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Innovative liquid vaporizing and gas mixing solutions

LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H

Operations & Maintenance

Manual

FILE: MANUAL PN 52642 rev 10-17-22

Samuel Oyen
2022.10.17
14:03:41 -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 2022 by Algas-SDI International, LLC, Kent, Washington 98032. 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, Kent, Washington,
USA.

APPROVALS
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.
This page left intentionally blank
 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
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

Excess Flow
Valve

Relief Valve

Vapor Distribution
Line
Vapor Regulator

Float Ball
Liquid
Heat Load

Liquid
Inlet
Valve
Burner
Regulator

Pressure
Vessel Liquid
Thermostat

Burner Pilot Assembly

Algas-SDI Operation and Maintenance Manual – P/N – 52642 1-1

Introduction

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.

1-2 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Introduction

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.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 1-3

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

Minimum Distance From

Exposure
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 25 feet (7.6 m)
(except buildings in which vaporizer is installed).

Reference NFPA58

2-4 Algas-SDI Operation and Maintenance Manual – P/N – 52642

 Installation

Figure 2 – Vaporizer Dimensions (shown in inches)

40/40H Vaporizer

80/40H and 120/60H Vaporizers

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)

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-5

Installation

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)

2-6 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Installation

120/60H Vaporizers 1-1/2” (DN40) 2” (DN50) 2-1/2” (DN80)

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.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-7

Installation

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).

2-8 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Installation

Note: Items 4, 5 and 6 are included with FILTAIRE assemblies.

Figure 4 – Filtaire Operation

BY PASS VALVE 1
(NORMALLY CLOSED)

1ST STAGE
3 REGULATOR
OUTLET VALVE

“FILTAIRE” OIL DEMISTER

VAPOR FROM
VAPORIZER

VAPOR LINE 4
6

2 INLET VALVE

PIPE
STAND 5 DRAIN
VALVE

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

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-9

Installation

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

2-10 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Installation

ENCLOSURE AIR REQUIREMENTS

If vaporizer must be housed inside an enclosure or other enclosed area, the

following requirements for fresh air intake and exhaust outlet area must be met.
Failure to do so will result in improper operation and damage to the equipment.

Table 4 – Cross-Sectional Inlet/Outlet Air Requirements

Outlet Exhaust, Flue

Inlet Air, Louver Area
Vaporizer Annular Area
in2 (cm2)
in2 (cm2)

40/40H 25.7 (166) 7.9 (51)

80/40H 51.4 (332) 15.8 (102)

120/60H 77.1 (497) 23.7 (153)

LEAK TEST

CAUTION
Leak test the entire installation prior to operating the system.

1. Close the outlet valve.

2. Slowly open the 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.

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 leaks.

NOTE
If using direct fired vaporizers in mobile or temporary applications,
leak test must be performed each time vaporizer has been moved or
re-located.

CHECK BURNER INPUT PRESSURE

See Adjusting burner input pressure on page 4-22.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 2-11

Installation

Installation Safety Requirements

NOTE
Burner supply regulator 1st and 2nd stage vents shall be piped away
from vaporizer if required by local codes and regulations, or when
installed in a building, enclosure, or other situation with potential to
accumulate flammable gases.

Ensure that vent piping is adequately supported to prevent damage

to regulator. Reference equipment drawing for vent location and
thread size. Always pipe away regulator vents to a safe location
with no source of ignition. Ensure vents are not blocked with
debris.

NOTE
For installations or locations in Canada it may be required to vent
the integral pressure relief of the burner supply regulator. For those
installations or locations venting must be installed in accordance
with all requirements defined by CSA B149.1 Natural Gas and
Propane Installation code latest revision.

NOTE
Pressure relief valve discharge on direct fired vaporizers shall be
piped to a point outside the structure or a building and shall point
vertically upwards and be unobstructed.

2-12 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Operation 3
Direct Fired Vaporizer start up procedure
1. Before starting the vaporizer, close the outlet valve in the vapor service
line.

2. Fill the vaporizer with LP gas liquid by slowly opening the liquid supply
line valve between the storage tank and the vaporizer. If this valve is
opened too quickly, the excess flow valve in the tank may close. If this
occurs, close the liquid supply line valve and allow the excess flow valve
to equalize and re-open.

3. If the vaporizer is installed with a separate burner supply line not

connected to the vaporizer (see page 2-8), open the valve supplying gas
to the burner supply regulator.

4. Turn the temperature control dial on the thermostatic gas control valve
counterclockwise to the "RUN" position. “RUN” position indicates that
the pilot and main burner can start operating.

Figure 7 – Temperature control dial in “RUN” position

5. Turn the reigniter switch to “ON” and press the pilot button down (see
Figure 8). Continue to hold the pilot button for 30 to 60 seconds and
release. Pilot should remain lit.

NOTE: If the ambient temperature is below 10°F (-12°C) when the pilot
button is released it is likely that the main burner will immediately cycle on.
As soon as the LP gas inside the heat exchanger heats up above this
temperature the main burner will cycle off. This is normal operation for the
thermostatic gas valve.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 3-13

Operation

Figure 8 –Pilot button pressed down and igniter switch ON

WARNING
If pilot light goes off after releasing the pilot button, turn control dial
to "OFF", wait 5 minutes and repeat step 4.

6. Set temperature control dial to 7. This will cause burner(s) to cycle on.

7. Allow burner(s) to heat the vaporizer until they cycle off.

8. Make sure all the valves on consuming equipment are closed and slowly
open the valve in the vapor distribution line. Open all consuming
equipment valves.

Direct Fired Vaporizer setpoint adjustment

Set the temperature control dial to setpoint 7. If a lower setpoint is desired,
contact Algas-SDI for evaluation of suitability for the given installation.

3-14 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Operation

Direct Fired Vaporizer shut down procedure (See Figure 9)

1. Turn temperature control dial to “OFF” position. Pilot flame should
immediately extinguish.

2. Once the pilot flame has extinguished turn the igniter switch to “OFF”.

3. Close the isolation valve ahead of the burner regulator on the side of the
vaporizer. This will prevent any fuel from going downstream to the
thermostat, pilot and the main burner.

Figure 9 – Vaporizer shut down procedure

Isolation valve

Regulator

Thermostat

Direct Fired Vaporizer purge procedure

If the vaporizer is not going to be used for a long period of time, it should
be purged. The information contained below is a step-by-step procedure on
how to purge Algas-SDI direct fired vaporizer. This procedure should be
followed anytime a vaporizer needs to be maintained, serviced, relocated,
or shut down for any other reason.

WARNING
Prior to purging the vaporizer, ensure that there are no closed ball
valves or back check valves restricting the flow of liquid to the tank.

1. Ensure all tank valves are open with no restrictions of flow back to the
storage tank. A check valve restricting flow back to the storage tank
must never be used in a vaporizer installation.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 3-15

Operation

2. Close outlet shut-off valve at the exit of the vaporizer.

3. Start burner per Direct Fired Vaporizer startup procedure and turn the
thermostat temperature control dial to the highest setpoint (7).
4. After the burner cycles off, turn thermostat temperature control dial to
“OFF” position, shut off reigniter (if installed) and check that the pilot flame
is extinguished.
5. After the pilot flame is extinguished, close shut off valve prior to the
vaporizer in the liquid line.
6. Now open vaporizer outlet valve and flare or allow attached equipment to
consume the remaining gas in the line.
7. After verifying the pressure in the lines is zero and no sources of ignition
are present in the area, the vaporizer can now be disconnected.

AUTOMATIC RE-IGNITION OPERATION

Lighting or re-lighting of the pilot flame is accomplished by a spark across a gap

of approximately 1/8" (3 mm) from the electrode tip to the grounded surface of
the pilot. When the flame is established, the pilot flame conducts a current to the
grounded pilot burner and a solid-state switch in the unit turns off the spark. If
the pilot flame is extinguished, current to ground is interrupted and the solid-state
switch turns on the spark, which sparks at a nominal timing of 100 times per
minute, re-lighting the pilot flame well before the thermocouple cools enough to
drop out the thermostat safety system.

3-16 Algas-SDI Operation and Maintenance Manual – P/N - 52642

Maintenance 4
Maintenance Recommendations
Direct Fired Vaporizers are designed for trouble free and safe operation.
Because of the nature of their use, and the severe duty they receive, it is
important to provide scheduled maintenance. The maintenance schedule, type
and frequency, provided in this manual is the minimum maintenance required for
proper and safe operation of your vaporizer. Ambient conditions surrounding the
vaporizer installation and LPG quality may require a more frequent maintenance
schedule. A list of spare parts and repair kits for proper maintenance is located
in the Appendix section of this manual.

CAUTION
The equipment described in this manual is designed to operate with
LP gas, a flammable fuel under pressure. The nature of the
application involves inherent hazards that could result in injury.
ONLY a trained and fully qualified person should service this
equipment.

CAUTION
When servicing a component in the liquid or vapor line, BE SURE
that the LP-gas supply is shut off to that component before removal
or disassembly. Vaporizer must be completely purged before
performing service. Be sure that ALL sources of ignition are
extinguished within 25 feet (7.6 m) of the work area.

When flaring the contents of the vaporizer, be sure that the burners
are on to prevent freezing during the flaring operation.

Table 5 – Initial Installation and Operation Inspections

Required 30-60 days after initial installation

Component Action Required
Inlet Strainer Inspect strainer and remove accumulated debris. NOTE: if debris accumulation is
heavy check every 3-6 months or more frequent as required.
Main Burner Check orifices and air supply openings on the burner tips for debris or foreign objects.
Assembly If needed, clean any plugged or obstructed orifices before restarting the vaporizer.
NOTE: In some applications vaporizer may be installed in an environment where
excessive amounts of dust or debris are present. When vaporizer is located in this
type of an environment, it may be necessary to check the burner tips on a frequent
basis to ensure proper operation and capacity of the vaporizer.
Drip Leg Check the vaporizer drip leg, and any others present in the installation, for heavy ends
and oil build-up. If present, first ensure there are no sources of ignition within 25 feet
(7.6 m), and then drain heavy ends. NOTE: In areas where LPG quality is poor it may
be necessary for drip legs to be checked for heavy ends more frequently (monthly or
bi-monthly depending on quality of LPG). Once it is verified that no significant quantity
of heavy ends is accumulating during vaporizer operation, this maintenance can be
performed on an annual basis.

4-17 Algas-SDI Operation and Maintenance Manual – P/N – 52642

Maintenance

Table 6 – Annual Maintenance Requirements

Annual Maintenance Items

Strainer Remove the plug and clean the screen. Replace screen if tears or holes
are present (40 – 80 Mesh). If oils or contaminants are present, it may be
necessary to use a cleaner to remove all of the contaminants.
Thermostat Check thermostat for proper operation per the Start-up procedure.
Establish pilot and turn the thermostat dial counterclockwise to high,
burners should cycle on. Turn the dial clockwise to the OFF” position,
main burner and pilot should both extinguish in a short period of time.
Replace the thermostat if not operating properly (thermostat cannot be
serviced). NOTE: Before replacing the thermostat, be sure the
thermocouple is delivering the proper voltage to the thermostat (see
below).
Thermocouple Check electrical output of the thermocouple with a multimeter. The
thermocouple output (when hot) should be 13 - 30 mV DC. Lower than
13 mV DC reading indicates the thermocouple should be replaced.
NOTE: Be careful not to over tighten the thermocouple! First, hand
tighten and then turn 1/8th turn with wrench.
Pilot Assembly Inspect pilot flame to ensure flame is enveloping 3/8” to ½” (9-13 mm) of
the thermocouple tip. Clean pilot orifice. If pilot assembly is corroded or
significantly deteriorated, replace complete pilot assembly.
Main Burner Assembly Inspect burner tips to ensure each tip has proper flame. For easy access
to clean the burner tips, disconnect burner supply line and remove the
burner from the unit. With compressed air (if possible), blow out main
burner ring prior to cleaning the burner tips. Check orifices and air supply
openings for debris, insects and/or dirt. Clean any plugged or obstructed
orifices.
Pilot Flame Guide / Flame Upon initial installation and during periodic maintenance inspections,
Spreader Bar check for corrosion on the ends of the pilot flame guide. If flame
diverter(s) are corroded more than 1/8” replace flame guide.
Additionally on 80/40H and 120/60H, check flame spreader bar position to
ensure both burners light simultaneously and smoothly. Straighten
spreader bar if it is positioned at an angle or not positioned on top of the
pilot properly.
Liquid Inlet Valve Use repair kit to replace internal components of the liquid inlet valve. See
detailed Liquid Inlet Valve Maintenance Instructions for further
information.
Capacity Control Valve Use repair kit to replace internal components of the capacity control valve.
See detailed Capacity Control Valve Maintenance Instructions for further
information.
Vaporizer Tubing Inspect all tubing for pitting or flaking - run hands along the underside of
each of the tubes to check for signs of corrosion. Replace tubes if
corroded. Disconnect all tubing and blow tubes free of debris. Re-install
tubing to the vaporizer and check and tighten all fittings.
Relief Valves Inspect all relief valves on the vaporizer, liquid, and vapor lines for signs
of corrosion and damaged or missing rain caps. Replace rain cap if it is
damaged or missing. Replace relief valves per manufacturer’s
recommended replacement period. Also replace relief valve if it shows
significant corrosion on the outlet or has relieved.
Burner Regulator Check regulator delivery pressure at the drip leg and at the burner
pressure port to ensure proper pressure is delivered to the thermostat and
burners. See page 1-3 for burner pressure specifications.
Heat Exchanger 1. Check heat exchanger flue for holes or excessive scale.
2. Remove debris, soot build-up and any obstructions from the
outside surface of the heat exchanger between the fins and in the

4-18 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Maintenance

area between the heat exchanger and flue. High pressure air or
a wire brush may be used for removal. A large amount of build-
up on the outside of the heat exchanger can lead to a reduced
capacity from your vaporizer.
3. Check bottom head of the heat exchanger for pitting and/or
scaling. Should heat exchanger head thickness be less than
0.156” (4 mm) the heat exchanger should be removed from
service. Nominal wall thickness 0.250” (6.4 mm). An Ultrasonic
thickness tester can be used to determine wall thickness.
4. Check heat exchanger for heavy ends accumulation inside the
vessel. Remove the liquid inlet valve and tilt the vaporizer on its
side to drain the heavy ends. Re-install liquid inlet valve and
uniformly torque bolts to 30-35 ft.-lbs (40.7-47.5 Nm) using a
star/cross pattern.
NOTE: In areas where LPG quality is poor it may be necessary for heat
exchangers to be checked for heavy ends more frequently. Once it is
verified that no significant quantity of heavy ends are accumulating during
vaporizer operation, this maintenance can be performed on an annual
basis.
Drip Leg Remove plug below the tee on the drip leg and drain the drip leg to
prevent it from filling with contaminants and passing them into the
thermostat. NOTE: In areas where LPG quality is poor it may be
necessary for drip legs to be checked for heavy ends more frequently.
Once it is verified that no significant quantity of heavy ends are
accumulating during vaporizer operation, this maintenance can be
performed on an annual basis.
Vaporizer Cabinet Inspect the door, inside enclosure, inlet louvers and vent caps for debris
and/or combustible material. If needed, clean areas so they are free of all
debris.

CAUTION
When servicing a component in the liquid or vapor line, BE SURE
that the LP-gas supply is shut off to that component before it is
removed or disassembled. The vaporizer must be completely
purged before performing service. Be sure that ALL sources of
ignition are extinguished within 25 feet (7.6 m) of the work area.

When flaring the contents of the vaporizer, be sure that the burners
are on to prevent freezing during the flaring operation.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-19

 Maintenance

Use the Direct Fired Vaporizer Inspection & Maintenance Checklist included in this manual to record and keep
track of your annual maintenance and inspections.

DIRECT FIRED VAPORIZER INSPECTION CHECKLIST

Model:_________________ Serial Number:___________________

Maintenance Checklist Items Inspected Replaced or

Yes/No Kit Installed?
1. Thermostat Operation:
- Did burner(s) cycle on?
- Did the burner(s) and pilot extinguish after a short period of time when turned
off?
2. Thermocouple: Was the millivolt output between 13-30 mV DC?
3. Pilot Assembly:
- Pilot assembly inspected for corrosion?
- Pilot orifice cleaned or replaced?
4. Burner Assembly: Burner tips and orifices cleaned?
5. Flame Spreader Bar: Is it present and positioned properly or does it have signs of
damage/corrosion (applicable to 80/40H and 120/60H)
6. Liquid Inlet Valve:
- Repair Kit installed?
- Inlet orifice cleaned?
- Did valve pass “water test” to ensure seat is sealing properly?
7. Capacity Control Valve:
- Repair Kit installed?
- Piston and valve body cleaned?
8. Strainer: Screen inspected for tears or holes and/or cleaned?
9. Relief Valve:
- Inspected for corrosion?
- Is rain cap present?
- Manufacture date checked for replacement?
10. Drip Leg: Drained of all contaminants and oils?
11. Burner Regulator: Pressure setting verified? Record pressure setting here.
12. Vaporizer Tubing:
- All tubing checked for pitting or flaking and blown free of debris?
- All fittings tightened?
13. Heat Exchanger:
- Flue inspected?
- Debris removed from and around heat exchanger?
- Heat exchanger head thickness tested?
- Heat exchanger drained of heavy ends?
14. Vaporizer Cabinet: Are door, enclosure, inlet louvers and rain caps cleared of
debris and combustible materials?

Once the above items have been maintained and/or inspected, leak test all fittings and connections inside
and outside the cabinet, including the inlet valve flange and bolts, to ensure there are no leaks.
Connect LPG Supply and light the pilot and engage main burners. Ensure pilot is strong and main
burners are igniting and burning properly.

INSPECTED BY:__________________________________ INSPECTION DATE:_________________

4-20 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Maintenance

Replacing reigniter battery

1. Turn the reigniter switch “OFF”. Open the battery access door on the bottom
right corner of the thermostat housing.

Figure 10 – Opening the battery access door

2. Pull out the battery, disconnect it and replace with new 9VDC battery. Push
the battery back in the thermostat housing and close the battery access door
prior to turning the reigniter switch “ON”.

Figure 11 – Replacing the battery

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-21

 Maintenance

Adjusting burner input pressure

1. Close the supply valve to the burner supply regulator and vent lines.
2. Using a 3/8” FNPT barb fitting and hose, connect a 0-30” manometer (or
similar pressure indicating device) to the pressure tap port at the outlet of the
thermostat. You will have to remove the 3/8” plug. If the vaporizer does not
come equipped with the port at the outlet of the thermostat then connect the
manometer to drip leg ahead of the thermostat.
3. Open the supply valve to the burner supply regulator.
4. Turn the reigniter switch “ON”. Establish pilot by turning temperature control
dial to "RUN" position. Push down the "PILOT" button while igniting pilot
(hold button down for 30 - 60 seconds). After pilot flame is established,
rotate the temperature control dial counterclockwise. The main burner(s)
should now engage.
5. With the main burner operating, check the gas pressure at the thermostat
outlet pressure port using a manometer (see No. 2 above). For the required
burner input pressure for each model refer to page 1-3. To adjust the
pressure, remove the cap on the burner supply regulator (See Figure 12) and
turn the adjustment screw clockwise with a standard screwdriver to increase
the pressure. Return burner supply regulator cap when complete.
6. Close the supply valve to the burner supply regulator and wait until the pilot
and main burner have extinguished. Turn the temperature control dial to
“OFF" position. Remove the manometer and fittings. Replace all plugs
before proceeding and perform a leak test.
Figure 12 – Adjusting burner input pressure

BURNER SUPPLY
REGULATOR ADJUSTMENT
SCREW

ROTATE GAS CONTROL DIAL

COUNTER-CLOCKWISE FOR
BURNER TO ENGAGE

ALTERNATE PRESSURE PRESSURE PORT

PORT INSERT – INSERT MANOMETER
MANOMETER HERE HERE

4-22 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Maintenance

Liquid inlet valve maintenance procedure

Use Repair Kit P/N: 40764 (see Appendix A for kit details)

NOTE: Vaporizer must be purged and empty of all liquid and vapor prior to performing maintenance on the liquid
inlet valve.

CAUTION
Follow the below instructions carefully to prevent hazardous
conditions. Leak test the entire installation prior to operating the
system.

1. Loosen the four bolts to remove liquid inlet valve cover on the outside of the vaporizer cabinet.

2. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity control valve sensing line
fitting on the top of the inlet valve.

3. With a 1-1/2” box end wrench (suggest using 6 point), loosen the large nut on the top of the inlet valve
(inlet valve cap)

4. Loosen the 6 inlet valve flange bolts and remove the inlet valve from the vaporizer through the hole in the
cabinet.

5. Once the valve is removed from the vaporizer, remove the inlet valve cap (large nut on top) and remove
the spring from the valve.

6. Remove the valve seat and stem from the valve body and orifice.

7. After the seat and stem have been removed, using a socket, remove the inlet valve orifice and wipe the
top of the inlet valve orifice with a rag/cloth (one that does not leave lint on surface) or lightly with a
scotch-brite type material to remove any debris and/or oils from the orifice surface.

8. Replace the O-ring under the orifice (use smallest O-ring from kit). Lightly grease new O-ring before
replacing it.

9. Once the inlet valve orifice O-ring has been replaced, return the orifice to the valve and tighten
accordingly.

10. Compare the length of the new stem from the repair kit to the old one that was removed from the
vaporizer to make sure they are the same. It is important to make sure the new valve stem isn’t longer
than the original stem because it might prevent the valve from sealing properly. If needed, use a metal
file to shorten the stem to match the original stem length. New vaporizers are fitted correctly and tested
at the factory to make sure the seat and stem assemblies have the proper length. If the seat and stem
assemblies have been changed in the field without checking the length against the original stem or the
valve was not tested in the shop to ensure it is sealing (see “Water test” procedure below) there is a
chance the stem could be too long and not allow the inlet valve to close properly. If you are uncertain
about the prior replacement history of the valve stem you should ensure the valve is tested in water to
make sure the new stem and seat assembly close fully before returning the inlet valve to the vaporizer.

11. Insert the new valve seat and stem assembly into the valve body lining up the stem with the hole in the
inlet orifice.

12. Replace the spring making sure it is centered on the top of the inlet valve seat.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-23

Maintenance

13. Lightly grease and replace the O-ring around the inlet valve cap (large flange nut).

14. Install inlet valve cap (large flange nut) and tighten into valve body. You may apply NEVER-SEEZ
compound to the flange nut to allow for easy removal of the flange nut in the future.

15. Once the internal components of the valve are replaced perform a “water test” to ensure your inlet valve
is sealing properly. To perform this test: apply a 1/8” plug in the top of the inlet valve cap using Teflon
tape to ensure it is leak-proof. Using an air hose, apply 80-100 psig (6-7 bar) of air pressure at the inlet of
the valve and completely submerge the valve in a bucket or sink full of water. Wait approximately 5-10
seconds and observe for air bubbles exiting the valve around valve stem that protrudes from the middle of
the inlet valve. If no bubbles are present, the valve is sealing properly.

16. Remove any remnants of the old inlet valve flange gasket from the surface of the flange on the inlet valve
itself and on the flange at the heat exchanger. Inspect surfaces for marks or other damage and clean of
any other debris.

17. Inspect new inlet valve flange gasket for damage – primarily any tears, bends, or significant scratches.

18. Lightly spray flange gasket with a dry lubricant (graphite) before installing it on the unit.

19. When re-installing the inlet valve on the vaporizer, place flange gasket on the gasket surface and slide
the stem under the float ball inside the heat exchanger. Slightly tighten the bottom two flange bolts
allowing the flange gasket to be supported by the two bottom bolts. Working your way around the valve,
hand tighten the remainder of the bolts inspecting as you tighten them to ensure the position of the inlet
valve flange gasket is correct.

20. To tighten the inlet valve bolts, torque the 6 bolts to 30-35 ft.-lbs (40.7-47.5 Nm) in a cross/star pattern.

21. Leak test inlet valve flange bolts prior to re-starting the vaporizer.

4-24 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Maintenance

Capacity control valve maintenance procedure

Use Repair Kit p/n: 40764 (see Appendix A for kit details)

1. Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity control valve sensing line
fitting on the top of the capacity control valve and carefully slide tube out of the way in order to remove
the large flange nut (capacity control valve cap). Note: you may need to loosen the tube on the other
end at the top of the inlet valve to remove the tube completely.

2. With a 1-1/2” box end wrench (suggest using 6 point), loosen the large flange nut on the top of the
capacity control valve (capacity control valve cap).

3. Remove the piston from the valve and wipe the piston with a rag/cloth (one that does not leave lint on
surface) or lightly with a scotch-brite type material to remove any debris and/or oils from the piston
surface. If the piston is stuck in the valve or difficult to remove, thread an 8-32 bolt or screw into the screw
tap at the top center of the piston. This will allow you to have leverage and grasp the screw with a pair of
pliers to remove the piston from the valve.

4. Remove the old O-ring from the piston and replace it with the smallest O-ring from the kit. Lightly grease
new O-ring before installing it on the piston.

5. Remove spring from the capacity control valve.

6. Thoroughly wipe the inside of the valve body with a rag/cloth (again, one that does not leave lint on
surface) to remove any debris or oils from the valve body.

7. Insert new spring into the Capacity Control Valve.

8. Lightly spray the surface of the capacity control valve piston with a dry lubricant (graphite) and insert
piston into the valve moving it up and down thereby lubricating the body of the valve and ensuring the
piston is moving up and down freely.

9. Lightly grease and replace the O-ring around the capacity control valve cap (large flange nut).

10. Install the capacity control valve cap (large flange nut) and tighten into valve body. You may apply
NEVER-SEEZ compound to the flange nut to allow for easy removal of the flange nut in the future.

11. Re-install capacity control valve sensing line and tighten fittings.

12. Leak test prior to restarting the vaporizer.

Algas-SDI Operation and Maintenance Manual – P/N – 52642 4-25

Troubleshooting 5
1. PILOT - TROUBLESHOOTING TREES #1 & #2

◼ The pilot flame is adjusted at the factory to provide a non-blowing blue flame.
If the flame is not adequate or the pilot does not stay lit, check the pilot
burner to see if it is clear of any obstructions.

◼ Flame should envelope 3/8” to 1/2" (9 to 13 mm) of the thermocouple tip. If

the pilot flame is too low, the thermocouple will not generate sufficient
voltage to hold the main burner’s valve open. If the pilot flame is too small,
clean the pilot burner orifice, or replace the pilot. The 40/40H vaporizers use
#18 pilot orifices, while the 80/40H and 120/60H use #23 pilot orifices.

2. IGNITER WILL NOT SPARK – TROUBLESHOOTING TREE #3

◼ Check the reigniter battery and replace if necessary.

◼ Verify that the spark electrode is not in contact with the pilot hood and that
spacing from the hood is not greater than 1/8” (3 mm).

◼ Check if the spark electrode is saturated with moisture/water. Wipe any

moisture/water or light the vaporizer manually with a torch to dry it.

◼ Check the rocker switch by removing the leads and touching them together.
If the reigniter spark is established, then the rocker switch is faulty.

3. MAIN BURNER WILL NOT IGNITE - TROUBLESHOOTING TREE #4

◼ Check the pilot burner as per 1. above.

◼ Check burner regulator. Disconnect tube from outlet side of regulator and
check output pressure.

◼ If pilot burner and burner regulator check out OK, the problem is in the
thermostat. Replace thermostat (the main burner will not come on unless the
temperature in the heat exchanger drops).

4. IF VAPOR PRESSURE DROPS - TROUBLESHOOTING TREE #5

◼ Check burner; check pilot as per 1. and 2. above.

◼ If vapor pressure drops, but main burner(s) is working, vapor demand

exceeds vaporizer capacity.

◼ Check liquid excess flow valve and shut off valve; make sure they are open.

◼ Close liquid inlet valve upstream of strainer. Bleed down system and clean
strainer filter.

5-26 Algas-SDI Operation and Maintenance Manual – P/N – 52642

 Troubleshooting

TROUBLESHOOTING TREE #1
PILOT WILL NOT LIGHT

CHECK THE BURNER

PRESSURE IS OK INPUT PRESSURE PRESSURE IS HIGH/LOW
REFER TO PAGE 1-3

NO PRESSURE

REPLACE REGULATOR

PRESSURE WILL
PRESSURE IS OK ADJUST NOT ADJUST
DISCONNECT THE PILOT
REGULATOR
PRESSURE FUEL LINE FROM THE
IS OK THERMOSTAT AND NO PRESSURE
CHECK PRESSURE AT
THE THERMOSTAT PILOT
CONNECTION BY
PRESSING THE PILOT LIGHT PILOT
BUTTON DOWN AND CHECK
OPERATION

CHECK PILOT
INLET PRESSURE INLET PRESSURE
TUBE AND PILOT
IS LOW IS OK
ORIFICE FOR VERIFY YOU
OBSTRUCTIONS HAVE A
REPLACE MINIMUM OF 6
THERMOSTAT PSIG INPUT TO
REGULATOR

REPAIR OR
REPLACE PILOT
ASSEMBLY DETERMINE CAUSE OF LOW REPLACE THE
PRESSURE AND REPAIR REGULATOR

RETEST THE RETEST THE

VAPORIZER VAPORIZER

Algas-SDI Operation and Maintenance Manual – P/N – 52642 5-27

Troubleshooting

TROUBLESHOOTING TREE #2
PILOT LIGHTS BUT WILL NOT HOLD

CHECK TO SEE THAT THE

PILOT IS OK PILOT IS IMPINGING ON THE PILOT IS LOW
THERMOCOUPLE BULB,
APPROXIMATELY 3/8” TO 1/2”
(9 to 13 mm)

SEE TROUBLESHOOTING TREE

CHECK THE THERMOCOUPLE SIGNAL TO #1: PILOT WILL NOT LIGHT
THERMOSTAT CONTROL VALVE. SIGNAL
SHOULD BE 13 TO 30 mV DC WHEN
THERMOCOUPLE IS HOT

SIGNAL OK SIGNAL LOW

REPAIR OR REPLACE
REPLACE PILOT THERMOCOUPLE
ASSEMBLY

5-28 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Troubleshooting

TROUBLESHOOTING TREE #3
IGNITER WILL NOT SPARK

BATTERY OK CHECK BATTERY DEAD

REIGNITER
BATTERY

CHECK IF
ELECTRODE IS
CONTACTING HOOD REPLACE BATTERY
OR FURTHER THAN
1/8” (3 mm)

OUT OF OK
POSITION

ADJUST AND CHECK IF

CHECK ELECTRODE
OPERATION IS WET

YES

WIPE
ELECTRODE
NO DRY OR LIGHT
MANUALLY
WITH TORCH

CHECK ROCKER SWITCH BY

REMOVING LEADS AND
TOUCHING TOGETHER

SPARK
ESTABLISHED

ROCKER
SWITCH IS
FAULTY -
REPLACE

Algas-SDI Operation and Maintenance Manual – P/N – 52642 5-29

Troubleshooting

TROUBLESHOOTING TREE #4
MAIN BURNER WILL NOT LIGHT

CHECK TO SEE THAT THE

NO PILOT IS IMPINGING ON THE YES
THERMOCOUPLE BULB,
APPROXIMATELY 3/8” TO 1/2”
(9 to 13 mm)

TURN THE THERMOSTATIC GAS VALVE

TEMPERATURE CONTROL DIAL UP TO
SEE TROUBLESHOOTING TREE THE HIGHEST SETTING. DID THE
#1 OR #2 TO CHECK CONTROL “CLICK”?
THERMOCOUPLE AND
REGULATOR
YES NO

CHECK FOR REPLACE

PLUGGED GAS THERMOSTAT
LINE TO THE
BURNER

5-30 Algas-SDI Operation and Maintenance Manual – P/N - 52642

 Troubleshooting

TROUBLESHOOTING TREE #5
VAPOR SERVICE PRESSURE DROPS

NOTE: SERVICE PRESSURE WILL DROP IF THE

DEMAND EXCEEDS VAPORIZER’S CAPACITY: 40/40H
3.6 MMBTU/hr (1,055 kW), 80/40H 7.3 MMBTU/hr (2,139
kW), 120/60H 10.9 MMBTU/hr (3,195 kW). THE
FOLLOWING TROUBLESHOOTING TREE ASSUMES
THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS
MAXIMUM CAPACITY.

YES IS THE BURNER NO

OPERATING?
SEE TROUBLESHOOTING TREE #3:
MAIN BURNER WILL NOT LIGHT

CHECK THE
OK THERMOSTAT PORT
LOW/HIGH
OUTLET PRESSURE
REFER TO PAGE 1-3

OK ADJUST BURNER WILL NOT ADJUST

PRESSURE
REGULATOR

SET THERMOSTAT FOR

HIGHER TEMPERATURE

CHECK
OPERATION
CHECK FOR
MINIMUM OF
CHECK IF BURNER 6psig (0.4 bar) AT
TIPS CLOGGED REGULATOR
(ORANGE/NO PRESSURE INLET PRESSURE
FLAME) LOW
OK
NO YES

REPLACE REPAIR PRESSURE

REGULATOR SOURCE

REPLACE
THERMOSTAT CLEAN
BURNER TIPS
AND ORIFICES

DOES NOT OK
FUNCTION

REPLACE CHECK
THERMOSTAT OPERATION

Algas-SDI Operation and Maintenance Manual – P/N – 52642 5-31

 APPENDIX A

TECHNICAL INFORMATION
 Figure 13 – 40/40H Vaporizer Replacement Parts

16 9

12
3

14

11

1 13
6 15
10 2

24
 Figure 14 – 80/40H and 120/60H Vaporizer Replacement Parts

NOTE
Drawing shown for an 80/40H Vaporizer.

14

16
9

12

11

26

18
19 13
17 20 25
15
2
 Figure 15 – Inlet Valve and Capacity Control Valve

LIQUID INLET VALVE

23 Inlet valve cap o-ring

23 Inlet valve spring

23 Inlet valve seat

Inlet valve orifice
23 Inlet valve gasket
23 Inlet
valve orifice
o-ring

23 Pivot arm gasket

CAPACITY CONTROL VALVE

22 Capacity control valve

Cap o-ring

22 Piston o-ring

21 Piston

22 Spring
Figure 13, 14 and 15 Descriptions
1. Burner Manifold – 40/40H P/N: 1502-4020
2. Burner tip #69 burner jet orifice – All models P/N: 34323
3. Capacity control valve 1” – All models P/N: 1508-4001
4. Drip leg kit – All models P/N: 40403
5. Liquid inlet valve – All models P/N: 1501-4001
6. Pilot assembly with thermocouple – 40/40H P/N: 40774
7. Pilot flame Guide – 40/40H P/N: 1502-5010
8. Regulator, Burner Supply – All Models P/N: 34800
9. Relief valve, ¾” NPT UL/CE/ASME – All models P/N: 34876
10. Thermocouple – All models P/N: 37050
11. Thermostat/Thermowell w/9VDC igniter – All models P/N: 41073
12. Tube kit, burner regulator supply – All models P/N: 40542
13. Tube kit, burner supply – All models P/N: 42012
14. Tube kit, capacity control – All models P/N: 42013
15. Tube kit, pilot supply – All models P/N: 42014
16. Vent cap assembly – All models P/N: 1501-4015
17. Burner manifold left – 80/40H, 120/60H P/N: 1501-4020
18. Burner manifold right – 80/40H, 120/60H P/N: 1501-4021
19. Pilot assembly with thermocouple – 80/40H-120/60H P/N: 40768
20. Pilot flame guide – 80/40H,120/60H P/N: 1501-5086
21. Piston, Capacity control valve – All models P/N: 1508-5005
22. Repair kit, Capacity control valve – All models P/N: 40764
*See Capacity Control valve in Figure 15
23. Repair kit, Liquid Inlet valve – All models P/N: 40764
*See Liquid Inlet valve in Figure 15
24. Strainer, ¾” NPT (ships loose) P/N: 30655
25. Tube kit, burner manifold connector – 80/40H, 120/60H P/N: 3-0783
26. Tube, heat exchanger connector – 80/40H, 120/60H P/N: 3-0792
 Table 7 – Repair Kits and Other Available Replacement Parts

40631: Master rebuild kit 40/40H

Part number Description
3-0034 40/40H Repair kit
34323-10 Burner tip #69 orifice (qty 10)
34800 Burner supply regulator

40633: Master rebuild kit 80/40H

Part number Description
3-0035 80/40H Repair kit
34323-10 Burner tip #69 orifice (qty 10)
34800 Burner supply regulator

40634: Master rebuild kit 120/60H

Part number Description
41040 120/60H Repair kit
34323-10 Burner tip #69 orifice (qty 10)
34800 Burner supply regulator

3-0034: Repair kit 40/40H

Part number Description
40764 Repair kit, Liquid inlet valve & Capacity control valve
41073 Thermostat/Thermowell with 9 VDC reigniter
40774 Pilot assembly with thermocouple 40/40H

3-0035: Repair kit 80/40H

Part number Description
40764 Repair kit, Liquid inlet valve & Capacity control valve
41073 Thermostat/Thermowell with 9 vdc reigniter
40768 Pilot assembly with thermocouple 80/40H & 120/60H

41040: Repair kit 120/60H

Part number Description
40764 Repair kit, Liquid inlet valve & Capacity control valve
40768 Pilot assembly with thermocouple, 80/40H & 120/60H
41073 Thermostat/Thermowell with 9 vdc reigniter
 3-0014: Repair kit 40/40H Pilot orifice and thermocouple
Part number Description
37050 Thermocouple for all models
46-6 Orifice pilot burner 40/40H, #18
3-0013: Repair kit 80/40H Pilot orifice and thermocouple
Part number Description
37050 Thermocouple for all models
37510 Orifice pilot burner 80/40H & 120/60H, #23

41041: Repair kit, 120/60H Pilot orifice and thermocouple

Part number Description
37050 Thermocouple for all models
37510 Orifice pilot burner 80/40H &120/60H, #23

42015: 40/40H, 80/40H & 120/60H Tubing replacement kit

Part number Description
40403 Drip leg kit
40542 Tube kit, Burner regulator supply
42012 Tube kit, Burner supply
42013 Tube kit, Capacity Control Valve
42014 Tube kit, Pilot supply
 Liquid inlet valve pin gasket installation procedure

1. Clean pivot screw hole opening from any residue.

2. Apply blue (medium strength) Locktite 243 or Permatex to threads on the liquid inlet valve body or
pivot screw.
3. Slide pin gasket (P/N 8135-101) over the pivot screw (P/N 3-4169) threads as shown in the picture.

4. Screw in pivot screw to the inlet valve body and apply 8 in-lbs (0.9 Nm) of torque (approximately 1/8
full turn).
5. Align valve stem with pivot screw and repeat the same step with the pin gasket and pivot screw on
the opposite side of the liquid inlet valve.
6. Verify there is no damage to the pin gasket. Set inlet valve assembly aside for an hour to allow
Locktite to properly dry before reinstalling valve assembly back on the vaporizer.
7. Re-install valve in vaporizer with new flange gasket and uniformly torque bolts to 30-35 ft-lbs (40.7-
47.5 Nm).
8. Re-connect sensing line to capacity control valve.
9. After assembly pressurize with 125-150 psig (8.6-10.3 bar) compressed air and apply soap solution
or leak detection fluid to both pin gasket areas and to the valve flange area to make sure there are no
leaks
 442 562 PRESSURE
CAPACITY ISOLATION RELIEF
17 3 " 22 1 " VALVE
8 CONTROL 8 VALVE
VALVE

3/4" FNPT
LIQUID INLET BURNER
918 REGULATOR
36 3 " LIQUID 1" MNPT
16 INLET B VAPOR
VALVE OUTLET
744
29 5 " DRIP LEG START/SHUTDOWN
16 INSTRUCTIONS
PILOT DRAIN
VALVE
504
19 7 " BURNER
8 THERMOSTAT AND
HEAT
EXCHANGER REIGNITOR
ASSEMBLY

ISOMETRIC VIEW
A A NO SCALE
LEFT VIEW FRONT VIEW RIGHT VIEW
DOOR REMOVED
FOR CLARITY

NOTES:
4 X 1/2" [13mm] 1. ALL DIMENSIONS ARE IN INCHES [mm].
1ST STAGE VENT MOUNTING HOLES 2. VAPORIZER PRESSURE VESSEL RATED AT 290 PSIG [20 BAR] MAWP.
(1/8" FNPT) 9. 3. VAPORIZER RELIEF VALVE SETTING 250 PSIG [17.2 BAR].
4. cULus APPROVED.
419 5. CE MARKED (PED).
16 1 " 6. VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET CONDITION
2 40 GPH [80 KG/HR].
7. VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON
ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.
8. HEAT INPUT 51,360 BTU/HR [54,185 KJ/HR].
9. USE THE 1/8" FNPT PORT TO PIPE AWAY 1ST STAGE VENT IF REQUIRED.
10. USE THE 3/4" FNPT PORT TO PIPE AWAY 2ND STAGE VENT IF REQUIRED.
254 11. APPROXIMATE SHIPPING WEIGHT 155 LBS [70 KG].
10"

Drawn By:
THIRD ANGLE TOLERANCES RWP
PROJECTION Checked By:
UNLESS OTHERWISE
SECTION A-A SPECIFIED DN
DETAIL B Approved By:
.X
SCALE 1 : 4 Date:
.XX 5/22/12
DO NOT .XXX 151 S. Michigan St., Seattle, Washington. USA 98108 Scale:
2ND STAGE VENT SCALE ANGLE 0 30' Tel: (206) 789-5410 Fax: (206) 789-5414 1:10 AND NOTED
Part # Job #
(3/4" FNPT) 10. DRAWING FRACTIONS 1/4" A.S.D.I. STD.
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR SMALL DF VAPORIZER 40/40H EQUIPMENT DRAWING
USED IN ANY MANNER DETRIMENTAL TO IT'S
INTERESTS. ALL RIGHTS RESERVED. Size: Dwg. # Sht. No.: Rev.:
© COPYRIGHT ALGAS-SDI B 1502-6001 1of 1 D
 PRESSURE
440 807 ISOLATION RELIEF
17 5 " VALVE VALVE
16 31 3/4"

BURNER
REGULATOR
1" MNPT
3/4" FNPT VAPOR
928 LIQUID INLET OUTLET
36 9/16" CAPACITY
CONTROL
LIQUID VALVE
INLET B
VALVE
744 START/SHUTDOWN
29 5/16" INSTRUCTIONS
PILOT

504 THERMOSTAT
AND REIGNITOR
19 7 " BURNER HEAT ASSEMBLY
8
EXCHANGER
DRIP LEG
DRAIN
VALVE
LEFT VIEW A FRONT VIEW A ISOMETRIC VIEW
RIGHT VIEW
DOOR REMOVED NO SCALE
FOR CLARITY

1ST STAGE VENT

(1/8" FNPT) 9. NOTES:
1. ALL DIMENSIONS ARE IN INCHES [mm].
2. VAPORIZER PRESSURE VESSEL RATED AT 290 PSIG [20 BAR] MAWP.
4 X 1/2" [13mm] 3. VAPORIZER RELIEF VALVE SETTING 250 PSIG [17.2 BAR].
MOUNTING HOLES 4. cULus APPROVED.
664 5. CE MARKED (PED).
6. VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET CONDITION
26 1 " 80 GPH [160 KG/HR].
8 7. VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON
ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.
8. HEAT INPUT 102,720 BTU/HR [108,370 KJ/HR].
9. USE THE 1/8" FNPT PORT TO PIPE AWAY 1ST STAGE VENT IF REQUIRED.
10. USE THE 3/4" FNPT PORT TO PIPE AWAY 2ND STAGE VENT IF REQUIRED.
305 11. APPROXIMATE SHIPPING WEIGHT 207 LBS [94 KG].
12"
Drawn By:
THIRD ANGLE TOLERANCES RWP
PROJECTION Checked By:
UNLESS OTHERWISE
SPECIFIED DN
DETAIL B Approved By:

SCALE 1 : 4 .X
2ND STAGE VENT SECTION A-A Date:
.XX 5/23/12
(3/4" FNPT) 10. DO NOT .XXX 151 S. Michigan St., Seattle, Washington. USA 98108 Scale:
SCALE ANGLE 0 30' Tel: (206) 789-5410 Fax: (206) 789-5414 1:12 AND NOTED
Part # Job #
DRAWING FRACTIONS 1/4" A.S.D.I. STD.
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
SMALL DF VAPORIZER 80/40 EQUIPMENT DRAWING
USED IN ANY MANNER DETRIMENTAL TO IT'S
INTERESTS. ALL RIGHTS RESERVED. Size: Dwg. # Sht. No.: Rev.:
© COPYRIGHT ALGAS-SDI B 1504-6001 1of 1 D
 PRESSURE
442 803 ISOLATION RELIEF
17 3/8" 31 5/8" VALVE VALVE 1" MNPT
VAPOR
3/4" FNPT BURNER OUTLET
LIQUID INLET REGULATOR

1157 LIQUID CAPACITY

45 9/16" INLET CONTROL
VALVE VALVE B START/SHUTDOWN
INSTRUCTIONS

977
38 1/2"
PILOT THERMOSTAT
AND REIGNITOR
731 ASSEMBLY
28 13/16"

HEAT DRIP LEG

BURNER EXCHANGER DRAIN
VALVE

A A
LEFT VIEW FRONT VIEW RIGHT VIEW
DOOR REMOVED
FOR CLARITY

NOTES:
1. ALL DIMENSIONS ARE IN INCHES [mm].
2. VAPORIZER PRESSURE VESSEL RATED AT 290 PSIG [20 BAR] MAWP.
4 X 1/2" [13mm] 3. VAPORIZER RELIEF VALVE SETTING 250 PSIG [17.2 BAR].
MOUNTING HOLES 4. cULus APPROVED.
1ST STAGE VENT 5. CE MARKED (PED).
(1/8" FNPT) 9. 6. VAPORIZER CAPACITY AT 0 F AND 100 PSIG PROPANE INLET CONDITION
664 120 GPH [240 KG/HR].
26 1/8" 7. VAPORIZER TO BE SECURED THROUGH THE FOUR MOUNTING HOLES ON
ABOVE GROUND, LEVEL, SOLID, NON-COMBUSTIBLE BASE.
8. HEAT INPUT 154,080 BTU/HR [162,555 KJ/HR].
9. USE THE 1/8" FNPT PORT TO PIPE AWAY 1ST STAGE VENT IF REQUIRED.
10. USE THE 3/4" FNPT PORT TO PIPE AWAY 2ND STAGE VENT IF REQUIRED.
305
12" 11. APPROXIMATE SHIPPING WEIGHT 260 LBS [118 KG].

Drawn By:
THIRD ANGLE TOLERANCES RWP
PROJECTION Checked By:
UNLESS OTHERWISE
SPECIFIED DN
SECTION A-A Approved By:
SCALE 1 : 12 .X
DETAIL B Date:
.XX 5/23/12
SCALE 1 : 4 .XXX Scale:
2ND STAGE VENT DO NOT 151 S. Michigan St., Seattle, Washington. USA 98108
SCALE ANGLE 0 30' Tel: (206) 789-5410 Fax: (206) 789-5414 1:12 AND NOTED
(3/4" FNPT) 10. Part # Job #
DRAWING FRACTIONS 1/4" A.S.D.I. STD.
INTERPRET THIS DRAWING IN ACCORDANCE Title:
WITH ANSI/ASME Y14.5-2009
THIS DRAWING SHALL NOT BE REPRODUCED OR
SMALL DF VAPORIZER 120/60 EQUIPMENT DRAWING
USED IN ANY MANNER DETRIMENTAL TO IT'S
INTERESTS. ALL RIGHTS RESERVED. Size: Dwg. # Sht. No.: Rev.:
© COPYRIGHT ALGAS-SDI B 1506-6001 1of 1 E
Algas-SDI International, LLC
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Kent, Washington 98032
USA

Ph: +1.206.789.5410
Fax: +1.206.789.5414

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