...

Innovative liquid vaporizing and gas mixing solutions

Operations & Maintenance

Manual

151 South Michigan Street, Seattle, Washington, USA 98108

Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com
FILE: Manual PN 52632 Rev 08-08-07 Power.doc
Introduction 1
DESCRIPTION

The Algas-SDI POWER Series Vertical Electric Vaporizer heats liquid propane
and transforms it from a liquid to a vapor. The Power Series vaporizers are
“indirect fired”, meaning no open flame is involved in the heating process.
The vaporizers are Factory Mutual and CSA approved and comply with Class I,
Division 1 or Division 2, Group D requirements as specified in NFPA Pamphlet
58. An annotated cut-away drawing of a single unit vaporizer is shown in
Figure 1. Six tubular heater elements are cast into the aluminum heater core.
These elements provide the heat required to vaporizer the LPG. A dual sensor
thermocouple is located in the center of the heater core. One sensor monitors
the heater core temperature and controls the heater ON and OFF cycles.
A second sensor acts as a high temperature safety and shuts the vaporizer off
if an over-temperature situation occurs. A High Liquid Level Safety Float Switch
is integral to each vaporizer. In case of liquid propane build-up in the pressure
vessel due, for example, to demand in excess of the vaporizer’s capacity, the
float will shut the vaporizer off. This will prevent liquid propane carry-over.

Two basic safety devices eliminate the possibility of over-pressurization of the

vaporizer. Over-pressure during normal operation relieves through the Solenoid
Valve and returns to the tank. Abnormal over-pressure relieves
to the atmosphere through a 250 psig (17.58 kg/cm2) pressure Relief Valve.

Three high temperature safety devices protect against over-heating of the

vaporizer. These safety devices are 2 High Temperature Limits on the Control
Board, 1 software shutdown and 1 hardware shutdown and FUSIBLE LINKS on
the heaters.

Algas-SDI Operations & Maintenance Manual P/N 52632 1-1

Introduction

Figure 1 – Typical Configuration Drawing

Control System.wmf

1-2 Algas-SDI Operations & Maintenance Manual P/N 52632

Major Component 2
Figure 2 – Vaporizer Major Components - Division 1 Models

Major Components (1).dxf

1. Vapor outlet isolation valve 7. Control panel
2. Liquid inlet manifold 8. Relief valve
3. Liquid inlet isolation valve 9. Liquid level safety switch
4. Liquid inlet safety solenoid valve 10. Outlet vapor header
5. Outlet manifold pressure gauge 11. Liquid inlet strainer
6. Outlet temperature gauge 12. Vaporizer heater core

Algas-SDI Operations & Maintenance Manual P/N 52632 2-3

 Major Components
______________________________________________________________________________________
Figure 3 – Vaporizer Major Components - Division 2 Models

Major Components (2).dxf

1. Vapor outlet isolation valve 7. Control panel
2. Liquid inlet manifold 8. Relief valve
3. Liquid inlet isolation valve 9. Liquid level safety switch
4. Liquid inlet safety solenoid valve 10. Outlet vapor header
5. Outlet manifold pressure gauge 11. Liquid inlet strainer
6. Outlet temperature gauge 12. Vaporizer heater core

2-4 Algas-SDI Operations & Maintenance Manual P/N 52632

 Major Components
______________________________________________________________________________________
Figure 4 – Control Box Major Components - Division 1 Models

Control Box (1).dxf

1. Start pushbutton (momentary) 5. Transformer/solenoid valve fuses
2. Control board 6. Input power distribution blocks
3. Stop pushbutton (momentary) 7. Hermetically Sealed Heater control relay
4. Transformer-Control Board/Solenoid Valve

Algas-SDI Operations & Maintenance Manual P/N 52632 2-5

 Major Components
______________________________________________________________________________________
Figure 5 – Control Box Major Components - Division 2 Models

Control Box (2).dxf

1. Indicator lamps 7. Single float switch PC board
2. ON/OFF switch (maintained) 8. Line power distribution block
3. Start pushbutton (momentary) 9. Heater protection fuses
4. Transformer/solenoid valve fuses 10. Ground lug
5. Control board 11. Hermetically Sealed Heater control relay
6. Transformer-Control Board/Solenoid Valve

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Installation 3
WARNING
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.

GENERAL

Installation requirements vary according to local, provincial, and state

requirements. Requirements often differ from those provided in NFPA
Pamphlet 58. Consult the authorities having jurisdiction over your installation.

A drawing of a typical installation of a Power Series Vertical vaporizer can be

found below. Install the ASDI Power vaporizer on a firm, level base. Bolt it
securely through the four mounting holes in the vaporizer stand base plate.
Adequately shield the vaporizer installation against vehicular damage. Prior to
making the final piping connections, clean all foreign material from the pipes.

All piping joints should be made up using joint compound approved for LP-Gas.
Carefully test the completed piping connections for leaks using a COMPRESSED
INERT GAS and a soapy solution. Carbon dioxide or nitrogen applied at
approximately 100 psig ( 7.03 kg/cm2 ) work well as testing agents. Remember a
bubble indicates a leak! Even a tiny bubble is unacceptable! NO LEAK IS
TOLERABLE! Repeat the test process until all leaks are eliminated.

Algas-SDI Operations & Maintenance Manual P/N 52632 3-7

Installation

Figure 6 – Installation Drawing with Pump

Installation.dxf

Figure 6B – Typical Installation Drawing with Vapor Bypass and No Pump

Installation (B).dxf

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 Installation

Figure 6C – Typical Installation Drawing with Economy and Vapor Bypass

Installation (C).dxf

NOTE
The vapor bypass line is not required except when you have the
Economy Operation option. In other installations, it is
recommended because it will provide vapor from the tank to the
load in case of vaporizer failure or power failure but it is not
required. The vaporizer will operate properly without the bypass.

LIQUID LINE PIPING

The liquid line from the storage tank to the vaporizer should be Schedule 80 steel
pipe and must incur a minimal pressure drop while supplying the vaporizer at
capacity operation. Table 1 provides a handy guideline to assist in determining
the appropriate pipe size for a given size vaporizer over a given distance. Install
a liquid line strainer with a magnet for iron particle pickup upstream of the
vaporizer.

WARNING
Propane flows in both directions in the Liquid Line. This allows the
vaporizer and storage tank to maintain a “Pressure Balance”.
Never install a check valve in the liquid propane line!

CAUTION
A liquid pump must be installed if the pressure drop in the liquid
line between the vaporizer and the tank exceeds the hydrostatic
liquid head in the storage tank. ONE FOOT OF LIQUID PROPANE
EQUALS 0.21 psi ! Liquid line frosting is a sure indication of too
much pressure drop in the liquid line.

Algas-SDI Operations & Maintenance Manual P/N 52632 3-9

Installation

Table 1 – Sizing Chart for Liquid Propane Supply Lines to Vaporizers

(use schedule 80 steel pipe or approved equal)

Capacity of Units Distance in feet from Storage to Vaporizer

MMBTU GPH 100 200 300 400 500 750 1000 2000
20.0 220 1 ¼” 1 ¼” 1 ½” 2” 2” 2” 2” 2 ½”
30.0 330 1 ¼” 1 ½” 2” 2” 2” 2” 2 ½” 2 ½”
40.0 440 1 ¼” 1 ½” 2” 2” 2” 2” 2 ½” 2 ½”
50.0 550 1 ½” 2” 2” 2” 2” 2” 2 ½” 2 ½”
60.0 660 2” 2” 2” 2” 2” 2 ½” 2 ½” 2 ½”
80.0 880 2” 2” 2” 2” 2” 2 ½” 2 ½” 3”
100.0 1100 2” 2” 2” 2” 2 ½” 2 ½” 2 ½” 3”
150.0 1640 2” 2” 2” 2 ½” 2 ½” 2 ½” 3” 3”
200.0 2200 2” 2” 2 ½” 2 ½” 2 ½” 3” 3” 3 ½”
300.0 3300 2” 2 ½” 2 ½” 2 ½” 3” 3” 3 ½” 4”
400.0 4400 2 ½” 2 ½” 2 ½” 3” 3” 3 ½” 4” 4”
500.0 5500 2 ½” 3” 3” 3” 3 ½” 4” 4” 4”
750.0 8200 3” 3” 3” 3 ½” 4” 4” 5” 5”
1000.0 10950 3” 3 ½” 3 ½” 4” 4” 5” 5” 6”

NOTE
Per NFPA 58, a storage tank shall have piping downstream large
enough to assure closure of the excess flow valve if the pipe is
ruptured. If the pipe is too small to allow this flow, it must be
protected downstream with an excess flow valve.

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 Installation

Table 2 – Liquid Temperature vs. Tank Pressure Chart

Propane Butane Ammonia

Liquid Tank Gauge Tank Gauge Tank Gauge
Temperature Pressure Pressure Pressure
°F °C psi KPa psi KPa psi KPa
-43.73 -41.65 0 0
-40 -39.6 1.3952 9.6196
-30 -36.85 3.421 23.5871

-30 -34.1 5.639 38.877

-25 -31.35 8.06 55.57 1.234 8.511
-20 -28.6 10.697 73.751 3.539 24.401
-15 -25.85 13.561 93.503 6.156 42.648
-10 -23.1 16.666 114.91 NOTE: 8.968 61.834
Below 30°F or -10°C,
-5 -20.35 20.024 136.06 Butane is a liquid at normal 12.216 84.228
Atmospheric pressure.
0 -17.6 23.648 163.05 15.622 107.710
5 -14.85 27.551 189.96 19.565 134.893
10 -12.1 31.747 218.88 23.688 163.323
15 -9.35 36.248 249.92 28.424 195.977

20 -6.6 41.068 283.15 33.366 230.051

25 -3.85 46.222 318.69 39.001 268.899
30 -1.1 51.723 356.67 44.867 309.347
35 1.65 57.586 397.04 1.25 8.6185 51.513 355.168
40 4.4 63.825 440.06 2.92 20.133 58.418 402.778

45 7.15 70.455 485.77 4.82 33.233 66.035 455.295

50 9.9 77.49 534.27 6.85 47.229 74.254 511.963
55 12.65 84.945 585.68 9 62.053 83.106 572.996
60 15.4 92.836 640.08 11.32 78.049 92.622 638.606
65 18.15 101.179 697.6 13.82 95.286 102.84 709.057

70 20.9 109.988 758.34 16.5 113.76 113.78 784.486

75 23.65 119.28 822.4 19.3 133.07 125.49 865.223
80 26.4 129.0715 889.91 22.44 154.72 137.99 951.408
85 29.15 139.737 963.45 25.81 177.95 151.33 1043.384
90 31.9 150.215 1035.7 29.21 201.4 165.54 1141.358

95 34.65 161.603 1114.21 32.67 225.25 181.12 1248.778

100 37.4 173.558 1196.64 36.67 252.83 196.7 1356.199
105 40.15 186.098 1283.1 41.02 282.82 214.235 1477.098
110 42.9 199.241 1373.72 46.57 321.09 231.77 1597.998
115 45.65 213.007 1468.63 50.28 346.67 251.415 1733.445

120 48.4 227.414 1567.96 55.28 381.14 271.06 1868.893

125 51.15 242.483 1671.86 60.53 417.34 292.97 2019.957
130 53.9 258.235 1780.47 66.13 455.95 314.88 2171.021
135 56.65 274.691 1893.93 72.13 497.32 339.21 2338.771
140 59.4 291.875 2012.4 78.17 538.96 363.54 2506.520

Algas-SDI Operations & Maintenance Manual P/N 52632 3-11

Installation

LIQUID PUMP

Is a Liquid Pump necessary? What are your vapor pressure requirements?

Pressure in the storage tank depends on temperature ( See Table 2 ). A good

“rule of thumb” for determining when a Liquid Pump is necessary is this: If the
storage pressure will not always exceed the required distribution pressure by 5
psig ( 0.35 kg/cm2 ), a pump is necessary. Install an ASDI STABILAIRE LIQUID
PUMP in the liquid line close to the storage tank. To prevent cavitation, place the
liquid strainer at least five feet upstream of the pump inlet. Typically a pump is
not required unless a mixing system is used or temperature at the installation will
be extremely low, causing the pressure to drop below the pressure the required
process pressure.

VAPOR LINE

Install an appropriate regulator immediately downstream of the vapor outlet port.

Pipe from the outlet port of the regulator to the distribution system. Further
reduction of downstream pressure requires a “Second Stage” regulator close to
the consuming equipment. Properly sized piping and regulators will insure
satisfactory service.

NOTE
For safety reasons both FIRST and SECOND stage regulators must
be 250 psig ( 17.58 cm/kg2 ) inlet pressure rated!

SAFETY RELIEF VALVE

If the vaporizer is installed within an enclosure or building, VENT THE SAFETY

RELIEF VALVE OUTSIDE THE ENCLOSURE AND REDIRECT THE
DISCHARGE UPWARD. An optional breakaway adapter is required for piping
from the relief valve. Always install a rain-cap or similar device to prevent water
and other debris from entering the relief discharge. If water enters, it may freeze
and prevent the relief valve from proper discharge, creating a potentially
hazardous situation.

ELECTRICAL SERVICE

The Nameplate on the vaporizer and the Data Sheet provided with the manual
provides your specific vaporizer’s electrical power requirements and the drawing
numbers of the appropriate wiring diagrams and schematics. This unit is
constructed to meet NFPA 70 Class I, Division 1 or Division 2, Group D
requirements. All wiring to the unit, including the ground connection, must meet
the applicable codes for the area in which it is being installed. Wire size and type
must comply with the applicable codes for the area in which it is being installed.
Provide a fused disconnect outside of the classified area. If it is not within sight
of the vaporizer, the fused disconnect must have a locking device. Run wire
within rigid conduit, and install a seal-off at the connection of the field conduit to
the vaporizer.

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 Installation

DETERMINING WIRE SIZE

When selecting the type and size of wire used to install the POWER Series
electric vaporizers, please take into account the following information:

■ Current draw of vaporizer and distance of vaporizer from the disconnect: See
vaporizer Nameplate or the Data Sheet for specific information for the
vaporizer.

■ Single Vaporizer with 60 / 100 amp:

Contactor terminal lug wire size range: #2 - 8 AWG

■ Division 1 Multiple Vaporizer (1-12) 380V to 575V:

Contactor terminal lug wire size range: #2 - 8 AWG

Power is applied to each individual control boxes 1-12.

■ Division 2 Multiple Vaporizer (2-4) 380V to 575V:

Power distribution terminal lug wire size range: 350MCM - 6 AWG

Branch distribution terminal lug wire size range: #6 - 14 AWG

■ Division 2 Multiple Vaporizer (5-6) 380V to 575V built in 2007 forward:

Power distribution terminal lug wire size range: 500MCM - 2 AWG

Branch distribution terminal lug wire size range: #4 - 14 AWG

Applies to 2 separate control boxes.

■ Division 2 Multiple Vaporizer (5-8) 380V to 575V ( applies to units built before
2004):

Power distribution terminal lug wire size range: 2 - 500MCM - 2 AWG

Branch distribution terminal lug wire size range: #4 - 14 AWG

As the length of the wire run affects the overall wire size requirements, always
refer to NFPA 70 (NEC) for proper wire selection.

When installing the wire it is important to have a good connection at the terminal
lugs. Loose terminations may cause an excessive temperature rise at the
terminal lugs, which can lead, to premature contactor failure, transformer failure,
and/or overheating and possible destruction of the transformer. For this reason it
is strongly recommended that the wire terminations be checked and re-tightened
periodically to prevent excessive overheating at the terminals due to loose
connections.

Algas-SDI Operations & Maintenance Manual P/N 52632 3-13

Operation 4

STOP! Have you rechecked the wiring,

tested for leaks, and made sure the
vaporizer is properly installed???

WARNING
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.

System Control Description

The electric vaporizer operates by maintaining a finned aluminum heater core at
an operating temperature. The heater core consists of multiple cast-in resistance
heater elements. Multiple wiring configurations allow a variety o AC input
Voltages to suit local power supply requirements.

Liquid LPG enters the vaporizer through an inlet safety solenoid valve at the
base of the pressure vessel. The solenoid is normally closed valve. The
solenoid opens at a preset temperature after initial start-up, and remains open
under normal operation. Any safety violation causes the solenoid to de-energize
(close). The liquid LPG that comes in contact with the heated core absorbs the
heat, vaporizes, and cools the core. The heaters then come on as necessary to
keep the core temperature above 194°F ( 90°C ). The amount of LPG that can
be vaporized depends directly on the amount of heat that the core can produce.
The amount of heat that the core can produce depends on the size ( wattage ) of
the heaters and the power (voltage) available to produce the heat. Other factors
such as pressure and temperature also affect the amount a vaporizer can
vaporize.

The core temperature-sensing device is a dual thermocouple inserted in the

center of the aluminum core. The thermocouple signal is used to turn the
heaters on and off, turn the solenoid valve on during initial startup, and sense for
over-temperature conditions by the control board. The control board also
monitors a liquid level switch to shut off the vaporizer if it cannot keep up with the
demand for vaporized LPG. The control board turns the mercury relay on and off
to apply power to the heaters as needed for temperature control.

Algas-SDI Operations & Maintenance Manual – P/N – 52632 4-15

Operation

Figure 7 – Control System

Control System.wmf

Control Board
BROWN-OUT FEATURE

The vaporizer is equipped with a Brown-Out feature. The Brown-Out feature will
return the vaporizer to normal operation if there is a power disturbance that is
less than 5 seconds. Do not get the Brown-Out feature confused with the Auto
Restart Option. The Brown-Out feature will only maintain vaporizer operation for
power disturbances less than 5 seconds. The Auto Restart Option will restart the
vaporizer if there is a loss of power for more than 5 seconds. If the vaporizer
should shut down on a safety during the above procedure, open the control box
and read the Operation / Fault code on the annunciator in the upper left corner of
the control board. The annunciator should display a failure code for reference in
troubleshooting. Follow the troubleshooting procedures in this manual to
determine the cause of the problem.

NOTE: Vaporizer controls prior to 53050-X series control board do not have a
brown-out feature.

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 Operation

NEW - AUTO RESTART AND ANNUNCIATOR FUNCTIONS

A new revision of the control board was introduced in fall of 2004. This revision
of the control board is backward compatible with previous control boards. The
control board will feature a EEPROM memory chip. This EEPROM memory chip
will allow the controls to retain failure codes when the ON/OFF switch is set to
OFF or the STOP button is pushed, or main power lost. On any failure
occurrence, the AUTO RESTART feature will be disabled and will not allow the
vaporizer to restart when power returns. For units with STOP/START push
buttons with AUTO RESTART, pushing the STOP button will latch the vaporizer
off. The vaporizer will remain off even if main power is cycled. Pushing the
START button starts the vaporizer and allows the AUTO RESTART feature to
resume normal operation. Any failure code will be reset once the problem is
resolved and the START button is pushed. See the Troubleshooting Section
in the manual for more troubleshooting help.

NEW - ADDED AUTO RESTART DELAY

The AUTO RESTART will have a 2 second delay before starting the vaporizer.
This will allow adequate time for the power to stabilize and for any externals
components to re-energize. The Display Lamps will remain blank for 2 seconds,
then will light as the unit starts up. If the vaporizer is on and power is lost or
drops for less than 5 seconds, the vaporizer will immediately restart. This is
normally referenced as a Brown-Out.

NEW - INCREASED SWITCH BOUNCE DELAYS

This new revision will also have increased switch input bounce delay. The Float
Switch, Economy Pressure Switch Option and the Down Stream Pressure Switch
( AUTO RESTART ) inputs have 2 second delays. The Float Switch will have to
be open for more than 2 seconds before the vaporizer shuts down. This should
minimize any nuisance tripping due to surges or momentary load increases. The
Economy Pressure Switch Option will have to remain open for more than 2
seconds before turning OFF the Solenoid and Heater on increasing pressure.
The Economy Pressure Switch Option will have to remain closed for more than 2
seconds before turning ON the Solenoid and Heater on decreasing pressure.
The Down Stream Pressure Switch ( AUTO RESTART ) is normally configured
either always open or always closed via a jumper. However, the Down Stream
Pressure Switch input is used on special configuration as a switch input.

NOTE
This control board revision will be effective on control boards
shipped with the P/N: 53050-3 and above. ( Released September
2004 )

Algas-SDI Operations & Maintenance Manual – P/N – 52632 4-17

Operation

Operating Instructions
STARTING THE VAPORIZER - DIVISION 1 MODELS

CAUTION
Do not start the vaporizer when both inlet and outlet hand valves
are closed. Pressure can build in the vaporizer during startup and
blow the relief valve.

QUICK START - DIVISION 1 MODELS

1. Close all vaporizer manual outlet valves.

2. Open the manual valve(s) between the propane storage tank and the
vaporizers to allow liquid to flow to the vaporizers. At this time liquid propane
exerts pressure against the still closed solenoid valves.

3. Turn power ON at the Main disconnect.

4. Push the START button located on the left side of the control box.

8. The inlet valve will open with a distinctive “click” sound after approximately
30 seconds of warm-up.

8. Repeat steps 3 - 5 for multiple vaporizer configurations.

8. Slowly open the vaporizer manual outlet valve. Liquid propane is now
flowing into the heated vaporizers and vaporization is now occurring. The
heaters will turn on and off automatically in response to heater core
temperature to match demand.

CAUTION
Make an operational check of the inlet solenoid valve once the
vaporizer is started.

8. Press the STOP button. The valve should stop the flow of liquid as indicated
by the loss of pressure at the outlet. Pressing the START button should
immediately restore operation.

DETAILED START - DIVISION 1 MODELS

Close the outlet hand valve. Open the inlet hand valve. The division 1 units are
equipped with Auto Restart as a standard feature as of September 2004.
Vaporizers shipped before this date with control board 53050-2 and below the
Auto Restart was an Optional feature. The Auto Restart is a feature that allows
the vaporizer to Restart Automatically when the main power is disrupted. See
the Options Chapter to learn more about this feature and other Options that the
vaporizer may have before starting the vaporizer. When the power at the
disconnect is turn on the vaporizer may Automatically start due too this feature.
If not, press and release the "START" switch. From a cold start, the heaters
should come on immediately. The solenoid valve should come on after 30
seconds and the heaters should go off after 55 seconds. If the "HEAT ON" lamp
stays on longer than 55 seconds (starting with a cold unit 60°F ( 15.5°C ) or less),

4-18 Algas-SDI Operations & Maintenance Manual P/N 52632

 Operation

it indicates a possible problem, SEE THE TROUBLESHOOTING SECTION. If

the vaporizer does not start after push the START button, SEE THE
TROUBLESHOOTING SECTION. Vaporizers equipped with the Auto Restart
option may start the vaporizer operation immediately. Vaporizers equipped with
the Economy Option may not start immediately due to high tank pressure.

If the vaporizer is equipped with additional options, See the Options Chapter to
learn more about the other Option Operations.

The vaporizer is now ready to operate.

Slowly open the outlet hand valve. The heaters should begin to cycle to meet the
demand for propane.

If the vaporizer should shut down on a safety during the above procedure, open
the control box and read the Operation / Fault code on the annunciator in the
upper left corner of the control board. Look up the Operation / Fault code on the
annunciator to find out why the vaporizer failed. Follow the troubleshooting
procedures in this manual to determine the cause of the problem.

STOPPING THE VAPORIZER - DIVISION 1 MODELS

1. Push the STOP button(s) located on the right side of the control box(s).

2. Close the manual outlet shutoff valve.

3. Extended period shutdown requires closing the liquid propane withdrawal

valve at the storage tank while there is demand on the system. This allows
the pressure to bleed out of the system. Turn power off at the Main
disconnect and shut the manual outlet valve at the vaporizer. Drain the
system at the strainer to get rid of any accumulated oil and “heavy ends”.

NOTE
Whenever the vaporizer has been turned off and allowed to cool,
the entire STARTUP PROCEDURE must be repeated. Liquid
carryover and a safety shutdown can result from failure to follow
this procedure.

NOTE
When shutting down the vaporizer, always shut off the vaporizer
outlet isolation hand valve.

Algas-SDI Operations & Maintenance Manual – P/N – 52632 4-19

Operation

STARTING THE VAPORIZER - DIVISION 2 MODELS

CAUTION
Do not start the vaporizer when both inlet and outlet hand valves
are closed. Pressure can build in the vaporizer during startup and
blow the relief valve.

QUICK START - DIVISION 2 MODELS

1. Close all manual outlet valves on vaporizer.

2. Open the manual valve(s) between the propane storage tank and the
vaporizers to allow liquid to flow to the vaporizers. At this time liquid propane
exerts pressure against the still closed solenoid valves.

3. Set all ON/OFF toggle switch(s) to the OFF position.

4. Turn power ON at the Main disconnect. Flip the toggle switch to the ON
position at the control panel. Observe that the POWER ON lamp lights
indicating “POWER” to the control box. The HEAT ON and VAPORIZER
OPERATING ( SAFETY CIRCUIT LATCHED ) lamps should illuminate.

5. The INLET VALVE OPEN lamps will illuminate after approximately 30

seconds of warm-up. The inlet valve will open with a distinctive “click” sound,
and its control panel indicator lamp will illuminate. Liquid propane is now
flowing into the heated vaporizers and vaporization is now occurring.

6. Repeat steps 4 & 5 for multiple vaporizer configurations.

7. Slowly open the vaporizer manual outlet valve. Liquid propane is now
flowing into the heated vaporizers and vaporization is now occurring. The
heaters will turn on and off automatically in response to heater core
temperature to match demand.

CAUTION
Make an operational check of the inlet solenoid valve once the
vaporizer is started.

8. Turn the Vaporizer OFF. The valve should stop the flow of liquid as indicated
by the loss of pressure at the outlet. Pressing the START button should
immediately restore operation.

4-20 Algas-SDI Operations & Maintenance Manual P/N 52632

 Operation

DETAILED START - DIVISION 2 MODELS

Close the outlet hand valve. Open the inlet hand valve. The division 2 units are
equipped with Auto Restart as a standard feature. The Auto Restart is a feature
that allows the vaporizer to Restart Automatically when the main power is
disrupted. See the Options Chapter to learn more about this feature and other
Options that the vaporizer may have before starting the vaporizer. When the
ON/OFF switch is set to the ON position the vaporizer will automatically start due
too this feature. Once the ON/OFF switch is set to the "ON" position. The lamp
marked "POWER ON", "VAPORIZER OPERATING ( SAFETY CIRCUIT
LATCHED )" and the "HEAT ON" lamp should come on immediately. The
"SOLENOID VALVE OPEN" lamp should come on after 30 seconds and the
"HEAT ON" lamp should go off after 55 seconds. The START button is used to
restart the unit on any safety failure and reset the Annunciator Display. The
same START sequence should occur when the "START" button is pushed. The
"VAPORIZER OPERATING ( SAFETY CIRCUIT LATCHED )" lamp and the
"HEAT ON" lamp should come on immediately. The "SOLENOID VALVE OPEN"
lamp should come on after 30 seconds and the "HEAT ON" lamp should go off
after 55 seconds. If the "HEAT ON" lamp stays on longer than 55 seconds
(starting with a cold unit 60°F (15.5°C) or less), it indicates a possible problem,
SEE THE TROUBLESHOOTING SECTION. If the vaporizer does not start after
push the START button, SEE THE TROUBLESHOOTING SECTION.
Vaporizers equipped with the Auto Restart option may start the vaporizer
operation immediately. Vaporizers equipped with the Economy Option may not
start immediately due to high tank pressure.

The vaporizer is now to operating. The "POWER ON" lamp, "SOLENOID OPEN"
lamp, and "VAPORIZER OPERATING ( SAFETY CIRCUIT LATCHED )" lamp
should be on, and the "HEAT ON" lamp will cycle to match the demand on the
vaporizer.

Slowly open the outlet hand valve. The "Heat ON" lamp begins to cycle to meet
the demand for propane.

If the vaporizer should shut down on a safety during the above procedure,
indicated by the "VAPORIZER OPERATING ( SAFETY CIRCUIT LATCHED )"
lamp going out, open the control box and read the Operation / Fault code on the
annunciator in the upper left corner of the control board. Look up the Operation /
Fault code on the annunciator to find out why the vaporizer failed. Follow the
troubleshooting procedures in this manual to determine the cause of the problem.

The vaporizer is now to operating. The "POWER ON" lamp, "SOLENOID OPEN"
lamp, and "VAPORIZER OPERATING ( SAFETY CIRCUIT LATCHED )" lamp
should be on, and the "HEAT ON" lamp will cycle to match the demand on the
vaporizer.

Slowly open the outlet hand valve. The "Heat ON" lamp begins to cycle to meet
the demand for propane.

If the vaporizer should shut down on a safety during the above procedure,
indicated by the "VAPORIZER OPERATING ( SAFETY CIRCUIT LATCHED )"
lamp going out, open the control box and read the Operation / Fault code on the
annunciator in the upper left corner of the control board. Look up the Operation /
Fault code on the annunciator to find out why the vaporizer failed. Follow the
troubleshooting procedures in this manual to determine the cause of the problem.

Algas-SDI Operations & Maintenance Manual – P/N – 52632 4-21

Operation

STOPPING THE VAPORIZER - DIVISION 2 MODELS

1. Turn the ON\OFF switch(es) to the OFF position on the vaporizer control
panel.

2. Close the manual outlet shutoff valve.

3. Extended period shutdown requires closing the liquid propane withdrawal

valve at the storage tank while there is demand on the system. This allows
the pressure to bleed out of the system. Turn power off at the Main
disconnect and shut the manual outlet valve at the vaporizer. Drain the
system at the strainer to get rid of any accumulated oil and “heavy ends”.

NOTE
Whenever the vaporizer has been turned off and allowed to cool,
the entire STARTUP PROCEDURE must be repeated. Liquid
carryover and a safety shutdown can result from failure to follow
this procedure.

NOTE
When shutting down the vaporizer, always shut off the vaporizer
outlet isolation hand valve.

REPLACING & COMPATIBILITY OF CONTROL BOARDS

There has been many different part number for the control boards due to
obsolete parts and improvements. All the control boards operate in the same
manner are compatible with the previous versions. Here are most of the
previous part numbers that were used, oldest to new:

Control board PN: 51199 has limited compatibility to the follow control
boards. Control board PN: 51199 can be directly replaced for Division 2
by the following control boards so long as there is no option and is not
explosion proof. For vaporizer with options or are explosion proof the
module on J1 needs to be replaced by a new wire assembly.
For explosion proof without Auto Restart use wire assembly PN: 50920.
For explosion proof with Auto Restart use wire assembly PN: 51343 with
control board 53050-3 and above.
For explosion proof with Economy use wire assembly PN: 50921 with
control board 53050-3 and above.

50167, 50898, 50969, 55209, 52217, 52527, 52223, 52614,

53050-3, PN: Current PN: 53050-4 released May 1, 2007.

4-22 Algas-SDI Operations & Maintenance Manual P/N 52632

Maintenance 5
General
The POWER vaporizer is designed for long term trouble free operation. Because
of the nature of its use, and the severe duty it receives, it is important to provide
scheduled maintenance. A list of RECOMMENDED SPARE PARTS is located in
the back of this manual.

WARNING
To prevent injury from electric shock, disconnect the supply circuit
before servicing the unit.

Table 3 – Maintenance Schedule

ITEM 1 MONTH 3 MONTHS 6 MONTHS ANNUALLY

Liquid Propane Visually
Visually inspect and
Strainer inspect and
clean.
(installed by others) clean.
Visually check.
Safety Relief Valve
Replace if any leakage is observed.
Inspect and clean piston as necessary.
Annually change the inlet solenoid
diaphragm once per year.
Inlet Solenoid
See the enclosed Maintenance &
Operation sheet for ASCO 2-way
valves: Appendix A Figure 21.

Electrical Wiring and Visually inspect for loose connections,

Connections corrosion, or evidence of heating.
(in control box) Replace if necessary.

NOTE
When servicing an individual unit, disconnect power at the Main
disconnect. Isolation valves in the Vapor Outlet manifold and
Liquid Inlet Manifold allows removal of individual units.

Algas-SDI Operations & Maintenance Manual P/N 52632 5-23

Troubleshooting 6
Vaporizer Repair and Troubleshooting
NOTE
Refer to Data Sheet and drawings that came with your unit during
troubleshooting to determine correct readings for various test
procedures. A reference note will direct you to the Data Sheets as
necessary.

The vaporizer control board has a built-in “First-Out” annunciator to assist in

pinpointing problems with vaporizer operation. If the vaporizer shuts down, the
annunciator will indicate what safety or operational condition caused the
shutdown. You can use that information and the following procedures to track
down the cause of the problem.

If the vaporizer has been operating and has shut down, do not reset until you
have opened the control box and recorded the fault indication of the annunciator
readout. Use the following troubleshooting procedures to find the cause of the
shutdown.

If the vaporizer will not start, cycle the power and then press the START switch.
Now open the control box and check the annunciator readout. Use the following
troubleshooting procedures to find the cause of the problem.

A standard electronic multimeter is necessary for many of the diagnostic tests.

WARNING
Do not tip the vaporizer or the control box on its side when power is
on at the disconnect! This could cause run-away heating of the
vaporizer.

WARNING
High voltage is present on the vaporizer. Disconnect the supply
circuit before servicing this unit.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-25

Troubleshooting

Figure 8 – High Voltage Areas of Control Box (Division 1 Models)

High Voltage Areas (1).wmf

6-26 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Figure 9 – High Voltage Areas of Control Box (Division 2 Models)

High Voltage Areas (2).wmf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-27

Troubleshooting

Typical Control Board

Figure 10 - Control Board Layout

Control Board.wmf

COMPONENT IDENTIFICATION

1. Typical Control Board Test Points

2. 6 Pin Molex Connector (for control panel lights J2)
3. Typical Board Adjustment Potentiometer
4. Typical Quick Disconnect Board Connector Points
5. Typical Board Lights
6. Operation / Fault Annunciator code (see annunciator code explanation)
7. 12 Pin Molex (for power ON switch, start button,
economy/auto-restart options J1)
8. Terminal Block (for thermocouple connections J4)

6-28 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

BOARD CONNECTION POINTS

P1 and P2 Liquid LPG Float Switch (5 VDC)

P3 and P4 Alarm – Optional Use (12 VDC, Max. 100 mA)
J4 – (TOP) Terminals 1 and 2 Temperature Control Thermocouple TC1
J4 – (BOTTOM) Terminals 3 and 4 High Temperature Thermocouple TC2
P9 and P10 Heater Relay Power (12 VDC)
P11 and P12 Inlet Solenoid Valve (Power 208 to 240 VAC)
P13 and P14 AC Control Power (15 VAC) into control board

Figure 11 - Vaporizer Operating Temperature Chart

(as measured at TP1 on the control board)

349°F
2nd High Temperature Safety Shutdown
(176°C)

320°F
1st High Temperature Safety Shutdown
(160°C)

266°F
(130°C)
When the heaters shut off, the temperature reading
may continue to climb before it starts to again
decrease.

203°F
Heaters off temperature
(95°C)

194°F
Heaters on temperature
(90°C)
When the heaters come on, the vaporizer temperature
reading may continue to drop before the temperature
starts to increase.
176°F
(80°C)

158°F
Temperature when LPG inlet solenoid opens
(70°C)

Cold Start

Algas-SDI Operations & Maintenance Manual P/N 52632 6-29

Troubleshooting

Control Board Test Points (

TP1 - Operational Temperature Monitoring Test Point, ( 0.XX VDC = XX°C )

TP2 - Solenoid ON Temperature Adjustment Test Point, R6 to adjust

( 0.70 VDC = 70°C )

TP3 - Heat OFF Temperature Adjustment Test Point, use R7 to adjust

( 0.95 VDC = 95°C )

TP4 - Heat ON Temperature Adjustment Test Point, use R8 to adjust

( 0.90 VDC = 90°C )

TP5 - #1 Thermocouple Over-Temperature Safety Adjustment Test Point,

use R9 to adjust ( 0.XX VDC = XX°C )

TP6 - #2 Thermocouple Over-Temperature Safety Adjustment Test Point,

use R25 to adjust ( 0.XX VDC = XX°C )

TP7 - DC Ground

TP8 - 2nd Thermocouple Monitoring Test Point, ( 0.XX VDC = XX°C )

Normal Set Point

R6 - Solenoid ON – Temperature Adjustment Potentiometer .70 VDC

(Fixed setpoint on PN: 53050-4)

R7 - Heat OFF – Temperature Adjustment Potentiometer .95 VDC

R8 - Heat ON – Temperature Adjustment Potentiometer .90 VDC

R9 - #1 Thermocouple – (CAUTION: FACTORY ADJUSTMENT ONLY.

DO NOT ADJUST! Fixed setpoint on PN: 53050-4)

R25 - #2 Thermocouple – (CAUTION: FACTORY ADJUSTMENT ONLY.

DO NOT ADJUST! Fixed setpoint on PN: 53050-4)

OPERATION / FAULT ANNUNCIATOR CODE EXPLANATION

P “P” will be displayed when power has been turned on, indicating power
is being supplied to the control board. On Division 2 models the Power
"ON" lamp will be on.

L “L” will be displayed after the START button has been pushed.
The “L” will display during normal operation. On Division 2 models the
all lamps will be "ON" and the heater lamp will cycle with operating
temperature.

A “A” will be displayed when a power interruption has occurred and auto-
restart has restarted the vaporizer. The vaporizer will be operating
normally. This is an information display and does not indicate a fault.
To reset the annunciator to "L" on the display for Division 2 models, turn
the power switch to OFF and then back to ON and restart the vaporizer.
On Division 2 models the all lamps will be "ON" and the heater lamp will
cycle with operating temperature.

6-30 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

0 “0” is an indication that the unit shut down to the loss of AC voltage for
units without Auto Restart. The Vaporizer is designed to restart itself
when a power glitch or momentary power loss occurs up to 5 seconds. If
power loss is more than 5 seconds the annunciator will display “0” and
the alarm will activate. If power loss is longer than 5 seconds, you may
want to add the Auto Restart Option. See Auto Restart Option.

NOTE
Annunciator numbers 1, 2, 3, 4, 5, 6, 7, 8, and 9 indicate a serious
safety problem and thus shut off the vaporizer and activate the
alarm. Before manually restarting the vaporizer, a service
technician should determine the cause of the problem and rectify it.

Control Board - Operation / Fault Annunciator

Code Indications and Troubleshooting
#0 - AC FAIL
There has been a power interruption long enough to shut the vaporizer off.
Check your incoming power source. Restart the vaporizer.
The alarm will activate on loss of AC voltage. See above note.

#1 - TEMPERATURE SENSOR INOPERATIVE

Open or reversed thermocouple leads on the #1 thermocouple. Check the
thermocouple leads for breaks or loose or reversed connections. See
“Thermocouple Tests”.

#2 - OVER-TEMPERATURE (1ST HIGH TEMPERATURE SAFETY SHUTDOWN AT 356°F / 180°C)

This indicates a control board failure or thermocouple positioning problem.

CHECKS

Shut the vaporizer outlet hand valve. Leave the inlet hand valve open. Set your
meter to volts DC and connect it to TP1 and TP7. This reading will correspond to
the vaporizer core temperature ( 0.75 VDC = 75°C ) Turn power on and press the
START switch. Monitor the meter. The heaters should shut off at approximately
95°C ( 0.95 on the meter ).

If the heaters do not shut off at 95°C ( 203°F ), shut the unit off, disconnect power
and change the control board.

If the heaters shut off at 95°C ( 203°F ), but the temperature climbs above 140°C
( 284°F ), the thermocouple is not properly positioned in the vaporizer. See
Thermocouple Position Failure.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-31

Troubleshooting

#3 - THERMOCOUPLE IS OPEN OR THE VAPORIZER TEMPERATURE REACHED THE 2ND HIGH

TEMPERATURE LIMIT 419°F / 215°C

Check for an open or broken thermocouple connection. Verify the connection to

the control board is secure, on Division 1 and Multiple Vaporizer system check
that the thermocouple connector is still connected at the bottom of the core. To
reset "3" indications the power must be reset at the Main disconnect. Always
verify that the polarity is correct when connecting the thermocouple.

If the vaporizer has overheated to this point, it indicates a total failure of the
primary temperature control circuit. Replace the control board and thoroughly
test the operation of the vaporizer. Call or fax the factory for possible warranty
and disposition of the failed circuit board.

If you change the control board and the annunciator still shows a “3", change or
repair the #2 thermocouple. See Thermocouple Tests.

If the vaporizer has not overheated, the #2 thermocouple has a fault. See
Thermocouple Tests.

#4 - HIGH LIQUID LEVEL SWITCH OPEN

This indicates that the vaporizer is unable to provide enough heat to vaporize the
amount required by the load or the liquid level switch is inoperative. Do the
following tests:

1. Attempt to restart the vaporizer. If the vaporizer operates normally - do tests

#3, 4, and 5 below. If the vaporizer will not start - do test #2.
2. Close the vaporizer outlet hand valve. Open the inlet hand valve. Apply
power to the vaporizer. Press and hold the START switch for 60 seconds.
The heaters should come on for a few seconds and then go off. This
procedure forces any liquid in the vaporizer back toward the tank. Release
the START switch. Does the vaporizer stay on?
If NO: Check the liquid level switch. See Liquid Level Switch Test.
If YES: Your vaporizer was full of liquid. Do the “Solenoid Valve Leak
Test". If it checks good, proceed to Tests #3, 4, and 5.
3. Check voltage and full load amperage of the vaporizer.
See Voltage and Amperage Test.
4. Check the vaporizer control system for correct operation.
See Control System Operation.
5. If the previous tests do not indicate a problem with the vaporizer, it is likely
that the load is greater than the vaporizer’s capacity. Check the load and
match that number against the capacity rating of your vaporizer. (See the
Nameplate on the vaporizer or Data Sheet.) Your total added load should
be equal to or less than the vaporizer capacity rating.

6-32 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

#5 - SOLENOID VALVE FAIL INDICATION

NOTE: Control boards 53050-3 and above now have a resettable fuse for
additional Solenoid Circuit protection. Once the fault is corrected, the vaporizer
should resume normal operation after pushing the start button.
This indicates an electrical failure of the solenoid valve. Check the wiring and the
solenoid valve coil. A shorted solenoid may damage the control board. After
repairing the solenoid and the solenoid is still not operational the control board
most likely is not operational.
See Solenoid Valve Electrical Checks.

#6 - OPERATING TEMPERATURE MISADJUSTED

The "ON" and "OFF" temperatures on the control board are maladjusted. This
condition typical occurs when the "ON" temperature setpoint is adjusted higher
than the "OFF" temperature setpoint.
See Operating Temperature Adjustment Procedure.

#7 - DOWNSTREAM PRESSURE SWITCH

No longer used. But if encountered means that the Economy Options is being
used without the Auto Restart Option enabled. Some Custom configurations use
this input

#8 - SOFTWARE ERROR:

This is a self-test of the control board microprocessor. If this failure occurs,

replace the control board. Call the factory for disposition of the control board:
Customer Service, (206) 789-5410.

#9 - ON BOARD FUSE BLOWN

NOTE: Control boards 53050-3 and above now have a resettable fuse. Once
the fault is corrected, the vaporizer should resume normal operation after
pushing the start button.
For control board below 53050-3 version this indicates that a fuse is blown on
the control board. A fuse protects the switch inputs on J1 and the float switch. If
you encounter this failure you must check that none of the switch inputs are
shorted to ground or wired to a power source during installation. The control
board is not field repairable and needs to be returned to the factory for repair.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-33

Troubleshooting

Adjustment of Operating Temperature

WARNING
Dangerous voltages are present during this test. Use extreme
caution.

SETUP CONDITIONS
1. Turn the vaporizer power on.

2. Do not start the vaporizer.

3. Set the meter to DC volts and put the negative lead on TP7.

“OFF” TEMPERATURE ADJUTSMENT

To adjust the "OFF" temperature, put the positive meter lead on
TP3 and adjust R7 for 0.95 VDC ( 95°C ).

This reading must always be higher than the reading at TP4.

VDC NOTE
Clockwise rotation increases temperature setting.

“ON” TEMPERATURE ADJUSTMENT

To adjust "ON" temperature, put the positive meter lead on TP4
and adjust R8 for 0.90 VDC ( 90°C ).

VDC

CORE TEMPERATURE MONITORING

Put the positive meter lead on TP1 and turn the vaporizer on.
The heaters should turn off and on at the set temperatures as
measured here. Observe the heat "ON" lamp on the control
board or on the control box.

VDC

6-34 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Full Load Voltage Tests

WARNING
THIS IS HIGH VOLTAGE! Exercise great caution in making the
following tests. Carelessness could result in grave injury or death.

The current flow to the heaters is directly dependent on the applied voltage. Low
voltage causes low current. All measurements must be made while the heaters
are on.

FULL LOAD VOLTAGE CHECK

NOTE
Check voltage when heaters are energized.

Check heater voltage by measuring voltage at the power relay when the
contactor is engaged. See the Data Sheet or the Nameplate on the vaporizer
to determine the correct voltage reading for your vaporizer. Check between all
three poles of the relay. The readings should be equal +/- 3%.

NOTE
Low voltage will reduce the capacity of your vaporizers.

Figure 12 - Full Load Voltage Check

Full Load Voltage Check.dxf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-35

Troubleshooting

FULL LOAD CURRENT CHECK

Measure the current on each of the three heater power wires when the
contactors are closed. See the Data Sheet or Nameplate on the vaporizer for
the correct reading (line current) for your vaporizer. All three wires should have
equal readings +/- 3%.

If current readings are uniformly low, you have a low voltage. If current readings
are very different from each other, you may have a defective heater, defective
wiring or open fuse links. See Heater Resistance Check.

Figure 13 - Full Load Current Check

AC AMP

Full Load Current Check.dxf

6-36 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Testing the Heater Elements

WARNING
Shut off power at the Main disconnect before doing this test. This
is the high voltage section of the vaporizer.

Refer to the Data Sheet for the drawing number and model size. Then refer to
the bussing diagram in Appendix A then select the model number from the Data
for important resistance measurements are shown: heater resistance wire to wire
and individual resistance.

1. HEATER RESISTANCE WIRE TO WIRE

Perform this procedure from inside the control box as shown below. Measure
across any two poles using an ohmmeter on a low resistance scale. The reading
should be the same as called out on the Bussing Diagram. Next, check between
any two other poles. Again, the readings should be the same as called out on
the Bussing Diagram.

Figure 14 - Heater Resistance Wire to Wire

Wire to Wire.wmf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-37

Troubleshooting

2. HEATER RESISTANCE TO GROUND

Change your meter to a high resistance scale and check from each pole to the
vaporizer shell or the ground lug in the box. The resistance should be 100 mega
ohms or more.

If both checks are good, the heaters are good. If either check is bad, proceed to
check #3.

Figure 15 - Heater Resistance to Ground

OHM

To Ground.wmf

6-38 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

3. INDIVIDUAL HEATER RESISTANCE TESTS

Remove the vaporizer bottom cover. Remove the wires and jumper bars from
the heater connections.

Figure 16 - Individual Heater Resistance Tests

OHM

Individual Heater Tests.wmf

Using the diagram above, check the individual heaters for correct resistance
using a low resistance scale. See the Bussing Diagram for "Individual Heater
Resistance."

Check from each heater terminal to ground (shell). It should read 100 mega
ohms or more.

NOTE
If either reading is incorrect, consult with the factory for advice and
possible warranty.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-39

Troubleshooting

Power “ON” Lamp Does Not Illuminate - Division 2

If the "POWER ON" lamp does not illuminate when the power switch is turned
on:

1. On current units the Division 2 indicating lamps are 12 VDC LED's and
should not require replacement for a very long time. However on older
vaporizers an incandescent bulb is used. Check the bulb and replace if
necessary.

2. Check branch fusing.

3. Check the two input fuses to the transformer and replace if necessary.

4. Check for 15 VAC at the transformer terminals Y1 and Y2, and the control
board terminals P13 and P14.

A. If there is 15 VAC at terminals P13 and P14 – replace the control board.

B. If there is no 15 VAC at terminals P13 and P14 – check for high voltage
input to the transformer.

1. Voltage OK – change the transformer.

2. No voltage – repair the wiring from the input power terminal to the
transformer.

See the Electrical Drawing that came with your unit for other transformer
wiring configuration.

Figure 17 - Power ON Lamp Does Not Illuminate

VAC

Power ON Lamp.wmf

6-40 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Heat “ON” Lamp Testing

When the heat ON lamp is on, but no heat is produced:

1. On current units the Division 2 indicating lamps are 12 VDC LED's and
should not require replacement for a very long time. However on older
vaporizers an incandescent bulb is used. Check the bulb and replace if
necessary.

2. Check for correct voltage on both sides of the mercury relay.

3. If the voltage is good go to “Testing the Heater Elements”.

4. If there is no voltage on the heater side of the relay check for 12 VDC on the
relay coil terminals.

5. If there is no 12 VDC: change the control board.

6. If there is 12 VDC: change the relay.

Figure 18 - Heat ON Lamp Testing

Heat On Lamp.wmf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-41

Troubleshooting

Solenoid Valve Electrical Checks

WARNING
Turn off all power at the Main disconnect before proceeding.

Figure 19 - Solenoid Valve Electrical Checks (A)

OHM

Solenoid Electric Check (A).dxf

Remove cover on conduit "T". Pull the two red wires and remove the wire nuts.
Separate the wires and test the solenoid valve.

If it checks good, reconnect the wiring and do the same continuity check from the
control board position as shown on Figure 20.

6-42 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Remove the red wire from P11 and the red wire from the fuse block. Check for
proper resistance as indicated.

If this test is bad, repair the wiring. If this test is good, reconnect the wiring and
retest the vaporizer. If the display shows #5 again, replace the control board.

See the Electrical Drawing that came with your unit for other solenoid
wiring configuration.

Figure 20 - Solenoid Valve Electrical Check (B)

OHM

Solenoid Electric Check (B).dxf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-43

Troubleshooting

Solenoid Valve Leak Test

Shut the outlet hand valve. The inlet hand valve should be open. Start the
vaporizer and allow it to heat up until the heaters shut off. This allows any
accumulated liquid in the vaporizer to be forced back toward the supply tank.
Turn the vaporizer off. Shut off power at the Main disconnect. Shut the inlet
hand valve. Cautiously bleed off or use up any gas pressure in the vaporizer and
outlet supply piping. When the pressure is at 0 psi on the vaporizer pressure
gauge shut the outlet hand valve off. Open the inlet hand valve. The solenoid
valve is closed and you should not have any pressure build up in the vaporizer.
If pressure increases, the solenoid valve is leaking and needs to be repaired or
replaced. If it is not leaking in this condition, turn power back on at the Main
disconnect. DO NOT start the vaporizer. Check again for a leaking solenoid
valve. Pressure should remain at zero. If pressure does not remain at zero,
change the control board.

Figure 21 - Solenoid Valve Leak Test

Solenoid Valve Leak Test.wmf

6-44 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Liquid Level Switch Tests (P120 through P320)

Disconnect power from the vaporizer at the Main disconnect. Open the control
box and disconnect the two blue wires from terminals P1 and P2 on the control
board. Check for continuity between the two wires as shown below. If your
meter reads 0 ohms, the float switch is good. Recheck vaporizer operation. If
the switch is good and the control board still reads "4", change the control board.
If the switch reads open (OL on the meter) perform the following tests:

Remove the conduit elbow cover at the liquid level switch. Disconnect and
separate the four wires and test as shown below. A reading other than what is
indicated shows a bad liquid level switch. Replace it. If the liquid level switch is
OHM good, repair the wiring between the liquid level switch and the control board.

Figure 22 - Liquid Level Switch Tests P120 - P320

Liquid Level Switch Test.dxf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-45

Troubleshooting

Replacing the Liquid Level Switch

CAUTION
Turn power off at the Main disconnect.

CAUTION
Close the inlet hand valve and bleed off all pressure in the vaporizer
before proceeding.

1. Remove the conduit cover (1).

2. Pull out and separate the wires (2).

3. Disconnect the conduit union (3).

4. Unscrew the conduit elbow from the liquid level switch (4).

5. Remove the liquid level switch (5). The arrow on the float switch must be up
in order to pull the float back through the mounting hole. See below.

Figure 23 - Replacing the Liquid Level Switch

Replacing Liquid Level Switch.dxf

When re-installing the float switch, use a teflon based thread compound. Check
for leaks.

6-46 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Liquid Level Switch Tests (P480 through P1280)

The P480 through P1280 have a single liquid level switch in the vapor outlet
header with a consolidation module to connect it to three or more control boards.
See the Figure 24.

TROUBLESHOOTING

1. Are all of the control boards showing a #4 annunciator?

Yes: Go to step #2 No: Go to step #4
2. Remove the two float switch wires and check for continuity on the wires on
the control liquid carryover board.
Open: Go to step #5 Continuity: Go to step #3
3. Apply power to the vaporizer. Check for 15 VAC on the 15 volt input to the
card.
15 volts: OK: replace the common liquid carryover board.
No 15 volts: Repair wiring to the transformer or replace the transformer.
4. With power applied to the vaporizer, but ON/OFF switch off, remove the float
switch wires from each vaporizer control board (P1 and P2) and check for
continuity on each pair of wires.
Open: Repair wiring to the consolidation module or replace the module.
Closed: Replace the vaporizer control board showing a #4 on the
annunciator.
5. Remove the cover on the liquid level switch conduit. Disconnect the wires.
Check the liquid level switch.
Open: Replace the switch
Closed: Repair wiring to the consolidation module
Figure 24 - Liquid Level Switch Tests P480 – P1280

OHM

TO COMMON
LIQUID
CARRYOVER
BOARD

Liquid Level Switch Tests (C) and (D).dxf

Algas-SDI Operations & Maintenance Manual P/N 52632 6-47

Troubleshooting

Figure 25 - Common Liquid Carryover Boards ( P480 to P1280 )

NOTE: Refer to drawings that came with the vaporizer for wiring changes.
The configuration shown represents previous versions. Vaporizers built after September 2004 use a 4-
pole relay/s.

Liquid Carryover Boards.dxf

6-48 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Replacing the LPG Level Switch (P480 through

P1280)
CAUTION
Turn off power at the Main disconnect.

CAUTION
Close the inlet hand valve and bleed off pressure in the vaporizer
before proceeding.

1. Remove the conduit cover (1).

2. Pull out and separate the wires (2).

3. Disconnect the conduit union (3).

4. Unscrew the conduit elbow from the liquid level switch (4).

5. Remove the switch.

Figure 26 - Replacing LPG Level Switch

Replacing LPG Level Switch.wmf

When re-installing the float switch, use a teflon base thread compound. Check
for leaks.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-49

Troubleshooting

Thermocouple Tests
NOTE
Thermocouples seldom fail. Most thermocouple problems will be
broken wires or loose connections or shorted wires due to
insulation problems.

Using the following Figure 27 as a guide, check for frayed or loose wiring and
correct color-coding of the connections.

Figure 27 - Thermocouple Tests

Thermocouple Tests.dxf

NOTE
The two thermocouples are interchangeable. You may trade the
wires of #2 thermocouple and #1 thermocouple for aid in
troubleshooting. Color coding of each pair must be observed.

6-50 Algas-SDI Operations & Maintenance Manual P/N 52632

 Troubleshooting

Thermocouple Positioning Problem Tests

WARNING
Shut off the power at the Main disconnect before proceeding.

Use the following information to insure proper insulation of the thermocouple.

Remove the bottom cover on the vaporizer core. Use the following diagrams and
information to insure proper installation of the thermocouple.

Figure 28 - Thermocouple Position Problem Tests

To remove the thermocouple, push up on the bayonet fitting and turn it 1/4 turn
counter-clockwise. The thermocouple should now pull out easily. Check that the
tip is well coated with heat transfer compound. If not, coat the thermocouple tip
with heat transfer compound. Back the bayonet fitting down the armor cable and
reinsert the thermocouple. Push it into the well as much as possible and adjust
the bayonet fitting to lock it with maximum tension on the thermocouple. Test
your vaporizer.

Algas-SDI Operations & Maintenance Manual P/N 52632 6-51

Troubleshooting

NOTE
Division 1 and Multiple Vaporizer systems - Will have a
thermocouple connection at the bottom of the core. The
thermocouple is connected to a thermocouple extension wire that
matches the thermocouple type "K". When thermocouple
Extension wire is used, always be sure that only one end of the
shield is grounded to ensure proper operation. Typically the
extension wire ground wire is grounded at the transformer
mounting screw. This allows units with a seal-off the ability to
replace the thermocouple.
Division 2 Single Vaporizer systems - The thermocouple is routed
straight to the control board.

6-52 Algas-SDI Operations & Maintenance Manual P/N 52632

Options 7
Auto Restart Testing
The Auto Restart feature is standard on Division 2 models and as of September
2004 ( ASDI PN: 53050-3 Boards and above ) the Auto Restart feature is
standard on Division 1 models as well. The Auto Restart automatically restarts
the vaporizer after a power failure when the power switches in the on position.

To test the Auto Restart, start the vaporizer and open the outlet hand valve. Go
to the power Main disconnect that provides power to the vaporizer and shut it off.
Keep it off for five seconds or more. Turn it back on. The vaporizer should
restart and be in normal operation. The annunciator on the control board will
display an “A”. Whenever you see an “A”, you know that power has failed at
one time or another during operation and it has restarted. To reset the display
set the toggle switch to OFF and back ON. The display will now show an "L",
meaning that the unit is operating properly. The vaporizer will shut down on any
failure. Caution should be taken at this point since once the fault is cleared the
vaporizer will Auto Restart when the power is cycled.

NOTE
Division 1 Vaporizer built before September 2004 ( ASDI PN: 53050-
2 Boards and below ) - Will have an explosion proof toggle switch in
place of the Stop Button. This allows the user to set the toggle
switch to the off position to prevent the vaporizer from Auto
Restarting when first turning on the unit from the Main disconnect.
Once the toggle switch is set to the ON position the vaporizer will
start. Division 1 Vaporizer build September 2004 ( ASDI PN: 53050-
3 Boards and above ) - Will no longer require the explosion proof
toggle switch in place of the push button.

Algas-SDI Operations & Maintenance Manual P/N 52632 7-53

Options

Options
ECONOMY OPERATION OPTION

The ECONOMY OPERATION OPTION minimizes the electric power required to

meet the vapor demand. The factory-installed system keeps the vaporizer off
when natural vaporization rates are adequate to meet the vapor demand. During
this period, vapor is supplied to the load via a bypass vapor line linking the
storage tank and vapor distribution line downstream of the vaporizer. When
natural vaporization can no longer meet the vapor demand due to decreased
tank pressure, the economy operation option automatically energizes the
vaporizer. The vaporizer supplies the demand until natural vaporization is again
sufficient to supply the load. The Auto Restart Function is required for
Economy operation and is included with the system.

Units equipped with the Economy Options have a selector switch for Economy or
Manual operation. When set to Economy Operation the vaporizer operation is
based on the tank pressure and will cycle as necessary to maintain adequate
vapor pressure. When set to Manual Operation the tank pressure switch is
bypassed and the vaporizer is continuously operating and maintaining operating
temperature.

TESTING YOUR ECONOMY OPERATION

1. Determine the storage tank pressure.

2. Determine the ON pressure setting of the pressure switch.

3. Put the Economy/Manual switch in MANUAL.

4. Turn the vaporizer power on. The vaporizer should come on.

5. If the tank pressure is higher than the ON setting of the pressure switch, put
the Economy/Manual switch to ECONOMY and the vaporizer should shut off.
For Division 2 models with indicating lamps the Power ON lamp and
VAPORIZER OPERATING ( Safety Circuit Latched ) Lamps will remain on.
The Inlet Solenoid and Heaters will be disabled until tank pressure drops.
Once the tank pressure drops the Heat ON lamps lights and the Solenoid will
energize after the vaporizer has heated to the solenoid setpoint.

6. If the tank pressure is lower than the ON setting of the tank pressure, put the
Economy/Manual switch to MANUAL and the vaporizer should stay on.

See the Electrical Drawing in your manual for the wiring information on the
inlet pressure switch.

See Auto-Restart Testing for checking the auto restart portion of the
economy operation.

7-54 Algas-SDI Operations & Maintenance Manual P/N 52632

 Options
______________________________________________________________________________________
Figure 29 - Installation Schematic

Installation (B).wmf

ECONOMY OPERATION INSTALLATION

The following installation schematic depicts the economy operation option.

Please take a moment to review the layout. The option incorporates a
downstream vapor by-pass line, liquid inlet pressure switch, and additional
circuitry for the control system.

When pressure in the storage tank is higher than the inlet pressure switch set
point 50 psig (3.52 kg/cm2), the switch is “OPEN” and the vaporizer is not
energized. Vapor demand is consequently met by natural vaporization from the
storage tank through the bypass vapor line. When pressure in the storage tank
is less than the inlet pressure switch set point, the switch “CLOSES” and the
vaporizer is energized. The inlet solenoid valve to the vaporizer will open. Liquid
propane then enters the vaporizer, is vaporized, and meets the vapor demand of
the distribution system. The first stage regulator is set to 2 to 4 psig (0.14 - 0.28
kg/cm2) higher than the bypass vapor regulator. This restricts all vapor flow from
the storage tank when the vaporizer is on. This allows the storage tank to rebuild
sufficient pressure to open the inlet pressure switch and de-energize the
vaporizer. The Economy Switch will re-open when the tank pressure reaches 70
psig (4.92 kg/cm2). Natural vaporization then resumes, supplying vapor through
the bypass vapor line. Both of the operating pressure set points are adjustable.

Algas-SDI Operations & Maintenance Manual P/N 52632 7-55

Options

REMOTE BOX

The remote control box provides on/off control, an alarm, and four status lamps
for each vaporizer control system. It requires ten wires for each core between
the remote box and the vaporizer. No external power is required. An additional
terminal strip for each core is provided in the main vaporizer control box for
connecting the remote box. See additional drawings in Appendix.

ASDI PN: 80455-05, Remote box kit

Figure 30 – Remote Box (1 of 2)

Remote Box (B).dxf

REMOTE BOX - ALARM INDICATOR BOX

There are 2 versions of this remote control box which provides alarm indication
only. One version requires 2 wires from the alarm output on the vaporizer control
board. No external power is required. The second version requires 2 wires from
the alarm output on the vaporizer control board See additional drawings in
Appendix.

ASDI PN: 80457, Remote Alarm Indicator Box, Self Powered

ASDI PN: 60710, Remote Alarm Indicator Box, 120VAC Required

7-56 Algas-SDI Operations & Maintenance Manual P/N 52632

 Options
______________________________________________________________________________________
Figure 31 – Remote Box, Division 2 (2 of 2)

Division 2 Remote Box (A).dxf

Algas-SDI Operations & Maintenance Manual P/N 52632 7-57

Options

VALVE AND STRAINER PACKAGE

For a P120 & P160 use: ASDI PN: 36930 3/4"NPT inlet, 1"NPT outlet

For Multiple Vaporizers use: ASDI PN: 36931 1"NPT inlet, 2"NPT outlet

7-58 Algas-SDI Operations & Maintenance Manual P/N 52632

 Options
______________________________________________________________________________________
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.

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 32 ).

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

Figure 32 – Filtaire Operation

BYPASS 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

Filtaire.wmf
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 pipe connections.

4. Check for any leaks by observing new bubble formation in the soap/water solution.

5. Repair any leaks before continuing.

Algas-SDI Operations & Maintenance Manual P/N 52632 7-59

Figure 33 - ASCO Valve used by Algas-SDI 2.9.98

WARNING: TURN OFF ELECTRICAL POWER

AND DE-PRESSURIZE VALVE BEFORE MAKING
ANY REPAIRS.

TORQUE CRISSCROSS TO
110 in-Lbs [ 12.4 N-m ]

TORQUE TO
175 in-Lbs [ 19.7 N-m ]

Algas-SDI ASCO Valve Draw.wmf

SOLENOID NOISE

Solenoid valves emit a sound when operated. When energized, they emit a
clicking sound. Also, accompanying the operation of most AC valves, is AC hum.
Whether or not AC hum is objectionable actually depends on the requirements
and opinion of the user. Normal AC hum is the result of the constantly reversing
magnetic field produced by alternating current. The constantly reversing
magnetic field can cause vibrations in the solenoid parts.

1. Solenoid noise due to damage solenoid parts such as bent solenoid base
assembly, stretched return springs, loose parts, etc.

Solution: Inspect valve internals and exterior. Replaced damaged

parts.

2. Solenoid noise due to foreign matter between the core and plug-nut. When
foreign matter is trapped between the core and plug-nut, the core assembly
will rock back and forth at 60 hertz. Eventually, the core and plug-nut face
will be distorted, at which time the noise can continue even though the
foreign material may have been flushed or removed from the valve.

Solution: Replace damaged parts entirely, clean and reassemble.

3. Solenoid noise due to damaged coil. On rare occasions, a severe voltage

spike or over voltage can potentially short a small portion of the coil winding.
This shorting can cause solenoid noise and coil overheating. However, it
would normally lead to rapid coil burnout. The solenoid parts, however,
could be damaged enough that the noise would continue even after the coil
was replaced due to the deformation produced during the peening process.

4. Missing solenoid parts can severely weaken the magnetic circuit. This can
produce a solenoid noise condition. As discussed above, it will probably also
result in coil burn-out.

Solution: Replace damaged parts, replace lost parts, clean and re-
assemble.

In general, when a noise condition has been encountered, the source of the
problem should be determined and eliminated. The valve should then be
thoroughly inspected to insure that it is yet repairable. Most times, simple
installation of a spare parts kit and a solenoid base sub assembly can restore a
valve to like new condition. The restored and reinstalled solenoid valve should
be tested to insure proper operation, and a voltage check should be made at the
solenoid valve while the valve is energized. In addition, a current reading can be
obtained and compared with catalog specifications to verify normal solenoid and
coil operation.

Note: The coil may have been damaged due to excessive current draw of at
damaged shading coil within the solenoid valve. A partial rebuilding of a valve
damaged by a noise condition can prove useless as the noise condition would
continue. The entire valve should be dismantled and inspected and cleaned. All
parts supplied in a spare parts kit should be installed. Further, and additional
solenoid parts damaged by a noise condition such as a solenoid base sub
assembly, should be replaced. Examine valve seating, pistons and the valve
body to verify that they have not been damaged. Damage to major portions of
the valve may make repairing the valve uneconomical.

Should a noise condition be encountered, immediate action may prevent any

damage to the solenoid valve itself.
 P-Series Electric Vaporizer Data Sheet

Additional Drawings: Rev.

Rev.

Refer to Nameplate on unit for the model and voltage information then look up specific information on
the tables below.

General Specifications: Applies to all units, see Capacity Table below for specific information.
Electrical: 3 Phase, 3 Wire, 50-60 Hz
Electrical Enclosure Rating: Nema 4
Starting Temperature: 70 Deg. C 158 Deg. F
Operating Temperature: 90 - 95 Deg. C 194 - 203 Deg. F
1st High Temperature Limit: 160 Deg. C 320 Deg. F
2nd High Temperature Limit: 176 Deg. C 349 Deg. F
Connections P120 / P160: 3/4" NPT Inlet 1" NPT Outlet
Conduit: 1-1/4" Conduit Seal-Off on Division 1 units by others
Type of Service: Propane Vaporization
ASME Pressure Vessel: 250 PSIG MAWP

Wiring: Meets NFPA Pamphlet 70 requirements for Class 1 Division 1 Group D or Class 1 Division 2 Group D
Other: Meets NFPA Pamphlet 58 requirements for electric vaporizers and may be installed per indirect fired
vaporizer limitations.

Table: Single Vaporizer

Capacities based on 0OF (-17.8OC) @ 100 psig (7.0 kgG/cm 2)

HEAT
VOLTAGE CURRENT POWER Million Million WEIGHT
MODEL VAC AMPS KW
GPH KG/HR
BTU/HR KCAL/HR
EXCHANGE
LBS / KG
AREA
P120 208 74.3 26.8 107 205 9.8 2.47 5.5ft2/0.51m2 180 / 81.9
2 2
P120 220 78.6 29.9 120 230 11.0 2.77 5.5ft /0.51m 180 / 81.9
P120 240 85.8 35.6 142 273 13.1 3.29 5.5ft2/0.51m2 180 / 81.9
2 2
P120 380 45.4 29.8 119 229 10.9 2.76 5.5ft /0.51m 180 / 81.9
P120 415 49.6 35.6 142 273 13.0 3.29 5.5ft2/0.51m2 180 / 81.9
2 2
P120 440 39.3 29.9 120 230 11.0 2.77 5.5ft /0.51m 180 / 81.9
2 2
P120 480 42.9 35.6 142 273 13.1 3.29 5.5ft /0.51m 180 / 81.9
P120 575 30 29.8 119 229 10.9 2.76 5.5ft2/0.51m2 180 / 81.9
2 2
P160 208 97.8 35.2 141 270 12.9 3.25 7.1ft /0.66m 225 / 102
P160 220 103.5 39.4 157 302 14.4 3.64 7.1ft2/0.66m2 225 / 102
2 2
P160 240 94.9 39.4 157 302 14.4 3.64 7.1ft /0.66m 225 / 102
2 2
P160 380 59.7 39.3 157 301 14.4 3.63 7.1ft /0.66m 225 / 102
P160 415 54.8 39.3 157 302 14.4 3.64 7.1ft2/0.66m2 225 / 102
2 2
P160 440 51.7 39.4 157 302 14.4 3.64 7.1ft /0.66m 225 / 102
2 2
P160 480 47.4 39.4 157 302 14.4 3.64 7.1ft /0.66m 225 / 102
P160 575 39.4 39.2 157 301 14.4 3.63 7.1ft2/0.66m2 225 / 102
Shipping weight is an approximation

"POWER is a trademark of Algas-SDI, Patent Number 4645904

 P-Series Electric Vaporizer Data Sheet
Connections- Multiple Vaporizer: 1" NPT Inlet 2" NPT Outlet

Table: Multiple Vaporizer

Capacities based on 0OF (-17.8OC) @ 100 psig (7.0 kgG/cm 2)

HEAT
VOLTAGE CURRENT POWER Million Million WEIGHT
MODEL VAC AMPS KW
GPH KG/HR
BTU/HR KCAL/HR
EXCHANGE
LBS / KG
AREA
P240 208 148.6 53.5 214 410 19.6 4.94 11ft2 / 1.02m2 570 / 260
P240 220 157.2 59.8 240 460 22.0 5.54 11ft2 / 1.02m2 570 / 260
2 2
P240 240 171.6 71.2 284 546 26.2 6.58 11ft / 1.02m 570 / 260
P240 380 90.8 59.7 238 458 21.8 5.52 11ft2 / 1.02m2 570 / 260
2 2
P240 415 99.2 71.2 284 546 26.0 6.58 11ft / 1.02m 570 / 260
2 2
P240 440 78.6 59.8 240 460 22.0 5.54 11ft / 1.02m 570 / 260
P240 480 85.8 71.2 284 546 26.2 6.58 11ft2 / 1.02m2 570 / 260
2 2
P240 575 60.0 59.7 238 458 21.8 5.52 11ft / 1.02m 570 / 260
P320 380 119.4 78.5 314 602 28.8 7.26 14.2ft2 / 1.32m2 700 / 318
P320 415 109.6 78.7 314 604 28.8 7.28 14.2ft2 / 1.32m2 700 / 318
P320 440 103.4 78.7 314 604 28.8 7.28 14.2ft2 / 1.32m2 700 / 318
P320 480 94.8 78.7 314 604 28.8 7.28 14.2ft2 / 1.32m2 700 / 318
P320 575 78.8 78.4 314 602 28.8 7.26 14.2ft2 / 1.32m2 700 / 318
P480 380 179.1 117.7 424 813 38.9 9.80 21.3ft2 / 1.98m2 1050 / 477
P480 415 164.4 118.0 424 815 38.9 9.83 21.3ft2 / 1.98m2 1050 / 477
P480 440 155.1 118.1 424 815 38.9 9.83 21.3ft2 / 1.98m2 1050 / 477
P480 480 142.2 118.1 424 815 38.9 9.83 21.3ft2 / 1.98m2 1050 / 477
P480 575 118.2 117.6 424 813 38.9 9.80 21.3ft2 / 1.98m2 1050 / 477
P640 380 238.8 157.0 534 1023 49.0 12.34 28.4ft2 / 2.64m2 1300 / 590
P640 415 219.2 157.4 534 1027 49.0 12.38 28.4ft2 / 2.64m2 1300 / 590
P640 440 206.8 157.4 534 1027 49.0 12.38 28.4ft2 / 2.64m2 1300 / 590
P640 480 189.6 157.4 534 1027 49.0 12.38 28.4ft2 / 2.64m2 1300 / 590
P640 575 157.6 156.8 534 1023 49.0 12.34 28.4ft2 / 2.64m2 1300 / 590
P800 380 298.5 196.2 628 1204 57.6 14.52 35.5ft2 / 3.3m 2 1650 / 749
P800 415 274.0 196.7 628 1208 57.6 14.56 35.5ft2 / 3.3m 2 1650 / 749
P800 440 258.5 196.8 628 1208 57.6 14.56 35.5ft2 / 3.3m 2 1650 / 749
P800 480 237.0 196.8 628 1208 57.6 14.56 35.5ft2 / 3.3m 2 1650 / 749
P800 575 197.0 196.0 628 1204 57.6 14.52 35.5ft2 / 3.3m 2 1650 / 749
P960 380 358.2 235.5 707 1355 64.8 16.34 42.6ft2 / 3.96m2 1900 / 863
P960 415 328.8 236.1 707 1359 64.8 16.38 42.6ft2 / 3.96m2 1900 / 863
P960 440 310.2 236.1 707 1359 64.8 16.38 42.6ft2 / 3.96m2 1900 / 863
P960 480 284.4 236.2 707 1359 64.8 16.38 42.6ft2 / 3.96m2 1900 / 863
P960 575 236.4 235.2 707 1355 64.8 16.34 42.6ft2 / 3.96m2 1900 / 863
Shipping Weight is an approximation.

"POWER is a trademark of Algas-SDI, Patent Number 4645904

 Vaporizer Model & Voltage
P120 P120 P160 P160 P240 / P320 P240
Division 1 Division 2 Division 1 Divisin 2 Division 1 Division 2
Description 208V 380V 440V 208V 380V 440V 380V 440V 208V 380V 440V 208V 380V 440V 208V 380V 440V
220V 415V 480V 220V 415V 480V 415V 480V 220V 415V 480V 220V 415V 480V 220V 415V 480V
240V 575V 240V 575V 575V 240V 575V 240V 575V 240V 575V
0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620-
Bussing Diagram
7012 7010 7011 7012 7010 7011 7010 7011 7029 7010 7011 7012 7010 7011 7012 7010 7011
0608-
Equipment Drawing 0608 - 6002 0608 - 6001 0608 - 6002 0608 - 6001 0609 - 6004 0609 - 6001
6010
Electrical Drawing 0608 - 7105 0608 - 7103 0608 - 7105 0608 - 7103 0608 - 7105 0609 - 7003
Options - Auto Restart
Equipment Drawing 0608 - 6007 0608 - 6001 0608 - 6007 0608 - 6001 0609 - 6004 0609 - 6001
Electrical Drawing 0608 - 7105 0608 - 7103 0608 - 7105 0608 - 7103 0608 - 7105 0609 - 7003
Options - Economy
Equipment Drawing 0608 - 6008 0608 - 6015 0608 - 6008 0608 - 6015 0609 - 6004 0609 - 6001
Electrical Drawing 0608 - 7105 0608 - 7103 0608 - 7105 0608 - 7103 0608 - 7105 0609 - 7007
Options - Remote
Electrical Drawing 0608 - 7102 0608 - 7107 0608 - 7102 0608 - 7107 0608 - 7102

Vaporizer Model & Voltage

P320 P480 P480 P640 P640 P800 P800 P960 P960
Division 2 Division 1 Division 2 Division 1 Division 2 Division 1 Division 2 Division 1 Division 2
Description 380V 440V 380V 440V 380V 440V 380V 440V 380V 440V 380V 440V 380V 440V 380V 440V 380V 440V
415V 480V 415V 480V 415V 480V 415V 480V 415V 480V 415V 480V 415V 480V 415V 480V 415V 480V
575V 575V 575V 575V 575V 575V 575V 575V 575V
0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620- 0620-
Bussing Diagram
7010 7011 7010 7011 7010 7011 7010 7011 7010 7011 7010 7011 7010 7011 7010 7011 7010 7011
Equipment Drawing 0609 - 6001 0610 - 6004 0610 - 6001 0613 - 6002 0613 - 6001 0614 - 6002 0614 - 6001 0615 - 6003 0615 - 6001
Electrical Drawing 0609 - 7003 0608 - 7105 0610 - 7002 0608 - 7105 0613 - 7001 0614 - 7004 0614 - 7006 0614 - 7004 0615 - 7001
Options - Auto Restart
Equipment Drawing 0609 - 6001 0610 - 6004 0610 - 6001 0613 - 6002 0613 - 6001
Electrical Drawing 0609 - 7003 0608 - 7105 0610 - 7002 0608 - 7105 0613 - 7001
Options - Economy
Equipment Drawing 0609 - 6001 0610 - 6004 0610 - 6001 0613 - 6002 0613 - 6001
POWER P-SERIES ELECTRIC VAPORIZER DATA SHEET ( Continued )

Electrical Drawing 0609 - 7007 0608 - 7105 0610 - 7009 0608 - 7105 0613 - 7006
Options - Remote
Electrical Drawing 0608 - 7102 0608 - 7102

Algas-SDI Operation Maintenance Manual P/N 52632

 ...Innovative liquid vaporizing and gas mixing solutions

CE Declaration of Conformity
WE, Algas-SDI
151 South Michigan Street
Seattle, WA 98108 USA

Declare, solely under own responsibility, that the product

Model: Power Series, LPG vaporizer for converting liquefied petroleum to
vapor by means of an electric heater/heat exchanger.

Mentioned in this declaration, complies with the following standards and/or

normative documents:
Requirements Remarks Certificates No.

97/23/EC Pressure Equipment Directive PED-H-91

Module H

Technical Standards Applied: ASME B&PV Code, Section VIII, Div. 1

Notified Body: Det Norske Veritas AS 0575

Veritasveien 1
N-1322 Hovik, Norway

_________________________
Mike Zimmer, PE
Engineering Manager
June 1, 2007
1 of 1
 Innovative Liquid Vaporizing and Gas Mixing Solutions
1140 NW 46th Street
Seattle, WA 98107 U.S.A.
Phone: 206-789-5410
Fax: 206-789-5414

POWER VERTICAL SPARE PARTS LIST

Locate the replacement parts on the following diagrams then look up the Algas-SDI part number
on the tables located on the last pages.

SINGLE VAPORIZER SPARE PARTS

Figure 34 - View of Division 2 Single Vaporizer Unit

 Innovative Liquid Vaporizing and Gas Mixing Solutions

SINGLE VAPORIZER SPARE PARTS

Figure 35 - View of Division 2 Single Vaporizer Unit

 Innovative Liquid Vaporizing and Gas Mixing Solutions

SINGLE VAPORIZER SPARE PARTS

Figure 36 - View of Division 1 Single Vaporizer control box.

Drawing Reference Model / Voltage
P120 P120 P160 P160

Recommended
Division 1 Division 2 Division 1 Divisin 2
Description 208V 380V 440V 208V 380V 440V 380V 440V 208V 380V 440V

Spares
220V 415V 480V 220V 415V 480V 415V 480V 220V 415V 480V
Key

240V 575V 240V 575V 575V 240V 575V

1 Transformer 52912 52913 52914 52912 52913 52914 52913 52914 52912 52913 52914
2 Fuse - 2, Transformer * 50059 50898 50073 50059 50898 50073 50898 50073 50059 50898 50073
3 Fuse - 6, Power Distrtibution * 50081
4 Mercury Relay 52568 52243 52243 52568 52243 52243 52568 52243 52243 52568 52243
5 Start Switch 30887 50318 30887 50318
6 Start Switch Boot * 50302 50302 50302 50302
7 Stop (ON/OFF) Switch 30887 50311 30887 50311
8 Stop (ON/OFF) Switch Boot * 50302 No Longer Req. 04/03 50302 No Longer Req. 04/03
9 LED Lamp Green 52357 52357
10 LED Lamp Red, Alarm 52358 52358
11 Gasket, LED Lamp 52361 52361
12 O-Ring, Cover 33130 33130
13 Corrision Inhibitor Tape 60806 60806
14 Control board * 53050-4
15 Inlet Solenoid Valve 36112
16 Repair Kit, Inlet Solenoid * 40287

Single Vaporizer Spares Parts

17 Coil, Inlet Solenoid 35080
18 Liquid Level Switch (Float) 30897
19 Pressure Gaurge, 0-300 psig 30641
20 Pressure Relief Valve 35009
21 Pipe Away Adapter, Relief 30752
22 Fusible Link 33139
Manual 52632
24 Thermocouple, "K" Type 32592 32590 31822 31820
Options
Remote Box 80455-05
Remote Box, Alarm only 80457
Remote Box, Alarm only 60710
Economy Pressure Switch 35945 30925 35945 30925
Transducer, Economy Sw. 36084
Switch, Economy/Manual 35054 35054
Note: Fuse size may be different based on options
 Innovative Liquid Vaporizing and Gas Mixing Solutions

MULTIPLE VAPORIZER SPARE PARTS

Figure 37 - View of Division 2 Multiple Vaporizer control box.

 Multiple Vaporizer Spare Parts

Model / Voltage
Drawing Reference

P240 P240 P320 - P960 P320 - P960

Recommended
Division 1 Division 2 Division 1 Division 2
Description 208V 380V 440V 208V 380V 440V 380V 440V 380V 440V

Spares
220V 415V 480V 220V 415V 480V 415V 480V 415V 480V
Key

240V 575V 240V 575V 575V 575V

Bussing Diagram 0620-7012 0620-7010 0620-7011 0620-7012 0620-7010 0620-7011 0620-7010 0620-7011 0620-7010 0620-7011

1 Transformer 52912 52913 52914 52912 52913 52914 52913 52914 52913 52914
2 Fuse - 2, Transformer * 50059 50898 50073 50059 50898 50073 50898 50073 50898 50073
3 See Fuse Table
4 Mercury Relay 52568 52243 52243 52568 52243 52243 52568 52243 52568 52243
5 Start Switch 30887 50318 30887 50318
6 Start Switch Boot * 50302 50302 50302 50302
7 Stop (ON/OFF) Switch 30887 50311 30887 50311
8 Stop (ON/OFF) Switch Boot * 50302 No Longer Req. 04/03 50302 No Longer Req 04/03
9 LED Lamp Green 52357 52357
10 LED Lamp Red, Alarm 52358 52358
11 Gasket, LED Lamp 52361 52361
12 O-Ring, Cover 33130 33130
13 Corrision Inhibitor Tape 60806 60806
14 Control board * 53050-3 W/MEMORY ( New Revision Fall - 2005 53050-4 ), ( 53050-2 OLD )
15 Inlet Solenoid Valve 36112
16 Repair Kit, Inlet Solenoid * 40287
17 Coil, Inlet Solenoid 35080
18 Liquid Level Switch (Float) 30897 P320 use 30897, P480-P960 use 35196

19 Pressure Gaurge, 0-300 psig 30641

20 Pressure Relief Valve 35009
21 Pipe Away Adapter, Relief 30752
22 Fusible Link 33139
Manual 52632
24 Thermocouple, "K" Type 32592 31822
Note: Fuse size may be different based on options
Algas-SDI Operation Maintenance Manual P/N 52632
Multiple Vaporizer Spare Parts

Model / Voltage

Recommended
P240 P240 P320 - P960 P320 - P960
Division 1 Division 2 Division 1 Division 2
Description 208V 380V 440V 208V 380V 440V 380V 440V 380V 440V

Spares
220V 415V 480V 220V 415V 480V 415V 480V 415V 480V
240V 575V 240V 575V 575V 575V
Temperature Gauge 20-240F 36602
Common Float Relay 9005-120 53142
Common Float Board P480 to P960 use 51536
Common Economy Relay 9005-120 53142 9005-120 53142
Common Economy Board ( 51536 for older P-Multiples )
Valve & Strainer Package 36931
Magnetic Plug, 1" 32893
Balancing Orifice - Aluminum 31014
Balancing Orifice - Brass 64002

Options
Alarm Relay - 1 per core 80481 80456 80481 80456
Economy Pressure Switch 35945 30925 35945 30925
Transducer, Economy Sw. 36084
Switch, Economy/Manual 35054 50311 35054 50311
Remote Box 80455-05
Remote Box, Alarm only 80457
Remote Box, Alarm only 60710

Algas-SDI Operation Maintenance Manual P/N 52632

 Multiple Vaporizer Spare Parts

Multiple Vaporizer Fuse Table - Model / Voltage

Drawing Reference

P240 P320 P480 - P1280

Recommended
Division 2 Division 2 Division 2
Description
Size - Size - Part Size -

Spares
Part Number Part Number
Amps Amps Number Amps
Key

208 VAC 53225 90 50081 60

220 VAC 53226 100 50081 60
240 VAC 53226 100 50081 60
380 VAC 50076 60 50078 80 50078 80
415 VAC 50076 60 50077 70 50077 70
440 VAC 52707 50 50077 70 50077 70
480 VAC 52707 50 50076 60 50076 60
575 VAC 50075 40 52707 50 52707 50

Algas-SDI Operation Maintenance Manual P/N 52632

This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
 1140 N.W. 46th St., Seattle, Washington. USA 98107
Tel: (206) 789-5410 Fax: (206) 789-5414

This drawing is the property of Algas SDI

and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.
This drawing is the property of Algas SDI
and is not to be reproduced nor used in any
manner detrimental to our interests. All
rights are reserved.