Vaporizer Repair

and Maintenance Guide

Algas SDI 881 HERSEY STREET

DIRECT FIRED ST. PAUL, MN 55114
LPG Vaporizers PHONE (651) 646-1177
FAX (651) 646-1676
 Installation Example

Vaporizer Installation Best Practices

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.

Vapor Bypass
Regulator

Supplemental
Relief Valve
Storage
Tank
600 WOG

Burner Supply 600 WOG

Line Vapor
To Load
600 WOG
Oil
Separator
First Stage
Regulator
Liquid

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 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.

The vaporizer burner supply line is optional but Distances from vaporizer
highly recommended. Pulling cold vapor directly from
the storage tank greatly alleviates clogged controls, Storage tank 10 feet
pilots etc. in the vaporizer from oily heavy ends. Storage shutoffs 15 feet
Point of transfer 15 feet
Buildings 25 feet

Vaporizer Repair and Maintenance Guide

 Maintenance Schedule

Vaporizers and ancillary equipment should be serviced ONLY by trained

and fully qualified personnel. This equipment operates with LP gas which
FLAMMABLE GAS
is flammable and under pressure. Inherent hazards exist and a thorough
understanding of the equipment is required for safe maintenance.

Monthly Check List

Items to Service Monthly Service to Perform

Strainer Remove screen and clean.

Pilot Burner Assembly Inspect pilot for proper flame.

Main Burner Assembly Inspect for proper flame.

Check for signs of corrosion and replace

Relief Valves any missing caps.

Check entire enclosure, louvers and

Enclosure
vent cap for debris.

Annual Check List

Items to Service Annually Service to Perform
Check thermostat for proper operation.
Thermostat Replace if needed.

Thermocouple Check thermocouple position in pilot

and verify proper millivolt output.

Replace valve seat, spring and O-ring

Liquid Inlet Valve using Kit # 3-0016.

Clean piston and replace the spring and

Capacity Control Valve
O-ring using Kit # 3-0017.

Check flues for holes or excessive scale.

Remove debris. Check bottom of the
Heat Exchanger heat exchanger for pitting. Replace if the
pitting is in excess of 0.125".

Check for proper flame. Clean debris and

Main Burner check air supply. Clean orifices as needed.

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.

Vaporizer Repair and Maintenance Guide

 40/40 Parts

Repair Parts for Algas 40/40 Vaporizer

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.

Vaporizers Vaporizers
1 Built Built
16 17 Key Description To Oct 2002 Post Oct 2002
2 1 Capacity Control Valve 40C68 40C68
3 1 Capacity Control Piston 40C66 40C66
1 Capacity Control Kit 3-0017 3-0017

2 Relief Valve 3129G T3131G

2 Relief Valve Cap 3129-40P 3131-54
15
4 3 Regulator Supply Tube 3-0776 3-0776

4 Burner Regulator Kit 41045 41045

4 Regulator Only 920V 920V

5 Thermostat 3-3540 3-3540

5 Thermostat Cover 1501-5015-02 1501-5015-02
5
6 Thermostat Supply Tube 3-0787 3-0787
14
7 Burner Supply Tube 3-0782 41022
6
8 Pilot Tube 3-0777 41024

9 Thermocouple 1980-36 1980-36

13
7 10 Pilot Assembly 3-0631 3-0631
10 Pilot Orifice BA-718 .018 BA-718 .018

12 8 11 Burner Manifold 40C39A 1502-4006

9
11 10 40C14 33581
12 Burner Jet

13 Flue 3-0529 451-506-01

14 Inlet Valve Gasket 40C37 40C37

15 Liquid Inlet Valve 3-4150 3-4150

New Burner Regulator Assy 15 Inlet Valve Kit 3-0016 3-0016
41045 Kit - Upgrades to 920V
regulator with shutoffs, tubing 16 Loading Tube 3-0778 3-0778
assemblies and drip leg. 3-0549 3-0549
17 Vapor Out Nipple

920V - Regulator only.

WARNING
READ ALL INSTRUCTIONS
BEFORE LIGHTING

GH
I
H W
LO

ROB
ERTSHAW

New Burner Arrangement Old Burner Arrangement

Post October 2002 Pre October 2002

Vaporizer Repair and Maintenance Guide

 80/40 Parts

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.

New Burner Arrangement

Post October 2002
2 3
20 1
19

18

21 5 Old Burner Arrangement

6
Pre October 2002

17

WARNING
READ ALL INSTRUCTIONS
BEFORE LIGHTING

GH

I
H W
LO
ROB
ERTSHAW

7 New Burner Regulator Assy

16
41045 Kit - Upgrades to 920V
regulator with shutoffs, tubing
8 assemblies and drip leg.
15
9 920V - Regulator only.
14 13 12 11 10

Vaporizers Vaporizers Vaporizers Vaporizers

Built Built Built Built
Key Description To Oct 2002 Post Oct 2002 Key Description To Oct 2002 Post Oct 2002
1 Vapor Out Nipple 3-0549 3-0549 12 Pilot Assembly 3-0644 41021
12 Pilot Orifice BA-718 .023 BA-718 .023
2 Capacity Control Valve 40C68 40C68
2 Capacity Control Piston 40C66 40C66 13 Burner Manifold Tube 3-0783 3-0783
2 Capacity Control Kit 3-0017 3-0017
14 Left Burner Manifold 40C39 1504-4004
3 Regulator Supply Tube 3-0779 3-0779
15 Burner Jet 40C14 33581
4 Burner Regulator Kit 41045 41045
4 Regulator Only 920V 920V 16 Left Flue 452-505-01 452-505-01

5 Thermostat 3-3540 3-3540 17 Inlet Valve Gasket 40C37 40C37

5 Thermostat Cover 1501-5015-02 1501-5015-02
18 Liquid Inlet Valve 3-4150 3-4150
6 Thermostat Supply Tube 3-0788 1504-5005 18 Inlet Valve Kit 3-0016 3-0016

7 Burner Supply Tube 3-0782 41019 19 Loading Tube 3-0786 3-0786

8 Pilot Tube 3-0781 40404 20 Relief Valve T3131G T3131G

20 Relief Valve Cap 3131-54 3131-54
9 Right Flue 1504-5009 1504-5009
21 Connector Tube 3-0792 3-0792
10 Thermocouple 1980-36 1980-36

11 Right Burner Manifold 80C99 1504-4005

Vaporizer Repair and Maintenance Guide

 Kits and Service

CAUTION
FLAMMABLE GAS
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.

Liquid Inlet Valve Capacity Control Kit

Remove the plug from the inlet valve and wipe away debris. Disassemble and clean the valve assembly inside the body.
Use kit # 3-0016 to replace the valve seat, spring and Use kit # 3-0017 to replace the spring and O-rings on
O-ring on the plug. the piston and plug. Use powdered graphite as a lubricant
on the piston and use grease on the plug O-ring.

Main Burner Pilot Flame

The burner flame should be a non blowing blue flame and The pilot flame should envelope 3/8" to 1/2" of the
evenly distributed over the burner ring. If uneven, clean thermocouple tip. Clean or replace the pilot if it is too small.
individual burner jets (#66 drill for new style jet. # 64 drill for
old style jet).

Old
66 Style
Jet
New Style Jet

40/40 80/40
Pilot Pilot

Pressure Adjustment Below

Thermostat Check ON PILOT

At ambient temperatures, rotating the temperature control knob from LOW

through HIGH will energize the main seat of the control producing a loud UNITROL 4
6 8

10

audible click. WARNING

READ ALL INSTRUCTIONS
2
15
12

BEFORE LIGHTING INCHES

The burner gas pressure must be at least 9" W.C. when checked at the HIGH

pressure tap with the main burner operating. Set the pressure with the
LOW

adjusting screw located beneath the cap on the Pilot-On-Off knob.

ALGAS - SDI

Using a suitable junction block tester, check the thermocouple millivolt

output. A reading of 13 to 30 millivolts is acceptable. Turn the gas valve 10-038
ADAPTER

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. TO MILLIVOLT
METER

Vaporizer Repair and Maintenance Guide