Algas SDI VAPORAIRE Series Manuale

Operations & Maintenance

Manual

151 S. Michigan Street, Seattle, Washington, USA 98108

Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com

MANUAL PN 54264 VAPORAIRE REV 08-26-19

Digitally signed by

Ana Torres

Date: 2019.08.26

15:28:24 -07'00'

WARNING

Read the OPERATION MANUAL before operating this equipment.

DISCLAIMER

Algas-SDI International, LLC (ASDI) shall not be liable for technical

and/or editorial errors or omissions in this manual. ASDI makes no

warranties, express or implied, including the implied warranties of

merchantability and fitness for a particular purpose with respect to

this manual. In no event shall ASDI be liable for any special or

consequential damages including, but not limited to loss of

production time, or loss of profits.

■NOTE: Algas-SDI reserves the right to use alternate manufacturers’

components as vendor delivery applicability dictates. Vendors

have supplied literature contained in the Operation Manual.

Please check to be sure supplied data matches your

configuration. Contact Algas-SDI if any questions exist.

■This equipment uses LPG-a flammable fuel, or NH3-a toxic gas,

(depending on the model), 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 consequences from such actions are

unpredictable and may lead to dire consequences. When components

are replaced with components not approved for use in our FM/CSA

listed equipment, the FM/CSA listing becomes void for that unit.

WARRANTY REGISTRATION

Fill out the Warranty Registration information on the last page of this manual to

at the bottom.

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.

Washington 98108.

form or by any means, photographic, electronic, or mechanical, without the prior

express written consent from Algas-SDI International, LLC, Seattle, 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

This symbol 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

This Symbol indicates a potential hazard, which can result in severe

personal injury or death. Use extreme care and follow the

instructions given.

ELECTRICAL DISCONNECT REQUIRED

This symbol 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.

ASDI CONTACT NUMBERS

If you have questions, need help with your equipment, or want

information on other products, contact Algas-SDI at:

Global Support Center: +1-206-762-HELP (4357)

Telephone: 206.789.5410

Facsimile: 206.789.5414

Email: sales@algas-sdi.com

Internet: http://www.algas-sdi.com

Table of Contents

1.Introduction.................................................................................................................................................... 1-1

General ............................................................................................................................................................ 1-1

DESCRIPTION ................................................................................................................................................ 1-1

MIXER OPERATION - LPG-VAPOR/AIR MIXING PROCESS .......................................................................... 1-2

LPG-Vapor/Air Mixing Process ........................................................................................................................ 1-2

Figure 1 - VAPORAIRE Mixing System Components .................................................................................1-3

Figure 2 - VAPORAIRE with Surge/Accumulator Tank Configuration.........................................................1-4

Figure 3 - VAPORAIRE M-Series Mixing System Components.................................................................. 1-5

Major Components of a Vaporaire M-Series Mixer ......................................................................................... 1-5

Figure 4 - VAPORAIRE M-Series Configuration .........................................................................................1-6

Figure 5 - Single Venturi Control Box..........................................................................................................1-7

Figure 6 - 8100 Sequencer Control Box......................................................................................................1-8

Control Box Components for Mixers using the Sequencer ............................................................................. 1-9

Figure 7 - SEQUENCER Diagram.............................................................................................................1-10

Figure 8 - 2080-TRIMPOT6(C), 6 Channel Potentiometer (Pot.)..............................................................1-11

Figure 9 - 2080-IF2, Analog Input Module(D)............................................................................................1-11

2.Installation.................................................................................................................................................... 2-13

Figure 10 - Typical VAPORAIRE Installation Drawing ..............................................................................2-14

Figure 11 - Typical VAPORAIRE M-Series Installation Drawing...............................................................2-15

Installation Instructions for all LPG-Air/Vapor Mixers .................................................................................... 2-16

Mixed Gas Outlet Installation for VAPORAIRE M-Series ................................................................................. 2-17

Surge/Accumulator Tank Requirements for Vaporaire M-Series Mixers ...................................................... 2-17

Surge/Accumulator Tank Sizing Formula ...................................................................................................... 2-17

Surge/Accumulator Tank Sizing .................................................................................................................... 2-18

Table 4 - Surge/Accumulator Tank Requirements .................................................................................... 2-18

3.Startup.......................................................................................................................................................... 3-19

4.Operation...................................................................................................................................................... 4-21

SINGLE VENTURI SYSTEMS .......................................................................................................................... 4-22

Mixer Operation ............................................................................................................................................. 4-22

Mixed Gas Operating Pressure Adjustments ................................................................................................ 4-22

High Mixed Gas Pressure Safety Switch ...................................................................................................... 4-23

Low Vapor Pressure Switch .......................................................................................................................... 4-23

MULTIPLE VENTURI SYSTEM ........................................................................................................................ 4-24

SEQUENCER Operation ............................................................................................................................... 4-24

Venturi Sequencing ....................................................................................................................................... 4-24

PLC Controller LED Indicators and Mode Switch ......................................................................................... 4-25

Analog Input Module(s) ................................................................................................................................. 4-25

Mixed Gas Pressure Transmitter ................................................................................................................... 4-25

Memory Module: ............................................................................................................................................ 4-26

Discrete Inputs ............................................................................................................................................... 4-27

Table 1 - Discrete Inputs............................................................................................................................ 4-27

Optional Alarm Inputs #1 to #3 ...................................................................................................................... 4-27

Discrete Output .............................................................................................................................................. 4-28

Pressure Adjustments ................................................................................................................................... 4-28

Mixed Gas Operating Pressure Control Setpoint: Trimpot MODULE(c) ...................................................... 4-28

Table 2 - Mixed Gas Pressure and Setpoint Ranges................................................................................4-29

High Mixed Gas Pressure Switch .................................................................................................................. 4-29

High Mixed Gas Pressure Safety Backup (no adjustment required) ............................................................. 4-29

Low Vapor Pressure Switch .......................................................................................................................... 4-30

LPG/Air Venturi Type Mixers ............................................................................................................................ 4-31

Figure 12 - LPG/Air Venturi Assembly Diagram........................................................................................4-31

Venturi Motive Pressure ................................................................................................................................ 4-32

Venturi Motive Pressure Adjustment................................................................................................................. 4-32

Adjusting the Heating Value of the Mixed Gas .............................................................................................. 4-32

Adjusting the Heating Value of the Mixed Gas with Individual Regulators ................................................... 4-32

Adjusting the heating Value of the Mixed Gas with a Single Regulating Station .......................................... 4-33

Figure 13 - Typical Venturi Performance Curve........................................................................................ 4-34

Shutdown ....................................................................................................................................................... 4-35

To Restart the System ................................................................................................................................... 4-35

Standby Condition ......................................................................................................................................... 4-35

5.Maintenance................................................................................................................................................. 5-37

Schedule for all Models of Mixers Operated Continuously ........................................................................... 5-37

Table 5 - Maintenance Schedule...............................................................................................................5-37

Schedule for all Models of Mixers Operated on Standby .............................................................................. 5-38

Table 6 - Maintenance Schedule...............................................................................................................5-38

VENTURI CHECK VALVE REMOVAL AND INSTALLATION INSTRUCTIONS .............................................. 5-39

Removal ........................................................................................................................................................ 5-40

Installation ..................................................................................................................................................... 5-41

Leak Check Procedure for Venturi Check Valves ......................................................................................... 5-44

MAINTENANCE FOR ALL SINGLE MIXERS USING A PRESSURE SWITCH FOR CONROL ….…………. 5-45

MAINTENANCE FOR ALL MIXERS USING THE SEQUENCER .................................................................... 5-45

SEQUENCER ................................................................................................................................................... 5-46

Replacing TRIMPOT6 (C) and Analog Input Module (D): ............................................................................. 5-46

Figure 14 - Module Removal & Installation Drawing .................................................................................5-46

Replacing the Relays .................................................................................................................................... 5-48

Corrosion Inhibitor Tape ................................................................................................................................ 5-48

Control Box Heater ........................................................................................................................................ 5-48

Testing the Control Box Heater ..................................................................................................................... 5-48

6.Troubleshooting.......................................................................................................................................... 6-49

GENERAL TROUBLESHOOTING FOR ALL LPG-VAPOR/AIR MIXERS ....................................................... 6-49

TROUBLESHOOTING GUIDE FOR LPG-VAPOR/AIR MIXERS USING THE SEQUENCER ........................ 6-50

Table 3 - Annunciator output for mixers having fewer than 7 venturis...................................................... 6-50

OPTIONS................................................................................................................................................................. 57

APPENDIX A........................................................................................................................................................... 61

Options

Mixer Options

Surge/Accumulator Tank Packages

Flare stack

Secondary Air Check Assembly

Venturi Silencer Assembly

Appendix A: Component Information

Figure 15 – Inlet Solenoid Assembly Diagram

Solenoid Noise

Component Specifications

Warranty Registration - Refer to the Nameplate on the unit to fill out the product registration.

Then photocopy and mail to address shown. Or register online by visiting Algas-SDI web site

under "Tech Support".

Revision History

August 26, 2019 - Initial Release

Algas-SDI Operations & Maintenance Manual – P/N - 54264 1-1

1. Introduction

GENERAL

The VAPORAIRE & VAPORAIRE M-Series mixing systems from Algas-SDI are

self-contained units providing a mixture of LPG-vapor and air which can replace

natural gas. The VAPORAIRE and VAPORAIRE M-Series are similar except the

VAPORAIRE is packaged with a surge/accumulator tank. The customer

provides the surge/accumulator tank for the VAPORAIRE M-Series or contact

Algas-SDI for surge/accumulator tank options.

DESCRIPTION

The VAPORAIRE mixing systems are available in various models providing a

gas/air mix from 2.5 to 250 million BTU/hr at pressures from 5 to 15 PSIG

depending on the model selected. The VAPORAIRE PA (Pressure Assist)

Series mixing systems is used when pressures greater than 15 PSIG are

required. Other models are available for butane and butane/propane mixtures.

The gas/air mix provided is compatible with natural gas and may be used as a

direct replacement without adjustments to your burner systems.

The gas is mixed and stored in the surge/accumulator tank to provide

uninterrupted flow of mixed gas from full flow to no flow, automatically.

All models are explosion proof and meet the requirements of Class I, Division 1,

Group D as defined by NFPA Pamphlets 58 and 70. That classification allows for

installation of the mixers almost anywhere with minimum clearances for

convenient installation.

Algas-SDI manufactures three types of venturi mixers for mixing LPG-vapor with

air that burns at specific BTU values:

1) VAPORAIRE, ambient air mixers with surge/accumulator tanks.

2) VAPORAIRE M-Series, ambient air mixers without surge/accumulator tanks.

3) VAPORAIRE PA-Series, pressure assisted mixers without surge/accumulator

tanks.

This manual provides information on installation, startup, operations,

maintenance, and troubleshooting for two LPG-vapor/air mixing systems;

VAPORAIRE and VAPORAIRE M-Series. An addendum is provided for the

VAPORAIRE PA-Series.

Most operating procedures for the three mixers are the same. When they are the

same, only one description is provided. However, each description is listed

separately when the operation differs between the mixers.

The Data Sheet for each mixer lists the capacity, designated pressure and

sequencer type.

Introduction

1-2 Algas-SDI Operations & Maintenance Manual – P/N - 54264

MIXER OPERATION - LPG-VAPOR/AIR MIXING PROCESS

LPG-vapor from a vaporizer enters the mixing system through a header manifold,

which distributes the gas to each venturi. A solenoid valve at the manifold

controls the flow of vapor to each venturi and a pressure switch monitors the

vapor pressure in the header. The venturi solenoid opens, feeding LPG-vapor

through a pressure regulator and then through the venturi nozzle. The LPG-

vapor creates a pressure lower than atmospheric pressure in the venturi housing

as it exits the venturi nozzle. Each venturi mixing train has a manual valve, so it

can be shut off separately.

The natural atmospheric pressure will force the air into the housing. Both air and

LPG streams are mixed and compressed in the diffuser section. The discharged

gas is then stored in the surge/accumulator tank as mixed gas. When the

pressure in the surge/accumulator reaches a preset level the venturi solenoid

valve will close. As the mixed gas is drawn off and used the mixed gas pressure

will decrease allowing the venturi solenoid valve to reopen. The system

maintains the mixed gas at a specified pressure in the surge/accumulator tank by

turning the venturis on and off within a small pressure deadband. This process

continues until the unit is switched off or shut down by a safety condition.

LPG-VAPOR/AIR MIXING PROCESS

See VAPORAIRE Mixer: Figure 1

Mixed gas is produced by the venturi assembly (5). LPG vapor enters the vapor

manifold and passes through the safety inlet solenoid valve (1). A High Mixed

Gas Pressure Switch in the explosion proof control box (9) monitors mixed gas

pressure within the surge/accumulator tank. If this pressure exceeds the normal

mixed gas delivery pressure, the mixer shuts down and the safety solenoid valve

will close, stopping LPG vapor flow into the mixer.

The SEQUENCER is a Programmable Logic Controller (PLC) that monitors

pressure in the surge/accumulator tank via a 4-20mA signal from a pressure

transmitter. The SEQUENCER controls 1 - 10 venturi valves. As the mixed gas

pressure decreases, the SEQUENCER energizes the number of solenoid valves

necessary to re-establish the proper mixed gas pressure. The SEQUENCER

controls the rate and sequence at which the solenoid valves are turned on and

off. The venturi solenoid valve (3) energizes upon command from the

SEQUENCER to allow LPG vapor to enter the venturi(s).

High pressure LPG vapor accelerates through the venturi nozzle (17) forming a

vacuum at the air inlet (19), which draws in air, mixing it with the vapor at a

specific rate. The mixed air/gas is propelled into the diffuser (18) where it

decelerates and gains pressure as it fills the mixer surge/accumulator tank. The

mixed gas is held in the surge/accumulator tank at the pressure set by the

SEQUENCER until withdrawn through the mixed gas discharge valve.

Single venturi mixers use one venturi with a pressure switch for control to mix

LPG vapor and air which is distributed to the surge/accumulator tank.

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