Kimray Pneumatic GEN II Instruction Manual

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
1
IM0015
Kimray Inc.- 52 NW 42nd Street Oklahoma City, Ok 73118 USA - Ph: [phone], Fax: [phone] - Kimray.com
INTRODUCTION
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.
Scope
This installation manual includes instructions
and maintenance information for both
Kimray pnuematic side mount and back
mount level controllers.
Do not install, operate, or maintain a
pneumatic GEN II without being fully trained
and qualied with Kimray installation and
maintenance manual. To avoid personal
injury or property damage, it is important to
carefully read, understand, and follow all the
contents of this manual, including all safety
cautions and warnings. If you have any
questions about these instructions, contact
your Kimray applications support group
before proceeding.
CONTENTS
PAGE
Introduction 1
Scope 1
Description 1
Specication 1
Control Installation 2
Table 1 - General Specications
Description: Pneumatically Operated
Level Controller.
Operating
Pressure:
(0-4000) psig (276 Bar)
Connection Size: 2in. - 6in.
Body Material: Steel
Connection Type: NPT, Flg, Grv, HU
Grooved
Actuation: Snap, Throttle
Adjustable
Control Range: 2 - 10 in.
Temperature: -50° to 300° F
-45° to 149° C
Specication
Description
The GEN II side mount and back mount
level controllers are designed for use in
liquid level and liquid/liquid interface control
applications. Both provide either a throttle
modulating or snap on/off pneumatic
output and can be set to operate in a
direct increasing liquid level output signal
or indirect mode increasing liquid level
decreasing output signal.
The GEN II level controllers are equipped
with a displacer or hanger for horizontal or
vertical installation.
Before beginning installation of the GEN II
•Read and follow instructions.
•Make sure all pressure has been removed
from the vessel before opening any connec
tions.
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 uid 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 uid, 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 by connected to
exhaust tubing or tubing connected to a
vapor recovery system.
Vent
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.
CAUTION
When ordered, the GEN II level controller
conguration and construction materials
were selected to meet specic pressure,
temperature, pressure drop and uid
conditions. Since some body/trim material
combinations are limited in their pressure
drop and temperature ranges, do not subject
the GEN II level controller to any other
conditions without rst contacting the Kimray
Inc, sales ofce or a sales / applications
representative.
WARNING
Do not exceed the maximum pressure
specied on the controller nameplate. Under
no circumstances should the controller
supply pressure ever exceed the maximum
psig.
The side mounted is reversible for rigtht hand
or left hand installation. The
back mount is center back mounted. Both
models are standard with a 1/4” NPT tapped
vent. No gas is released into the case.
Both models include a 40 micron lter
located just downstream of the instrument
gas inlet port.
Back Mount Side Mount
Issued 6/19

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
2
Installation
CAUTION
Do not pick up or carry the controller by
using the displacer arm as a handle.
NPT Connection: Apply TFE tape or
pipe compound to the male threads of the
threaded body, or use appropriate gaskets
for a anged body. When installing a
threaded body, tighten sufciently to seal the
threads. Use a wrench on the ats of the
body. Do not use the pilot case to tighten
the connection. Make sure the pilot case is
vertical when nished.
Flanged Connection: Flanged controllers
are available on request. Use a suitable
gasket between the body and the vessel
connection ange.
Note
Remove the plastic plugs from the 1/4” NPT
openings. 1/4” or 3/8” tubing not provided
must be installed.
1. SUPP - Connect to a source of clean, dry
instrument gas.
2. OUTPUT - Connect to the diaphragm
housing on the control valve being
operated.
3. VENT - Connect to a preferred location
for vented supply gas, or to a vapor
recovery system.
Changing Controller Mode or Action
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.
Side Mount Operation
A spring balances the weight of the displacer.
As liquid level rises around the displacer,
the net buoyancy of the displacer plus the
balancing force of the spring lifts the waggle
arm assembly. The opposite end of the
waggle arm is forced downward, pulling
down on the link and down on the tangent
arm. On the opposite side of the pilot
fulcrum, the tangent arm pushes up on the
actuator in the pilot.
As the actuator travels in response to
force from the tangent arm, it continually
respositions a small three-way valve the
pilot plug and seats which modulates the
output pressure. This output is most often
used to control diaphragm pressure in a
control valve. Proper function can best be
accomplished when the gas owing through
the pilot is clean and free of liquid.
CAUTION
If the level controller is installed on a vessel
that is to be shipped to a different location,
remove the displacer and rod extensions
before shipment. Failure to do so could
result in damage to the displacer, the
displacer rod, or even to the pilot, due to
vibration and impact during shipment. After
the vessel is in its nal location, reassemble
the displacer and displacer rod extension.
Note
Check clearances to be sure there are no
obstructions inside the tank that will interface
with displacer installation or operation.
Horizontal Displacer Installation
The level controllers are shipped with the
vertical adapter attached to the displacer. To
mount the displacer for horizontal service.
1. Remove displacer from hanger block.
2. Remove extension rod and coupling from
terminal arm.
3. Thread the displacer all the way onto
threads of terminal arm.
Side Mount
Figure 1
Figure 2
Figure 3
Figure 4
Standard Verticle
Remove
Install
Final
Figure 5
Displacer
Terminal Arm
Coupling
Extension Rod
Hanger Block
Horizontal
Pivot
Fulcrum
Actuator
Link

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
3
Changing Mode
The mode is selected with the switch plate.
After shutting off and venting instrument
gas pressure, loosen the selector knob
approximately one half turn. Then turn the
switch plate to “T” for throttle mode, or “S” for
snap mode. Then tighten selector knob.
Changing Action
1. Refer to the following diagram to
determine the proper orientation of parts
for the desired action direct or indirect.
2. Pull out the link knob, then move it to the
desired setting and press into hole.
Left of pivot for PC valve
Right of pivot for PO valve
Right of pivot for PC valve
Left of pivot for PO valve
Snap Setup Throttle Setup
CAUTION
Liquids, with specic gravity less than 1.0 it
is best to set the link for the most sensitive
response. This will result in less span.
Calling for greater spans with low specic
gravity can cause span to exceed the length
of the displacer, resulting in loss of control.
Snap Operation Span Adjustment
1. Refer to the following diagram above to
determine the proper orientation of parts
for the desired span.
2. Pull out the link knob, move to the desired
setting and press into hole.
Start-Up
Throttle- (No liquid on displacer)
PO Valve: At 0 psig turn adjusting knob
counter clockwise to produce 10 psig, then
turn clockwise one turn to 0 psig.
PC Valve: At 0 psig turn adjusting knob
clockwise to produce 20 to 30 psig.
Snap- (No liquid on displacer)
PO Valve: At 0 psig turn adjusting knob
clockwise to snap ON, then turn clockwise
two turns to 0 psig.
PC Valve: At 20 to 30 psig turn adjusting
knob counter clockwise to snap OFF, then
turn clockwise two turns from 20 to 30 psig.
Interface:
Cover displacers with the lighter uid.
Heavier uid must be below the displacer.
Then adjust same as above.
Figure 6 Figure 7
Figure 8 Figure 9 Figure 10
Slector
Knob
Switch
Plate
Throttle
Setting
Snap
Setting
Low
Sensitivity
(Large Span) High
Sensitivity
(Small Span)
START-UP:
THROTTLE (NO LIQUID ON DISPLACER)
PO VALVE- AT 0 psi TURN ADJ. KNOB CCW TO PRODUCE
~10 PSI, THEN TURN CW ~1 TURN TO 0 psi.
PC VALVE- AT 0 psi TURN ADJ. KNOB CW TO PRODUCE
20-30 PSI.
S
S
2" 2"
3" 3"
5"5"
PC VALVE
PROPORTIONAL BAND
SNAP MODE
PROPORTIONAL BAND
THROTTLE MODE
PO VALVE
PO VAL
VE
PC
VALVE
PATENT PENDING PART # 5521LH
GEN II LIQUID LEVEL CONTROLLER
NOTE: SPANS ARE FOR WATER & 30 psi SUPPLY
REDUCE ~20% FOR 20 psi SUPPLY
SELECTOR
PIVOT
LINK
ADJ. KNOB
THROTTLE
CONTROL
1. SET SELECTOR
TO "T" THROTTLE
W/ NO PRESSURE
ON PILOT
2. SET LINK
LEFT OF PIVOT
(P.O. VALVE)
RIGHT OF PIVOT
(P.C. VALVE)
3. SET ADJ KNOB
SEE START-UP
-CW TO LEVEL
-CCW TO LEVEL
SNAP
CONTROL
1. SET SELECTOR
TO "S" SNAP
W/ NO PRESSURE
ON PILOT
2. SET LINK
RIGHT OF PIVOT
(P.O. VALVE)
LEFT OF PIVOT
(P.C. VALVE)
3. SET ADJ KNOB
SEE START-UP
-CW TO LEVEL
-CCW TO LEVEL
5" 5"
7" 7"
10"10"
INTERFACE
COVER DISPLACER WITH LIGHTER FLUID. HEAVIER FLUID
MUST BE BELOW FLOAT. THEN ADJUST SAME AS ABOVE.
SNAP (NO LIQUID ON DISPLACER)
PO VALVE- AT 0 psi TURN ADJ. KNOB CCW TO SNAP
ON THEN TURN CW ~2 TURNS TO 0 psi.
PC VALVE- AT 20-30 psi TURN ADJ. KNOB CCW TO SNAP
OFF THEN TURN CW ~2 TURNS TO 20-30 psi.
Clockwise to raise level
Counter Clockwise to lower level
Level
Adjusting
Knob
Output
Guage
Supply
Guage

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
4
Installation
CAUTION
Do not pick up or carry the controller by
using the displacer arm as a handle.
NPT Connection: Apply TFE tape or
pipe compound to the male threads of the
threaded body, or use appropriate gaskets
for a anged body. When installing a
threaded body, tighten sufciently to seal the
threads. Use a wrench on the ats of the
body. Do not use the pilot case to tighten
the connection. Make sure the pilot case is
vertical when nished.
Flanged Connection: Use a suitable gasket
between the body and the vessel connection
ange.
Note
Remove the plastic plugs from the 1/4” NPT
openings. 1/4” or 3/8” tubing not provided
must be installed.
1. SUPP - Connect to a source of clean, dry
instrument gas.
2. OUTPUT - Connect to the diaphragm
housing on the control valve being
operated.
3. VENT - Connect to a preferred location
for vented supply gas, or to a vapor
recovery system.
Changing Controller Mode or Action
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.
Back Mount Operation
A spring balances the weight of the displacer.
As liquid level rises around the displacer,
the net buoyancy of the displacer plus the
balancing force of the spring lifts the waggle
arm assembly. The opposite end of the
waggle arm is forced downward, pulling
down on the link and down on the tangent
arm. On the opposite side of the pilot
fulcrum, the tangent arm pushes up on the
actuator in the pilot.
As the actuator travels in response to
force from the tangent arm, it continually
respositions a small three-way valve the
pilot plug and seats which modulates the
output pressure. This output is most often
used to control diaphragm pressure in a
control valve. Proper function can best be
accomplished when the gas owing through
the pilot is clean free of liquid.
CAUTION
If the level controller is installed on a vessel
that is to be shipped to a different location,
remove the displacer and rod extensions
before shipment. Failure to do so could
result in damage to the displacer, the
displacer rod, or even to the pilot, due to
vibration and impact during shipment. After
the vessel is in its nal location, reassemble
the displacer and displacer rod extension.
Note
Check clearances to be sure there are no
obstructions inside the tank that will interfere
with displacer installation or operation.
Horizontal Displacer Installation
The level controllers are shipped with the
vertical adapter attached to the displacer. To
mount the displacer for horizontal service.
1. Remove displacer from hanger block.
2. Remove extension rod and coupling from
terminal arm.
3. Thread the displacer all the way onto
threads of terminal arm.
Back Mount
Tangent
Arm
Link
Spring
Pivot
Waggle
Arm
Actuator
Figure 1
Standard Verticle
Remove
Install
Final
Figure 2
Figure 3
Figure 4
Figure 5
Displacer
Terminal Arm
Coupling
Extension Rod
Hanger Block
Horizontal

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
5
Changing Mode
The mode is selected with the switch plate.
After shutting off and venting instrument
gas pressure, loosen the selector knob
approximately one half turn. Then turn the
switch plate to “T” for throttle mode, or “S” for
snap mode. Then tighten selector knob.
Changing Action
1. Refer to the following diagram to
determine the proper orientation of parts
for the desired action direct or indirect.
2. Pull out the link knob, then move it to the
desired setting and press into hole.
Left of pivot for PC valve
Right of pivot for PO valve
Right of pivot for PC valve
Left of pivot for PO valve
Snap Setup Throttle Setup
CAUTION
Liquids, with specic gravity less than 1.0 it
is best to set the link for the most sensitive
response. This will result in less span.
Calling for greater spans with low specic
gravity can cause span to exceed the length
of the displacer, resulting in loss of control.
Snap Operation Span Adjustment
1. Refer to the following diagram above to
determine the proper orientation of parts
for the desired span.
Start-Up
Throttle- (No liquid on displacer)
PO Valve: At 0 psig turn adjusting knob right
to produce 10 psig, then turn left one turn to
0 psig.
PC Valve: At 0 psig turn adjusting knob left
to produce 20 to 30 psig.
Snap- (No liquid on displacer)
PO Valve: At 0 psig turn adjusting knob right
to snap ON, then turn left two turns to 0 psig.
PC Valve: At 20 to 30 psig turn adjusting
knob right to snap OFF, then turn left two
turns from 20 to 30 psig.
Interface:
Cover displacers with the lighter uid.
Heavier uid must be below the displacer.
Then adjust same as above.
Figure 6
Figure 7
Figure 8 Figure 9 Figure 10
Do Not Use
Throttle
Setting
Snap
Setting
Slector
Knob
Switch
Plate
Low
Sensitivity
(Large Span)
High
Sensitivity
(Small Span)
Pivot Pivot
LinkLink
Clockwise to raise level
Counter Clockwise to lower level
Level
Adjusting
Knob
Output
Guage
Output
Guage

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
6
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 controller,
the inspection interval may be decreased or
increased.
Trouble Shooting
Problem Possible Cause(s) Possible Solution
Check for leaks between upper and lower
anges.
Check for any damage to ange o-ring. Clean the lower ange groove so it is free of
debris.
The controller can be repaired without being
removed from the piping.
Repair kits are available. Consult the Kimray
catalog, section Y:175, or the packing slip
which is enclosed with each controller for the
correct repair kit number.
WARNING
A leaking controller indicates that service
is required. Failure to take the valve out of
service immediately may create a hazardous
condition.
Repair Tips
● If pilot bleeds gas continuously, the pilot
plug seat may be dirty.
●Evenly tighten the screws which hold the
bonnet on.
●Diaphragms will harden with age.
Inspection Schedule
Body Under normal conditions, the body will last for years.
Severe conditions will require inspection more frequently.
The body should be inspected every time valve trim is
inspected.
WARNING
Before any service, be certain that the
valve is fully isolated and that all pressure
upstream and downstream has been
relieved. Use bypass valves or fully shut off
the process.

Float Operated Level Controllers
Models Pneumatic GEN II
Installation and Maintenance
7
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 Kimray GEN II controllers.
All contents of this publication including illustrations are believed to be reliable. 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 application. 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.
Related Publications:
See Catalog Page - C1:01.2, C1:01.4