Kimray GEN 3 Owner's manual

PNEUMATIC LEVEL CONTROLLER
GEN 3

PNEUMATIC LEVEL CONTROLLERPNEUMATIC LEVEL CONTROLLER
MODEL: GEN 3
Installation, Operation & Maintenance Guide
MODEL: GEN 3
Installation, Operation & Maintenance Guide
All Rights Reserved.
All contents of this publication including illustrations are believed to be re-
liable. And while efforts have been made to ensure their accuracy, they
are not to be construed as warranties for guarantees, express or implied,
regarding Kimray products or services described herein or their use or ap-
plication. All sales are governed by our terms and conditions, which are
available on request.
Kimray reserves the right to modify or improve the designs or specications
of such products at any time without prior notice.
©2018 Kimray Inc.

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MODEL: GEN 3
Installation, Operation & Maintenance Guide
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Contents
INTRODUCTION
A1 Scope.................................................................4
A2 Description.........................................................4
 A3Denitions ..........................................................4
A4 Tools and Equipment .........................................4
CONFIGURATION
Mount Orientation ..................................................5
Displacer Orientation.............................................5
Pilot Action - Direct / Indirect Switch ..................5
Left hand / right hand conversion ........................5
INSTALLATION
Install Onto Vessel .................................................6
Connections ...........................................................7
Snap and throttle mode switch ............................7
OPERATION
Start up ...................................................................8
Calibration ..............................................................8
Span adjustment ...................................................8
MAINTENANCE
 Parafncleanoutport ..........................................9
Repair kit replacements ........................................9
Other replacements ...............................................9
Pilot Assembly......................................................10
Mount Assembly...................................................12
Spring Assembly ..................................................14
Filter.......................................................................14
TROUBLESHOOTING
Troubleshooting ...................................................16
If you have any questions about this manual, contact
your Kimray applications support group before
proceeding.

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CAUTION:
Whenordered,thecontrollerconguration&construction
materialswereselectedtomeetspecicpressure,
temperature,&uidconditions.Donotsubjectthe
controllertoanyotherconditionswithoutrstcontacting
theKimrayInc,salesofceorasales/applications
representative.
A4 Tools Needed for Installation,
Conversions & Repair
This Kimray controller DOES NOT require special tools
fordisassembly,inspection&assembly.
These are the standard tools required:
1.  PipeWrenchorotherWrenchtot2-1/2"Flats.
2.  7/8"wrenchforlower1/2"NPTs
3.  9/16"wrenchforGauges-or-AdjustableWrench
4.  9/16"socketforthemountscrews
5.  3/8"SocketforPilotCartridgeCaps
6. 1/4"hexkeyfor1/4"NPTplugs
7.  1/8"HexKey(includedwithunit)seebelow.
8. Thread tape
9.  Anyequipmentneededfortubingconnections
TheGen3includesa1/8"hexkeywhichwilltthepilot
&leverfasteners.
Forconvenience,thehexkeycanbestoredinthe
locationshownbelow.
1/8" Hex key
CAUTION:
Theinstructionsprovidedhereinshouldbecompletely
reviewed&understoodbeforeinstalling,operatingor
repairingthisequipment.AllCAUTION&WARNING
notesmustbestrictlyobservedtopreventinjuryto
personnelordamagetoequipment.
A1 Scope
ThisdocumentcontainsinformationfortheGen3Liquid
LevelController&includesdetailedinstallation,operation
&repair/maintenanceinformationfortheproduct.
A2 Description
TheGen3LiquidLevelControllerisdesignedforusein
single-phase&interfaceliquidcontrolapplications.The
pilotiscapableofbothSnapmode(on/off)&Throttle
mode(modulating).Pneumaticoutputcanbesetto
operateasDirectActingorIndirectActing.Themounting
bodycanbeippedtoeitherLeftHandorRightHand
Mount.Thedisplacermaybeassembledinverticalor
horizontalorientation.Changingbetweentheseoptions
doesnotrequireadditionalcomponentsnorswapping
out pilots.
A3Denitions
Snap Mode:On/Off,discreteoutput.Liquidlevelranges
fromhighpointtolowpoint,largespan.
Throttle Mode:Modulating,proportionaloutput.Holds
consistent level, with very small span.
DirectActing:ForFailClosed(FC)akaPressure-to-Open
(PO)Valve.Pilotprovidesmaximumoutputwhenliquid
level reaches set point at top of span.
IndirectActing:ForFailOpen(FO)akaPressure-to-
Close(PC)Valve.Pilotprovidesmaximumoutputwhen
liquidlevelreachesbottomofspan.
LeftHandMount:Withfrontofcontrollerfacingoperator,
unitismountedonleftsideofvessel.ForBackMount
applications, use this mount option due to the location of
the cover latch.
RightHandMount:Withfrontofcontrollerfacing
operator,unitismountedonrightsideofvessel.
Set Point: The liquid level at which the controller opens
the valve. In Snap Mode, this is at the top of the span. In
Throttle Mode, the liquid level should stay consistent at
the set point.
Span:Distancebetweenthehighest&lowestliquidlevel
duringoperation.ThiscanbesetwiththeSensitivity
Fulcrum.See“SpanAdjustment”below.
Introduction

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Kimrayreservestherighttomodifyorimprovethedesignsorspecicationsofsuchproductsatanytimewithoutnotice.
Conguration
Left Hand / Right Hand Conversion
1. RemoveSpringAdjustmentAssembly(F)and1/2"
NPTplug(E).
2. RemovePilotLeverAssembly(A).
3. LoosenSetScrew(D)atbottomofTorqueLever(B)
andslideTorqueLever(B)offshaft.
4. RemoveCapScrews(C)androtatetheMount(G)
180degrees.
5. ReinstallCapScrews(C)withthreadlocker,replace
TorqueLever(B),andtightenSetScrew(D).
6.ReassembleSpringAdjustmentAssembly(F)on
same side as displacer.
7. Reinstall1/2”NPTplug(E)ontheotherside.
8.ReinstallPilotLeverAssembly(A)onthesideshown
inthePilotLeverLocationtable.-
Pilot Lever
Assembly
Torque
Lever
Cap Screw
Set Screw
1/2" NPT Plug
Cap Screw
Spring
Adjustment
Assembly
Mount
A
B
C
D
C
E
F
G
Mount Orientation
TheGen3canbeorderedineitherLeftHandorRight
Handmount,butifyouneedtochangetheorientation
beforeinstalling,see“LeftHandandRightHand
Conversion”
Left Hand Right Hand
Displacer Orientation
Assembledisplacerasshownbelowforeitherverticalor
horizontal orientation.
Usethreadlockerondisplacerarmthread.
Displacer Arm
Thread Locker
Displacer Arm
Thread Locker
Pilot Action - Direct / Indirect Switch
ToswitchbetweenDirectandIndirect,movePilotLever
fromonesidetotheotheraccordingtothePilotLever
Locationtablebelow.MovetheSensitivityKnobsothatit
isfacingoutwardtowardoperator.
Pilot Lever Location
PilotConguration Throttle Snap
Direct
(ForPressureOpen/
FailClosedValve)
Same side as
spring
Opposite side
ofspring
Indirect
(ForPressureClose/
FailOpenValve)
Opposite side
ofspring
Same side as
spring
Pilot Lever
Sensitivity Knob

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Kimrayreservestherighttomodifyorimprovethedesignsorspecicationsofsuchproductsatanytimewithoutnotice.
Installation
NOTE:
Alwayscheckfastenertightnesspriortoinstallation,
testing,anduse,asfastenershavethepotentialto
loosen in transit. This is recommended to ensure your
safety and proper function of the unit.
*Kimrayassemblytorquemethodbelow*
Four Bolt
Four Bolt
1
1
2
2
3
3
4
4
Three Bolt
Three Bolt
2
2
3
3
1
1
Install Onto Vessel
WARNING:
Beforebeginninginstallation,Block&Bleedvalve.
Makesureallpressureisreleasedfromvessel,and
conrmnopressureremainsinsupplygas/instrument
airlines.DonotinstallinalocationwhereMaxAllowable
WorkingPressurecouldbeexceeded.Readandfollow
instructions.
NPTConnection:ApplyPTFEtapeorpipecompound
tothemalethreadsofthethreadedmount.Tighten
sufcientlytosealthethreadsusingawrenchontheats
ofthemountingpiece.
Donotuseawrenchonthealuminumenclosure/cover
totightentheconnection.Makesuretheenclosureis
alignedverticallywiththepilotontopwhennished.
FlangedConnection:Useasuitablegasketbetweenthe
mountandthevesselconnectionange.
NOTE:
WhenaSeatGasketisdisturbedduringdisassemblya
newGasketshouldbeinstalledduringre-assemblyto
ensurepropersealing.

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Connections
WARNING:Donotinstallortightenanyttings,
gauges,oranyotherconnectionswhilethereispressure
on the line.
Removeplasticplugsfrom1/4”NPTopenings.Use1/4”
or3/8”tubing(notprovided).
Throttle Mode:Connectsupplygaslterandpressure
gaugetoanyofthethreeportslabeled“T”andplugthe
remaining“T”port.Connectsupplylinetolter.Use“S”
portsforVent.
Snap Mode:Connectsupplygaslterandpressure
gaugetoanyofthethreeportslabeled“S”andplugthe
remaining“S”port.Connectsupplylinetolter.Use“T”
portsforVent.
Supply for
Snap Mode
Supply for
Throttle Mode
Installation
Vent:ConnectaVentLineorBreatherPlugtooneofthe
threeVentports,andinstallplugsinremainingtwoports.
Output:Connectpressuregaugetoeitherportlabeled
“OUT”,whereitiseasiestforoperatortosee.Connect
outputlinetoremaining“OUT”port.
CAUTION:Ensuresupplygasiscleananddry.
Vent for
Snap Mode
Vent for
Throttle Mode
Output
Snap and Throttle Mode Switch
Toswitchfromonemodetotheother,swapall“T”
(Throttle-toprow)portconnectionswith“S”(Snap-
bottomrow)portconnections(includingsupplygaslter)
andmovePilotLeverfromonesidetotheother.See
PilotLeverLocationtablebelow.

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Start-up
WARNING:
Verifyallpressureconnectionsaretightbefore
pressurizingthesystem.
WARNING:
Never stand directly in front of or over a controller when
the system is pressurized.
WARNING:
DonotexceedMaximumAllowableWorkingPressureor
maximuminstrumentsupplypressure.Never loosen or
tightenanyttingwhilethereispressureontheline.
Pressurize the system.Ifanyleaksaredetected,bleed
offpressureandaddress.Failuretotakethecontroller
out of service immediately may create a hazardous
condition.
Calibration
Calibratethecontroller’ssetpointwithnoliquidonthe
displacer.
Supply
Gauge Output
Gauge
Set Point
Adjustment
Knob
Throttle Mode:
DirectActing-FailClosed(akaPO)Valve:Withthe
outputat0psi,turnthesetpointadjustmentknob
counterclockwisetoproduceabout10psi.Next,turn
clockwiseuntiltheoutputreaches0psi.
IndirectActing-FailOpen(akaPC)Valve:Withthe
outputat0psi,turnthesetpointadjustmentknob
clockwiseuntilfulloutputpressureisproduced.
Operation
Snap Mode:
DirectActing-FailClosed(akaPO)valve:Withthe
outputat0psi,turnthesetpointadjustmentknob
counterclockwiseto“snapon”,producingthefulloutput
pressure.Thenturntheknobclockwiseuntiltheoutput
pressurereturnsto0psi.
IndirectActing-FailOpen(akaPC)valve:Atfull
outputpressure,turnthesetpointadjustmentknob
counterclockwiseto“snapoff”theoutputpressureto
0psi.Thenturntheknobclockwiseuntilfulloutput
pressure is reached.
Span Adjustment
Sensitivity Fulcrum
Throttle Mode:
Forthrottlemode,startwiththesensitivityfulcrumatthe
centerhashmarkofthepilotlever.Notethecurrentspan.
Ifspanistoolarge,movethesensitivityfulcruminward
oroutwardtoanotherhashmark.Ifresultingspanis
larger,movesensitivityfulcruminoppositedirectionand
note new span. If smaller, continue to move sensitivity
fulcrum further in the same direction until constant level
or minimum span is achieved.
Snap Mode:
Forsnapmode,startwiththesensitivityfulcrumatthe
innermosthashmark.Thisshouldyieldthesmallestspan.
Adjustthefulcrumoutwardasneeduntilthedesired
span is achieved.
Set Point Adjustment
RaiseSetPoint:TurntheSetPointAdjustmentKnob
clockwise
LowerSetPoint:TurntheSetPointAdjustmentKnob
counterclockwise

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ParafnCleanoutPort
TheGen3isequippedwithanaccessporttogivethe
abilitytoinspectandcleanouttheareainsidetheMount,
withouthavingtoremovetheunitfromthevessel.
Thiscanhelpifthereareparafnsorothersolidsthat
buildupovertimeinsidetheMount,restrictingmovement
oftheDisplacerRod.
WARNING:Makesureallpressureisreleased
fromthevesselbeforelooseningthecleanoutportplug.
Repair Kit Replacements
Repairkitscontainallsealsandwearcomponents
recommendedtobereplacedduringscheduled
maintenanceintervalsfortheentireunit,including
Pilot,Well-Wetted,andAdjustmentSpringAssembly
Components.Thefollowingsectionsinstructhow
toreplacethesecomponents.Alistofrepairkit
componentscanbefoundinthekitsheetRK:F001.
Other Replacements
Ifanyothercomponentsthatwereinspectedneedtobe
replaced,usetheTechnicalSpecsdocument08:05.1to
determinewhichpartnumber(s)areneededandcontact
yourlocalKimrayauthorizedstoreordistributortoorder.
WARNING:
Aleakingcontroller is an indication that service is
required.Failuretotakecontroller out of service
immediately may cause a hazardous condition.
WARNING:
Beforebeginningrepair,Block&Bleedvalve.Makesure
allpressureisreleasedfromvessel,andconrmno
pressureremainsinsupplygas/instrumentairlines.
TolocateanauthorizedKimrayrepairfacilityortond
yourlocalKimrayauthorizedDistributorvisitKimray.com.
Whenconductingrepairs,onlyusegenuineKimrayrepair
kitsandreplacementparts.Repairkitsanddetailed
repairinstructions&videosareavailableatKimray.com
Performmaintenanceonaregularbasis.Aninitial
inspectionintervalof6monthsisrecommended.
Dependingontheserviceconditionsandtheconditionof
thecontroller,theinspectionintervalmaybedecreased
or increased.
Thepilotcanberepairedwithoutremovingthecontroller
fromthevesselaslongasthesupplyair/gaspressure
hasbeenbleddownandfullyreleased.
Maintenance

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Maintenance - Pilot Assembly
Pilot - Disassembly
Step1–Remove3socketscrews(1/8"hexkey)holding
pilottoenclosure.Removepilotbypryingunderatsand
thenpullingpilotout.
Step2–Removeanddiscard4O-ringsaroundoutside
ofpilotcartridge.
Step3–Placeatsonlowerpilotcartridgeintoviseor
hold in place with wrench.
Step4–Unthreadandcarefullyremoveangedtoppilot
capto(3/8"socket).
Step5–Carefullyremoveupperdiaphragmassemblyto
avoiddamagingconicalspring.Ifdiaphragmisstuck,do
notprywithscrewdriver.Useplierstopulloutdiaphragm
assembly.
Toremovepilotplug,turnpilotassemblyoverandit
willfallout.Inspectpilotplugandseatsurfacesshown
forscratches,pitting,oranyotherpotentialleakpaths.
Cleanoffanydebris.
Step6–Holdingatsofpilotcartridgeinplace,unthread
andremovebottompilotcap(3/8"socket).
Step7-Removelowerdiaphragmassemblyandlower
spring.Ifdiaphragmisstuck,donotprywithscrewdriver.
Usepliersonstemofactuatortopulloutdiaphragm
assembly.
Step8-Cleanoutallcommunicationholes.
Pilot - Reassembly
Step1–Cleanpilotcartridgeandinstallpilotplug,small
diameterrst,intothesideofthecartridgewiththeupper
seat.
Step2–Placeconicalspringonupperdiaphragm
assembly.Applygreasetoassemblywherespringrests.
Step3–Placeboosterspringintopcap.Applygreasein
topcapwherespringsets.
Step4–Placediaphragmassemblyinpilotblocksuch
thatconicalspringcontactspilotplug.
Step5–Screwthetopcap(3/8"socket)intothepilot
cartridge.Ensurethatspringiscenteredontheupper
diaphragmassembly.Torquetopcapto25-30in·lbs.
Step6–Placelowerspringonlowerdiaphragm
assemblyandinstallintolowerportionofpilotcartridge.
Step7–Installlowercap(3/8"socket)overlower
diaphragmassembly.Torquelowercapto25-30in·lbs.
Step8–Install4newO-ringsintogroovesonoutsideof
cartridge.ApplygreasetoO-rings.
CAUTION:Donotallowgreasetogetonanyother
componentsorintocommunicationholes.Ifgreasegets
intopilotplug/seats,orblockscommunicationpaths,the
pilotmightnotoperatecorrectly.
Step9–Insertpilotcartridgeintoenclosure.
Step10–Install3socketscrews(1/8"hexkey)toretain
pilot.

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Maintenance - Pilot Assembly
Pilot
Pilot Screw
Top Cartridge Cap
Upper Diaphragm Assy.
Booster Spring
Pilot Plug
O-Ring
Bottom Cap
O-Ring
O-Ring
O-Ring
Booster Pilot Spring
Lower Diaphragm Assy.
Diaphragm Spacer
Cartridge Body
Lower Spring
Lower Seat
Upper Seat

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Maintenance - Mount Assembly
Mount - Disassembly
Step1–Mountcontrollerinviseorstandifavailable
Step2–Removedisplacerarmandextensionsfrom
mount.
Step3–Openandremovecover.Inspectcovergasket
for rips or tears.
Step4–Relieveforceonspringbyrotatingspring
adjusterknobclockwise.Removespringandupper
springplate.
Step5–Removetorqueleverbylooseningsetscrewon
underside.
Step6–Removemountscrewsandliftenclosureoff
ofmount,leavingmountinviseifavailable.Remove
andinspectgasketbetweenenclosureandmountfor
damage.
Step7–Removerstbearinghubandshaft.Flipmount
andremovesecondbearinghub.Removesocketplug
fromendofmount.RemoveanddiscardO-ringsfrom
threads.
Step8–Removeangedbearingsfromhubs.Inspect
angedbearingsforwearordamage.Removeand
discardO-ringsandback-upringsinsidehubs.
Step9–Inspectshaftforwearordamage.Cleanout
inside of mount.
Mount - Reassembly
Step1–InstallO-ringoverthreadedhubs&socketplug.
Toavoidsealdamage,donotpushO-ringoverthreads.
RollO-ringoverthreads.Installsocketplug.Tightento
30-35ft·lbs.
Step2–Insertcomponentsintobothhubsinthe
followingorder:back-upring,O-ring,angedbearing.
Step3–Installabearinghubononesideofmount.
Insertshaftwithatsfacingsideofmountthatattaches
toenclosure.Installsecondbearinghubovershaft.
Tightenbothbearinghubsto30-35ft·lbs.
Step4–Alignmountgasketandenclosureover
mountingholes.ApplyblueLoctitetomountscrewsthen
install.
Step5–ApplyblueLoctitetodisplacerarmand
extensionthreads(ifapplicable)andinstallinshaft.
Step6–Slidetorqueleveroveratsofshaftwithset
screwfacingdownward.Tightensetscrew.
Step7–Installspringandupperspringplate.
Step8–Installandclosecover.

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Maintenance - Mount Assembly
Back Up
Bearing Hub
Flanged Bearing
Torque Lever
Socket Plug
Displacer Arm
O-Ring
Gasket
Torque Shaft
Mount
O-Ring
O-Ring
Back Up
Flanged Bearing
Bearing Hub
O-Ring
O-Ring
Set Screw

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Maintenance - Spring Assembly
Spring Assembly - Disassembly
Step1–Rotatespringadjustingknobclockwiseto
relieveforceonspring.
Step2–Removespringandupperspringplate.
Step3–Remove½”NPTspringbushing.Unthread
springassemblyfromlowerspringplateandremove
from enclosure.
Step4–Removespringadjustingknobfrombushing.
RemoveandreplacePTFEwasherandO-ringonspring
adjustingknob.
Spring Assembly - Reassembly
Step1–Installspringadjustingknobinto½”NPT
bushing.
Step2–Installbushingandspringassemblyinto
enclosure.
Step3–Threadlowerspringplateontoadjustingknob.
Installspringandupperspringplate.
Step4–Rotatespringadjustingknobtosetcontroller
levelperCalibrationinstructionsonpg.8.
Adjusting Knob
Bushing
Lower Spring Plate
Washer
Upper Spring Plate
Spring
O-Ring

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Maintenance - Filter
Filter - Disassembly
Step1–Shutoffsupplypressuretocontrollerandbleed
supply line
Step2–Removethesupplylinefromthelterand
removethelterfromthecontroller
Step3–Cleanoutlterelement.Usingcompressedair
inthedownstream(male)connectionwillhelptoensure
debrisisdislodged.
Step4–Reinstalllter.
Directionofairow
tocleanlterelement

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TROUBLESHOOTING
Troubleshooting
Problem PossibleCauseandSolutions
Notsendingsignalorventingwhenitshould
1. Insufcientsupplygaspressure.Ensurethatsupply
gasisowingtocontrollerandisbetween15-45psi.
2. Blockageincontrollerpassages.Inspectports,lter,
andventplugsforanydebris,cleanifneeded.Ensurethat
atleastoneventportallowsow.Ensuresupplygasis
clean and dry.
3. Undersizeddisplacer.Ifspecicgravitydifferential
isbelow0.2,buoyantforcefromdisplacermaynotbe
sufcienttoactivatepilot.AlargerKimraydisplacermaybe
necessary.Whenusingalargerdisplacer(3x12or2x20)
ifspecicgravitydifferentialisbelow0.1,differentialmust
beincreasedto0.1orgreaterforcontrollertooperate
properly.
4. Damagedseals.Isolateandbleedpressurefrom
pilot.InspectpilotO-ringsanddiaphragms.Replaceif
necessary.
5. Displacerrodnotabletomovefullrange.Solidsor
otherobstructioninsideofvessel,restrictingmovementof
displacer.Bleedallpressurefromvesselandcheck/clean
outobstructioninsidevessel.
Controllerdoesnotrespondquicklyenough
1. Impropercalibration.Adjustsensitivityfulcrumper
Calibrationsectioninthisguide.
2. Improperlysizedtubing.Ensuretubingdiameterisat
least1/4”.3/8”diameterispreferable.Minimizelengthof
tubingbetweencontrollerandvalve.
3. Valveisinappropriatelysized.Doublechecksizingof
valvetoensureadequateowrateforprocessconditions.
Pilotbleedscontinuously
1. Pilotplugand/orseatdirty.Cleanpilotplugandseat,
andensurelterisclean.Instrumentgasmayneedup-
streamltrationormoistureremoval.
2. Damagedseals.Isolateandbleedpressurefrompilot.
InspectpilotO-ringsanddiaphragms.Replaceifneces-
sary.
Mountleakingaroundshaftorplugs 1. Damagedseals.Bleedpressurefromvesseland
replaceO-ringsandbackupringsonmountttings.

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‡ Configuration of Back Pressure Valve is a trademark of Kimray, Inc.
Kimray is an ISO 9001- certied manufacturer.
Kimray quality assurance process maintains strict controls
of materials and the certication of parts used in the Kimray severe service control valve.
Please visit our website for up to date product data www.Kimray.com
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MODEL: GEN 3
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MODEL: GEN 3
Installation, Operation & Maintenance Guide
Forquestionsorcomments,contactyourlocalKimrayauthorizeddistributor,orvisitwww.kimray.com.
Kimray Inc.
52 NW 42nd Street
Oklahoma City, OK 73118
Customer Service: 405.525.6601 | [e-mail] Product/Tech Support: 405.525.4264 | [e-mail]

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