimum 250 psig gas pressure
rating.
2. Install a thermometer after the vaporizer shut-off valve.
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 psig 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 psig above the first stage regulator delivery pressure.
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 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.
3. Although vapor bypass line is not required for proper operation, it is
recommended for all installations.
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.
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 vaporizer Thermostat Supply Regulator pressure adjustments please
refer to page 3.
LIQUID PUMP (OPTIONAL)

Operation
Algas-SDI Operation and Maintenance Manual – P/N – 54000 8
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 160H through 800H 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.
CONTAMINANT SEPARATOR – FILTAIRE (OPTIONAL)
The 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.
HEAVY ENDS DRAIN

Operation
Algas-SDI Operation and Maintenance Manual – P/N – 54000 9
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 5).
At 20 psig recommend using Algas-SDI FILTAIRE Model F6 ASDI PN: 20540 or
20540-ASME for Direct Fired Model 160H.
Note: Items 4, 5 and 6 are included with FILTAIRE assemblies.
Figure 5 –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
V
APOR
T
O LOAD
LEAK TEST
CAUTION 
The entire installation must be leak tested prior to operating the
system.

1. Close outlet valve.
2. Slowly open inlet valve and allow pressure to equalize in the vaporizer.
3. Apply a liberal amount of soap/water solution to ALL internal and external
flanged, threaded and tubing connections. For proper leak test procedure
around the thermowell please see Appendix A.
4. Check for any leaks by observing new bubble formation in the soap/water
solution.
5. Repair any leaks before continuing. Leak test until system has no leak
present.