All Pictures shown are for illustration purpose only. Actual product may vary due to product enhancement.
www.kimray.com
GEN 3 PNEUMATIC LEVEL CONTROLLERS
QUICK START 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 | service@kimray.com Product/Tech Support: 405.525.4264 | prodtechsupport@kimray.com
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 any service, be certain that the
controller is fully isolated and that all
pressure upstream and downstream has
been relieved. Use bypass valves or
fully shut off the process.
Be sure that any operating or instrument
gas lines have been disconnected.
Never stand directly in front of or
over a controller when the system
is pressurized. The controller could
suddenly open, blowing debris into the
person’s face and eyes.
NOTE
If conditions indicate the possibility of
backward ow you may wish to install
check valves.
Never assume that a check valve is fully
blocking the downstream line.
WARNING
Before beginning installation:
• Read and follow instructions.
• Make sure the valve cannot operate
during installation.
Do not exceed the maximum supply
pressure specied on the controller
nameplate.
Never tighten any tting or the main
connections to the controller while there
is pressure on the line.
Only use genuine Kimray replacement parts.
Repair kits and detailed repair instructions
are available for each valve.
Visit www.kimray.com or contact your
Kimray authorized distributor for additional
product information and / or literature.
SG:F003 Issued 11/21
WARNING
If a level controller is used in a hazardous
or ammable uid service, personal injury
and property damage could occur due to
re or explosion of vented gas that may
have accumulated. To prevent such injury
or damage, install piping or tubing to vent
the uid to a safe, well-ventilated area
or containment vessel. When venting a
hazardous gas, the piping or tubing should be
located far enough away from any buildings
or windows so as not to create further hazard.
The vent opening should be protected
against anything which could obstruct it, or
it should be connected to exhaust tubing or
tubing connected to a vapor recovery system.
NOTE
Do not pick up or carry the controller by using
the displacer arm as a handle.
CAUTION
To avoid personal injury caused by a sudden
release of pressure, shut off the instrument
gas supply pressure and bleed pressure
from the supply lines before performing any
change between snap and throttle mode.
Periodically check the vent opening or
the end of the remote vent pipe, if one is
required. Be certain they are clear. If a vent
should become blocked the pilot could lose
control.
Maintenance
Maintenance should be performed on a
regular basis. An initial inspection interval
of 6 months is recommended. Depending
on the service conditions of the valve, the
inspection interval may be decreased or
increased.
The controller can be repaired without being
removed from the piping.
Problem Possible Cause(s) and Solutions
Not sending signal or
venting when it should
1. Insufficient supply gas pressure. Ensure that supply gas is flowing to controller and is between 15-45psi.
2. Blockage in controller passages. Inspect ports, filter, and vent plugs for any debris, clean if needed. Ensure that at
least one vent port allows flow. Ensure supply gas is clean and dry.
3. Undersized displacer. If specific gravity differential is below 0.1, buoyant force from displacer may not be sufficient
to activate pilot. A larger Kimray displacer may be necessary.
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 tub-
ing between controller and valve.
3. Valve is inappropriately sized. Double check sizing of valve to ensure adequate flow rate for process conditions.
Pilot bleeds continuously
1. Pilot plug and/or seat dirty. Clean pilot plug and seat, and ensure filter is clean. Instrument gas may need up-
stream filtration or moisture removal.
2. Damaged seals. Isolate and bleed pressure from pilot. Inspect pilot O-rings and diaphragms. Replace if necessary.
Mount shaft or plugs leaking 1. Damaged seals. Bleed pressure from vessel and replace O-rings and backup rings on mount fittings.
Start-up and Test
With the installation completed and
appropriate relief and check valves installed
and set, slowly open the upstream and
downstream shutoff valves. In order to
test the function of the valve, allow only a
small amount of upstream pressure to ow
through the upstream shutoff valve. Check
for proper valve operation by cycling the span
adjustment arm several times.
Parafn Cleanout Port
The Gen 3 is equipped with an access port
to give the ability to inspect and clean out
the area inside the connection piece, without
having to remove the unit from the vessel.
WARNING:
Make sure all pressure is released from the
vessel before loosening the cleanout port
plug.
