Kimray GEN 3 Quick Start Manual

Pilot Lever Assembly
Torque Lever
Cap Screw
CAUTION
Set Screw
Prior to installing, the instructions provided herein should be completely
1/2" NPT Plug
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
Throttle
output can be set to operate as Direct Acting or Indirect Acting. The
mounting body can be flipped to either Left Hand or Right Hand Mount.
Snap
The displacer may be assembled in vertical or horizontal orientation.
Changing between these options does not require additional
components nor swapping out pilots.
CAUTION
This controller was ordered with material options selected to meet
specific pressure, temperature, and fluid conditions. Do not subject the
controller to conditions outside of its limits.
Displacer Assembly
Rod Assembly
Coupling
Arm
Displacer
Installation
NPT Connection: Apply PTFE tape or pipe compound to the male
threads of the body, tighten sufficiently to seal the threads. Use a
wrench on the flats 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 finished.
Flanged Connection: Use a suitable gasket between the body and
the vessel connection flange.
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.
Mount
Cap Screw
Spring Adjustment Assembly
Displacer
Arm
All Pictures shown are for illustration purpose only. Actual product may vary due to product enhancement.
GEN 3 PNEUMATIC LEVEL CONTROLLERS
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
Pilot Lever Assembly
Torque Lever
Cap Screw
Set Screw
Pilot Lever Assembly
1/2" NPT Plug
Torque Lever
1. Remove Spring Adjustment Assembly and 1/2" NPT plug
Cap Screw
2. Remove Pilot Lever Assembly
Set Screw
3. Loosen Set Screw at bottom of Torque Lever and slide it off shaft.
4. Remove Cap Screws and rotate the Mount 180 degrees.
1/2" NPT Plug
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
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.
Rod Assembly
Coupling
Pilot Action - Direct / Indirect Switch
Arm
To switch between Direct and Indirect, move Pilot Lever from one side
to the other according to the Pilot Lever Location table below.
Displacer
Pilot Lever Location
Rod Assembly
Pilot Configuration
Coupling
Arm
Direct (Fail Close) Same side as spring
Indirect (Fail Open) Opposite side of spring Same side as spring
Displacer
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Mount
Cap Screw
Mount
Spring Adjustment Assembly
Cap Screw
Spring Adjustment Assembly
Throttle
Snap
Throttle
Snap
Arm
Throttle Snap
Opposite side of spring
Arm
Displacer
Displacer