Kimray GEN II Operating instructions

GEN II
Repair Manual

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GEN II REPAIR MANUAL
INDEX
Introduction .................................................................................................... 1
Elastomer Materials ....................................................................................... 2
Terminal Arm Disassembly ........................................................................... 3
Terminal Arm Assembly ................................................................................ 7
Pilot Disassembly .......................................................................................... 9
Pilot Assembly ............................................................................................. 13
Pilot Installation ........................................................................................... 15
Settings ....................................................................................................... 17
NOTE: We reserve the right to modify or change, without prior
notice, any statement or information contained herein. If exact
dimensions or specifications are required by the customer
certified prints will be furnished for a minimum charge upon
request to KIMRAY, Inc.
® Copyright 2006, KIMRAY, Inc.

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GEN II REPAIR MANUAL
INTRODUCTION
SCOPE
This repair manual contains information for the GEN-II Liquid Level Controller. Included is detailed instruc-
tions in regard to its unique pilot.
DESCRIPTION
The GEN-II Liquid Level Controller uses a spring loaded float to operate a 3 way valve or pilot. This revolu-
tionary pilot can be set for snap mode or throttle mode with the simple turn of a knob. Controlling vessel liq-
uid level has been simplified with 1 control knob to adjust spring tension on float. The pilot assembly is easily
removed by taking out 2 screws. This gives you the choice of repairing the pilot or simply putting a new one
in and repairing the old one at your convenience. Replacement of the pilot assembly can be done in minutes
without taking the controller off line.
The GEN-II is NACE compliant out of the box and comes with a tapped vent hole to pipe bleed gas away.
Side and back npt connections are provided for ease of gas supply and output installation.
OPERATION
The GEN-II uses displacement of a float to control a vessel’s liquid level or it can be used as an interface
controller to maintain multiple liquids in a vessel. Simply mount controller to vessel, set pilot to snap or throt-
tle, and then set level with adjustment knob.
MAINTENANCE
Maintenance should be performed on a regular basis. An initial interval of 12 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, but the
controller will need to be removed for any float related repair.
WARNING
Before performing any service, make sure level controller is isolated from all gas sources. Be sure that all
operating or instrument gas lines have been disconnected.
Never tighten any fittings or the main connections to the level controller while there is pressure in the lines.
NOTE
Because of the how convenient the pilot assembly is to remove and replace, we suggest replacing the pilot
and rebuild old one on bench if a field repair is necessary.
• Use repair kit RMD
To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY
PARTS when doing repairs. Remember, parts made to less than Kimray specifications don’t save you
money!!!
ENG-002.6 Rev. 6 Issued 8-22-2017

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GEN II REPAIR MANUAL
ELASTOMER MATERIALS
TEMPERATURE:
-10° to +350° F
-23° to +177° C
APPLICATION:
Crude Oil & Gas Production, Glycol Dehydrators,
Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal,
Methanol Injection Pumps. (Also Vacuum Service) (Gas
permeability is very low)
FLUID / GAS:
Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline,
Diesel, Fuel Oil Systems
DO NOT USE WITH:
Hot Water, Not preferred for wet H2S, Methyl Alcohol,
Amines, Sodium hydroxide solutions
TEMPERATURE:
-65° to +300° F
-54° to +148° C
APPLICATION:
Steam Flood
FLUID / GAS:
Steam, Water, Alcohol
DO NOT USE WITH:
Crude Oil & Gas, Diester Lubricants (Lube Oils)
TEMPERATURE:
-40° to +220° F
-40° to +104° C
APPLICATION:
High abrasion resistance Seats, Diaphragms
FLUID / GAS:
Crude Oil gas and Water, Sour Gas (C02), propane,
butane, fuel, mineral oil and grease
TEMPERATURE:
±0° to +300° F
-17° to +149° C
APPLICATION:
Production Heaters, Thermostats
FLUID / GAS:
Crude Oil & Gas at High Temperature
DO NOT USE WITH:
Alcohol, Glycols
TEMPERATURE:
-25° to +500° F
-30° to +260° C
APPLICATION:
Crude Oil & Gas Production (High heat), Steam
Flood Production Chemicals (corrosion inhibitors) Amine
Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems
FLUID / GAS:
Crude Oil & Gas Production, H2S, Steam, Petroleum
fluids, Sea Water
TEMPERATURE:
-15° to +300° F
-26° to +149° C
APPLICATION:
Crude Oil & Gas Production w/ H2S C02
FLUID / GAS:
Crude Oil & Gas H2S, C02, Sea Water
TEMPERATURE:
Buna-N:
-40° to +220° F
-40° to +105° C
Low-Temp:
-85° to +120° F
-65° to +49° C
APPLICATION:
Crude Oil & Gas Production Glycol Dehydrators,
Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal,
Methanol Injection Pumps, Water pump seals, hydraulic
pump seals
FLUID / GAS:
Crude Oil & Gas, Good to Poor in Sour Production (See
HSN), Water, Glycols, Hydraulic Oils, Resistance to crude
oil in the presence of hydrogen sulfide and amines, Diesel
fuel, fuel oils
DO NOT USE WITH:
Aromatic hydrocarbons, chlorinated hydrocarbons,
phosphate esters (hydraulic fluids)
TEMPERATURE:
-350° to +500° F
APPLICATION:
High heat, high chemical resistance, highly resistance
to gas permeation
AFLAS ® is a trade mark of Asahi Glass Co VITON ®is a trade mark of Dupont
ETHYLENE PROPYLENE
POLYURETHANE
GYLON
POLYACRYLATE
HSN (Highly Saturated Nitrile)
NITRILE

Screw 2213
Pivot Plate 5442
Mounting Piece 5528
Case 5444
Cover 5445
Gasket 5446
Lens 5447, 2 Req’d.
Terminal Arm 5452
Ext. Rod Assy. 5453V Coupling 5454
Ext. Housing 5455
Wire 5458
Retainer 5459
Pivot Rod 5460
Float 5461
5462 Gauge, 2 Req’d.
Latch 5463
Adj. Lever 5465
Tangent Arm 5466
Spring Assy 5467A
Screw 5468, 2 Req’d.
O Ring 855V (Not Shown)
Screw 5484, 4 Req’d.
Screw 5485
Filter 5486
Link Body 5489
Link Cap 5490
Yoke 5491
Screw 5494
Link Screw 5495
Spring 5496
O Ring 5500V *
Screw 5501
Filter Cap 5502
Arm Post 5504
Pivot Post 5505
Lens Gasket 5506, 2 Req’d.
Lens Retaining Ring 5509, 2 Req’d.
Snap Ring 941
Snap Ring 941
AVariable Link Knob Assy. 5493
Plug 699SS6, 3 Req’d.
Apply 15 ft./lbs.
Using manual torque wrench
when installing 699SS6 plugs
Nut 5531
Decal Left Hand 5521LH
Decal Right Hand 5521RH
Name Plate 5498
NOT SHOWN
Screw 4918, 2 Req’d.
Adjusting Screw 5481
STEP 1
Mount Controller in vise or stand if avail-
able (Fig 1.1).
STEP 2
Open case and inspect Gasket between
cases for rips or tears (Fig 1.2).
If the Gen II is not able to be put on a
stand now is a good time to separate case
by removing Hinge Screw (Fig 1.3).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.1
Figure 1.2 Figure 1.3
Bolt

STEP 3
Pull out on Variable Link Knob and slide
off of Tangent Arm (Fig 1.4).
Using a flat blade screwdriver pry off
lower end of Variable Link Knobs yoke.
Do not turn the Link Arm for it is set at
factory (Fig 1.5).
STEP 4
Remove retainer Snap Rings from Pivot
Post (Fig 1.6).
STEP 5
Remove Adjustment Lever and Leaf
Spring assembly by pulling out on spring
then slide Adjustment Lever off (Fig 1.7)
and (Fig 1.8).
1. Slide out
2. Slide back
STEP 6
Remove Pivot Plate Screws and pull Pivot
Rod out (Fig 1.9) and (Fig 1.10).
Remove Screws
STEP 7
Remove Coupling on end of Terminal Arm
(Fig 1.11).
This step is optional if you cannot get a
wrench around housing. Remove Arm
Post only to make clearance for wrenches
(Fig 1.12).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.4 Figure 1.5
Figure 1.6
Figure 1.7 Figure 1.8
Figure 1.9 Figure 1.10
Figure 1.12Figure 1.11
Knob Pry here

STEP 8
Remove terminal Retainer Nut, make sure
to use a wrench around housing.
(Fig 1.13).
Pull Terminal Arm out from mounting
housing
(Fig 1.14).
STEP 9
Remove Retaining Nut from Arm and dis-
card O ring and seal (Fig 1.15).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.14Figure 1.13
Figure 1.15

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GEN II REPAIR MANUAL
NOTES

STEP 1
Install retaining nut, seal and O ring on
terminal arm. Do not push O ring over
threads or it may be cut by threads. Roll
O ring over threads (Fig 1.1).
Roll over threads
Very important
STEP 2
Apply Blue Loctite to housing threads
(Fig 1.2). Insert terminal arm and tighten
(Fig 1.3).
Loctite
STEP 3
Apply Blue Loctite to arm post and tighten
(Fig 1.4).
Loctite
STEP 4
Install adjustment assembly and spring
assembly. Put adjustment arm on first
then rotate back to align spring assembly
on post (Fig 1.5).
Install snap rings make sure they snap
into grooves on post (Fig 1.6).
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GEN II REPAIR MANUAL
Terminal Arm ASSEMBLY
Figure 1.1
Figure 1.2 Figure 1.3
Figure 1.4 Figure 1.5
Figure 1.6
Figure 1.7 Figure 1.8

STEP 5
Install Spring Clip. Insert back first then
use needle nose pliers to finish (Fig 1.9).
STEP 6
Insert Pivot Rod (Fig 1.10).
Make sure Pivot Rod moves freely & does
not bind Terminal Arm Assy.
Install Pivot Plate, be sure to use Loctite
on screws (Fig 1.11).
GEN II REPAIR MANUAL
Terminal Arm ASSEMBLY
Page 8 www.kimray.com
Figure 1.9
Figure 1.10 Figure 1.11
Loctite
Pivot Plate

Upper Cap 5449
112 Pilot Plug *
*Spring 585
* O Ring 5540V, 2 Req’d.
O Ring 920V *
Screw 7189, 6 Req’d.
Pilot Block 7346
Bottom Cap 5450
Switch Plate 6799
* Throttle Spring 5469
Spacer 5475 *
Lock Washer 4543
Thumb Screw 6780
Selector Pin 5483
* Spring 5541
Screw 4918, 2 Req’d.
O Ring 647V, 2 Req’d. *
Diaphragm Assy 7102AS *
Actuator Assy 7096AS *
STEP 1
Remove 2 flat head screws from Pilot and
remove Pilot from case. (Fig 1.1).
STEP 2
Remove 3 O-Rings from back of body and
discard (Fig 1.2).
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GEN II REPAIR MANUAL
PILOT DISASSEMBLY
Figure 1.1
Figure 1.2
Screws

STEP 3
Remove 3 screws from Upper Cap on
Pilot, be careful of Spring when removing
Cap (Fig 1.3 and 1.4).
STEP 4
Remove Diaphragm Plate being careful of
Spring (Fig 1.5).
Diaphragm may be stuck, do not pry with
screwdriver. To peel up use pliers and pull
up on Diaphragm Plate.
Remove Pilot Plug at this time, turn Pilot
Assembly over and it will fall out.
STEP 5
Remove 3 Retaining Screws on Lower
Cap and remove (Fig 1.6 and 1.7).
STEP 6
Remove Lower Diaphragm watch for
Spring to fall out (Fig 1.8).
Diaphragm may be stuck, do not pry with
screwdriver. To remove use pliers on stem
of Actuator and pull out.
STEP 7
Remove Lower Seat with large screw-
driver. This was installed using Loctite .
Remove and discard O ring (Fig 1.9).
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GEN II REPAIR MANUAL
PILOT DISASSEMBLY
Figure 1.8
Figure 1.9
Figure 1.6 Figure 1.7
Pull here
Pull here
Pilot Plug
Lower Seat
Figure 1.4
Figure 1.5
Figure 1.3

STEP 8
Remove Lock Nut from switch and pull up
on Selector Knob (Fig 1.10 and 1.11).
STEP 9
On Selector Knob make sure holes are
clear. These holes connect to one another
so blow air in to them in order so see if
pathway is clear (Fig 1.12).
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GEN II REPAIR MANUAL
PILOT DISASSEMBLY
Figure 1.10 Figure 1.11
Figure 1.12

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GEN II REPAIR MANUAL
NOTES

STEP 1
Clean Pilot Block and replace 4 O-rings
under Selector Knob. Clear holes of any
obstructions (Fig 1.1).
Apply grease between Selector Knob and
Pilot body before installing (Fig 1.2).
STEP 2
Tighten Lock Nut (Fig 1.3).
STEP 3
Install new O ring on Seat #5473. Make
sure to use Loctite on threads and tighten
Seat with screwdriver (Fig 1.4).
Place Booster Spring #5541 on Lower
Diaphragm Assembly and install (Fig
1.5). Make sure O ring #5540V is on
Diaphragm Assembly.
STEP 4
Make sure Lower Diaphragm is aligned in
bore before securing Lower Cap in place
use loctite on 3 screws (Fig 1.7).
Tighten 3 screws and check around edge
to make sure Diaphragm has not shifted
from bore (Fig 1.8).
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GEN II REPAIR MANUAL
PILOT ASSEMBLY
Figure 1.1 Figure 1.2
Figure 1.3
Figure 1.4 Figure 1.5
Figure 1.6
Figure 1.7 Figure 1.8
Diaphragm
O Ring

STEP 5
Install Pilot Plug small ball first (Fig 1.9).
Place Spring #5469 on Upper Diaphragm
Assembly. Apply grease to Assembly
were Spring rests (Fig 1.10).
STEP 6
Place Spring #585 in Upper Cap. Use
grease in Cap were Spring sets
(Fig 1.11).
STEP 7
Place Diaphragm Assembly in Pilot Block
Spring side down (Fig 1.12).
As with lower side it is very important to
make sure the Diaphragm sits in bore and
not hanging over bore (Fig 1.13).
STEP 8
Making sure Diaphragm is aligned, place
top Cap over assembly and secure use
loctite on 3 screws (Figure 1.14).
Check around edges to make sure Top
Cap sits evenly this way you know the
Diaphragm is still in bore (Fig 1.15).
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GEN II REPAIR MANUAL
PILOT ASSEMBLY
Figure 1.11
Figure 1.12 Figure 1.13
Figure 1.9 Figure 1.10
Figure 1.14 Figure 1.15
Diaphragm

STEP 1
Replace 3 O-rings on back of Pilot Body
(Fig 1.1).
Secure Pilot Body to Case with 2 screws
(Fig 1.2 and 1.3) do not use loctite on
these screws.
STEP 2
Install Variable Link Assembly by first put-
ting back side of Yoke into guide pin then
front side, you may need to use a screw-
driver as when removing it (Fig 1.4).
Pull out Adjustment Knob and slide on to
end of Tangent Arm and position pin in
hole it was removed from (Fig 1.5).
STEP 3
If vertical controller, Install coupling on
end of Terminal Arm, be sure to use loc-
tite on threads (Fig 1.6).
If cover was removed return screw and
shut lid (Fig 1.7).
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GEN II REPAIR MANUAL
PILOT INSTALLATION
Figure 1.1 Figure 1.2
Figure 1.3
Figure 1.4 Figure 1.5
Figure 1.6 Figure 1.7
O Rings
Screws

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GEN II REPAIR MANUAL
NOTES

PRE-SETTING LEVEL FOR THROTTLE
STEP 1
Attach Float at Coupling (Fig 1.1).
Regulate Supply Pressure to 20 pounds
and connect to side of GennII (Fig 1.1).
STEP 2
Switch Selector Knob on Pilot to throttle
and move Variable Link Arm to throttle
side (Fig 1.2).
STEP 3
With Supply Pressure turned on submerse
float in water until output begins. You can
see this by watching output gauge on Gen
II (Fig 1.3). Set level so that 3/4” of float is
underwater before you receive output.
STEP 4
Adjustment Knob is left hand thread. If
Liquid Level is to low turn Adjustment
Knob clockwise to allow more coverage
on Float or turn counter-clockwise to
bring level lower (Fig 1.4). After you find
the correct level tighten Lock Nut behind
Adjustment Knob.
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GEN II REPAIR MANUAL
SETTINGS
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Supply Line
Selector Knob
Variable Link Arm
Output Gauge
or use your own
Spring Adjustment Knob
for Level Control,
reverse threaded.

PRE-SETTING LEVEL FOR SNAP
STEP 1
Move Selector Knob from T to S for Snap
and move Variable Link Arm over to Snap
side (Fig 1.5).
STEP 2
Perform same test as for Throttle mode
with Float and Adjust Spring if necessary
with reverse threaded Adjustment Knob
(Fig 1.6).
When finished remove Float at Coupling
and remove all air lines and gauges.
Return Pilot and Variable Link to throttle
mode and shut case.
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GEN II REPAIR MANUAL
PILOT SETTINGS
Figure 1.5
Figure 1.6