Doc no :KSG/V/092
Rev no : A9
Eff date :12-04-2018
INSTRUCTION MANUAL
KOSANGAS LPG SDN. BHD.
Electrically Heated Vaporizer For
Zone2 Explosive Gas Atmosphere
Type: KD12-30 & 60Kg/h
Ex nR IIA T3
LPG Vaporizer
Type : KD12
Serial No :
Capacity kg/h :
Declaration of conformity :
Certification no :
Manufacturer date :
Medium : Butane / Propane
Design code : ASME VIII DIV 1
Design pressure : 35.8 bar
O
Design temperature : -20 / +90 C
Working temperature : 60OC
Voltage : 230Vac
Power : 3.9Kw
Current : 17.0A
R
Kosangas LPG Sdn Bhd.
2586, Lorong Perusahaan 10, Kawasan Perusahaan Perai,
13600 Perai, Penang, Malaysia.
Tel : +604-3993779 Fax : +604-3974902
WARNING
DO NOT OPEN WHEN
AN EXPLOSIVE
GAS ATMOSPHERE
MAY BE PRESENT
DO NOT OPEN
WHEN ENERGISED
KOSANGAS LPG SDN. BHD.
2586, LORONG PERUSAHAAN 10, PERAI INDUSTRIAL ESTATE, 13600 PERAI, PENANG, MALAYSIA.
Tel: +604-3993779 Fax: +604-3974902
Electrically Heated Vaporizer For
Zone2
Explosive Gas Atmosphere
Type KD12-30 & 60Kg/h
Technical Description.
Electrical control components are enclosed in a compartment on bottom of the vaporizer.
The electrical parts of the vaporizer are produced in accordance with the following Standard:
EN60079-15:2005 Restricted breathing enclosures
Decay time test
Ex nR IIA T3
The vaporizers are made with a heat exchanger (spiral tube) placed in aluminum cast
chamber. Heating elements are placed in the center of the heat exchanger.
Thermocouple install in the aluminum cast chamber, measuring the temperature to control
the heaters & switch off the inlet LPG solenoid valve.
Safety thermostat is install in the aluminum cast chamber prevent over heated temperature.
On the vaporizer outlet a safety relief valve is fitted, set to open at a predetermined pressure
and then preventing damage to the vaporizer in case of an abnormal pressure increase. To
prevent the safety valve from opening, all valves between the storage tank and the vaporizer
should always be kept open as long as the vaporizer contains liquid, allowing gas to return
freely to the storage tank.
Safety relief valve can be supplied with two different opening pressures:
1. Safety relief valve opening pressure 17bar (250 psig). Flow capacity (at 120%
of set pressure) : 295 ft³/min Air.
2. Safety relief valve opening pressure 24bar (350 psig). Flow capacity (at 480Psig)
:450 ft³/min Air.
PED (less than 1 liter capacity) practice SEP (Sound Engineering Practice).
Electrical specification.
Capacity (kg/h) Phase Power (kW) Voltage (V) Current (A)
30 1 3.9 230 17
60 1 7.8 230 34
Kosangas LPG Sdn Bhd 1
INSTALLATION
The vaporizer must be located on the solid wall.
The vaporizer can be placed in open air. It is advisable to provide weather protection.
If there is a risk of liquid impurities in the gas, a strainer should be placed at the vaporizer
inlet and an oil separator at the outlet.
The steel pipes of the installation must be seamless and rated to 25 - 40 bar (350 -560 psi)
over pressure. Pipes should be joined by welding and should be carried out by certified
welding personnel only.
Pipe connection shall be firmly supported on both sides of the vaporizer. It must be ensured
that no stress can be added to the vaporizer due to expansion in the pipe work.
The incoming power is connected to the proper terminals (refer to the electrical wiring
diagram), in order to retain the restricted breathing enclosure the following cable size must
be followed:
Cable Outer
Capacity (kg/h) Voltage(V) Cable size Cable Type
Diameter
2
4.0mm
30 230 Unarmoured 8.0-16.0mm
(3cores)
10.0mm2
60 230 Unarmoured 11.0-21.0mm
(3cores)
Pressure regulator adjustment.
To reduce the risk of re-condensation in the vapour lines, when using gas mixtures, the
regulator should be placed as close to the vaporizer as possible, and the outlet pressure
should be adjusted to the minimum permissible to ensure correct functioning of the gas
consuming appliance. Low regulator outlet pressure is also preferable from a safety point of
view.
Kosangas LPG Sdn Bhd 2
OPERATIONS AND MAINTENANCE INSTRUCTIONS
1. General
1.1 Installation to be conducted by fully qualified fitters and electricians only.
2. Start
2.1 Switch on power and wait approximately 10min. until the correct working
temperature has been reached.
2.2 The solenoid valve at the vaporizer inlet opens when the heating medium has
reached the set temperature.
3. Operation
3.1 If the vaporizer is fitted with an oil separator, this must occasionally be drained by
blowing off gas through the ball valve until all dirt are removed and only a pure gas
mist is visible. No naked flame is allowed in the vicinity during draining. Precaution
must be taken to prevent gas from seeping into basement or other low-lying areas.
4. Short stops overnight etc.
4.1 During short stops in gas usage it is not necessary to shut off the power supply.
Because of the vaporizer insulation and the power consumption will only be
marginal. When the power isn't shut off the vaporizer is ready for use instantly next
day.
4.2 The ball valve on the vaporizer outlet shall be closed during short stops.
5. Stops for longer periods of time.
5.1 During longer stops close the main valve in the liquid line while the gas-consuming
appliance is still burning gas. Allow all burners to burn until all the gas in the vaporizer
is consumed.
5.2 Close all other valves and shut off the power at main circuit breaker.
6. Repair and relocation.
6.1 As 5.1 and 5.2
6.2 If the vaporizer is to be moved, disconnected connection must be blanked off.
7. Maintenance.
7.1 Pipe connections should be checked against leaks using soap water.
NEVER USE NAKED FLAME IN THE VICINITY
WHEN CHECKING AGAINST LEAKS
Kosangas LPG Sdn Bhd 3
MALFUNCTION
Possible failures.
If the gas supply from a vaporizer in operation fails, the cause could be one of the following:
1. Overloading
If the heating element malfunctions or if the amount of vapor taken from the vaporizer
exceeds the nominal capacity, the gas temperature will decrease until the set point,
solenoid valve will shut off the gas flow.
If the heating element is out of function it must be replaced. If the stop is caused
by overloading the vaporizer will start functioning again once the consumption is
below the nominal capacity.
3. Power Failure
If it is ascertained that the power supply to the vaporizer is on, but the vaporizer iss till
failing to deliver gas, the control circuit fuse should be checked. This is placed in the
vaporizer bottom.
If replacement of the fuse doesn't remedy the problem, a qualified electrician should
be consulted to determine a possible fault in the electrical control circuit.
Kosangas LPG Sdn Bhd 4
Dimensions KD12-30 & 60Kg/h
160
340
540
484
Outlet LPG
LPG Vaporizer
Type : KD12
Serial No :
Capacity kg/h :
Declaration of conformity :
Certification no :
Manufacturer date :
Medium : Butane / Propane
Design code : ASME VIII DIV 1
Design pressure : 35.8 bar
O
Design temperature : -20 / +90 C
Working temperature : 60OC
Voltage : 230Vac
Power : 3.9Kw
Current : 17.0A
R
Kosangas LPG Sdn Bhd.
2586, Lorong Perusahaan 10, Kawasan Perusahaan Perai,
13600 Perai, Penang, Malaysia.
Tel : +604-3993779 Fax : +604-3974902
176 Inlet LPG
WARNING
DO NOT OPEN WHEN
AN EXPLOSIVE
GAS ATMOSPHERE
MAY BE PRESENT
DO NOT OPEN
Input power WHEN ENERGISED
Dimensions in mm
Kosangas LPG Sdn Bhd 5
Spare parts list for vaporizer
A KD12-30kg/h, 230Vac
Pos Part Description No.
A Safety Relief Valve 17 bar, 1/4” 400A013
A Safety Relief Valve 24 bar, 1/4” 400A014
H B Heater 1.3kw, 230Vac 400B000
0
C Over Heated Thermostat 120 C, Manual Reset 400B004
B D Fuse 0.2A ( 5 X 20mm ) 593B031
E Temperature Controller 400B003
F SSR 25A 400B005
G Solenoid Valve 1/4” 400B006
H Thermocouple 400B002
I Power relay 400B043
C
G
D 7 6 5 4
3 2 1
0.2A
G N L
N L G
E
NO
Bottom layer 1
com
L N
F I
4/A2-
1/L1
Bottom layer 2
SSR
3/A1+
2/T1
Kosangas LPG Sdn Bhd 6
Spare parts list for vaporizer
A KD12-60kg/h, 230Vac
Pos Part Description No.
A Safety Relief Valve 17 bar, 1/4” 400A013
A Safety Relief Valve 24 bar, 1/4” 400A014
H B Heater 1.3kw, 230Vac 400B000
0
C Over Heated Thermostat 120 C, Manual Reset 400B004
B D Fuse 0.2A ( 5 X 20mm ) 593B031
E Temperature Controller 400B003
F SSR 50A 400B019
G Solenoid Valve 1/4” 400B006
H Thermocouple 400B002
I Power relay 400B043
C
G
D 7 6 5 4
3 2 1
0.2A
G N L
N L G
E
NO
NO
Bottom layer 1
com
com
L N L N
F I
4/A2-
1/L1
Bottom layer 2
SSR
3/A1+
2/T1
Kosangas LPG Sdn Bhd 7
Electrical wiring diagram for KD12-30kg/h
Over heated
Thermostat
Thermocouple
Heater 1
Heater 2
Heater 3
3 4
+3 -2 1
Temperature
sensor
controller
A
1/L1 2/T1
3 4
NO
SSR Power
relay
230Vac
Control
Event1
com
4/A2- 3/A1+ L N
4+ 5- 6 7 8 9
1 1
12Vdc
2 2
A B
3 2 1
7 6 5 4
0.2A
3 2 1
G N L 7 6 5 4
0.2A
N L G
G N L
N L G
Input Power
230Vac
Over heated thermostat
Push up to reset
(White button)
Solenoid valve
Kosangas LPG Sdn Bhd 8
Electrical wiring diagram for KD12-60kg/h
Over heated
Thermostat
Thermocouple
Heater 1
Heater 3
Heater 5
Heater 2
Heater 4
Heater 6
3 4
+3 -2 1
Temperature
sensor
controller
A
1/L1 2/T1
3 4
NO
NO
SSR Power Power
relay relay
230Vac
Control
Event1
com
com
4/A2- 3/A1+ L N L N
4+ 5- 6 7 8 9
1 1
12Vdc
2 2
A B
3 2 1
7 6 5 4
0.2A
3 2 1
G N L 7 6 5 4
0.2A
N L G
G N L
N L G
Input Power
230Vac
Over heated thermostat
Push up to reset
(White button)
Solenoid valve
Kosangas LPG Sdn Bhd 9
