Kimray GEN 3 User manual

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
CAUTION
Prior to installing, the instructions provided herein should be completely
reviewed and understood before operating or repairing this equipment.
All CAUTION and WARNING notes must be strictly observed to
prevent personal injury or equipment damage.
Description
The Gen 3 Liquid Level Controller is designed for use in single-
phase and interface liquid control applications. The pilot is capable of
both Throttle mode (modulating) and Snap mode (on/off). 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.
Displacer Assembly
Throttle
Snap
Pilot Lever Assembly
Torque Lever
Cap Screw
Set Screw
1/2” NPT Plug
Mount
Cap Screw
Spring Adjustment Assembly
Displacer
Displacer
Arm
Rod Assembly
Arm
Coupling
Installation
NPT Connection: Apply PTFE tape or pipe compound to the male
threads of the body, tighten sufciently to seal the threads. Use 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 vertical with the pilot on top when nished.
Flanged Connection: Use a suitable gasket between the body and
the vessel connection ange.
Connections
Remove plastic plugs from 1/4" NPT openings. Use 1/4" or 3/8"
tubing (not provided).
Throttle Mode: Connect supply line and pressure gauge to any of
the three ports labeled “T” and plug the remaining “T” port with a steel
1/4" NPT plug. Use “S” ports for Vent.
Snap Mode: Connect supply line and pressure gauge to any of the
three ports labeled “S” and plug the remaining “S” port with a steel 1/4"
NPT plug. Use “T” ports for Vent.
Vent: In either mode, connect a Vent Line or Breather Plug to one of
the three Vent ports, and install steel 1/4" 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 last “OUT” port.
Calibration
Calibrate the controller’s set point with no liquid on the displacer.
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.
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
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
Left Hand / Right Hand Conversion
Throttle
Snap
Pilot Lever Assembly
Torque Lever
Cap Screw
Set Screw
1/2” NPT Plug
Mount
Cap Screw
Spring Adjustment Assembly
Displacer
Displacer
Arm
Rod Assembly
Arm
Coupling
1. Remove Spring Adjustment Assembly and 1/2" NPT plug
2. Remove Pilot Lever Assembly
3. Loosen Set Screw at bottom of Torque Lever and slide it off shaft.
4. Remove Cap Screws and rotate the Mount 180 degrees.
5. Reinstall Cap Screws with thread locker, replace Torque Lever, and
tighten Set Screw.
6. Reassemble Spring Adjustment Assembly on same side as displacer
7. Reinstall 1/2" NPT plug on the other side.
8. Reinstall Pilot Lever Assembly on the side shown in the Pilot Lever
Location table below.
Snap and Throttle Mode Switch
Throttle
Snap
Pilot Lever Assembly
Torque Lever
Cap Screw
Set Screw
1/2” NPT Plug
Mount
Cap Screw
Spring Adjustment Assembly
Displacer
Displacer
Arm
Rod Assembly
Arm
Coupling
To switch from one mode to the other, swap all “T” (Throttle - top row)
port connections with “S” (Snap - bottom row) port connections and
move Pilot Lever from one side to the other. See Pilot Lever Location
table below.
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.
Pilot Lever Location
Pilot Conguration Throttle Snap
Direct (Fail Close) Same side as spring Opposite side of spring
Indirect (Fail Open) Opposite side of spring Same side as spring
CAUTION
This controller was ordered with material options selected to meet
specic pressure, temperature, and uid conditions. Do not subject the
controller to conditions outside of its limits.

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 | [e-mail] Product/Tech Support: 405.525.4264 | [e-mail]
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 specied 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.
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 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.